Hi Delta 302B–902B Installation & Operating Instructions Manual

Types h, wh & p

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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. 1000.501K

INSTRUCTIONS

Effective: 01-16-13

Replaces: 03-29-11

LLC

P/N 240757 Rev. 12

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Summary of Contents for Hi Delta 302B–902B

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.
Page 2 Rev. 12 reflects the following: Changes to: ASME Marks on page 1, warnings on page 4, Direct Vent on page 12, Table I on page 19, Gas Supply Pressure on page 22, Fig. 24 on page 29, Termination instructions on page 29, Termination instructions on page 33, High Limit (Manual Reset) instructions on page 38, Condensate Management on page 42, Fig.
Page 3: Table Of Contents
CONTENTS Outdoor Installation WARNINGS Controls BEFORE INSTALLATION Product Receipt Heater Sequence of Operations Model Identification 87%-Efficiency Boilers – Ratings and Certifications Special Instructions Installations at Elevation Water Piping Component Locations Wiring Diagram General Information START-UP Pre Start-up GENERAL SAFETY Time/Temperature Relationships in Start-Up Scalds OPERATION...
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 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). The number which fol- heater. Please review the General Safety information lows identifies the firing mode (1 or 4 = on-off, 3 = before installing the heater.
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
(See Fig. 4.). Stacking Hi Delta units can be stacked two units high with an optional stacking rack. A stacking kit is available from Raypak for this type of installation.
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;...
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 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 with the intended purpose of the opening(s) for WARNING: Do not use one permanent opening 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: Hydronic Heating
Cold Water Run Failure to exceed 105ºF (41ºC) within 7 minutes may result in the premature failure of the hot surface ignit- Cold water run differs from cold water start in that the er, remote flame sensor, burners and heat exchanger. system water entering the heater remains below 105ºF It can cause operational problems, bad combustion, (41ºC) continuously.
Page 17 10°F T 20°F T 30°F T 40°F T Min. Flow Max Flow Model P (ft) gpm P (ft) gpm P (ft) gpm P (ft) gpm T gpm P (ft) P (ft) 302B 402B 10.0 502B 10.4 652B 10.8 752B 11.3 902B 11.7 Notes:...
Page 18: Domestic Hot Water
0 to 3 grains per gallon is known to be aggressive and corrosive. The Hi Delta pool heater is equipped with an external pump and bypass arrangement as standard equip- ment. This arrangement blends outlet water with the...
Page 19 A thermostatically controlled mixing valve is used to mix the outlet water with the pool water. This mixed water is supplied as the inlet water to the pool heater. The proper configuration is shown in Fig. 15. The active element of the valve adjusts the mixing ratio to maintain the inlet water above 105°F.
Page 20 **In salt water chlorinated pools, the total TDS can be as high as 4500ppm NOTE: The allowable concentrations of salt and of the Total Dissolved Solids are lower for the Hi Delta than for a typical residential pool heater, due to the higher water temperatures at which a Hi Delta operates.
Page 21: Gas Supply
Gas Supply ness level no lower than 5 grains per gallon. Water softened as low as 0 to 1 grain per gallon may be under-saturated with respect to calcium carbonate DANGER: Make sure the gas on which the heater resulting in water that is aggressive and corrosive. will operate is the same type as specified on the heater’s rating plate.
Page 22 9. Install a coupling, nipple, union and sediment trap CAUTION: Do not use Teflon tape on gas line pipe onto the right-hand end of the main gas line and thread. A pipe compound rated for use with natural then install the gas line, making sure that a manu- and propane gases is recommended.
Page 23: Electrical Power Connections
The gas valve pressure regulator(s) on the heater are NOTE: Field-supplied isolation relays should be nominally preset at 3.5 in. WC for natural gas, and installed when field-connected controllers are 10.5 in. WC for propane gas. The pressure at the gas mounted more than 50 equivalent feet (18 Ga) from valve outlet tap, measured with a manometer, while in heater.
Page 24: Field Wiring Connection
Making the Electrical Connections CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause im- Refer to Fig. 18-23. proper and dangerous operation. Verify proper operation after servicing. 1. Verify that circuit breaker is properly sized by referring to heater rating plate.
Page 25: Venting
Installer action is required to electrically enable your heater to operate after making the power connections. SINGLE You must make a closed contact connection on Stage STAGE 1 connector of the Central Point Wiring (CPW) board TANKSTAT for temperature control connections. This will be done based on the controller option selected with your heater order.
Page 26 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 302B 5” 011838 application on a Category III or IV vent system. 402B-502B 6”...
Page 27 7. Through-the-wall vents for Category II and IV 2. The vent must not be less than 7 ft above grade appliances and non-categorized condensing appli- when located adjacent to public walkways. ances shall not terminate over public walkways or over an area where condensate or vapor could 3.
Page 28: Changing The Flue Outlet
3. Within 6 ft (1.8 m) of a mechanical air supply inlet CAUTION: The silicone vent gaskets must be prop- to any building. erly reinstalled to prevent flue gas leakage. Replace any torn or worn vent gaskets. 4. Above a meter/regulator assembly within 3 ft (915 mm) horizontally of the vertical centre-line of the Venting Installation Tips regulator.
