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INSTALLATION & OPERATING
Models
302B –902B
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. 1000.501D
INSTRUCTIONS
Effective: 08-14-07
L
W
Replaces: 12-15-06
P/N 240757 Rev. 5
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Related Manuals for Rheem Raypak Hi Delta 302B
Summary of Contents for Rheem Raypak Hi Delta 302B
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 302B –902B 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.
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Page 3: Table Of Contents
CONTENTS WARNINGS Preventative Maintenance Schedule BEFORE INSTALLATION APPENDIX Product Receipt Inside Air Contamination Model Identification WARRANTIES Ratings and Certifications Type H and WH Installations at Elevation Type P Component Locations General Information GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Stacking Clearances... -
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 1262B 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 (DHW), 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 Vent Size Quantity of (in.) Model Burners Blowers Flue Intake Valves 302B 402B 502B 652B 752B 902B Table A: Basic Data # Burners per % Fire at Stages Model Valve Stage 302B 402B 502B 1, 2 652B 752B 902B 1, 2 1, 2, 3 66 Table B: Manifold Data... -
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
The temperature of the water in the heater can be reg- Equipment Base ulated by using the temperature controller. To comply with safety regulations, the temperature controller is The heater should be mounted on a level, structurally set at the lowest setting when shipped from the facto- sound surface. -
Page 10: 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 11 Fig. 7: 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 12: Combustion And Ventilation Air
Reversing Air Filter Follow these instructions to change the air duct con- nection from the left-hand side (standard) to the right-hand side: 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. -
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 with the intended purpose of the opening(s) for WARNING: Do not use one permanent opening ventilation air referred to in (1). - Page 15 5. Remove all plumbing fittings to the header. This Hydrostatic Test 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.
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Page 16: Hydronic Heating
shutting down the heater. Thus an automatic valve Failure to exceed 105ºF (41ºC) within 7 minutes may system, such as a three-way proportional valve or a result in the premature failure of the hot surface ignit- modulating two-way valve to control the bypass, er, remote flame sensor, burners and heat exchanger. - Page 17 Pressure Drop in Feet of Head heaters which are not subject to thermal shock. Raypak offers a full line of electronic sequencers that Feedwater Regulator produce direct reset of heater water temperature. (Refer to the Controls section of the Raypak Catalog.) Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the highest point of the system.
- Page 18 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 19 slowly throttle Valve B closed to increase the inlet circulate water through the heater from the main sys- water temperature to 105°F. tem piping. To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return wa- ter line, upstream of the heater.
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Page 20: Gas Supply
shut-off. Close isolation valves and remove water pip- Total Dissolved Solids ing from the in/out header on the heater. Drain the heater and any piping of all water that may experience Total dissolved solids (TDS) is the measure of all min- below-freezing temperatures. - Page 21 Gas Supply Connection CAUTION: Support gas supply piping with hangers, not by the heater or its accessories. Make sure the gas piping is protected from physical CAUTION: The heater must be disconnected from damage and freezing, where required. the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa).
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Page 22: Electrical Power Connections
9. Install a coupling, nipple, union and sediment trap Electrical Power Connections onto the right-hand end of the main gas line and then install the gas line, making sure that a manu- Installations must follow these codes: al shut-off valve has been installed within 10 ft of the heater. -
Page 23: Field Wiring Connection
prior to working with any electrical connections or components. BLACK CIRCUIT BREAKER 3. Observe proper wire colors while making electri- WHITE cal connections. Many electronic controls are polarity sensitive. Components damaged by GREEN improper electrical installation are not covered by GROUND warranty. - Page 24 DANGER: SHOCK HAZARD Installer action is required to electrically enable your heater to operate after making the power connections. Make sure electrical power to the heater is discon- You must make a closed contact connection on Stage nected to avoid potential serious injury or damage to 1 connector of the Central Point Wiring (CPW) board components.
