Raypak HI DELTA HD101 Installation & Operating Instructions Manual
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Raypak HI DELTA HD101 Installation & Operating Instructions Manual

H & wh series
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INSTALLATION & OPERATING
Models
HD101–HD401
Types H & WH
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. 1000.52
INSTRUCTIONS
®
Effective: 06-11-09
L
W
.
Replaces: NEW
P/N 241356 Rev. 1

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  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models HD101–HD401 Types H & WH 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 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 GENERAL SAFETY Time/Temperature Relationships in Scalds 8 INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating...

  • Page 4: Warnings

    WARNINGS — 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 Fig. 1: Component Locations — Angle View Fig. 2: Component Locations — Left Side Fig. 3: Component Locations — Front (Panels removed for clarity)

  • Page 7: General Information

    General Information Model Quantity of Burners HD101 HD151 HD201 HD251 HD301 HD401 Table A: Basic Data Vent Size (in.) Flue Intake Fig. 4: Air Shutter Adjustment Fig. 5: Gas Valves...

  • Page 8: General Safety

    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.

  • Page 9: Installation

    The temperature of the water in the heater can be reg- ulated by using the optional temperature control. To comply with safety regulations, the optional tempera- ture control will be 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...

  • Page 10: Outdoor Installations

    TOP VIEW Fig. 7: Minimum Installed Service Clearances — Indoor/Closet Installations CAUTION: Service clearances less than the minimums may require removal of the heater to service either the heat exchanger or the burners. The heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater.

  • 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 non-operating hours.

  • Page 12: Water Piping

    a. Where directly communicating with the out- doors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in. 4000 BTUH (5.5 cm per kW) of total input rat- ing of all equipment in the enclosure. b.

  • Page 13: Relief Valve Piping

    Reversing Water Connections Follow these instructions to change the water connec- tions from the left-hand side (standard) to the right-hand side. 1. Disconnect all electrical power from the heater (if applicable). 2. Label all electrical connections and conduit lines. This may include the flow switch, low water cut-off probe and/or pump.

  • Page 14: 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 ΔT as design ΔT. (ΔT is the temperature difference between the inlet and outlet water when the heater is firing at full rate).
  • Page 15 *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig. 10: Single Boiler — Low Temperature Application (Heat Pump) Primary/Secondary Piping *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig. 11: Dual Boiler—Primary/Secondary Piping...

  • Page 16: Three-Way Valves

    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 17: Gas Supply

    Fig. 12: Single Heater — Domestic Hot Water with One Storage Tank Gas Supply DANGER: Make sure the gas on which the heater will operate is the same type as specified on the heater’s rating plate. Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve locat- ed outside the heater jacket.

  • Page 18: Gas Supply Pressure

    CAUTION: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with gas systems is recommended. Apply sparingly only on male pipe ends. CAUTION: Support gas supply piping with hangers, not by the heater or its accessories. Ensure the gas piping is protected from physical damage and freezing where required.

  • 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 For operation with a Temp-Tracker controller, refer to Temp-Tracker Installation Instructions, Raypak Catalog number 5000.66 (P/N 241177). Consult the wiring diagram shipped with the heater in the instruction packet. The Stage 1 connections are for the remote tank control through the heaters 24 volt transformer.

  • Page 21: Venting

    Heater must be electrically grounded in accordance with NEC and C22.1(in Canada). NOTES: 1. Field installed ground to inside of junction box. 2. If any of the original wire as supplied with the heater must be replaced, it must be replaced with 105°C wire or its equivalent.

