Raypak HD401 manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.52 Effective: 06-1 1-09 Replaces: NEW P/N 241356 Rev . 1 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 liquids o[...]

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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 GENERAL SAFETY 8 T ime/T emperature Relationships in Scalds 8 INST ALLA TION 9 Installation Codes 9 Equipment Base 9 Clearances 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. 1: Component Locations — Angle View Fig. 2: Component Locations — Left Side Fig. 3: Component Locations — Front (Panels removed for clarity) 6 Component Locations[...]

General Infor mation T able A: Basic Data Model No. Quantity of Burners V ent Size (in.) Flue Intake HD101 2 4 4 HD151 3 4 HD201 4 5 HD251 5 5 HD301 6 5 HD401 8 6 7 Fig. 5: Gas V alves Fig. 4: Air Shutter Adjustment[...]

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[...]

TOP VIEW FRONT VIEW 2 Fig. 7: Minimum Installed Service Clearances — Indoor/Closet Installations The heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater . Outdoor Installations These heaters are design-certified for outdoor installa- tion. Heaters must not be installed u[...]

area per 20,000 BTUH (1 1 1 mm 2 per kW) of total input rating of all equipment in the room when the opening is communicating directly with the out- doors or through vertical duct(s). The total cross-sectional area shall be at least 1 in. 2 of free area per 10,000 BTUH (222 mm 2 per kW) of total input rating of all equipment in the room when the op[...]

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 tot[...]

13 WARNING: Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur . Refer to local codes. R ev er sing Wa ter Connections Follow these instructions to change the water connec- tions from the left-hand side (standard) to [...]

14 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 shipped loose for field installation. Hydronic Hea ting Pump Selection In order to ensure proper performance of your boiler system, you must in[...]

15 Fig. 10: Single Boiler — Low T emperature Application (Heat Pump) Primary/Secondary Piping Fig. 1 1: Dual Boiler—Primary/Secondary Piping *Maximum 4 times the pipe diameter or 12”, whichever is less. *Maximum 4 times the pipe diameter or 12”, whichever is less.[...]

16 T able F: 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 50 feet equivalent length of tubing and fittings.) gpm = Gallons per minute, flow rate. MTS = [...]

17 Gas Supply Connection CA UTION: The heater and its manual shutoff valve must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa). The heater must be isolated from the gas supply piping system by closing the manual shutoff valve during any pressure testing of t[...]

18 Fig. 13: Sediment T rap Orientation Gas Supply Pr essur e A minimum of 4 in. WC and a maximum of 10.5 in. WC upstream gas pressure is required under load and no load conditions for natural gas. A minimum of 1 1 in. WC and a maximum of 13 in. WC is required for propane gas. The gas pressure regulator supplied on the heater is for low pressure ser[...]

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 SINGLE ST AGE T ANKST A T ST AGE 1 CONNECTION A TT ACH ST AGE 1 CONNECTIONS ON HEA TER TO 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 [...]

See T able H for appliance category requirements for the Hi Delta. Deter mination of Appliance Categor y for V enting Pur poses and V enting Ar r angements 21 Heater must be electrically grounded in accordance with NEC and C22.1(in Canada). NOTES: 1. Field installed ground to inside of junction box. 2. If any of the original wire as supplied with t[...]

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 any 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 manently closed window ** D Ver tical clearan[...]

24 ances shall not terminate over public walkways or 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[...]

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 –0.01 in. to –0.08 in. WC as measured 12 in. from the appliance flue outlet to ensure [...]

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 the space and the vent is installed horizontally through the wall to the outdoors. Adequate combustion and ventilation air must be sup- plied in acc[...]

29 Fig. 20: Direct V ent Horizontal Thru-Wall V enting (Category III) 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 (inches) Max. Air Intake Length (feet) HD101 HD151 III Stainless Steel (Gas T ight) 4 100, 4 Elbows Max. Galvanized Steel PV[...]

30 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) Min. Max. HD101 HD151 I T ype B Equivalent 4 6 25* Galvanized Steel PVC ABS CPVC 4 100 HD201 HD251 HD301 5 (HD201) 6 (HD251) 6 (HD301) 1 [...]

31 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[...]

Modulating T emper ature Control (Optional) This heater can be equipped with a Raypak modulat- ing temperature control. For operation with this control, refer to the T emp-T racker Installation and Operating Instructions, Raypak Catalog number 5000.66 (P/N 241 177). High Limit (Manual R eset) The heater is equipped with a manual reset high limit te[...]

33 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 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig. 26: Flow Switch Fig. 28: Low W ater Cut Off Flow Switc h Dual-purpo[...]

34 WIRING DIA GRAM—MODELS HD101–HD401[...]

35 Ste p 8 HD Troubleshooting Ste p 8 Ste p 9 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Is there a Call For Heat? Is Disable connection intact? Does the Pump come on? Is 24VAC at the NC side of the air pressure switch? Is blower pressure setting correct? Does i g niter p rove? Is air switch bouncing? Call our Technical Service Department 1-8[...]

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. [...]

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38 Check the Gas Supply Pressur e 1. Slowly turn on main gas shut-off valve. 2. Read the gas supply pressure from the manome- ter; minimum supply pressure is 4 in. WC, recommended supply is 7 in. WC for natural gas (minimum 1 1.0 in. WC for LP gas). 3. If pressure is > 14 in. WC, turn off the valve. 4. Check if the service regulator is installed[...]

39 3. Carefully remove 2-stage solenoid. 4. Skip to Step 9 for LO-fire adjustment only . 5. Locate and remove Lo-fire adjustment cap. 6. Carefully remove the spring & weight. 7. Using an allen wrench, turn clockwise to increase and counterclockwise to decrease the HI-fire man- ifold pressure. Heater will not run while adjusting HI-fire pressure[...]

40 • Insert ignition control lockout tests as safety check. F ollo w-Up • Safety checks must be recorded as performed. • T urn unit on. After main burner ignition: • Check Manometer(s) for proper reading(s). • Cycle unit several times and recheck readings. • Re-analyze with unit running record or print results. • Remove all Manometers[...]

41 3. Remove the (4) screws holding the panel in place. 4. Pull the air filter out for inspection. Replace if nec- essary . 5. When replacing, note the direction of the air flow defined on the side of the filter . The arrow should be pointing downward. 6. Replace the panel and screws before operating. Fig. 33: Remove the Screws and Panel Fig. 34: I[...]

heater operating efficiency . Maintenance as outlined below may be performed by the owner . Y ear ly (Be ginning of each hea ting season): 1. Annual service call by qualified service agency . 42 MAINTENANCE Suggested Minimum Maintenance Schedule: Regular service by a qualified service agency and maintenance must be performed to ensure maximum JACKE[...]

43 2. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal. 3. Visually inspect venting system for proper func- tion, deterioration or leakage. 4. Check that heater area is free from combustible materials, gasoline, and other flammable vapors and liquids. 5. Check for and remove any obstructio[...]

44 • hydrochloric acid/muriatic acid • cements and glues • antistatic fabric softeners used in clothes dryers • chloride-type bleaches, detergents, and cleaning solvents found in household laundry rooms • adhesives used to fasten building products • ... and other similar products. Areas causing contaminated combustion air: • dry clean[...]

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