Rheem Raypak Hi Delta 302C Installation And Operation Manual
Cold water start & cold water run
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INSTALLATION AND OPERATION
Cold Water Start & Cold Water Run
For Hi Delta, MVB & Raytherm Heaters & Boilers
IMPORTANT SAFETY INSTRUCTIONS. READ AND FOLLOW ALL
INSTRUCTION. SAVE THESE INSTRUCTIONS.
NOTE: The instructions in this manual are for the use of qualified individuals specially trained
and experienced in the installation and maintenance of this type of equipment and related system
components. Installation and service personnel are required by some states to be licensed. Persons
not qualified shall not attempt to install, service, or maintain this equipment.
This manual should be maintained in legible condition and kept adjacent to the variable speed pump or in a safe
place for future use.
MANUAL
Effective: 03-05-21
Replaces: 02-27-13
P/N 241275 Rev. 11
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Table of Contents
Troubleshooting
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Summary of Contents for Rheem Raypak Hi Delta 302C
- Page 1 INSTALLATION AND OPERATION MANUAL Cold Water Start & Cold Water Run For Hi Delta, MVB & Raytherm Heaters & Boilers IMPORTANT SAFETY INSTRUCTIONS. READ AND FOLLOW ALL INSTRUCTION. SAVE THESE INSTRUCTIONS. NOTE: The instructions in this manual are for the use of qualified individuals specially trained and experienced in the installation and maintenance of this type of equipment and related system components.
- Page 2 Revision 11 reflects the following changes: Reformatted document to InDesign. Two introductory paragraphs added to section "Cold Water Start" on page 5. Caution revised on page 5. Revised first note on page 9. Figure 12 revised on page 9. Caution revised on page 9. Figure 21 revised on page 21. Obsolete text and figures relating to Elodrive removed.
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Page 3: Table Of Contents
CONTENTS 1. WARNINGS ............4 Connecting the CWS Control to the Multi-Boiler Interlock Box ..........16 Pay Attention to these Terms ........4 Connecting the Boiler to the CWS Multi-Boiler 2. GENERAL SAFETY ..........5 Interlock ............16 Time/Temperature Relationships in Scalds ..... 5 Actuator to Valve Orientation ........ -
Page 4: Warnings
1. WARNINGS Pay Attention to these Terms Indicates the presence of immediate hazards which will cause severe personal injury, death or DANGER substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, WARNING death or substantial property damage if ignored. -
Page 5: General Safety
2. GENERAL SAFETY Time/Temperature Relationships in Scalds To meet commercial hot water use needs, the high-limit safety control on this water heater is adjustable up to The following chart details the relationship of water 210°F (99°C). However, water temperatures over 125°F temperature and time with regard to scald injury and (51.7°C) can cause instant severe burns or death from may be used as a guide in determining the safest water... -
Page 6: Installation
Before beginning the installation, it’s important to first Mounting the Control Box inspect the system and determine what materials you will The control box should be mounted on the side of the need. Some parts are included with the controller while heater to which the system piping and valve assembly are others you will need to provide. - Page 7 VALVE ACTUATOR 11-1/8" (283 mm) THREE-WAY VALVE CONTROL BOX MTG PANEL CONTROL 1" (51 mm) LEFT SIDE FRONT OF HEATER 10-5/16" (262 mm) Figure 6. Component Locations—Raytherm Models Models 926–1826 302C-902C 7ʺ (178 mm) 2ʺ (51 mm 1-9/16ʺ (40 mm) 992C-2342C 13-1/4ʺ...
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Page 8: Connecting Power To The Controller
4. If the control is operating properly, the “START UP MODE” LED should go out in less than 7-minutes. At this point, the inlet water temperature should be stable at a temperature between 105°F (40.5ºC) and 120°F (48.9ºC) corresponding to the Setpoint 9-9/16"... -
Page 9: Cold Start Sequence Of Operation
14. Once the NO contacts of the DPST close, the heater NOTE: The minimum inlet water temperature to the 24VAC is sent back to the heater to complete the heater to prevent condensate is 105°F (40.5ºC) on heaters circuit (pin 3 of terminal block 3) and the interlock with an efficiency of 85% or less, and 120°F (48.9ºC) on circuit (pin 1 &... -
Page 10: Troubleshooting
Troubleshooting Check your power source using a Volt-Ohm meter; check the following voltages at TB1 terminal block: TB1-1 to TB1-2 = 108VAC Minimum, 132VAC Maximum TB1-1 to TB1-3 = 108VAC Minimum, 132VAC Maximum TB1-2 to TB1-3 = Must be less than 0.6VAC IF CALL FOR HEAT LED does not illuminate when the heater has a CFH signal, check for 24VAC between pins 4 and 5 of TB3 on the cold start control. -
Page 11: Installing The Three-Way Valve
Installing the Three-Way Valve When threading any pipe into the ports of the three-way valve, a backing wrench MUST be employed. You must PORT AB capture the valve body with a secondary wrench to avoid damaging the internal seals. Valve bodies leaking from improper installation are non-warrantable. -
Page 12: Cold Water Start Troubleshooting Guide
