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INSTALLATION
AND OPERATING
INSTRUCTIONS
Models 302-902
Type H, WH, & P
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of
this or any other appliance. To do so may result in an explosion or fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage,
personal injury or loss of life. Refer to the user's information manual provided with this boiler. Installation and
service must be performed by a qualified installer, service agency or the gas supplier.
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS:
·
Do not try to light any appliance.
·
Do not touch any electrical switch; do not use any phone in your building.
·
Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
·
If you cannot reach your gas supplier, call the fire department.
This manual should be maintained in legible condition
and kept adjacent to the boiler or kept in a safe place
for future reference.
CATALOG NO. 1000.50K
Effective:
08-01-03
Replaces: 01-15-03
P/N 240757
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Summary of Contents for Raypak 302-902
- Page 1 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Refer to the user’s information manual provided with this boiler. Installation and service must be performed by a qualified installer, service agency or the gas supplier.
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Page 2: Table Of Contents
SECTION M: SECTION N: SECTION O: SECTION P: SECTION Q: APPENDIX A: COMBUSTION AIR CONTAMINATION WARRANTY BEFORE INSTALLING THE BOILER BOILER INSTALLATION COMBUSTION AND VENTILATION AIR WATER PIPING - GENERAL HYDRONIC HEATING PIPING DOMESTIC HOT WATER PIPING POOL HEATING GAS SUPPLY CONNECTIONS... - Page 3 Make sure the gas on which the boiler will operate is the same type as that specified DANGER: on the boiler model and rating plate. Should overheating occur or the gas supply valve fail to shut, do not turn off or WARNING: disconnect the electrical supply to the boiler.
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Page 4: Section A: Before Installing The Boiler
If, after reviewing this manual, you still have questions which this manual does not answer, please contact the factory or your local Raypak representative. Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment. PRODUCT RECEIPT On receipt of your product it is suggested that you visually check for external damage to the shipping crate. -
Page 5: Model Identification
Altering any RAYPAK pressure vessel by installing replacement heat-exchangers, tube bundle headers, or any other ASME part not manufactured and/or approved by RAYPAK will instantly void the ASME, AGA, and CGA ratings of the vessel and any RAYPAK warranty on the vessel. Altering the ASME, AGA and CGA ratings of the vessel also violates national, state, and local approval codes. - Page 6 Combustion Air Filter (Inlet) Optional Combustion Air (Inlet) Alternate Flue Connection BACK Gas Supply Connection Pressure Relief Connection Water Outlet LEFT-SIDE Gas Train Pressure Relief Valve Heat Exchanger Burner Group FRONT Flue Exhaust Electrical Connection Water Inlet View Port Temperature and Pressure Gauge Operational Center Control Combustion Air Blower...
- Page 7 General Information...
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Page 8: Section B: Boiler Installation
NEVER be installed on carpeting. Gas fueled equipment installed in enclosed parking garages must be located at least 18 inches above the floor. Stacking Hi Delta units can be stacked two units high with an optional stacking rack. A stacking kit is available from Raypak for this type of installation. CAUTION: The boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliance or to the structure. -
Page 9: Top View
TOP VIEW When installed according to the listed minimum clearances from combustible construction mate- rials, the Raypak heaters can still be serviced without removing permanent structural construc- tion around the heater. However, for ease of servicing, we recommend a clearance of at least 24” in front, and at least 18”... -
Page 10: Outdoor Installations
Raypak Hi Delta Boilers are design certified for outdoor installation. Boilers must not be installed under an overhang that is less than three (3) feet from the top of the boiler. Three (3) sides must be open in the area under the overhang. -
Page 11: Section C: Combustion And Ventilation Air
Install combustion air direct vent in accordance with Section J-3 and Section J-4 of this manual. Provide adequate ventilation. In cold climates, and to mitigate potential freeze-up, Raypak highly recommends the installation of a motorized sealed damper to prevent the circulation of cold air through the boiler during the non-operating hours. - Page 12 Ventilation of the space occupied by the boiler shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors. The total cross-sectional area of such an opening(s) shall be at least 10% of the area required in (2) and (3), but in no case shall the cross-sectional area be less than10 square inches (6500 square mm).
