Raypak 992C Installation & Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Raypak Manuals
  4. Water Heater
  5. 992C
  6. Installation & operating instructions manual

Raypak 992C Installation & Operating Instructions Manual

Hi delta series 992c-2342c types h, wh & p
Hide thumbs
Table of Contents

Advertisement

Quick Links

INSTALLATION & OPERATING
Models
992C–2342C
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. 1000.512A
INSTRUCTIONS
Effective: 06-15-18
Replaces: 02-15-17
LLC
®
P/N 241664 Rev. 2

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 992C and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Raypak 992C

Summary of Contents for Raypak 992C

  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 992C–2342C 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 Revision 2 reflects the following changes: Removed California Proposition 65 warning on page 4.

  • Page 3: Table Of Contents

    BEFORE INSTALLATION Venting Installation Tips Product Receipt Venting Configurations Model Identification Sequence of Operation Ratings and Certifications Controls Installations at Elevation Wiring Diagrams 992C-1262C Component Locations Wiring Diagram 1532C-2342C START-UP General Information GENERAL SAFETY Pre Start-up Time/Temperature Relationships in Start-up...

  • 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

    Raypak representative. Standards: Thank you for purchasing a Raypak product. We hope • ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired you will be satisfied with the high quality and durability Hot Water Boilers 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 Vent Size (in.) Model Burners Blowers Flue Intake Valves 992C 2 + 1* 1262C 3 + 1* 1532C 1802C 2002C 2072C 2342C *Hidden solenoid valve located inside of air plenum. Table A: Basic Data Burners per Valve...

  • 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 page 47). optional stacking rack. A stacking kit (sales order option X-1) is available from Raypak for this type of For accurate control of water temperature, the sensors installation. For installations above grade, a reinforc- must be properly installed according with the piping ing kit (sales order option X-2) may also be required.
  • Page 10 Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening;...

  • Page 11: Clearances

    In addition, the heater shall be installed such that the When installed according to the listed minimum clear- gas ignition system components are protected from ances from combustible construction, these heaters water (dripping, spraying, rain, etc.) during appliance can still be serviced without removing permanent operation or service (circulator replacement, control structural construction around the heater.

  • Page 12: Combustion And Ventilation Air

    NOTE: In cold climates, and to mitigate potential drawn directly from outside. All installations must com- freeze-up, Raypak highly recommends the installa- ply with the requirements of the NFGC (U.S.) and tion of a motorized sealed damper to prevent the B149 (Canada), and all local codes.

  • Page 13: Conventional Combustion Air Supply

    TruSeal heater connection points are available as fol- lows: a. Where directly communicating with the out- doors or where communicating to the 992C to 1802C Left side – standard outdoors through vertical ducts, each opening Right side – optional shall have a minimum free area of 1 in.

  • Page 14: Water Piping

    b. Not less than the sum of the areas of all vent of not less than 1 in. for each 30,000 BTUH mm connectors in the confined space. per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere WARNING: Do not use one permanent opening with the intended purpose of the opening(s) for ventilation air referred to in (1).

  • Page 15: Relief Valve Piping

    The heat exchanger has already been fac- ples. tory-tested and is rated for 160 psi operating pressure. However, Raypak does recommend hydrostatic test- 7. Remove the eight flange nuts and the in/out head- ing of the piping connections to the heater and the rest er from the left-hand side.
  • Page 16 H models: MIX TYPE = PUMP CAUTION: Damage due to internal condensation may occur if the heater inlet water temperature does H models include a second option for individual Cold not exceed 105°F (41°C) within 7 minutes of start- Water Protection method (“PUMP”). MIX TYPE = up.

  • Page 17: Hydronic Heating

    Primary / Secondary piping to the system. arrangement is the method recommended and the only method supported by Raypak for installation of Hi See Fig. 13 as an example of a single heater applica- Delta equipment. Proper system design should tion.
  • Page 18 Hybrid sequencer (sales option B-36). Proper place- ment and method of installation are critical for proper Raypak recommends that a feedwater regulator be in- operation of the system. (See Fig. 7) The sensor must stalled and set at 12 psi minimum pressure at the be installed in a drywell in conjunction with heat con- highest point of the system.
  • Page 19 Catalog 5000.72. This manual can be found tank when operating temperatures above 150°F are in the document library at www.raypak.com. required. Care must be given to ensure water hard- ness is no more than 15 grains per gallon for scale S1 - Outlet Sensor free operation.

