Table of Contents
Advertisement
OPERATING AND
INSTALLATION
INSTRUCTIONS
Models 122-322
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 this manual. 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 heater or
in a safe place for future reference.
CATALOG NO. 1000.53F
Effective:
03-01-05
Replaces: 10-01-03
P/N 241112
Advertisement
Table of Contents
Related Manuals for Raypak 122-322
Summary of Contents for Raypak 122-322
-
Page 1: Installation Instructions
OPERATING AND INSTALLATION INSTRUCTIONS Models 122-322 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. -
Page 2: Table Of Contents
TABLE OF CONTENTS PAGE SECTION A: SECTION B: SECTION C: SECTION D: SECTION E: SECTION F: SECTION G: SECTION H: SECTION I: SECTION J: SECTION K: SECTION L: SECTION M: SECTION N: SECTION O: SECTION P: SECTION Q: APPENDIX A: COMBUSTION AIR CONTAMINATION ILLUSTRATED PARTS LIST WARRANTY BEFORE INSTALLING THE HEATER... - Page 3 Make sure the gas on which the heater will operate is the same type as that specified DANGER: on the heater 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 heater.
-
Page 4: Section A
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 • Gas Water Heaters, ANSI Z21.10.3 • CSA 4.3 - latest edition All Raypak heaters are National Board Approved, design certified and tested by the CSA International for U.S.A. and Canada. Each heater is constructed in accordance with Section IV of the American Society of Mechanical Engineers (ASME) Heater Pressure Vessel Code and bears the ASME stamp.
- Page 6 HI DELTA COMPONENT LOCATION BACK LEFT-SIDE (See detail page 7) (See detail page 7) FRONT...
-
Page 7: General Information
General Information Gas Valve Detail Air Shutter Adjustment... -
Page 8: Section B
SECTION B: HEATER INSTALLATION INSTALLATION CODES Installations must follow these codes: · Local, state, provincial, and national codes, laws, regulations and ordinances. · National Fuel Gas Code, ANSI Z223.1- latest edition (NFGC). · National Electrical Code, ANSI/NFPA 70 - latest edition (NEC). ·... - Page 9 When installed according to the listed minimum clearances from combustible construction materials, the Raypak 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 front, and at least 18” on the water connection side.
- Page 10 OUTDOOR INSTALLATIONS Raypak Hi Delta Heaters are design certified for outdoor installation. Heaters must not be installed under an overhang that is less than three (3) feet from the top of the heater. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from heaters installed under overhangs.
-
Page 11: Section C
SECTION C: COMBUSTION AND VENTILATION AIR COMBUSTION AND VENTILATION AIR (Indoor Units) The heater must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation. Combustion air can be supplied via conventional venting, where combustion air is drawn from the area immedi- ately surrounding the heater, or via direct vent, where combustion air is drawn directly from outside. - Page 12 COMBUSTION AND VENTILATION AIR SUPPLY (FOR CANADA INSTALLATION) CAUTION: All combustion air has to be drawn from the air outside the building (the mechanical equipment room directly communicates with the outdoors). Ventilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors.
-
Page 13: Section D
HYDROSTATIC TEST Unlike many other types of heaters, Raypak heaters do not require hydrostatic testing prior to being placed in operation. The heat exchanger has already been factory-tested and is rated for 160 PSI maximum operating pressure. However, Raypak does recommend hydrostatically testing the piping connections to the heater and the rest of the system prior to operation. -
Page 14: Section E
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. Refer to the Controls Section in our Complete Catalog. - Page 15 SINGLE BOILER - LOW TEMPERATURE APPLICATION (HEAT PUMP) PRIMARY/SECONDARY PIPING DUAL BOILER PRIMARY/SECONDARY PIPING...
-
Page 16: Section F
System head loss is based on the heater and tank placed no more than 5 feet apart and 25 feet equivalent length of pipe and fittings. TABLE F-1 DOMESTIC WATER HEATER FLOW RATE REQUIREMENTS P = Pressure Drop Ft. thru heat exchanger SHL = System Head Loss, Ft. - Page 17 SINGLE HEATER DOMESTIC HOT WATER WITH ONE STORAGE TANK...
-
Page 18: Section G
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 19: Section H
SECTION H: GAS SUPPLY CONNECTIONS DANGER: Make sure the gas on which the heater will operate is the same type as specified on the heater model and rating plate. Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. - Page 20 GAS PRESSURE REGULATOR The gas valve pressure regulator(s) on the heater 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
SECTION I: ELECTRICAL POWER CONNECTIONS Installations must follow these codes: · National Electrical Code and any other national, state, provincial or local codes or regulations having jurisdiction · Safety wiring must be N.E.C. Class 1 · Heater must be electrically grounded as required by N.E.C. ·... - Page 22 MAKING THE ELECTRICAL CONNECTIONS Refer to Fig. #9403 Wiring Connection, and Wiring Diagram #152564. Verify circuit breaker is properly sized by referring to heater rating plate. A dedicated circuit breaker should be provided. Turn off all power to the heater. 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 ELECTRICAL CONNECTIONS - DOMESTIC HOT WATER CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. DANGER - SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components.
