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INSTALLATION & OPERATING
Models
302C–902C
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. 1000.502A
INSTRUCTIONS
Effective: 06-07-18
Replaces: 02-15-17
LLC
®
P/N 241663 Rev. 2
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Related Manuals for Rheem Raypak Hi Delta P902C
Summary of Contents for Rheem Raypak Hi Delta P902C
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 302C–902C 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.
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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 302C-902C START-UP Component Locations General Information Pre Start-up GENERAL SAFETY Start-up OPERATION Time/Temperature Relationships in Scalds... -
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 H3-902C or similar depend- ing on the heater size and configuration. The letter(s) in the first group of characters identifies the application Raypak strongly recommends that this manual be re- (H = Hydronic Heating, WH = Domestic Hot Water, P viewed thoroughly before installing your Hi Delta = 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 302C 402C 502C 652C 752C 902C Table A: Basic Data Burners per Valve Stages % Fire at Stages Model 302C 1, 2 402C 1, 2 502C 1, 2 652C 1, 2 752C... -
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 42). - 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;...
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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.
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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 10ºF∆T 20ºF∆T 30ºF∆T 40ºF∆T Min. Flow Max. Flow Model gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) ∆T gpm ∆P (ft) ∆T 302C 402C 10.0 502C 10.4 652C 10.8 752C 11.3 902C 11.7 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).
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Page 20: Domestic Hot Water
*Maximum 4 times the pipe diameter or 12”, whichever is less. Fig. 19: Dual Heaters (Reverse/Return) with Primary/Secondary Piping Fig. 21: MODE 3 - Single Boiler with Indirect Mode 2 (Type H Units Only) on Boiler Loop Mode 3 (Type H Units Only) This mode selection is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in This mode selection is for hydronic heating systems... - 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.
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Page 22: Pool Heating
Soft* (3-4 grains per gallon) Medium (5-15 grains per gallon) Hard* (16-25** grains per gallon) Model gpm ∆P MTS SHL ∆T ∆T ∆P ∆T ∆P 302C 16.3 402C 16.4 502C 16.3 652C 16.2 752C 16.9 11.3 25.1 902C 17.2 11.7 25.5 ∆T = Temperature rise, °F ∆P = Pressure drop through heat exchanger, ft... - Page 23 Automatic Cold Water Protection (Optional) See Fig. 24 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. P models use a variable speed-pump to maintain the inlet water temperature 105°F.
- Page 24 Pool/Spa Water Chemistry pH of Water pH is a measure of relative acidity, neutrality or alka- NOTE: Chemical imbalance can cause severe linity. Dissolved minerals and gases affect water’s pH. damage to your heater and associated equipment. The pH scale ranges from 0 to 14. Water with a pH of 7.0 is considered neutral.
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Page 25: Gas Supply
heater due to lime scale build up on the heating sur- be placed a minimum distance of 10 times the pipe face is non-warrantable. The manufacturer of the pool diameter up-stream of the heater gas controls. Refer heater has no control of the water quality, especially to Table J for maximum pipe lengths. - Page 26 3/4” 1” 1-1/4” 1-1/2” 2” 2-1/2” Model 302C 402C 502C 652C 752C 902C Natural gas – 1,000 BTU per ft , .60 specific gravity at 0.5 in. WC pressure drop Propane gas – 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 Reversing Gas Supply Connection (502C-...
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Page 27: Electrical Power Connections
Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = less than 1 VAC Maximum BLACK CIRCUIT BREAKER WHITE Fig. 28: Gas Valve Electrical Power Connections GREEN GROUND Installations must follow these codes: •... -
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 in the control panel. The connections are dry contacts rated for pilot duty only (5A maximum).
- 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.
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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.
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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 For heaters connected to gas vents or chimneys, vent 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 CAT I CERTIFIED VENT PIPE Natural draft venting uses the natural buoyancy of the... - 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 Inlet Max. Length Model Venting Vent Size Equivalent Air Intake 6” 8” Material Vent Length* Pipe Material 302C 5” 100’ 70’ 402C Room Air Galvanized 6” Steel, 502C 75’ Category III 40’ PVC, 652C 100’ Ducted ABS, 40’...
- 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.
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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. The VERSA Control Board and PIM check the which matches the configuration stored in memory safety circuit and will stop from going into a trial for at the factory. If a valid ID Card is NOT present, ignition if any of the safety devices is in an the PIM generates a diagnostic fault and will shut error/fault condition.
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Page 42: Controls
Controls e. The flame sense is checked for successful lighting of the burner. If a valid flame is detect- ed, the main gas valve, operating pumps and WARNING: Installation, adjustment and service of blower relay remain energized and the PIM heater controls, including timing of various operating proceeds to the Heating mode. - Page 43 High Limit—Manual Reset Flow Switch This heater is equipped with a fixed-setting manual re- The flow switch is provided as standard and is factory set high limit temperature device as standard. It may mounted and wired. The switch shuts off heater in also have an additional optional adjustable manual- case of pump failure or low water flow.
- Page 44 Air Pressure Switch High and Low Gas Pressure Switches The low gas pressure switch (standard) connection This heater is equipped with a one or more air pres- mounts upstream of the gas valve to ensure that suffi- sure switches to prove blower operation prior to cient gas pressure is present for proper regulator ignition.
- Page 45 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 46 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 47 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 48 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 49 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 50 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 51 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 52 Wiring Diagram—Models 302C–902C Drawing #: 153149 rev 1 For a full-size drawing visit: www raypak com/commercial/wiring_diagrams...
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Page 53: 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 54: 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 55 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 56 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.
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Page 57: 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 58: 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 59 Weekly 7. Test air switch in accordance with manufacturer’s instructions. (Turn panel switch to the “On” posi- tion until blower is proven, then turn the switch to For low-pressure heaters, test low-water cut-off “Off”. device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance 8.
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Page 60: 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 61 LIMITED PARTS WARRANTY HI DELTA – TYPES H AND WH MODELS 302C–902C 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 62 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 63 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 64 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.
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Page 65: 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 66 NOTES...
- Page 67 NOTES...
- Page 68 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.