Cold Water Start Troubleshooting Guide Does TB1 of cold start Verify 120VAC at separate controller have 120 circuit breaker and correct. VAC? Step 1 Is there a Call For Heat at the heater? Heater is in standby mode Step 2 Are the 120/24VAC Correct wiring to transformer and 120VAC-... -
Page 13: Typical Cold Water Start Piping
Typical Cold Water Start Piping... -
Page 14: Wiring Diagrams-Cold Water Start
Wiring Diagrams–Cold Water Start... -
Page 15: Heater Interface Wiring
Heater Interface Wiring HEATER INTERFACE WIRING FOR CWS OR CWR CWS/CWR CONTROL OR MULTIPLE BOILER INTERFACE CWS/CWR CONTROL OR MULTIPLE BOILER INTERFACE CWS/CWR CONTROL OR MULTIPLE BOILER INTERFACE... -
Page 16: Cold Water Start-Multiple Boiler
way valve be installed as near the main system piping as 4. COLD WATER START- is feasible. Route control wiring in separate conduit to the MULTIPLE BOILER Cold Water Start control box and wire as shown in the diagram on page 19. (Maximum 4 Boilers) Materials Included Connecting Power to the Controller... -
Page 17: Three-Way Valve Ball Orientation
up as shown in Figure 16. Doing so will allow water and debris to collect in the cup where the wiring exits the actuator, potentially causing damage. Three-Way Valve Ball Orientation The ball orientation must be verified prior to mounting the flanged valve into the piping system. -
Page 18: Typical Cold Water Start Multiple Boiler Piping
Typical Cold Water Start Multiple Boiler Piping... -
Page 19: Wiring Diagram
Wiring Diagram Multiple Boiler... -
Page 20: Cold Water Run
5. COLD WATER RUN FROM SYSTEM NOTE: After testing at the factory it may be prudent to ship the piping assembly disassembled and attached to the heater pallet. This is done to avoid shipping damage and it must be reassembled on the jobsite. Use Figure 21 to assist you in reassembling the piping. -
Page 21: Injector & Heater Pump Comparison
Injector & Heater Pump Comparison Heater Pump Injector Pump Heater Flow Temp. Rise Press. Drop Pump Model/ Flow Temp. Rise Pump Model GPM (lpm) ºF (ºC) Ft. hd. (kPa) Imp. GPM (lpm) ºF (ºC) Model-HP 302C 32 (121.1) 16 (8.9) 2 (6.0) 13 (49.2) 40 (22.2) - Page 22 Heater Pump Injector Pump Heater Flow Temp. Rise Press. Drop Pump Model/ Flow Temp. Rise Pump Model GPM (lpm) ºF (ºC) Ft. hd. (kPa) Imp. GPM (lpm) ºF (ºC) Model-HP 926/962 79 (299.0) 20 (11.1) 8.5 (25.4) 1630/4.7 50 (189.3) 32 (17.8) 1911-1⁄4 1083/1125...
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Page 23: Check The Power Source
Check the Power Source WARNING: Using a multi-meter, check the following voltages at the circuit breaker panel prior to connecting any equipment. Make sure proper polarity is followed and house ground is proven. Check the power source: • AC = 104VAC Minimum, 126VAC MAX •... -
Page 24: Injection Pump Cover Installation
In order to install the pump cover, you will need to rotate the pump body so that the electrical box is pointing downward, as outlined in the following steps: 1. Loosen and remove the eight (8) 9/16" bolts holding the pump body in place. See Figure 27. Figure 25. - Page 25 Figure 31. Place the cover on the pump Figure 29. Be sure not to damage the seal when removing or replacing the pump body Figure 32. Pump cover - angle view Figure 30. Reposition the pump body so that the electrical box points downward 3.
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Page 26: Typical Cold Water Run Piping - Heating Apps
Typical Cold Water Run Piping - Heating Apps NOTES: LOCATE UNIONS TO FACILITATE SERVICING OF PLUMBING SIDE. PLUMB SWING CHECK VALVE IN GRAVITY-CLOSED POSITION. PIPE ALL RELIEF VALVES TO DRAIN, OR AS LOCAL CODES REQUIRE. SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES. ALTERNATE SENSOR POSITION 12”... -
Page 27: Operation
14. Pin FR on the TVC board outputs 10VDC to pin O Operation of the Inverter to drive injector pump at full speed for • Run full system flow for 2-minutes. 2-minutes waiting for the heater to reach full fire. •... -
Page 28: Cold Water Run Troubleshooting Guide
Cold Water Run Troubleshooting Guide *NOTE: See wiring diagrams for proper supply voltage based on inverter used on heater. Does TB1 of cold run Verify 120VAC* or 230VAC* controller have 120VAC* from separate circuit breaker or 230VAC*? Step 1 Is there a Call For Heat at the heater? Heater is in standby mode Is the inverter in the... -
Page 29: Wiring Diagrams
Wiring Diagrams Cold Water Run... -
Page 30: Replacement Parts
6. REPLACEMENT PARTS To order replacement parts, consult the Raypak Illustrated Parts Lists on the following pages. NOTE: To receive the correct part, it is important that you state the model number and serial number when ordering. Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to the Company freight... -
Page 31: Illustrated Parts Lists
7. ILLUSTRATED PARTS LISTS Cold Water Start Manufactured from 2006 through current. - Page 32 Cold Water Start...
- Page 33 Cold Water Start Multiple Boiler Interlock...
- Page 34 NOTE: Sizing is specific to the application.
- Page 35 Cold Water Run Manufactured 2006 thru current, except: 302B and 402B thru 5-31-2015. MVB MODELS ONLY 10-C 10-C...
- Page 36 Cold Water Run RAYTHERM MODELS 2100-4001 ONLY 12-M 11-M 10-M...
- Page 37 NOTE: Sizing is specific to the application.
- Page 38 NOTES...
- Page 39 NOTES...
- Page 40 ISO 9001 REGISTERED QUALITY MANAGEMENT SYSTEM Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 www.raypak.com...