Raypak 302A-902A manual

INST ALLA TION AND OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.501B Effective: 09-08-06 Replaces: 01-01-05 P/N 240757 Rev . 1 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property dam- age, personal injury or death. FOR Y OUR SAFETY : Do not store or use gasoline or other flammable vapors and liqu[...]

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WARNINGS 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 T ime/T emperature Relationships in Scalds 8 INST ALLA TION 9 Installation Codes 9 Equipment Base 9 Stacking 9 Clearances 10 Combustion and V entilation Air 12 Conventional Combustion [...]

4 D ANGER: Indicates the presence of immediate hazards which will cause severe person- al 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 [...]

5 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 manua[...]

6 Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front[...]

7 General Infor mation Quant ity of Vent Siz e (in. ) Mode l No. Bur ne rs Gas Va lves Blo wers F lue Intake 302A 6 1 1 5 6 402A 8 1 1 6 6 502A 10 2 1 6 6 652A 13 2 1 8 6 752A 15 2 1 8 6 902A 18 3 1 8 6 # Burners per Va lve St age s % Fire at Sta ge Mode l No. 123 1 2 1 2 302A 6 1 100 402A 8 1 100 502A 5 5 11 , 2 5 0 1 0 0 652A 7 6 11 , 2 5 4 1 0 0[...]

8 GENERAL SAFETY T o 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 . S[...]

9 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/NFP A 54 – latest edition (NFGC) • National Electrical Code, ANSI/NFP A 70 - latest edition (NEC) • Standard for Controls and Safet[...]

10 In addition, the heater shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation or service (circulator replacement, control replacement, etc.). Clearances Indoor Installations Heater Sid e Mini mu m Clear- ance from Co mbus t ible Surf a ces Recomme nded[...]

11 U.S. Installations 1 Cana d i a n I nst a lla tions 2 A Clearance above grade , veranda, porch , deck, or balcony 1 ft ( 30 cm) 1 ft ( 30 cm) B Clearance to window or door that may b e opened 4 f t ( 1.2 m) be low o r to sid e of openin g; 1 foo t (30 c m) above op ening 3 ft (91 c m) C Clearance to permanen tly closed window ** D Ver tical clea[...]

12 Fig. 8: Minimum Clearances from Combustible Surfaces – Outdoor Installations Combustion and V entilation Air Indoor Units The heater must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation. Combustion air can be sup- plied via conventional means where combustion air is drawn fr[...]

13 three or four sheet metal screws (not supplied) equal- ly distributed around the circumference of the duct. All ducting should be self-supported. The filter housing is not designed to support the air duct. T r uSeal™ Combustion Air In certain applications it may be necessary to utilize the T ruSeal option (sales order option D-21 or D-22) and [...]

14 b. Not less than the sum of the areas of all vent connectors in the confined space. 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) [...]

15 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. 6. Remove limits, control bulbs and/or thermocou- ples. 7. Remove the eight flange nuts and the in/out head- er from the left-hand side. 8. Remove the eight flange nuts and the return head- er [...]

16 Failure to exceed 105ºF (41ºC) within 7 minutes may result in the premature failure of the hot surface ignit- er , remote flame sensor , burners and heat exchanger . It can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the vent system. The bypass allows part of the heater discharge water to [...]

17 Pressur e Drop in Feet of Head F eedwater R e gula tor Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the high- est point of the system. Install a check valve or back flow device upstream of the regulator , with a manual shut-off valve as required by local codes. Piping All high points should be[...]

18 P ota ble W ater and Space Heating 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water . 2. T oxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating. 3. If the heater will be used to su[...]

19 circulate water through the heater from the main sys- tem piping. T o 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 . This will ensure that the heater will be energized at the right time. If the main water line is too far away from the heater and t[...]

20 shut-off. Close isolation valves and remove water pip- ing from the in/out header on the heater . Drain the heater and any piping of all water that may experience below-freezing temperatures. P ool/Spa Water Chemistr y Wa ter Har dness W ater hardness is mainly due to the presence of cal- cium and magnesium salts dissolved in the water . The con[...]

21 Gas Supply Connection The heater must be isolated from the gas supply pip- ing system by closing the manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa). Relieve test pressure in the gas supply line prior to reconnecting the heater and its manual shut-off va[...]

22 8. Remove the rubber grommet from the left-hand- side panel and reinstall into the standard main gas opening, located on the right-hand side of the heater . 9. Install a coupling, nipple, union and sediment trap onto the right-hand end of the main gas line and then install the gas line, making sure that a manu- al shut-off valve has been install[...]