  • Page 20: Domestic Hot Water

    Mode 3 (Type H Units Only) This mode selection is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4) with indirect DHW on the boiler loop (with priority). The system temperature is con- trolled by the Supply sensor (S3) whenever the indirect call for heat is not active.
  • Page 21 Potable Water and Space Heating CAUTION: When this heater is used for both potable water and space heating, observe the following to ensure proper operation. 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water.

  • Page 22: Pool Heating

    Follow these instructions to make sure your ate to a pool application. heater is properly installed. All Raypak pool heaters are certified to ANSI Z21.56, NOTE: The recommended setting for the outlet which is the nationally recognized standard for swim- thermostat is 110°F.
  • Page 23 See Fig. 23 for the poolstat/sensor location. Install limit in supply to pool as shown in Fig. 22. For data on acceptable pool chemistry, see Table I. *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig. 24: Single Pool Heater - H-Bypass H-Bypass (Standard) Fig.
  • Page 24 Pool/Spa Water Chemistry generate a scale accumulation on the heat transfer surface that will greatly reduce the service life of a pool heater. This scale accumulation can also impede ade- NOTE: Chemical imbalance can cause severe quate flow of water and may totally block the water damage to your heater and associated equipment.

  • Page 25: Gas Supply

    Gas Supply CAUTION: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with natural DANGER: Make sure the gas on which the heater and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two will operate is the same type as specified on the heater’s rating plate.

  • Page 26: Electrical Power Connections

    2” 2-1/2” 3” 4” Model 992C 1262C 1532C 1802C 2002C 2072C 2342C Natural gas – 1,000 BTU per ft , .60 specific gravity at 0.5 in. WC pressure drop Propane gas (HD-5) – 2,500 BTU per ft , 1.53 specific gravity at 0.6 in. WC pressure drop...
  • Page 27 Making the Electrical Connections shipped with the heater in the instruction packet. Before starting the heater check to ensure proper volt- age to the heater and pump. Refer to Fig. 27-31. Install a separate disconnect means for each load. 1. Verify that circuit breaker is properly sized by Use appropriately sized wire as defined by NEC, CSA referring to heater rating plate.

  • Page 28: Field Wiring Connection

    Field Wiring Connection remote thermostat) across these terminals will enable the Hi Delta unit to run. Caution should be used to ensure neither of the terminals becomes connected to CAUTION: Label all wires prior to disconnection ground. when servicing controls. Wiring errors can cause im- proper and dangerous operation.
  • Page 29 “limp along” mode set than 4 connected boilers, an external sequencer PIM operator dial to be equal to DHW Target tem- such as the Raypak Temp Tracker Mod+ Hybrid perature to prevent an over temperature condition can be used.
  • Page 30 VERSA MASTER Fig. 34: Hi Delta Cascade System Wiring Cascade System Pump and Sensor Wiring 1. On the boiler designated as the Master, connect the system pump enable wiring to the terminal block at the rear of the unit. The connections are dry contacts rated for pilot duty only (5A maxi- mum).
  • Page 31 Fig. 36: Cascade Master Pumps Fig. 37: VERSA Follower Alarm Connection 5. Connect the Enable/Disable wiring to terminals 11 and 12 on the field wiring strip located on the Master boiler (See Fig. 33). This connection must An alarm annunciator or light may be connected to the be provided through dry contacts closure.

  • Page 32: Venting

    WARNING: Contact the manufacturer of the vent Model Diameter Order Number material if there is any question about the appliance categorization and suitability of a vent material for 992C 10” 011841 application on a Category III or IV vent system. 1262C, 1532C 12”...
  • Page 33 Vent Terminal Location 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. 1. Condensate can freeze on the vent cap. Frozen 10. DO NOT terminate above any door, window, or condensate on the vent cap can result in a blocked gravity air intake.

  • Page 34: Changing The Flue Outlet

    Changing the Flue Outlet 6. DO NOT terminate vent closer than 5 ft below roof overhang. The flue connection may be changed from the top to 7. The vent terminal requires a 12 in. vent terminal the rear of the heater using the optional flue exhaust clearance from the wall.

