Raypak HI DELTA 122-322 Installation & Operating Instructions Manual
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Raypak HI DELTA 122-322 Installation & Operating Instructions Manual

Types h, wh & p hi delta
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INSTALLATION & OPERATING
Models
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 combustible 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. 1000.53H
INSTRUCTIONS
122–322
Effective: 09-19-08
L
W
.
Replaces: 11-16-07
P/N 241112 Rev. 9

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Summary of Contents for Raypak HI DELTA 122-322

  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 122–322 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 combustible materials in the vicinity of this or any other appliance.
  • Page 2 Rev. 9 reflects the following: Changes to: The text in the BEFORE INSTALLATION section on page 5; the text in paragraph one of the GENERAL SAFETY section on page 8; the text in paragraph one of the Outdoor Installations section on page 10;...

  • Page 3: Table Of Contents

    WARNINGS Pay Attention to These Terms BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information Time/Temperature Relationships in Scalds 8 GENERAL SAFETY Clearances Equipment Base INSTALLATION Installation Codes Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Domestic Hot Water Piping...

  • Page 4: Warnings

    WARNINGS - Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal 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 your local Raypak representative or visit our website at www.raypak.com. 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 FLUE EXHAUST PRESSURE RELIEF CONNECTION WATER OUTLET HI LIMITS HI-LIMITS Fig. 1: Component Locations—Back Fig. 2: Component Locations—Left Side Panels removed for clarity Fig. 3: Component Locations—Front COMBUSTION AIR INTAKE GAS CONNECTION WATER INLET VIEW PORT Fig# 9399...

  • Page 7: General Information

    General Information Quantity of Model Burners Gas Valves Blowers *Second valve located inside air plenum Table A: Basic Data Burners per Valve Model Table B: Manifold Data Fig. 4: Gas Valve Detail Vent Size (in.) Flue Intake Stages % Fire at Stage Fig.

  • Page 8: Time/Temperature Relationships In Scalds

    GENERAL SAFETY To meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 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: Clearances

    The temperature of the water in the heater can be reg- ulated by using the temperature control. To comply with safety regulations, the temperature control is set at the lowest setting when shipped from the factory. To adjust the water temperature, insert a small straight screwdriver into the adjustment screw on the front of temperature control and turn the wheel to the desired setting (See Fig.

  • Page 10: Outdoor Installations

    TOP VIEW Fig. 7: Minimum Clearances from Combustible Surfaces—Indoor Installations When installed according to the listed minimum clear- ances from combustible construction, these heaters can still be serviced without removing permanent structural construction around the heater. However, for ease of servicing, we recommend a clearance of at least 24 in.

  • Page 11: 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 12: Water Piping

    Btu per hr (11 cm per kW) of total input rating of all equipment in the enclosure. 2. One permanent opening, commencing within 12 in. (30 cm) of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 in.

  • Page 13: Hydronic Heating

    In order to ensure proper performance of your boiler system, you must install a properly sized pump. Raypak recommends using a 20°F Delta T as design Delta T. (Delta T is the temperature difference between the inlet and outlet water when the heater is firing at full rate).
  • Page 14 EC '!'$ Fig. 9: Single Boiler—Low Temperature Application (Heat Pump) Primary/Secondary Piping ig. #M8336 rev 0 Fig. 10: Dual Boiler—Primary/Secondary Piping...

  • Page 15: Domestic Hot Water Piping

    Valves designed to blend water temperatures or reduce water circulation through the boiler should not be used. Raypak boilers are high recovery low mass boilers not subject to thermal shock. Raypak offers a full line of electric sequencers that produce direct reset of boiler water temperature.
  • Page 16 Fig. 11: Single Heater—Domestic Hot Water with One Storage Tank...

  • Page 17: Pool Heating

    Pool Heating 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 MANUAL SHUT OFF VALVE FLOW SUPPLIED BY OTHERS SEDIMENT TRAP EXTENTS OF UNIT ENCLOSURE TO BURNERS Gas Supply Connection CAUTION: The heater and its manual shutoff valve must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 PSIG (3.45 kPa).

  • Page 19: Electrical Power Connections

    Electrical Power Connections Installations must follow these codes: · National Electrical Code and any other national, state, provincial or local codes or regulations hav- ing jurisdiction · Safety wiring must be N.E.C. Class 1 · Heater must be electrically grounded as required by N.E.C.
  • Page 20 Electrical Connections—Domestic Hot Water DANGER—SHOCK HAZARD: electrical power to the heater is disconnected to avoid potential serious injury or damage to components. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

