Raypak 122-322 manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.53H Effective: 09-19-08 Replaces: 1 1-16-07 P/N 241 1 12 Rev . 9 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property damage, personal injury or death . FOR Y OUR SAFETY : Do not store or use gasoline or other flammable vapors and l[...]

2 Rev . 9 reflects the following: Changes to: The text in the BEFORE INST ALLA TION section on page 5; the text in paragraph one of the GENERAL SAFETY section on page 8; the text in paragraph one of the Outdoor Installations section on page 10; T able E on page 10; the wiring diagram on page 35.[...]

WARNINGS 4 Pay Attention to These T erms 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 T ime/T emperature Relationships in Scalds 8 GENERAL SAFETY 8 Clearances 9 Equipment Base 9 INST ALLA TION 9 Installation Codes 9 Combustion[...]

D ANGER: Indicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored. CA UTION: Indicates the presence of hazards or unsa[...]

BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your Hi Delta heater . Please review the General Safety information before installing the heater . Factory warranty does not apply to heaters that have been improperly installed or operated (refer to the warranty at the back of this man- ual[...]

Fig# 9399 HI-LIMITS W A TER OUTLET W A TER INLET GAS CONNECTION VIEW PORT PRESSURE RELIEF CONNECTION FLUE EXHAUST COMBUSTION AIR INT AKE Component Locations Fig. 1: Component Locations—Back Fig. 2: Component Locations—Left Side Panels removed for clarity Fig. 3: Component Locations—Front 6 HI LIMITS[...]

General Infor mation T able A: Basic Data T able B: Manifold Data Model No. Quantity of V ent Size (in.) Burners Gas V alves Blowers Flue Intake 122 3 2* 1 4 5 162 4 2* 1 5 5 202 5 2* 1 5 5 242 6 2* 1 5 5 322 8 2* 1 6 5 Model No. Burners per V alve Stages % Fire at Stage A B 1 2 1 2 122 2 1 A AB 66 100 162 3 1 A AB 75 100 202 3 2 A AB 60 100 242 4 [...]

GENERAL SAFETY T o meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 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 [...]

INST ALLA TION INST ALLA TION Installation Codes Installations must follow these codes: · Local, state, provincial, and national codes, laws, regulations and ordinances. · National Fuel Gas Code, ANSI Z223.1- latest edi- tion (NFGC). · National Electrical Code, ANSI/NFP A 70 - latest edition (NEC). · Standard for Controls and Safety Devices for[...]

10 Fig. 7: Minimum Clearances from Combustible Surfaces—Indoor Installations When installed according to the listed minimum clear- ances from combustible construction, these heaters can still be serviced without removing permanent structural construction around the heater . However , for ease of servicing, we recommend a clearance of at least 24 [...]

11 a motorized sealed damper to prevent the circula- tion of cold air through the heater during the non-operating hours. Con v entional Combustion Air Supply U .S. Installations All Air from Inside the Building The confined space shall be provided with two perma- nent openings communicating directly with an additional room(s) of sufficient volume s[...]

12 WARNING: Do not use one permanent opening method if the equipment room is under negative pressure conditions or the equipment is common vented with other gas-fired appliances. 1. V entilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors. The [...]

13 Low T emper ature System Heater requires minimum inlet temperature of 105°F . Consult the following sections for piping details. T emperature & Pr essur e Gauge The temperature and pressure gauge is factory- mounted in the in/out header . Hydronic Hea ting Pump Selection In order to ensure proper performance of your boiler system, you must [...]

14 Fig. 9: Single Boiler—Low T emperature Application (Heat Pump) Primary/Secondary Piping Fig. 10: Dual Boiler—Primary/Secondary Piping[...]

15 T able G: Domestic W ater Heater Flow Rate Requirements Δ T = T emperature rise, °F . Δ P = Pressure drop through heat exchanger , ft. SHL = System head loss, ft. (System head loss is based on the heater and tank placed no more than 5 feet apart and 25 feet equivalent length of pipe and fittings.) gpm = Gallons per minute, flow rate.) MTS = M[...]