  • Page 35: Venting Configurations

    2 ft above the highest of the common vent be less than the area of the point of the roof that is within 8 ft. for Model 992C and largest heater exhaust outlet. 10 ft for all other models. The vent cap should have a...
  • Page 36 Certified Vertical Venting Height* Combustion Air Air Inlet Max. Length** Vent Model Venting Intake Pipe Size Min. Max. 10” 12” Material Material 992C 10” 1262C 75’ 100’ 12” 1532C Galvanized Steel, Category I*** PVC, 1802C (Type B 5’ 25’ ABS,...
  • Page 37 40’ of straight pipe and three elbows must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved The vent cap is not considered in the overall length of stainless steel flue direct vent cap MUST be used the venting system.
  • Page 38 Certified Maximum Combustion Air Air Inlet Max. Length* Model Vent Venting Equivalent Intake Pipe Size 10” 12” Material Vent Length* Material 992C 10” 1262C 75’ 100’ 70’ 12” Room Air 1532C Galvanized Steel, PVC, 1802C Category III 40’ ABS, Ducted...
  • Page 39 approved condensate trap must be installed per Combustion air supplied from outdoors must be free of applicable codes. particulate and chemical contaminants. To avoid a blocked flue condition, keep the vent cap clear of 2. The intake vent must be insulated through the snow, ice, leaves, debris, etc.

  • Page 40: Sequence Of Operation

    2 ft above the highest Install above grade level and above normal snow point of the roof within 8 ft. for Model 992C or 10 ft. for levels. all other models. The vent cap should have a minimum...
  • Page 41 The PIM confirms the presence of a valid ID Card 12. If no fault condition is found, the air pressure which matches the configuration stored in memory switch (if present) is verified to be in the open at the factory. If a valid ID Card is NOT present, position before the blower is energized.
  • Page 42 Models 1532C-2342C For systems with CWP enabled, the MIX out- put is released to its control point based on distance from Inlet temperature target. Upon initial application of 24VAC power, the PIM resets with all outputs in the “OFF” state. g.
  • Page 43 (1 or multiple) and proceeds to Pump Purge will post-purge and go into a hard lockout condi- mode. tion. 10. The VERSA IC Control will turn on the system, 22. The Hi Delta units are equipped with a Hot boiler and/or DHW pump as necessary to address Surface Igniter: the call-for-heat.

  • Page 44: Controls

    m. The configured heat-up delay takes place to and the LED on the PIM indicates the fault code for allow the HSI element to reach ignition tem- ignition lockout. The VERSA IC Display should also perature. state Ignition Lockout. Freeze Protection n.

  • Page 45: Flow Switch

    High Limit—Auto-Reset (Optional) RESET button located on the user interface. The con- trol will automatically reset after 1 hour. When in lock-out the control will run the blower through a post- This heater may be equipped with an optional adjust- purge cycle.
  • Page 46 Low Water Cut-Off (Optional) These safety devices can emit small amounts of fuel gas, and must be vented to a safe discharge location outdoors, per local code requirements. The low water cut-off (Sales option F-10) automatically shuts down the burner whenever water level drops Air Pressure Switch below the level of the sensing probe.

  • Page 47: User Interface

    User Interface Menu - Initial Adjustment To change settings use the MENU key to scroll to the The user interface consists of several Menu options. Press the MENU button to scroll through the different SETUP/ADJUST menu. The ADJUST menu allows menus in the interface.
  • Page 48 View Menu The “View” icon is turned on. BOILER and 1 segment are turned on if BOILER 2, 3 or 4 are set to ON. Item Display Range When is it Displayed Description MASTER Outdoor air temperature, the number field displays “----” if OUT- ---, -76 to 149ºF OUTDOOR PIM Identity is H...
  • Page 49 This adjustment is for various types and sizes of units as well as vari- H/WH/P MIX MIX TRIM -5ºF to 5ºF ous actuator motor speeds and types supplied by Raypak. FAST <> MED <> H/WH/P MIX MIX SPEED This setting defines speed of response.
  • Page 50 Identifies the unit as boiler, water heater or IDENTITY pool heater. IGN TYPE PIM Board type. ID CARD Identifies Raypak Identity Card. SW ID PIM Software identification number. ERROR CODE Current Error Code. Table Q: Boiler Menu * Fixed values based on ID card...
  • Page 51 Monitor Menu The Monitor Menu records and displays critical Boiler information, such as, Cycle times, Run times, and Maximum/Minimum temperature readings depending on the setup. Item Application Description RUN TIME Burner 1 Burner run time (hours). Press UP/DOWN for 1 sec to clear. Cycles Burner Number of burner cycles.
  • Page 52 MAX HEAT be set to OFF again by the user. (See VERSA IC Manual for details.) J1214I Software number of the Raypak VERSA Resets to factory settings. Press UP and DOWN for 1 second to show CLR and load DEFAULTS factory defaults to all settings. This will also clear all history.
  • Page 53 RESET RATIO (See Fig. 52) The control uses the four following settings to determine the reset ratio: Boiler Start (Boil START) The Boil START temperature is the theoretical boiler supply water temperature that the heating system requires when the outdoor air temperature equals the OUT START temperature setting.
  • Page 54 Wiring Diagram—Models 992C–1262C...

