Raypak 902B manual

INST ALLA TION & OPERA TING INSTR UCTIONS  / '*" )* % ;;:8I>K:  -:EA68:H  +)  -:K    WARNING: If these instructions are not followed exactly , a fire or explosion may result causing propert[...]

 Rev . 1 1 G:;A:8IHI=: ;DAADL>C< Changes to: W$CHI6AA6I>DCH 6I A:K6I>DCX 6C9 ADLA:69 8:GI>;>86I>DC DC E6<:  / 67A: % DC E6<:  W A:8IG>86A +DL:G DCC:8I>DCHX DC E6<:  / 67A:/ DC E6<:  2&g[...]

WARNINGS 4 BEFORE INST ALLA TION 5 +GD9J8I -:8:>EI  (D9:A $9:CI>;>86I>DC  -6I>C<H 6C9 :GI>;>86I>DCH  $CHI6AA6I>DCH 6I A:K6I>DC  DBEDC:CI 'D86I>DCH  ":C:G6A $C;DGB6I>DC  GENERAL SAFETY 8 / >B:/ :BE:G6IJG: -:A6I>DCH=>EH >C .86A9H  [...]

 D ANGER: $ C9>86I:H I=:EG:H:C8: D;>BB:9>6I: =6O6G9H L=>8=L>AA 86JH: H:K:G:E:GHDC 6A >C?JGN  9:6I= DG HJ7HI6CI>6A EGDE:GIN 96B6<: >; ><CDG:9 WARNING: $C9>86I:H I=: EG:H:C8: D; =6O6G9H DG JCH6;: EG68I>8:H L=>8= 8DJA9[...]

 BEFORE INST ALLA TION -6NE6@ HIGDC<AN G:8DBB:C9H I=6I I=>H B6CJ6A 7: G: K>:L:9 I=DGDJ<=AN 7:;D G: >CHI6AA>C< NDJG #> :A I6 =:6I:G  +A:6H: G:K>:L I=: ":C:G6A .6;:IN >C;DGB6 I>DC 7:;DG:>CHI6AA>C< I=:=:6I:G  !68IDGNL6G[...]

 Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side +6C:AH G:BDK:9;DG 8A6G>IN Fig. 3: Component Locations – Front[...]

 General Infor mation Qua nt it y o f Ve nt Si ze ( in.) Mode l No. Bur ne rs Gas Va lve s Blowers Fl u e Int ake 302B 6 1 1 5 6 402B 8 1 1 6 6 502B 10 2 1 6 6 652B 13 2 1 8 6 752B 15 2 1 8 6 902B 18 3 1 8 6 # B ur ne r s pe r Va lve St ag e s % F ire at Sta ge Mode l No. 123 12 12 302B 6 1 100 402B 8 1 100 502B 5 5 1 1, 2 50 10 0 652B 7 6 11 , [...]

 GENERAL SAFETY / D B::I 8DBB:G8>6A =DI L6I:G JH: C::9H I=: =><= A>B>I H6;:IN 8DCIGDADC I=>HL6I:G =:6I:G>H 69?JHI67A:JE ID P!  #DL:K:G  L6I:G I:BE:G6IJG:H DK:G P! 86C 86JH: >CHI6CI H:K:G: 7JGCH DG 9:6I= ;GD[...]

 INST ALLA TION INST ALLA TION Installation Codes $CHI6AA6I>DCH BJHI ;DAADL I=:H: 8D9:H Q 'D86A HI6I: EGDK>C8>6A 6C9 C6I>DC6A 8D9:H A6LH G:<JA6I>DCH 6C9 DG9>C6C8:H Q )6I>DC6A !J:A "6H D9:).$5)!+    V A6[...]

 $C 699>I>DC I=: =:6I:G H=6AA 7: >CHI6AA:9 HJ8= I=6I I=: <6H ><C>I>DC HNHI:B 8DBEDC:CIH 6G: EGDI:8I:9 ;GDB L6I:G 9G>EE>C< HEG6N>C< G6>C :I8 9JG>C< 6EEA>6C8: DE:G6I>DC DG H:GK>8: 8>G8JA6IDG[...]

 U.S . In sta llatio n s 1 Canadi a n I nstall ations 2 A Cl earan ce abo ve grade , ve ran da , por ch, deck , or ba lc o n y 1 f t (3 0 c m ) 1 f t (3 0 c m ) B Cl earan ce t o w ind ow o r doo r t ha t may b e opened 4 f t (1 . 2m) be low or to s id e of ope n in g ; 1 foo t ( 30 c m) abo v e o p en in g 3 f t (9 1 c m ) C Cl e aran ce to [...]