16 Fig. 1 1: Single Heater—Domestic Hot Water with One Storage T ank[...]

17 Gas Supply Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve locat- ed outside the heater jacket. A pounds to inches regulator must be installed to reduce to gas supply pressure to under 10.5 in. WC. The regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the he[...]

18 Fig. 12: Sediment T rap Orientation SUPPLIED BY OTHERS EXTENTS OF UNIT ENCLOSURE GAS FLOW TO BURNERS SEDIMENT TRAP MANUAL SHUT OFF VA LV E SUPPLIED BY OTHERS EXTENTS OF UNIT ENCLOSURE GAS FLOW TO BURNERS UNION SEDIMENT TRAP MANUAL SHUT OFF VA LV E Gas Supply Connection Gas Suppl y Pr essur e A minimum of 7 in. WC and a maximum of 10.5 in. WC ups[...]

19 Electrical P ow er Connections Installations must follow these codes: · National Electrical Code and any other national, state, provincial or local codes or regulations hav- ing jurisdiction · Safety wiring must be N.E.C. Class 1 · Heater must be electrically grounded as required by N.E.C. · In Canada, C22.1 The heater is wired for 120 V AC,[...]

20 Fig. 14: Single Stage and 2-Stage T ankstat Electrical Connections—Domestic Hot Wa ter Installer action is required to electrically enable your Hi Delta heater to operate after making the power con- nections. Y ou must make a connection on T erminal Block #3 for temperature control connections. This will be done based on the controller option [...]

21 SINGLE ST AGE T ANKST A T ST AGE 1 CONNECTION A TT ACH ST AGE 1 CONNECTIONS ON HEA TER T O THE SINGLE ST AGE T ANKST A T AS SHOWN IN THE DIAGRAM ABOVE. 2-ST AGE T ANKST A T ST AGE 1 CONNECTION ST AGE 2 CONNECTION OR ST AGE 1 CONNECTION OF HEA TER 2 A TT ACH ST AGE 1 CONNECTIONS ON HEA TER TO ST AGE 1 CONNECTION ON T ANKST A T . A TT ACH ST AGE 2[...]

22 T able H: V enting Category Requirements Combustion Air Supply Exhaust Configuration V enting Category Certified Appliance Material Combustion Air Inlet Material From Inside Building (Non-Direct V enting) V ertical Natural Draft V enting I T ype B or and Category I V enting System* Horizontal Thru-wall V enting III Stainless Steel (Gas T ight) F[...]

23 U.S. Installations 1 Can adian I nstalla tions 2 A Clearance abov e grade , veran da, porch , deck, or balcony 1 ft ( 30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 f t ( 1 .2 m) be lo w o r to s id e of openin g; 1 foot (30 c m) above op ening 3 ft (91 c m) C Clearance to per manen tly closed wind ow ** D Ver tical clear[...]

24 over an area where condensate or vapor could create a nuisance or hazard or could be detrimen- tal to the operation of regulators, relief valves, or other equipment. Where local experience indi- cates that condensate is a problem with Category I and III appliances, this provision shall also apply . f) Locate and guard vent termination to prevent[...]

25 V enting Installation Tips Support piping: · horizontal runs- at least every five (5) feet. · vertical runs - use braces: · under or near elbows Follow items listed below to avoid personal injury or property damage. · Cut nonmetallic intake pipe with fine-toothed hack- saw . · Do not use nonmetallic intake pipe or fittings that are cracked [...]

26 Natural Draft V er tical V enting System Installation Natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The neg- ative draft must be within the range of -.01 in. to -.08 in. WC as measured 12 in. from the appliance flue out- let to ensure prop[...]

