Table of Contents
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INSTALLATION AND OPERATING
Models
302A-902A Types H, WH & P
WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property dam-
age, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other com-
bustable materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.
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.
Installation and service must be performed by a qualified installer, service agency or the
gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.
CATALOG NO. 1000.501B
INSTRUCTIONS
Effective: 09-08-06
L
W
Replaces: 01-01-05
P/N 240757 Rev. 1
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Related Manuals for Raypak Hi Delta 302A-902A
Summary of Contents for Raypak Hi Delta 302A-902A
- Page 1 INSTALLATION AND OPERATING INSTRUCTIONS Models 302A-902A Types H, WH & P WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property dam- age, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other com- bustable materials in the vicinity of this or any other appliance.
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Page 3: Table Of Contents
CONTENTS WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Component Locations General Information GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Stacking Clearances Combustion and Ventilation Air Conventional Combustion Air Supply 13 Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connection... -
Page 4: Pay Attention To These Terms
WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe person- DANGER: al injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. -
Page 5: Before Installation
If, after reviewing this manual, you still have questions which this manual does not answer, please contact the manufacturer 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. -
Page 6: Component Locations
Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front... -
Page 7: General Information
General Information Quantity of Model Burners Blowers Flue Intake Valves 302A 402A 502A 652A 752A 902A Table A: Basic Data # Burners per Stages Model Valve 302A 402A 502A 652A 752A 902A 1, 1A 1, 1A, 2 66 Table B: Manifold Data # Burners Valve Model... -
Page 8: General Safety
GENERAL SAFETY To meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the rec- ommended initial setting for the temperature control is 125°F. -
Page 9: Installation
Hi Delta units can be stacked two units high with an optional stacking rack. A seismic-certified stacking kit is available from Raypak for this type of installation. CAUTION: The heaters should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the struc- ture. -
Page 10: Clearances
In addition, the heater shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation or service (circulator replacement, control replacement, etc.). Clearances Indoor Installations Minimum Clear- ance Heater Side from Combustible Surfaces Floor*... - Page 11 Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- tance of 2 ft (61cm) from the centerline of the terminal...
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Page 12: Combustion And Ventilation Air
3. In cold climates, and to mitigate potential freeze- up, Raypak highly recommends the installation of a motorized sealed damper to prevent the circula- tion of cold air through the heater during the non- operating hours. -
Page 13: Conventional Combustion Air Supply
three or four sheet metal screws (not supplied) equal- ly distributed around the circumference of the duct. All ducting should be self-supported. The filter housing is not designed to support the air duct. CAUTION: Use TrueSeal combustion air if damag- ing airborne contaminants are or will be present in the heater area. -
Page 14: Canadian Installations
b. Not less than the sum of the areas of all vent connectors in the confined space. WARNING: Do not use one permanent opening method if the equipment room is under negative pressure conditions or the equipment is common vented with other gas-fired appliances. Canadian Installations CAUTION: All combustion air must be drawn from the air outside of the building;... -
Page 15: Hydrostatic Test
The heat exchanger has already been factory- tested and is rated for 160 psi operating pressure. However, Raypak does recommend hydrostatic test- ing of the piping connections to the heater and the rest of the system prior to operation. This is particularly true for hydronic systems using expensive glycol- based anti-freeze. -
Page 16: Temperature & Pressure Gauge
Failure to exceed 105ºF (41ºC) within 7 minutes may result in the premature failure of the hot surface ignit- er, remote flame sensor, burners and heat exchanger. It can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the vent system. - Page 17 Raypak heaters are high-recovery, low-mass heaters which are not subject to thermal shock. Raypak offers a full line of electronic sequencers that produce direct reset of heater water temperature. (Refer to the Controls section of the Raypak Catalog.) Fig.
- Page 18 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water. 2. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating.
- Page 19 circulate water through the heater from the main sys- tem piping. To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return wa- ter line, upstream of the heater. This will ensure that the heater will be energized at the right time.
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Page 20: Gas Supply
Heat exchang- er failure due to total dissolved solids in excess of 2,500 ppm is a non-warrantable condition. Raypak offers basic temperature guidelines for operation of a potable water heater on normal to moderate levels of... -
Page 21: Gas Supply Connection
Gas Supply Connection CAUTION: The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa). The heater must be isolated from the gas supply pip- ing system by closing the manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45... -
Page 22: Gas Supply Pressure
8. Remove the rubber grommet from the left-hand- side panel and reinstall into the standard main gas opening, located on the right-hand side of the heater. 9. Install a coupling, nipple, union and sediment trap onto the right-hand end of the main gas line and then install the gas line, making sure that a manu- al shut-off valve has been installed within 10 ft of the heater. -
Page 23: Making The Electrical Connections
BLACK CIRCUIT BREAKER WHITE GREEN GROUND A B C Fig. 18: Wiring Connections Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum Fig. 19: Multi-meter If the heater does not have a factory-wired stage con- troller, it is factory-wired in an on-off configuration with other stage terminals jumpered. - Page 24 DANGER: SHOCK HAZARD Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. Fig. 21: Wiring Connections...
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Page 25: Venting
Installer action is required to electrically enable your heater to operate after making the power connections. You must make a closed contact connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connections. This will be done based on the controller option selected with your heater order. -
Page 26: Vent Terminal Location
Category III – A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent. Category IV – A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent. -
Page 27: Changing The Flue Outlet
8. Locate and guard vent termination to prevent acci- dental contact by people or pets. 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. 10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations. -
Page 28: Venting Installation Tips
5. Remove the screws, retaining ring and rain gasket from top of heater. 6. Remove the screws, flue collar and gasket from the run side of the tee located in the flue box on top of the heater. 7. Reverse the components and reattach in the new location. - Page 29 Termination The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the high- est point of the roof that is within 10 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft hori- zontal distance is maintained) electric meters, gas me- ters, regulators and relief equipment.