  • Page 55: Wiring Diagram 1532C-2342C

    Wiring Diagram—Models 1532C–2342C...

  • Page 56: Start-Up

    START-UP • Use only your hand to push in or turn the gas con- trol knob. Never use tools. If the knob will not turn by hand, do not try to repair it, call a qualified serv- Pre Start-up ice technician. Forced or attempted repair may result in a fire or explosion.

  • Page 57: Start-Up

    Start-Up Preparation Blower Adjustment WARNING: Do not turn on gas at this time. 1. Turn off power. Check Power Supply 2. Unplug cap at pressure switches and connect ma- With multi-meter at incoming power, check voltage nometer(s) to the tee. between: 3.

  • Page 58: Safety Inspection

    Safety Inspection Local Heat/DHW/EMS demands must be present • for burner operation. 1. Check all thermostats and high limit settings. Number Output Action Field 2. During the following safety checks leave manome- System Pump relay turns on. ters hooked up, check and record. DHW Pump relay turns on.
  • Page 59 2. Open test point A and connect a manometer to it. This completes leak testing for a single Hi Delta mani- Verify that there is gas pressure and that it is with- fold riser. Repeat steps 1-8 for each riser. in the proper range (NOTE: must not exceed 14.0 Post Start-Up Check in.

  • Page 60: Operation

    d. Wait 5 minutes. tion on the front cover of this manual. If you do not smell gas, go to next step. e. Reattach cap on tee. Burner should re-ignite after pre-purge time delay. 8. Turn on all electrical power to the appliance. 10.

  • Page 61: Maintenance

    MAINTENANCE 2. Visually inspect venting system for proper func- tion, deterioration or leakage. Suggested Minimum 3. Check that area is free from combustible materi- Maintenance Schedule als, gasoline, and other flammable vapors and liquids. Regular service by a qualified service agency and 4.
  • Page 62 Weekly 6. Perform leakage test on gas valves. (See Fig. 47.) 7. Test air switch in accordance with manufacturer’s For low-pressure heaters, test low-water cut-off instructions. (Turn panel switch to the “On” posi- device. (With at least one stage of the appliance on, tion until blower is proven, then turn the switch to depress the low water cut-off test button, appliance “Off”.

  • Page 63: Appendix

    APPENDIX • furniture refinishing areas and establishments • new building construction • remodeling areas Inside Air Contamination • open pit skimmers Check for areas and products listed above before in- All heaters experience some condensation during stalling heater. If found: start-up.

  • Page 64: 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 65 SCOPE OF WARRANTY Raypak, Inc. (Raypak) warrants to the original owner that the above model gas pool and spa heater (the “Heater”) when installed in the 50 states of the United States of America with a pool or spa by a properly licensed installer will be free from defects in materials and workmanship under normal use and service for the Applicable Warranty Period.
  • Page 66 Limited Warranty is VOID if the Heater is repaired or altered in any way by ANY persons or agencies other than those authorized by Raypak. Raypak reserves the right at all times to inspect, or require the return of, the defective Heater or component part and to verify warranty coverage at its factory.

  • Page 67: Start-Up Checklist

    RAYPAK PRODUCTS 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 68: Important Instructions For The Commonwealth Of Massachusetts

    Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance (b) EXEMPTIONS: The following equipment is exempt from with regulation 248 CMR 4.00 and 5.00 for installation of 248 CMR 5.08(2)(a)1 through 4: through – the – wall vented gas appliances as follows: 1.
  • Page 72 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:

1262c1532c2072c2342c1802c2002c

Table of Contents