Raypak HIDELTA 992B Installation & Operating Instructions Manual
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Raypak HIDELTA 992B Installation & Operating Instructions Manual

Models 992b–2342b types h, wh & p
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INSTALLATION & OPERATING
Models
992B–2342B
Types H, WH & P
WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustable 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. 1000.511F
INSTRUCTIONS
Effective: 06-23-09
L
W
Replaces: 08-21-08
P/N 241259 Rev. 7

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  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 992B–2342B Types H, WH & P WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustable materials in the vicinity of this or any other appliance.
  • Page 2 Rev. 7 reflects the following: Changes to: Fig. 3 on page 6; the UDB Diagnostic Board and UDB Fault History sections on page 44; the Wiring Diagrams on pages 50 and 51.

  • Page 3: Table Of Contents

    WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation 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...

  • Page 4: Warnings

    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 OPTIONAL FLUE CONNECTION 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 Model 1262B 1532B 1802B 2002B 2072B 2342B *Hidden solenoid valve located inside of air plenum. Burners per Valve Model 992B 1262B 1532B 1802B 2002B 2072B 2342B Quantity of No. Burners Blowers Flue Valves 992B 2 + 1* 3 + 1* Table A: Basic Data Stages 1, 2...

  • 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 structure.
  • Page 10 Fig. 6: 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...

  • Page 11: 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 Clearance Heater from Combustible Side Surfaces Floor*...

  • 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 damaging 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

    This piping is like a pri- mary/secondary boiler installation with a bypass acting as the secondary boiler piping. Raypak strongly rec- ommends that thermometer(s) be placed into the heater piping next to the in/out header to facilitate tem- perature adjustment.

  • 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.) *Maximum 4 times the pipe diameter or 12”, whichever is less.
  • 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.

  • 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

    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. 10.

  • Page 23: Making The Electrical Connections

    NOTE: Minimum 18 AWG, 105°C, stranded wire must be used for all low voltage (less than 30 volts) external connections to the unit. Solid conductors should not be used because they can cause excessive tension on contact points. Install conduit as appropriate.
  • 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: On-Off Wiring Connections Fig. 22: 2-Stage Wiring Connections Fig. 23: 3-Stage Wiring Connections Fig. 24: 4-Stage Wiring Connection Installer action is required to electrically enable your heater to operate after making the power connections.

  • Page 25: Venting

    ured to operate in an on-off firing mode. This means that you will connect a single-pole control to stage one of the CPW board. Then jumper the remaining firing stages. For example, if your heater is a Model 1532B, you will jumper stages two, three and four.

  • Page 26: Vent Terminal Location

    Category II – A heater which operates with a non-pos- itive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent. 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.

  • 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 highest 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 meters, 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 992B 1262B 1532B 1802B Category III 2002B 2072B 2342B * Subtract 10 ft per elbow. Max. 3 elbows. Maximum combustion air duct length terminated at 100 equivalent ft. Table L: 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.

  • 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 approved condensate trap must be installed per applicable 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 Operation

    Fig. 31: Status LED Indicator Decal Heater Sequence of Operation Models 992B-1262B 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. When the main power switch is placed in the “ON” position, 120 VAC is applied to the 120 VAC termi- nal block on the circuit board and the 120/24 VAC transformer is powered.
  • Page 35 Light Power Call For Heat Safety Ignition Flow Blower 1 Blower 2 Blower 3 Stage 1 Stage 2 Stage 3 Stage 4 24. Power is also sent from pin 2 of the stage 1 con- nection to pin P1-3 of the universal diagnostic board.
  • Page 36 gized by a 120 VAC signal from S-1 on the ignition module for approximately 30 seconds. (The hot surface igniter must draw greater than 3.1 amps while being energized or ignition lockout will occur after three tries.) 43. Once the ignition module determines that the hot surface igniter has heated up and operating prop- erly, a 24 VAC signal is output from pin GV on the module.
  • Page 37 9. 24 VAC is applied to the blue power light located on the status display board. 10. 24 VAC is also applied to the red LED safety shut- down light on the front status board until the safeties have been proven. 11.
  • Page 38 36. After proper air pressure is received in the air plenum, the air pressure switches will close. 37. If there is insufficient air pressure and the air pres- sure switch does not close, a 24 VAC signal is sent to the Universal Diagnostics Board to indicate the fault.
  • Page 39 60. If ignition module two locks out, a signal will be sent to the Universal Diagnostics Board and to the status display board to indicate an ignition fault. 61. The coil of relay K-5 (N.O.) is now energized with the (K-5) contacts closing downstream of the stage 4 connections.
  • Page 40 23. When a CFH occurs, a 24 VAC signal is sent to the CFH light on the status panel located on the lower left front of the control compartment. 24. Power is also sent from pin 2 of the stage 1 con- nection to pin P1-3 of the universal diagnostic board.
  • Page 41 49. When power is sent to gas valve 1 it is also sent to time delay relay 1 (TD-1) which starts a 5-second countdown. 50. After the 5-second countdown from TD-1 and the internal contacts close, time delay relay 2 (TD-2 ) receives 24 VAC.
  • Page 42 Ignition Module When additional heat is needed, the combustion air blower starts to purge air from the combustion cham- ber for about 15 seconds. On proof-of-air flow, the air- Fig. 32: Ignition Module proving switch closes and the igniter is energized. To ensure safe operation, the gas valve cannot open until the igniter is verified.
  • Page 43 sheets supplied with your heater paperwork. See the General Safety Section for safety precautions con- cerning domestic hot water applications. Fig. 35: Operating Control Low Water Cut-Off (Optional) The low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe.
  • Page 44 Economaster II. It is an electronic device that allows the operator to set a variable time (3 to 10 minutes) for the pump to run after the boiler shuts off. See Fig. 40 (A) . The time is factory-set at 7 minutes and it can be re-adjusted in the field.

  • Page 45: 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- 20°F T Model P (ft)
  • Page 46 Common Venting System Manifolds that connect more than one boiler to a com- mon chimney must be engineered to handle the combined load. Consult available guides for proper sizing of the manifold and the chimney.
  • Page 47 Fig. 43: 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 48 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 49 Direct Vent - Vertical Requires optional vent tee if vented horizontally out back of heater. Certified Model Venting Material 992BE 1262BE 1532BE Category II 1802BE or IV 2002BE 2072BE 2342BE * 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.

  • Page 50: Wiring Diagrams

    Wiring Diagram—Models 992B–1262B...
  • Page 51 Wiring Diagram—Models 1532B–2342B...

  • Page 52: 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 53: 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 54: 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 55: Post Start-Up Check

    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.

  • Page 56: 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 57: Troubleshooting

    TROUBLESHOOTING Does the power switch provide power to the control panel? Step 1 Is there a Call For Step 2 Is Disable j um p er intact? ( J1 ) Do the combustion air Step 3 blowers come on? Step 4 Are the blower lights illuminated? Is 24VAC at PS on...

  • Page 58: 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 59: 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). Monthly 1.

  • Page 60: Appendix

    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 61: Warranties

    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 62 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 63 START-UP CHECKLIST FOR FAN-ASSISTED This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct.
  • Page 64 NOTES: _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________...
  • Page 65 NOTES: _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________...
  • Page 66 NOTES: _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________...
  • Page 68 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

This manual is also suitable for:

Hi delta 2342bHi delta 992bHi delta 1262bHi delta 1532bHi delta 1802bHi delta 2002b ... Show all

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