- Page 30 The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved stainless steel flue direct vent cap must be used (sales order option D-15).
- Page 31 Certified Model Venting Material 302A 402A 502A Category III 652A 752A 902A * Subtract 10 ft per elbow. Max. 3 elbows. Maximum combustion air duct length terminated at 100 equivalent ft. Table M: Category III Horizontal and Direct Venting Use only the special gas vent pipes listed for use with Category III gas burning heaters, such as the AL29-4C stainless steel vents offered by Heat Fab Inc.
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Page 32: Direct Vent - Vertical
For installations in extremely cold climate, it is re- quired that: 1. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of hori- zontal run to the vent terminal. In this case, an ap- proved condensate trap must be installed per ap- plicable codes. -
Page 33: Outdoor Installation
Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that might ob- struct combustion air flow. -
Page 34: Heater Sequence Of Operations
Fig. 28: External LED Indicator Decal Heater Sequence of Operation Models 302A, 402A, 502A, 652A, 752A and 902A 1. The black (hot) wire lead goes directly to the main power switch. This black toggle switch is located at the middle front of the control compartment. 2. - Page 35 Light Power Call For Heat Safety Ignition Flow Blower 1 Stage 1 Stage 2 Light Board Power Low Water Cut-Off Blocked Vent Manual Reset Hi-Limit Low Gas Pressure Switch High Gas Pressure Switch (Not Used) PVC Vent Limit Auto Reset High Limit 24.
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Page 36: Ignition Module
36. Once the pressure switch signal is received at the ignition module the hot surface igniter is energized by a 120 VAC signal from S-1 on the ignition mod- ule. (The hot surface igniter must draw greater than 3.1 amps while being energized or ignition lockout will occur after three tries.) 37. -
Page 37: High/Low Gas Pressure Switches
The optional single-try ignition module will lock out after failing to light one time. To reset it, press and release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case. Turning off the power to the heater WILL NOT reset the ignition module. - Page 38 Fig. 34: High/Low Gas Pressure Switch Fig. 35: Fan-Proving Switch Fig. 36: Blocked Vent Switch...
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Page 39: 87%-Efficiency Boilers - Special Instructions
Fig. 15, must be piped into the system at the time of installation. This piping is like a primary/secondary boiler installation with a bypass in the secondary boiler piping. Raypak strongly recomm- 10°F T Model P (ft) - Page 40 Common Venting System Manifolds that connect more than one boiler to a com- mon chimney must be engineered to handle the com- bined load. Consult available guides for proper sizing of the manifold and the chimney.
- Page 41 Fig. 38: Horizontal Through-the-Wall Venting (Category IV) Installation These installations utilize the boiler-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the out- doors.
- Page 42 The stainless steel direct vent cap must be furnished by the boiler manufacturer in accordance with its list- ing (sales order option D-15). Use only double-wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burn- ing boilers, such as the stainless steel Saf-T vent by Heat Fab Inc.
- Page 43 Direct Vent - Vertical Certified Model Venting Vent Size Material 302A 402A 502A Category II or IV 652A 752A 902A * Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. When vertical height exceeds 25 ft, consult factory prior to installation.
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Page 44: Wiring Diagram
Wiring Diagram... -
Page 45: Start-Up
START-UP Pre Start-up Filling System (Heating Boilers) Fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. -
Page 46: Start-Up
Preparation WARNING: Do not turn on gas at this time. Check Power Supply With multi-meter at incoming power, check voltage between: Hot - Common (≈120 VAC) Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) WARNING: If Common - Ground is > 1 VAC, STOP: Contact electrician to correct ground failure. -
Page 47: Safety Inspection
Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record. 3. If other gas-fired appliances in the room are on the same gas main, check all pressures on the Hi Delta with all other equipment running. - Page 48 1. Manually close the downstream leak test valve. 2. Open test point A and connect a manometer to it. Verify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in. WC). 3.
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Page 49: Operation
10. To restart system, follow lighting instructions in the Operation section. 11. Check to see that the high limit control is set above the design temperature requirements of the system. For multiple zones: Check to make sure the flow is adjusted as required in each zone. -
Page 50: Troubleshooting
TROUBLESHOOTING Does the power switch provide power to the control panel? Step 1 Is there a Call For Step 2 Is Disable jumper intact? (J1) Do the combustion air Step 3 blowers come on? Step 4 Are the blower lights illuminated? Is 24VAC at PS on ignition module? Is... -
Page 51: Maintenance
MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. Maintenance as outlined below may be performed by the owner. Daily 1. Check that the area where the heater is installed is free from combustible materials, gasoline, and other flammable vapors and liquids. -
Page 52: Semi-Annually
Weekly For low-pressure heaters, test low-water cut-off device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance should shut-off and ignition fault light should come on. Depress reset button to reset). 1. Check igniter. (Resistance reading should be 42- 70 ohms at ambient temperature.) 2. -
Page 53: Inside Air Contamination
APPENDIX Inside Air Contamination All heaters experience some condensation during start-up. The condensate from flue gas is acidic. Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high effi- ciency systems. - Page 54 SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
- Page 55 SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
- Page 56 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A.
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