23 CIRCUIT BREAKER WHITE GROUND BLACK GREEN AB C Fig. 18: Wiring Connections Check the power source: AC = 108 V AC Minimum, 132 V AC MAX AB = 108 V AC Minimum, 132 V AC MAX BC = <1 V AC Maximum If the heater does not have a factory-wired stage con- troller , it is factory-wired in an on-off configuration with other stage terminals jumpered. T o [...]

24 D ANGER: SHOCK HAZARD Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. Fig. 21: Wiring Connections[...]

25 Installer action is required to electrically enable your heater to operate after making the power connections. Y ou must make a closed contact connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connections. This will be done based on the controller option selected with your heater order . 1. For Pool [...]

26 Combustion Air Su p pl y Exh aus t Configuration Heater Venting Category Certified Mate rial s Combustion Air Inlet M ater ial Ver tic al N atur al Draft Ventin g I “B” Ven t From Ins ide Building (Non-Direct Venting) Horizontal Through- the-Wall Venting II I Stainless Steel (Gas Tight) Ver tic al N atur al Draft Ventin g I “B” Ven t Fro[...]

27 8. Locate and guard vent termination to prevent acci- dental contact by people or pets. 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. 10. DO NOT terminate above any door , window , or gravity air intake. Condensate can freeze, causing ice formations. 1 1. Locate or guard vent to prevent condensate [...]

28 5. Remove the screws, retaining ring and rain gasket from top of heater . 6. Remove the screws, flue collar and gasket from the run side of the tee located in the flue box on top of the heater . 7. Reverse the components and reattach in the new location. 8. Make sure that the stainless steel cover , now lo- cated on the run side of the tee, is s[...]

29 T er mination The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the high- est point of the roof that is within 10 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 me- [...]

30 speed. Do not operate summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliances being inspected. Follow the manufacturer ’s instructions for lighting each appliance. Adjust thermostat so appliance will operate continuously . 5. Check the pressure at a pressure tap located 12 in. above the bottom joint of the first verti[...]

31 Air Inlet Max . Len gth Mo del No. Certified Vent in g Mate ria l Vent Size Max i mum Eq uiv ale n t Vent Le ngt h* Combustion Air Intake Pipe Mate ria l 6” 8” 302A 5” 402A 100’ N/A 502A 6” 75’ 652A 752A 40’ 100’ 902A Category I I I 8” 70’ Room Air 40’ Ducted Combus t ion Air Galvanized Ste el , PVC , ABS, CPVC 30’ 80’ [...]

32 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 ap- proved condensate trap must be installed per ap- plicable codes. 2. The intake vent must be insulated through the length of [...]

33 Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that might ob- struct combustion air flow . This dimension is critical to the correct operation of the heater[...]

34 Fig. 28: External LED Indicator Decal Heater Sequence of Operation Models 302A, 402A, 502A, 652A, 752A and 902A 1. The black (hot) wire lead goes directly to the main power switch. This black toggle switch is located at the middle front of the control compartment. 2. When the main power switch is placed in the “ON” position, 120 V AC is appl[...]

35 External Lights Light Color Ind icat ion Power Bl ue Main power is on Call For Heat Yel low Ther m ost a t i s clo sed Sa fety Re d One or more sa feties is inopera- tiv e Ign iti on Re d Igni tion mod ul e i s ino p era tiv e Flow Green Flow is prese nt Blower 1 Green Blower 1 is on Stage 1 Green Stage 1 i s on Stage 2 Green Stage 2 i s on Inte[...]

Ignition Module When additional heat is needed, the combustion air blower starts to purge air from the combustion cham- ber for about 15 seconds. On proof-of-air flow , the air- proving switch closes and the igniter is energized. T o ensure safe operation, the gas valve cannot open until the igniter is verified. The main burner is automatically lit[...]

37 The optional single-try ignition module will lock out after failing to light one time. T o reset it, press and release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case. T urning off the power to the heater WILL NOT reset the ignition module. High Limit (Manual R eset) [...]

38 Fig. 34: High/Low Gas Pressure Switch Fig. 35: Fan-Proving Switch Fig. 36: Blocked V ent Switch[...]

39 87%-Ef ficienc y Boiler s – Special Instr uctions Wa ter Piping An 87%-efficiency boiler requires a minimum inlet water temperature of 120ºF (49ºC) to prevent exces- sive condensation in the combustion chamber . An 87%-efficiency boiler operated with an inlet tempera- ture of less than 120ºF (49ºC) must have a manual bypass or an approved [...]