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Page 13: Section D: Water Piping - General
HYDROSTATIC TEST Unlike many other types of boilers, Raypak boilers do not require hydrostatic testing prior to being placed in operation. The heat exchanger has already been factory-tested and is rated for 150 PSI operating pressure. However, Raypak does recom- mend hydrostatically testing the piping connections to the boiler and the rest of the system prior to operation. -
Page 14: Section E: Hydronic Heating Piping
Valves designed to blend water temperatures or reduce water circulation through the boiler should not be used. Raypak heaters are high recovery low mass heaters not subject to thermal shock. Raypak offers a full line of electric sequencers that produce direct reset of boiler water temperature. Refer to the Controls Section in our Complete Catalog. - Page 15 SINGLE BOILER - LOW TEMPERATURE APPLICATION (HEAT PUMP) PRIMARY/SECONDARY PIPING Fig. #9223 DUAL BOILER PRIMARY/SECONDARY PIPING Fig. #9232.2...
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Page 16: Section F: Domestic Hot Water Piping
A. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water. B. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating. -
Page 17: Section G: Pool Heating
SECTION G: POOL HEATING CAUTIO CAUTION: Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation. Improper flow control can damage the heater. Uncontrolled flow (too high) or restricted flow (too low) can seriously damage the heater. -
Page 18: Automatic Chlorinators And Chemical Feeders
AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place chlorine tablets or bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (i.e. -
Page 19: Section H: Gas Supply Connections
Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve located outside the heater jacket. A pounds to inches regulator must be installed to reduce to gas supply pressure to under 14" W.C. The regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the boiler gas controls. -
Page 20: Gas Pressure Regulator
GAS PRESSURE REGULATOR The gas valve pressure regulator(s) on the boiler are nominally preset at 3.5" W.C. for Natural gas, and 10.5" W.C. for Propane gas manifold pressure. The pressure at the gas valve outlet tap, measured with a manometer,while in operation should be 3.5 ±... -
Page 21: Section I: Electrical Power Connections
All sensitive control components should be protected by a suitable commercial-grade surge protection device. If any of the original wire as supplied with the boiler must be replaced, it must be replaced with 105°C wire or its equivalent. -
Page 22: Making The Electrical Connections
Verify circuit breaker is properly sized by referring to boiler rating plate. A dedicated circuit breaker should be provided. Turn off all power to the boiler. Verify that power has been turned off by testing with a volt-ohm meter prior to working with any electrical connections or components. -
Page 23: Shock Hazard
For multi-stage controller connections, connect each stage of the control to the corresponding stage of TB-3 in the boiler. Stage 1 of the boiler to stage 1 of the control. Stage 2 of the boiler to stage 2 of the control, and so on. -
Page 24: Section J: Venting Connections
GENERAL CAUTION: Proper installation of flue exhaust venting is critical for the safe and efficient operation of the boiler. Definition of Appliance Categories Boilers are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. - Page 25 * As defined in the latest edition of the National Fuel Gas Code, or in Canada, the latest edition of the CAN/CGA B149.1 and B149.2. TABLE J-1...
- Page 26 Support of Vent Stack The weight of the vent stack or chimney must not rest on the boiler vent connection. Support must be provided in compliance with applicable codes. The vent should also be supported to maintain proper clearances from combustible materials.
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Page 27: Venting Installation Tips
Canada Installations - Refer to latest edition of CAN/CGA-B149.1 and .2 A vent shall not terminate: a) Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings b) Less than 7 ft.(2.13m)above a paved sidewalk or paved driveway located on public property c) Within 6 ft(1.8m) of a mechanical air supply inlet to any building d) Above a meter/regulator assembly within 3 ft(900mm) horizontally of the vertical centre-line of the regulator e) Within 6 ft.(1.8m) of any gas service regulator vent outlet... - Page 28 **Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the National Fuel Gas Code for further details. (ANSI Z223.1) 10' OR LESS VENT CAP 2' MIN VENT PIPE COMBUSTION AIR FILTER BOILER UNIT 2' MIN Fig. #9228...
- Page 29 The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot from the boiler to the vent terminal. The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints.
- Page 30 Common venting systems may be too large when an existing unit is removed. At the time of removal of an existing appliance, the following steps must be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
- Page 31 Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or, in Canada, the latest edition of CAN/CGA-B149.1 and .2 Installation Code for Gas Burning Appliances and Equipment.
