Rheem Raypak Hi Delta H Series Installation & Operating Instructions Manual
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Rheem Raypak Hi Delta H Series Installation & Operating Instructions Manual

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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. 1000.512B
INSTRUCTIONS
Effective: 10-15-18
Replaces: 06-15-18
LLC
®
P/N 241664 Rev. 3

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  • 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 3 reflects the following changes: Updated the “Gas Supply Pressure” section on page 26. Updated the “Main Burner Adjustment” section on page 57.

  • Page 3: Table Of Contents

    CONTENTS WARNINGS Changing the Flue Outlet 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

    BEFORE INSTALLATION number will have the form H9-1262C or similar depending on the heater size and configuration. The letter(s) in the first group of characters identifies the Raypak strongly recommends that this manual be re- application (H = Hydronic Heating, WH = Domestic viewed thoroughly before installing your Hi Delta Hot Water, P = Pool).

  • 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 Stages % Fire at Stages Model...

  • 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

    Stacking The temperature of the water in the heater can be reg- ulated by adjusting the setpoint, this process is fully described in the manual in the “Controls” section (see Hi Delta units can be stacked two units high with an page 47).
  • 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

    1. Remove the four screws and the dust cover from the right-hand side of the heater. 2. Remove the four screws and the air filter bracket from the left-hand side of the heater. 3. Reverse the components and reattach in the new location, making sure that the air filter locking Front View bracket is on the bottom.

  • Page 13: Conventional Combustion Air Supply

    three or four sheet metal screws (not supplied) equal- space shall be considered in making this determina- ly distributed around the circumference of the duct. All tion. Each opening shall have a minimum free area of ducting should be self-supported. The filter housing is 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 Hydrostatic Test 5. Remove all plumbing fittings to the header. This will include both inlet and outlet water pipe unions and the pressure relief valve and drain piping. Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in 6.
  • 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

    Fig. 12: Low Temp Process - Open Loop: H model, Cascade with Storage Tank Hydronic Heating Cold Water Protection: WH models Direct DHW heating systems utilize a variable speed System Design pump arrangement (MIX TYPE = PUMP) to keep the heater inlet at or above 105°F (41°C). The integrated Hot water heating systems all have unique levels of VERSA IC control system provides functionality to operating diversity.
  • Page 18 20ºF∆T 30ºF∆T 39ºF∆T Min. Flow Max. Flow Model ∆P (ft) ∆P (ft) ∆P (ft) ∆P (ft) ∆T ∆P (ft) ∆T 992C 13.1 1262C 14.8 1532C 15.7 16.5 1802C 10.7 18.3 2002C 13.8 19.0 2072C 14.8 19.0 2342C 21.1 12.7 12.7 21.4 Notes: 1.
  • Page 19 Drywell Fitting System Thermal Sensor (S3) Paste Fig. 17: MODE 1 - Single Boiler with Primary/Secondary Piping Fig. 15: System Sensor Installation Mode 1 (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).

  • 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

    Soft* (3-4 grains per gallon) Medium (5-15 grains per gallon) Hard* (16+** grains per gallon) Model ∆T ∆P MTS SHL ∆T ∆P ∆T ∆P MTS SHL 992C 2½ 2½ 13.3 13.1 2½ 23.6 1262C 2½ 11.3 2½ 19.4 14.8 2½ 25.3 1532C 2½...
  • 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 Table J: Maximum Equivalent Pipe Length Gas Supply Pressure A minimum of 5.6 in.
  • 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 Wiring the Indirect Sensor 2. To enable this remote control function, set dip switch 5 to the UP position on the PIM. DIP switch 5 Toggles between an EMS (UP) signal or a 1. An indirect sensor connection is not required if an demand signal from the VERSA (DOWN).
  • 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