  • Page 21: Venting

    SINGLE STAGE TANKSTAT STAGE 1 CONNECTION ATTACH STAGE 1 CONNECTIONS ON HEATER TO THE SINGLE STAGE TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE. Fig. 15: Single Stage Tankstat 2-STAGE TANKSTAT STAGE 2 CONNECTION OR STAGE 1 STAGE 1 CONNECTION CONNECTION ATTACH STAGE 1 CONNECTIONS ON HEATER TO STAGE 1 CONNECTION ON TANKSTAT.
  • Page 22 Combustion Air Exhaust Supply Configuration Vertical Natural Draft Venting From Inside Building (Non-Direct Horizontal Venting) Thru-wall Venting Vertical Venting From Outside Building (Direct Horizontal Venting) Thru-wall Venting *As defined in the latest edition of the NFGC, or in Canada, the B149. Barometric Damper A barometric damper may be required when vent heights exceed 25 feet or when the draft is greater...
  • Page 23 Fig. 17: 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 24 over an area where condensate or vapor could create a nuisance or hazard or could be detrimen- tal to the operation of regulators, relief valves, or other equipment. Where local experience indi- cates that condensate is a problem with Category I and III appliances, this provision shall also apply.

  • Page 25: Venting Installation Tips

    Venting Installation Tips Support piping: · horizontal runs- at least every five (5) feet. · vertical runs - use braces: · under or near elbows Follow items listed below to avoid personal injury or property damage. · Cut nonmetallic intake pipe with fine-toothed hack- saw.
  • Page 26 Natural Draft Vertical Venting System Installation Natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The neg- ative draft must be within the range of -.01 in. to -.08 in.
  • Page 27 COMBUSTION AIR FILTER BOILER UNIT Fig. 19: Horizontal Thru-Wall Venting (Category III) each appliance. Adjust thermostat so appliance will operate continuously. e) Check the pressure at a pressure tap located 12 in. above the bottom joint of the first vertical vent pipe.
  • Page 28 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.
  • Page 29 INTAKE VENT COMBUSTION AIR FILTER BOILER UNIT Fig. 20: Direct Vent Horizontal Thru-Wall Venting (Category III) Certified Model Appliance Venting Category Material Stainless Steel (Gas Tight) VENT PIPE Max. Combustion Vent Size Venting Air Intake (inches) Length (feet) Galvanized Subtract 10 ft per elbow, Max.
  • Page 30 Horizontal Thru-wall Direct Vent System (Category III) Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent com- bustion products to the outdoors. The total length of the thru-wall exhaust vent cannot exceed forty (40) feet in length for the flue outlet. Each elbow used is equal to ten (10) feet of straight pipe.
  • Page 31 12" MIN. INTAKE VENT COMBUSTION AIR FILTER BOILER UNIT Fig. 21: Direct Vent—Vertical Venting (Category I) Certified Model Appliance Venting Category Material Type B Equivalent 36" VENT CAP VENT PIPE Min./Max. Combustion Vertical Vent Size Air Intake Venting (inches) Pipe Height Material (feet)

  • Page 32: Outdoor Installation

    Vertical Direct Vent System Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The negative draft must be within the range of -0.01 to -0.08 in.

  • Page 33: High Limit (Manual Reset)

    CONTROLS WARNING: Installation, adjustment and service of heater controls including timing of various operating functions must be performed by a qualified installer, service agency or the gas supplier. Failure to do so may result in control damage, heater malfunction, property damage, personal injury, or death. WARNING: Turn off the power to the heater before installation, adjustment or service of the heater controls.

  • Page 34: Low Water Cut Off (Optional)

    Flow Switch Dual-purpose control shuts off heater in case of pump failure or low water flow. Mounted and wired in series with the main gas valve. Check with Manufacturer for proper paddle size. Utilize correct paddle size for prop- er operation. NOTE: Flow switch will not operate if flow is less than 20 gpm.

  • Page 35: Wiring Diagram-Models 122-322

    WIRING DIAGRAM—MODELS 122–322...

  • Page 36: Pre-Start-Up

    PRE-START-UP Filling System-Heating Heaters Fill system with water. Purge all air from the system using purge valve sequence. After system is purged of air, lower system pressure. Open valves for normal system operation, fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent.

  • Page 37: Start-Up

    WARNING: If Common - Ground is > 1 VAC, STOP: Contact electrician to correct ground failure. Failure to do this may burn out 120V-24V transformer, or may cause other safety control damage or failure. Attach Manometers to Measure Pressures • Attach 24"...
  • Page 38 Follow-Up • Safety checks must be recorded as performed. • Turn unit on. After main burner ignition: • Check Manometer for proper reading. • Cycle unit several times and recheck readings • Re-analyze with unit running record or print results. •...

  • Page 39: Suggested Minimum Maintenance Schedule

    8. Turn on all electric power to the appliance. 9. Set thermostat to desired setting. The appliance will operate. The igniter will glow after the pre- purge time delay (15 seconds). After igniter reaches temperature (45 seconds) the main valve will open.
  • Page 40 Monthly: 1. Check for piping leaks around circulators, mixing valves, relief valves, and other fittings. If found, repair at once. DO NOT use petroleum-based stop leak compounds. 2. Visually inspect burner flame. 3. Visually inspect venting system for proper func- tion, deterioration or leakage.
  • Page 41 SCOPE: Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this boiler 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 44 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

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