- Page 32 The total length of the horizontal thru-wall exhaust vent system should not exceed seventy (70) feet in length. If horizontal run exceeds 70 feet, an appropriately sized extractor must be used. To maintain proper operation pressure reading must be between -.01 to -.1 W.C. as measured 12 inches from the appliance flue outlet. Each elbow used is equal to ten (10) feet of straight pipe.
- Page 33 The flue exhaust direct vent cap MUST be mounted on the exterior of the building. The direct vent cap cannot be installed in a well or below grade. The direct vent cap must be installed at least one (1) foot above ground level and above normal snow levels. The Raypak supplied flue exhaust direct vent cap must be utilized. WARNING: No substitutions of flue pipe or vent cap material are allowed.
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Page 34: Direct Vent
SECTION J-3 BOILER UNIT HORIZONTAL THRU-WALL VENTING TABLE DIRECT VENT Horizontal Thru-wall Venting (Category III) 9" MIN. CONDENSATE TRAP FILTER 6" MIN. EXHAUST VENT INTAKE 36" VENT MIN. 12" MIN. Fig. #9230.1... - Page 35 The Stainless Steel flue exhaust direct vent cap must be furnished by the boiler manufacturer in accordance with its listing. Use only the special gas vent pipes listed for use with category III gas burning heaters, such as the stainless steel Saf-T vent by Heat Fab Inc.
- Page 36 SECTION J-4 DIRECT VENT Vertical Venting (Category I) VENT MIN. 3' MIN. 1' MIN. INTAKE VENT EXHAUST VENT BOILER AIR FILTER UNIT Fig. #9231.1 VERTICAL VENTING TABLE...
- Page 37 The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot from the boiler to the vent terminal. The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints.
- Page 38 Outdoor models are self -venting when installed with the factory-supplied restricted direct vent cap and require no additional vent piping. This special vent cap is provided with the boiler in accordance with AGA/CGA requirements. It must be installed directly on the boiler. See Section B for correct clearances.
- Page 39 HI DELTA OUTDOOR VENT INSTRUCTIONS 1. Turn off the power and shut off the gas to heater. 2. Slide the vent collar from kit over the collar on heater as shown in Fig. 1. 3. Drill a 3/16” pilot hole into the heater collar through each of the holes on the lower vent collar.
- Page 40 HI DELTA OUTDOOR VENT INSTRUCTIONS CONTINUED 6. Slide the collector over vent collar, aligning the holes over the openings in the tinnerman clips as shown in Fig. 4. 7. Take four of the screws from the kit and screw into the holes as shown in Fig.
- Page 41 HI DELTA FILTER BOX KIT NOTICE: These instructions are intended for use by qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel are required to be licensed in some states. Persons not qualified shall not attempt repairs according to these instructions.
- Page 42 HI DELTA FILTER BOX INSTRUCTIONS CONTINUED 11. Mark the four holes through filter box for screw locations. 12. Using a 1/16 drill bit, drill a pilot hole in each of the holes previously marked. 13. Mount the filter box to the unit using four screws provided in the kit.
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Page 43: Section K: Controls
WARNING: Turn off the power to the boiler before installation, adjustment or service of the Central Point Wiring board or any boiler controls. Failure to do so may result in board damage, boiler malfunction, property damage, personal injury, or death. - Page 44 Control, Low Gas Pressure Switch (optional) and the High Gas Pressure Switch (optional). At this point if all the preceding safety switches are closed, then Relay K. 1 (n.c.) will be energized and the safety light will turn off. The boiler is now ready for a call for heat.
- Page 45 Control, Low Gas Pressure Switch (optional) and the High Gas Pressure Switch (optional). At this point if all the preceding safety switches are closed, then Relay K 1 (n.c.) will be energized and the safety light will turn off. The boiler is now ready for a call for heat.
- Page 46 Relay No. 1 (n.c.) will be energized and the safety light will turn off. The boiler is now ready for a call for heat. When STAGE 1 calls for heat, the CALL FOR HEAT LIGHT will turn on. The Economaster Board will be energized and the pump will turn on.