    Venting NOTE: For additional information on appliance categorization, see appropriate ANSI Z21 Standard CAUTION: Proper installation of flue venting is criti- and the NFGC (U.S.), or B149 (Canada), or cal for the safe and efficient operation of the heater. applicable provisions of local building codes. General CAUTION: When condensate traps are installed, condensate must be routed to an appropriate...
  • 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

    Venting Configurations 8’ OR LESS (MODEL 992B) 10’ OR LESS For heaters connected to gas vents or chimneys, vent (ALL OTHER MODELS) installations shall be in accordance with the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes. Natural Draft Vertical Venting (Category I, Fan Assisted) Installation...
  • Page 36 hoods and bathroom exhausts, at maximum- WARNING: Vent connectors serving appliances speed. Do not operate summer exhaust fan. Close vented by natural draft shall not be connected into fireplace dampers. any portion of mechanical draft systems operating under a positive pressure. 4.
  • Page 37 CAT III CERTIFIED INSULATED EXHAUST VENTING *Requires rear vent tee, sales option D-14. Fig. 40: Horizontal Through-the-Wall Venting (Category III) Horizontal Through-the-Wall Venting 1. The vent must be installed with a slight downward (Category III) slope of not more than 1/4 inch per foot of hori- zontal run to the vent terminal.
  • 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 CPVC 2002C 14”...
  • 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

    The connection from the appliance flue to the stack directly on the heater. Correct clearances can be must be as direct as possible and should be the same found earlier in this section. size or larger than the vent outlet. Care must be taken when locating the heater out- Unsealed flue pipe may allow flue products to enter a doors, because the flue gases discharged from the...
  • 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 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 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 Item Application Range Description Default H MODE 1,2,3 TARGET RSET <> SETP SETP RSET = Outdoor Reset, SETP =Setpoint. TANK SETP OFF, 50ºF to 150ºF 125°F Tank setpoint temperature. TANK DIFF 2ºF to 10ºF Tank differential temperature. POOL SETP 50ºF to 104ºF, 106ºF 80ºF Pool setpoint temperature.
  • Page 50 Boiler Menu The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information. Item Application Description BOILER 1 Enables Boiler for operation. BOILER 2 CASCADE Enables Boiler for cascade operation. BOILER 3 CASCADE Enables Boiler for cascade operation.
  • 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 Toolbox Menu The Toolbox Menu logs all error codes from the VERSA and PIM, as well as other functions. Up to 15 error codes can be logged for a maximum of 24 days. Item Description Lookup Active Error Look up and display the active error info. Select ON to start the function.
  • Page 53 the system. The OUT START is typically set to the desired building temperature. Outdoor Design (OUT DESIGN) The OUT DESIGN is the outdoor air temperature that is the typical coldest annual temperature where the building is located. This temperature is used when completing heat loss calculations for the building. Boiler Design (Boil DESIGN) The Boil DESIGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the OUT DESIGN temperature.
  • 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

    Preparation Start-Up WARNING: Do not turn on gas at this time. Blower Adjustment Check Power Supply 1. Turn off power. With multi-meter at incoming power, check voltage 2. Unplug cap at pressure switches and connect ma- between: nometer(s) to the tee. Hot - Common (≈120 VAC) 3.
  • Page 58 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 LIMITED PARTS WARRANTY HI DELTA – TYPES H AND WH MODELS 992C–2342C 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 Catalog Number: 6200.88A Effective 01/25/17 LIMITED WARRANTY HI DELTA PROFESSIONAL SERIES POOL HEATER Models: P0302C thru P2342C 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 Catalog Number: 6200.88A Effective 01/25/17 HOW TO MAKE A WARRANTY CLAIM You should immediately notify your dealer and provide proof of purchase model number serial number and date of installation. Your dealer will contact Raypak for instructions regarding the claim and to determine the location of the nearest authorized service center.
  • Page 67 START-UP CHECKLIST FOR FAN-ASSISTED 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. Additionally this form will be used to record all equipment operation functions and required settings.

  • Page 68: Important Instructions For The

    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 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

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