-
Page 24: Section J
SECTION J: VENTING CONNECTIONS GENERAL CAUTION: Proper installation of flue exhaust venting is critical for the safe and efficient operation of the heater. Definition of Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. - Page 25 Category Determination for Venting Purpose and Venting Arrangement...
- Page 26 Support of Vent Stack The weight of the vent stack or chimney must not rest on the heater vent connection. Support must be provided in compliance with applicable codes. The vent should also be supported to maintain proper clearances from combustible materials.
-
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 SECTION J-1 Natural Draft Vertical Venting (Category I) NATURAL DRAFT VERTICAL VENT NOTE: **Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the NFGC for further details. (ANSI Z223.1)
- Page 29 • 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 negative draft must be within the range of -.01” to -.08” W.C. as measured 12 in. from the appliance flue outlet to ensure proper operation.
- 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 SECTION J-2 Horizontal Thru-Wall Venting (Category III) Fig # 9402 HORIZONTAL THRU-WALL VENTING (CATEGORY III) TABLE • Horizontal Thru-wall Venting System (Category III) Installation These installations utilize the heater-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 outdoors.
- Page 32 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.
- Page 33 SECTION J-3 DIRECT VENT Horizontal Thru-wall Venting (Category III) HORIZONTAL THRU-WALL VENTING TABLE...
- Page 34 • Horizontal Thru-wall Direct Vent System (Category III) Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent combustion 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 35 SECTION J-4 DIRECT VENT Vertical Venting (Category I) VERTICAL VENTING TABLE...
- Page 36 • 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”...
- Page 37 SECTION J-5 Outdoor Installation 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 heater in accordance with CSA requirements. It must be installed directly on the heater.
-
Page 38: Section K
SECTION K: 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 39 IGNITION CONTROL MODULE The interrupted proved ignition device conserves energy. When additional heat is needed, the combustion air blower starts to purge all air from the combustion chamber for about 15 seconds. On proof of air flow, the air proving switch closes and the igniter is energized, eliminating the fuel costs of maintaining a constant pilot.
- Page 40 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. A 3-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Drw.
-
Page 42: Section L
TIME/TEMPERATURE RELATIONSHIPS IN SCALDS The temperature of the water in the hot water heater 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 heater was shipped from the factory. -
Page 43: Section M
SECTION M: 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 44: Section N
SECTION N: INITIAL START-UP TOOLS NEEDED • One 12-0-12, 24” scale manometer • Two 6-0-6, 12” scale manometers • 7/16” open end wrench • 1/2” open end wrench • Screwdriver • Volt meter • 3/16” Allen wrench PREPARATION FOR START-UP WARNING: DO NOT TURN ON GAS AT THIS TIME Check Power Supply... - Page 45 3.0 START-UP 3.1 Blower Adjustment Disconnect fan pressure switch tubing at plenum and connect manometer using a tee. Close all manual firing valves. Turn power on; Check manometers attached to fan pressure switch. The readings should be : .5 + .1” W.C. for models 102 and 122 .7 + .1”...
-
Page 46: Section O
SECTION O: POST START-UP CHECK Check off steps as completed: Heater and heat distribution units or storage tank filled with water? Automatic air vent, if used, open two full turns during venting procedure? Air purged from system? Air purged from gas piping? Piping checked for leaks? Followed start-up procedure for proper start-up? Is burner flame visible? Test safety controls: If heater is equipped with a low water cut-off or additional safety controls, test for operation as... -
Page 47: Section P
SECTION P: OPERATION OPERATING INSTRUCTIONS Lighting Instructions STOP! Read the safety information first. Set the thermostat to the lowest setting. Turn off all electric power to the appliance. This appliance is equipped with an ignition device which automatically lights the burner. Do Not try to light the burner by hand. -
Page 48: Section Q
SECTION Q: MAINTENANCE SUGGESTED MINIMUM MAINTENANCE SCHEDULE: Regular service by a qualified service agency and maintenance must be performed to ensure maximum heater 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 49 APPENDIX A INSIDE COMBUSTION AIR CONTAMINATION: All heaters experience some condensation during start-up. The condensate from flue gas is slightly acidic. In most cases the pH level is not harmful to vents or drains. When combustion air is contaminated by vapors from products in areas listed below, the acidic levels in the condensate increase. Higher acidic levels attack many materials, including stainless steel commonly used in high efficiency systems.
- Page 50 Fig # 241093...
- Page 51 HEAT EXCHANGER DETAIL...
-
Page 55: Warranty
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 Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (805) 278-5300 Fax (800) 872-9725 • • (905) 677-7999 Fax (905) 677-8036 • • Litho in U. S. A.