40 WARNING: Contact the vent material manufactur- er if there are any questions about the appliance cat- egory or suitability of a vent material for Category II, III or IV applications. Using improper venting materi- als can result in personal injury , death or property damage. V ent T er minal Location 1. Condensate can freeze on the vent cap. Fro[...]

41 Horizontal Thr ough-the-Wall V enting (Categor y IV) WARNING: V ent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure. Fig. 38: Horizontal Through-the-W all V enting (Category IV) Installation These installations utilize the boiler-mounted[...]

42 The stainless steel direct vent cap must be furnished by the boiler manufacturer in accordance with its list- ing (sales order option D-15). Use only double-wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burn- ing boilers, such as the stainless steel Saf-T vent by Heat Fab Inc. (800-772-0739), Protech Sys[...]

43 Direct V ent - V er tical Vert ica l Ve nt in g Height* Air I nlet Max . Length** Mode l Certified Vent in g Mate rial Vent Siz e Min. Max . Combustion Air Intake Pipe Mate rial 6” 8” 302A 5” 402A 100’ N/A 502A 6” 75’ 652A 752A 902A Category II or IV 8” 5’ 25’ Galvanized Steel, PVC , ABS, CPVC 40’ 100’ Note: When vertical h[...]

44 W iring Dia gr am[...]

45 ST ART -UP Pre Star t-up Filling System (Heating Boilers) Fill system with water . Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. Air Pur ge (Domestic Hot W ater Heaters) Pu[...]

46 Prepar ation Check P ower Supply With multi-meter at incoming power , check voltage between: Hot - Common (≈120 V AC) Hot - Ground (≈120 V AC) Common - Ground (< 1 V AC) Attach Manometers to Measure Pr essures 1. T urn off main gas valve. 2. Attach 24” scale manometer to the first main gas shut-off valve pressure tapping. 3. Attach (1) [...]

47 Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record. 3. If other gas-fired appliances in the room are on the same gas main, check all pressures on the Hi Delta with all other equipment running. 4. Check thermostats for ON-OFF operation. 5. Check [...]

48 1. Manually close the downstream leak test valve. 2. Open test point A and connect a manometer to it. V erify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in. WC). 3. Open test point B and connect a rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up of pr[...]

49 10. T o restart system, follow lighting instructions in the Operation section. 1 1. Check to see that the high limit control is set above the design temperature requirements of the system. For multiple zones: Check to make sure the flow is adjusted as required in each zone. 12. Check that the heater is cycled with the thermo- stat. Raise to the [...]

50 TR OUBLESHOO TING Ste p 7 Ste p 6 Ste p 5 Step 1 Step 2 Step 3 Step 4 Is there a Call For Heat? Is Disable j um p er intact? ( J1 ) Is there 120VAC at J8 Connecto r on the CPW board? Do the combustion air blowers come on? Is 24VAC at present at TH (J3 & J12 on CPW board and orange wire on ignition module)? Check flow switch, all connectors o[...]

51 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency . Maintenance as outlined below may be performed by the owner . Daily 1. Check that the area where the heater is installed is free from combustible materials, gasoline, and othe[...]

52 W eekl y For low-pressure heaters, test low-water cut-off device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance should shut-off and ignition fault light should come on. Depress reset button to reset). 1. Check igniter . (Resistance reading should be 42- 70 ohms at ambient temperature.) 2. Chec[...]

53 APPENDIX Inside Air Contamination All heaters experience some condensation during start-up. The condensate from flue gas is acidic. Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high effi- [...]

LIMI TED P ARTS WA RRANTY HI DELTA – TYPES H AND WH MODELS 302A–902A SCOP E Ray pak, Inc . ( “Ray pak ”) w arr ants to th e o rigin al ow ner that al l par ts of this hea ter w hic h a re act ual ly m an ufac tur ed by R aypak w ill b e fre e fro m fai lur e under n ormal us e a nd s erv ice for th e sp ecif ie d wa rra nty per iods a nd s [...]

LIMI TED P ARTS WA RRANTY HI DELTA – TYPE P MODELS 302A–902A SCOP E Ray pak, Inc . ( “Ray pak ”) w arr ants to th e o rigin al ow ner that al l par ts of this hea ter w hic h a re act ual ly m an ufac tur ed by R aypak w ill b e fre e fro m fai lur e under n ormal us e a nd s erv ice for th e sp ecif ie d wa rra nty per iods a nd s ubjec t [...]

ww w .raypak.c om Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A.[...]