27 each appliance. Adjust thermostat so appliance will operate continuously . e) Check the pressure at a pressure tap located 12 in. above the bottom joint of the first vertical vent pipe. Pressure should be anywhere between -.01 to -.08 in. WC. f) After it has been determined that each appliance remaining connected to the common venting sys- tem p[...]

28 Horizontal Thr u-wall V enting System (Categor y III) Installation These installations utilize the heater-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the out- doors. Adequate combustion and ventilation air must be supplied [...]

29 Fig. 20: Direct V ent Horizontal Thru-Wall V enting (Category III) 12" 36" MIN. 12" MIN. 6" VENT CAP VENT PIPE COMBUSTION AIR FIL TER BOILER UNIT INT AKE VENT INT AKE VENT Model No. Appliance Category Certified V enting Material V ent Size (inches) Max. V enting Length (feet) Combustion Air Intake Pipe Material Air Inlet Size[...]

30 Horizontal Thr u-wall Direct V ent System (Categor y III) Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent com- bustion products to the outdoors. The total length of the thru-wall exhaust vent cannot exceed forty (40) feet in length for the flue outlet. Each elbow used is equal to t[...]

31 36" 12" MIN. 36" MIN. VENT CAP VENT PIPE COMBUSTION AIR FIL TER BOILER UNIT INT AKE VENT Model No. Appliance Category Certified V enting Material V ent Size (inches) Min./Max. V ertical V enting Height (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) 122 I T ype B Equivalent 4 5/25 G[...]

32 V er tical Dir ect V ent System Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The negative draft must be within the range of -0.01 to -0.08 in. WC as mea[...]

33 CONTR OLS Ignition Control Module The interrupted proved ignition device conserves ener- gy . When additional heat is needed, the combustion air blower starts to purge all air from the combustion chamber for about 15 seconds. On proof of air flow , the air proving switch closes and the igniter is ener- gized, eliminating the fuel costs of mainta[...]

34 Lo w Wa ter Cut Of f (Optional) The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 3-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig. 24: Flow Switch Fig. 25: Low W ater Cut Off Flow Switc h Dual-purpo[...]

35 WIRING DIA GRAM—MODELS 122–322[...]

36 PRE-ST ART -UP Filling System-Heating Hea ter s Fill system with water . Purge all air from the system using purge valve sequence. After system is purged of air , lower system pressure. Open valves for normal system operation, fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. [...]

37 Attach Manometers to Measur e Pressur es • Attach 24" scale manometer to the first main gas shut-off valve pressure tapping. • Attach one 12" scale manometer to the manifold gas pressure tapping. (See gas valve detail on page 7.) • Attach one 12" scale manometer to — Pull rubber tube from air pressure switch off the alumin[...]

38 F ollo w-Up • Safety checks must be recorded as performed. • T urn unit on. After main burner ignition: • Check Manometer for proper reading. • Cycle unit several times and recheck readings • Re-analyze with unit running record or print results. • Remove all Manometers and replace hose, remove jumper , replace all gas pressure caps. [...]

39 8. T urn on all electric power to the appliance. 9. Set thermostat to desired setting. The appliance will operate. The igniter will glow after the pre- purge time delay (15 seconds). After igniter reaches temperature (45 seconds) the main valve will open. System will try for ignition three (3) times. If ignition is not sensed, lockout will com- [...]

40 Monthly: 1. Check for piping leaks around circulators, mixing valves, relief valves, and other fittings. If found, repair at once. DO NOT use petroleum-based stop leak compounds. 2. Visually inspect burner flame. 3. Visually inspect venting system for proper func- tion, deterioration or leakage. 4. Check air vents for leakage. Quar ter l y: 1. C[...]

41 LIMITED P ARTS W ARRANTY COMMERCIAL BOILERS TYPE HI-DEL T A SIZES 122 T O 322 MODELS H AND WH SCOPE: Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this boiler 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 condit[...]

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ww w .ra y pak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.[...]