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Page 47: Ignition Control Module
HIGH LIMIT (MANUAL RESET) The boiler is equipped with a manual reset high limit temperature device. Push the reset button and adjust the setting to 30° F or 40° F above desired operating temperature. -
Page 48: Low Water Cut Off (Optional)
The low gas pressure switch automatically shuts down the boiler if gas supply drops below the factory setting of 5" W.C. for Natural gas, and 10" W.C. for Propane gas. - Page 49 WIRE DIAGRAM MODEL 302-402 Reference Drawing Number M152462-Rev. M H4/W1...
- Page 50 WIRE DIAGRAM MODEL 302-402 Reference Drawing Number M152470-Rev. J H3/W3...
- Page 51 WIRE DIAGRAM MODEL 502-752 Reference Drawing Number M152464-Rev R H3/HW3...
- Page 52 WIRE DIAGRAM MODEL 902 Reference Drawing Number M152465 Rev-P H3/W3...
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Page 53: Section L: General Safety Precautions
TIME/TEMPERATURE RELATIONSHIPS IN SCALDS The temperature of the water in the hot water boiler can be regulated by setting the temperature dial on front of the thermostat. To comply with safety regulations the thermostat was set at its lowest setting before the hot water boiler was shipped from the factory. -
Page 54: Section M: Pre-Start-Up
DOMESTIC HOTWATER BOILERS Purge all air from system before lighting boiler. This can be normally be accomplished by opening a downstream valve. INSPECT VENTING SYSTEM: Check all vent pipe connections and flue pipe material. -
Page 55: Section N: Hi-Delta Initial Start-Up
SECTION N: HI-DELTA INITIAL START-UP TOOLS NEEDED • One 12-0-12, 24” scale manometer • 6-0-6, 12” scale manometers • 7/16” open end wrench • 1/2” open end wrench • Screwdriver • Volt meter • 3/16” Allen wrench • Jumper cable PREPARATION FOR START-UP WARNING: DO NOT TURN ON GAS AT THIS TIME... - Page 56 Turn off unit. Open manual firing valves. Turn on the unit, wait 15 seconds, and the igniter should glow. Sight glass to check ignitor at both ends of the boiler. Gas valves should be open after 45 seconds. If burner does not light on first trial. It will retry, up to 3 times Main burner ignition –...
- Page 57 Identical readings will be found at the plugged port labeled as Alternate C”. Refer to attached diagrams. Numbers on the diagram refer to the steps below: These tests are to be conducted with the electrical power to the boiler turned off. Manually close the downstream leak test valve.
- Page 58 After no leakage has been verified at all valve seats and test valves, open downstream leak tests valve and restore electrical power to boiler. This completes leak testing for a single Hi Delta manifold riser. Repeat steps 1-8 for each riser.
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Page 59: Section O: Post Start-Up Check
Is burner flame visible? Test safety controls: If boiler is equipped with a low water cutoff or additional safety controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when controls are tested. When safety devices are restored, burners should reignite after pre-purge time delay. -
Page 60: Section P: Operation
If boiler fails to start, check for: • Loose connections, blown fuse or service switch off? • High temperature limit switch set below boiler water temperature? • Thermostat set below room temperature? • Gas not turned on at meter or boiler/ •... -
Page 61: Section Q: Maintenance
SECTION Q: MAINTENANCE SUGGESTED MINIMUM MAINTENANCE SCHEDULE: Regular service by a qualified service agency and maintenance must be performed to assure maximum boiler operating efficiency. Maintenance as outlined below may be performed by the owner. Yearly (Beginning of each heating season): Annual service call by qualified service agency. -
Page 62: Preventive Maintenance Schedule
Recondition or replace low water fuel cutoff device. For gas fired burners, check drip leg and gas strainers. Flame failure detection system, pilot turndown test. Test safety/safety relief valves in accordance with ASME Boiler and Pressure Vessel Code Sections VI and VII. (Remove front panel and visually... -
Page 63: Inside Combustion Air Contamination
Higher acidic levels attack many materials, including stainless steel commonly used in high efficiency systems. The boiler can use special corrosion-resistant nonmetallic intake vent material. You may, however, choose to use outside combustion air for one or more of these reasons: •... -
Page 64: Warranty
PARTS REPLACEMENT: Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty. - Page 65 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX: (800) 872-9725 Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX: (905) 677-8036 6-99 Litho in U. S. A.
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