Page 29 Termination 8’ OR LESS The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the highest point of the roof that is within 8 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft hori-zontal distance is maintained) electric meters, gas meters, regulators and relief equipment.
Page 30 Horizontal Through-the-Wall Venting Common venting systems may be too large once an existing unit is removed. At the time of removal of an (Category III) existing appliance, the following steps must be fol- lowed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
Page 31 For installations in extremely cold climate, it is re- 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.
Page 32 Certified Maximum Combustion Air Inlet Max. Length Model Venting Vent Size Equivalent Air Intake 6” 8” Material Vent Length* Pipe Material 302B 5” 100’ 70’ 402B Room Air Galvanized 6” Steel, 502B 75’ Category III 40’ PVC, 652B 100’ Ducted ABS, 40’...
Page 33 Direct Vent - Vertical Use only the special gas vent pipes listed for use with Category III gas burning heaters, such as the AL29-4C stainless steel vents offered by Heat Fab Inc. (800- 772-0739), Protech System, Inc. (800-766-3473), Z-Flex (800-654-5600) or American Metal Products (800-423-4270).
Page 34: Outdoor Installation
Outdoor Installation NOTE: Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Outdoor models are self-venting when installed with the optional factory-supplied outdoor vent kit and re- quire no additional vent piping. A special vent cap, flow switch cover and air intake hood are provided in accor- NOTE: The vent cap, flow switch cover and air dance with CSA requirements, which must be installed...
Page 35: Heater Sequence Of Operation
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 36 External Lights Light Color Indication Power Blue Main power is on Call For Heat Yellow Thermostat is closed One or more safeties is Safety inoperative 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 37: Ignition Module
Ignition Module 45. The stage 1 LED on the status display board is now illuminated. When additional heat is needed, the combustion air blower starts to purge air from the combustion cham- 46. The coil of relay K-2 is now energized with the ber for about 15 seconds.
Page 38 High Limit (Manual Reset) Low Water Cut-Off (Optional) The low water cut-off automatically shuts down the The heater is equipped with a manual reset high limit burner whenever water level drops below the level of temperature device. Push the reset button and adjust the sensing probe.
Page 39 UDB Diagnostic Board This heater is equipped with a diagnostic board which will indicate faults as they occur. Refer to the following section for instructions on accessing, reviewing and clearing these faults. Fig. 34: Fan-Proving Switch Fig. 37: UDB Diagnostic Board UDB Fault History To view the fault codes in the UDB history file: Fig.
Page 40 Detection Hi Delta Delay LCD Display Readout with Fault Cond Drain Blocked/Vent Temp Limit Err PVC Vent Limit-CHX Check Drain Switch, Check Drain/Check Vent System Man Hi Limit Fault Manual High Limit Confirm Settings, Reset Hi Limit Auto Hi Limit Fault...
Page 41: 87%-Efficiency Boilers
See Table T for appliance category requirements for system to prevent problems with condensation. A man- the 87%-efficiency Hi Delta. ual bypass, shown in Fig. 15, must be piped into the system at the time of installation. This piping is like a...
Page 42 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 43 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 44 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 45 Direct Vent - Vertical 12” 6” Note: When vertical height exceeds 25 ft, consult factory prior to installation. *Requires optional vent tee for rear discharge. Fig. 41: Direct Vent - Vertical Vertical Venting Air Inlet Certified Combustion Air Height* Max. Length** Model Venting Vent Size...
Page 46: Wiring Diagram
Wiring Diagram...
Page 47: Start-Up
WHAT TO DO IF YOU SMELL GAS: START-UP • Do not try to light any appliance. • Do not touch any electrical switch; do not use any Pre Start-up telephone in your building. Filling System (Heating Boilers) • Immediately call your gas supplier from a neigh- bor’s telephone.
Page 48: 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 49: Safety Inspection
On the manual valve, this is a bleedle valve. Identical readings will be found at the plugged port labeled as The Hi Delta heaters, depending on their size, have Alternate C. one to three burner sections. Each burner section is supplied gas by gas valves incorporated into a single Refer to Fig.
Page 50 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...
Page 51: 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 52: 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 53: Maintenance
Schedule annual service call by qualified service agency. The following is required procedure in CSD-1 states 1. Visually check top of vent for soot. Call service and good practice for all Hi Delta installations. person to clean. Some sediment at bottom of vent is normal. Daily 2.
Page 54 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 55: 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 56: Warranties
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 57 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 Wa rranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but a re the owner’s responsibility.
Page 58: Start-Up Checklist
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 59: 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 60 www.raypak.com 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:

302b 902b 402b 502b 652b 752b