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Page 25: Venting
SINGLE Model Diameter Order Number STAGE TANKSTAT 302B 5” 011838 402B-502B 6” 011839 652B, 752B, 8” 011840 902B Table K: Flue Exhaust Tee Kits STAGE 1 Appliance Categories CONNECTION Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. - Page 26 1. Condensate can freeze on the vent cap. Frozen CAUTION: When condensate traps are installed, condensate on the vent cap can result in a blocked condensate must be routed to an appropriate flue condition. container for neutralization before disposal, as required by local codes.
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Page 27: Changing The Flue Outlet
8. Locate and guard vent termination to prevent acci- Canadian Installations dental contact by people or pets. Refer to latest edition of the B149 Installation code. 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. A vent shall not terminate: 10. -
Page 28: Venting Installation Tips
5. Remove the screws, retaining ring and rain gasket The maximum and minimum venting length for Cate- from top of heater. gory I appliances shall be determined per the NFGC (U.S.) or B149 (Canada). 6. Remove the screws, flue collar and gasket from the run side of the tee located in the flue box on The diameter of vent flue pipe should be sized accord- top of the heater. - Page 29 Termination WARNING: Vent connectors serving appliances vented by natural draft shall not be connected into The vent terminal should be vertical and should termi- any portion of mechanical draft systems operating nate outside the building at least 2 ft above the highest under a positive pressure.
- Page 30 speed. Do not operate summer exhaust fan. Close The total length of the horizontal through-the-wall flue fireplace dampers. system should not exceed 70 equivalent ft in length. If horizontal run exceeds 70 equivalent ft, an appropri- 4. Place in operation the appliances being inspected. ately sized extractor must be used.
- Page 31 Combustion Air Inlet Certified Maximum Model Max. Length Venting Vent Size Equivalent Intake Pipe Material Vent Length* 6” 8” Material 302B 5” 70’ 100’ 402B Room Air Galvanized 6” Steel, 502B 75’ Category III 40’ PVC, 100’ 652B Ducted ABS, 40’...
- Page 32 For installations in extremely cold climate, it is re- Direct Vent - Vertical quired that: 1. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of hori- zontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes.
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Page 33: Controls
Flues supported only by flashing and extended above NOTE: Condensate can freeze on the vent cap. the roof more than 5 ft should be securely guyed or Frozen condensate on the vent cap can result in a braced to withstand snow and wind loads. blocked flue condition. -
Page 34: Heater Sequence Of Operations
12. Power is applied to terminal P1-1 of the Universal Diagnostics Board. 24 VAC power is then applied in series to all typically closed safeties wired into the heater. All safeties are verified to ensure that it is safe to operate the heater. The safety compo- nents wired into the diagnostic board are: low water cut-off (optional), blocked vent switch, man- ual vent temp switch (optional), manual reset high... - Page 35 External Lights Light Color Indication Power Blue Main power is on Call For Heat Yellow Thermostat is closed One or more safeties is inopera- Safety tive Ignition Ignition module is inoperative Flow Green Flow is present Blower 1 Green Blower 1 is on Stage 1 Green Stage 1 is on...
- Page 36 erly, a 24 VAC signal is output from pin GV on the Ignition Module module. When additional heat is needed, the combustion air 44. 24 VAC signal is received at gas valve 1 thus ener- blower starts to purge air from the combustion cham- gizing it.
- Page 37 The optional single-try ignition module will lock out General Safety Section for safety precautions con- after failing to light one time. To reset it, press and cerning domestic hot water applications. release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case.
- Page 38 UDB Diagnostic Board This heater is equipped with a diagnostic board which will indicate faults as they occur. It has the ability to retain up to 256 faults in history. Refer to the section below for instructions on accessing, reviewing and clearing these faults.