  • Page 22: Barometric Damper

    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 ances shall not terminate over public walkways or 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 –0.01 in. to –0.08 in.
  • Page 27 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. Pressure should be anywhere between -.01 to -.08 in.
  • Page 28 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 the space and the vent is installed horizontally through the wall to the outdoors. Adequate combustion and ventilation air must be sup- plied in accordance with the NFGC or, in Canada, the B149 Installation Code.
  • Page 29 Fig. 20: Direct Vent Horizontal Thru-Wall Venting (Category III) Certified Model Appliance Venting Category Material HD101 HD151 Stainless HD201 Steel HD251 (Gas Tight) HD301 HD401 Max. Combustion Vent Size Venting (inches) Length (feet) Galvanized 100, 4 Elbows Max. Table L: Horizontal Thru-Wall Venting Max.
  • Page 30 Fig. 21: Direct Vent—Vertical Venting (Category I) Certified Model Appliance Venting Category Material HD101 HD151 Type B HD201 Equivalent HD251 HD301 HD401 *Over 25 feet, use single acting barometric damper. Consult the factory for additional information. Min./Max. Vertical Vent Venting Height (feet) Size (inches) Min.

  • Page 31: 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 32: Controls

    The unit performs its own safety check. Fig. 22: Ignition Module Modulating Temperature Control (Optional) This heater can be equipped with a Raypak modulat- ing temperature control. For operation with this control, refer to the Temp-Tracker Installation and Operating Instructions, Raypak Catalog number 5000.66 (P/N 241177).

  • Page 33: Flow Switch

    The optional adjustable auto reset high limit is located behind the front panel (see Fig. 3). Adjust the setting to approx. 20°F (10°C) above desired outlet tempera- ture. Fig. 25: High Limit — Auto Reset (Optional) Flow Switch Dual-purpose control shuts off heater in case of pump failure or low water flow.

  • Page 34: Wiring Diagram-Models Hd101-Hd401

    WIRING DIAGRAM—MODELS HD101–HD401...

  • Page 35: Hd Troubleshooting

    Does the main power switch provide power to the green power LED? Step 1 Is Disable connection intact? Is there a Call For Heat? Step 2 Does the Pump come on? Step 3 Does the combustion air Step 4 blower come on? Is 24VAC at the NC side of Step 5 the air pressure switch?

  • 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 38: Start-Up

    Check the Gas Supply Pressure 1. Slowly turn on main gas shut-off valve. 2. Read the gas supply pressure from the manome- ter; minimum supply pressure is 4 in. WC, recommended supply is 7 in. WC for natural gas (minimum 11.0 in. WC for LP gas). 3.

  • Page 39: Gas Type Conversion On Valve

    3. Carefully remove 2-stage solenoid. 4. Skip to Step 9 for LO-fire adjustment only. 5. Locate and remove Lo-fire adjustment cap. 6. Carefully remove the spring & weight. 7. Using an allen wrench, turn clockwise to increase and counterclockwise to decrease the HI-fire man- ifold pressure.

  • Page 40: Follow-Up

    • Insert ignition control lockout tests as safety check. Follow-Up • Safety checks must be recorded as performed. • Turn unit on. After main burner ignition: • Check Manometer(s) for proper reading(s). • Cycle unit several times and recheck readings. •...

  • Page 41: Heat Exchanger Removal

    3. Remove the (4) screws holding the panel in place. Fig. 33: Remove the Screws and Panel 4. Pull the air filter out for inspection. Replace if nec- essary. Fig. 34: Inspect the Air Filter 5. When replacing, note the direction of the air flow defined on the side of the filter.

  • Page 42: Maintenance

    JACKET TOP REMOVAL ACCESS PANEL REMOVAL MAINTENANCE Suggested Minimum Maintenance Schedule: Regular service by a qualified service agency and maintenance must be performed to ensure maximum Fig. 35: Heat Exchanger Removal heater operating efficiency. Maintenance as outlined below may be performed by the owner. Yearly (Beginning of each heating season): 1.

  • Page 43: Appendix

    2. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal. 3. Visually inspect venting system for proper func- tion, deterioration or leakage. 4. Check that heater area is free from combustible materials, gasoline, and other flammable vapors and liquids.
  • Page 44 • hydrochloric acid/muriatic acid • cements and glues • antistatic fabric softeners used in clothes dryers • chloride-type bleaches, detergents, and cleaning solvents found in household laundry rooms • adhesives used to fasten building products • ... and other similar products. Areas causing contaminated combustion air: •...
  • Page 48 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:

Hd401Hd401Hd151Hd201Hd251Hd301

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