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Page 39: 87%-Efficiency Boilers - Special Instructions
87%-Efficiency Boilers – ends that a thermometer be placed into the boiler inlet piping next to the in/out header to facilitate tempera- Special Instructions ture adjustment. Inlet water temperatures below 120ºF (49ºC) can excessively cool the products of combus- tion, resulting in condensation on the heat exchanger. NOTE: The constructions of the 84%- (standard) and 87%-efficiency (optional) boilers are very similar, Venting... - Page 40 11. Locate or guard vent to prevent condensate from WARNING: Contact the vent material manufacturer damaging exterior finishes. Install a rust-resistant if there are any questions about the appliance sheet metal backing plate against brick or mason- category or suitability of a vent material for Category ry surfaces.
- Page 41 pressure reading must be between -0.01 and -0.1 in. WARNING: Vent connectors serving appliances WC as measured 12 in. from the appliance flue outlet. vented by natural draft shall not be connected into Each elbow used is equal to 10 ft of straight pipe. This any portion of mechanical draft systems operating will allow installation in one of the four following com- under a positive pressure.
- Page 42 The stainless steel direct vent cap must be furnished The flue exhaust direct vent cap is not considered in by the boiler manufacturer in accordance with its list- the overall length of the venting system. ing (sales order option D-15). Care must be taken during assembly that all joints are Use only double-wall vent pipe and the special gas sealed properly and are airtight.
- Page 43 Direct Vent - Vertical Note: When vertical height exceeds 25 ft, consult factory prior to installation. *Requires optional vent tee for rear discharge. Fig. 40: Direct Vent - Vertical Vertical Venting Air Inlet Certified Combustion Air Height* Max. Length** Model Venting Vent Size Intake Pipe...
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Page 44: Wiring Diagram
Wiring Diagram... -
Page 45: Start-Up
START-UP • If you cannot reach your gas supplier, call the fire department. • Use only your hand to push in or turn the gas con- Pre Start-up trol knob. Never use tools. If the knob will not turn by hand, do not try to repair it, call a qualified serv- Filling System (Heating Boilers) ice technician. -
Page 46: Start-Up
Preparation Start-Up 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 47 Safety Inspection The burner section that is ignited directly by the hot surface ignition system serves as a supervised pilot to light the burner sections on either side of it. The burn- 1. Check all thermostats and high limit settings. er sections on either side of the supervised section (pilot) are electrically interlocked with the supervised 2.
- Page 48 1. Manually close the downstream leak test valve. This completes leak testing for a single Hi Delta mani- fold riser. Repeat steps 1-8 for each riser. 2. Open test point A and connect a manometer to it. Post Start-Up Check Verify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in.
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Page 49: Operation
10. To restart system, follow lighting instructions in the 9. Set thermostat to desired setting. The appliance Operation section. will operate. The igniter will glow after the pre- purge time delay (15 seconds). After igniter 11. Check to see that the high limit control is set reaches temperature (45 seconds) the main valve above the design temperature requirements of the will open. -
Page 50: Troubleshooting
TROUBLESHOOTING Does the power switch provide power to the Check the switch control panel? Step 1 and/or line voltage Replace ignition module Is there a Call For Heat? Unit is in standby mode. Check all safety limit devices and voltage from the transformer to J10 on Reattach. -
Page 51: Maintenance
MAINTENANCE 4. Check for and remove any obstruction to the flow of combustion or ventilation air to heater. 5. Follow pre-start-up check in the Start-up section. Suggested Minimum Maintenance Schedule 6. Visually inspect burner flame. It should be light blue. Remove and visually inspect hot surface ig- Regular service by a qualified service agency and niter and sensor for damage, cracking or debris maintenance must be performed to ensure maximum... - Page 52 Weekly 5. Check coils for 60 cycle hum or buzz. Check for leaks at all valve fittings using a soapy water solu- tion. Test other operating parts of all safety shut-off For low-pressure heaters, test low-water cut-off and control valves and increase or decrease set- device.
- Page 53 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 54 LIMITED PARTS WARRANTY HI DELTA – TYPES H AND WH MODELS 302B–902B 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 55 LIMITED PARTS WARRANTY HI DELTA – TYPE P MODELS 302B–902B 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 56 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS ADB, HI-DELTA & MV B 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 57 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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