 Fig. 8: Minimum Clearances from Combustible Surfaces – Outdoor Installations Combustion and V entilation Air Indoor Units /=: =:6I:G BJHI 7: HJEEA>:9 L>I= HJ;;>8>:CI FJ6CI>I>:H D; CDC8DCI6B>C6I:9 6>G ID HJEEDGI EGDE:G 8DB7JHI>DC 6C9 :FJ>EB:CIK:CI>A6I>DC?[...]

 I=G:: DG ;DJG H=::I B:I6A H8G:LH CDI HJEEA>:9 :FJ6A AN9>HIG>7JI:9 6GDJC9 I=: 8>G8JB;:G:C8:D; I=: 9J8I AA 9J8I>C< H=DJA9 7: H:A;HJEEDGI:9 /=: ;>AI:G =DJH>C< >H CDI 9:H><C:9 ID HJEEDGI I=: 6>G 9J8I?[...]

 7 )DI A:HH I=6C I=: HJB D; I=: 6G:6H D; 6AA K:CI 8DCC:8IDGH >C I=: 8DC;>C:9 HE68: WARNING: D CDI JH: DC: E:GB6C:CI DE:C>C< B:I=D9 >; I=: :FJ>EB:CI GDDB >H JC9:G C:<6I>K: EG:HHJG: 8DC9>I>DCH DG I=: :FJ>EB:CI?[...]

  -:BDK: 6AA EAJB7>C< ;>II>C<H ID I=: =:69:G  /=>H L>AA>C8AJ 9:7DI= >CA:I 6C9 DJIA:I L6I:G E>E: JC>DCH 6C9 I=: EG:HHJG: G:A>:; K6AK: 6C9 9G6>C E>E>C<  -:BDK: A>B>IH 8DCIGDA 7JA7H 6C9DG [...]

 !6>AJG: ID :M8::9 S! S L>I=>C  B>CJI:H B6N G:HJAI >C I=: EG:B6IJG: ;6>AJG: D; I=: =DI HJG;68: ><C>I :G  G:BDI: ;A6B: H:CHDG  7JGC:GH 6C9= :6I :M8=6C<:G  $I 86C 86JH: DE:G6I>DC6A EGD7A:BH?[...]

 Pressur e Dr op in F eet of Head F eedwater Regulator -6NE6@G:8DBB:C9HI=6I6 ;::9L6I:GG:<JA6IDG7:>C HI6AA:9 6C9 H:I 6I  EH> B>C>BJB EG:HHJG: 6I I=: =><=:HI ED>CI D; I=: HNHI:B $CHI6AA 6 8=:8@ K6AK: DG 768@ ;ADL 9:K>8: JEH[...]

  P ota ble Wa ter and Space Heating  AAE>E>C< B6I:G>6AH6C9 8DBEDC:CIH8DCC:8I:9 ID I=: L6I:G =:6I:G ;DG I=: HE68: =:6I>C< 6EEA>86I>DC H=6AA 7: HJ>I67A: ;DG JH: L>I= EDI67A: L6I:G   / DM>88=:B>86AH HJ8=6H JH:9 [...]

   I=:GBDHI6I>86AAN 8DCIGDAA:9 B>M>C< K6AK: >H JH:9 ID B>M I=: DJIA:I L6I:G L>I= I=: EDDA L6I:G   /=>H B>M:9 L6I:G >H HJEEA>:9 6H I=: >CA:I L6I:G ID I=: EDDA =:6I:G  /=: EGDE:G 8DC;><JG6I>DC >H [...]

 -6NE6@ L6I:G =:6I:GH 86C DE:G6I: A>B:H86A:;G:: JH>C<EDI67A: L6I:GL>I=6 =6G9C:HHCDI :M8::9>C< <G6>CHE:G<6AADC+GDE:GDE:G6I>DC>H68=>:K:97NH:I I>C<I=: I:BE:G6IJG: G>H:L6I:G ;ADL E:G I=: <J>9:[...]

6I I:HI EG:HHJG:H :FJ6A ID DG A:HH I=6C  EH>  @+6-:A>:K:I:HIEG:HHJG:>C I=:<6HHJEEANA>C:EG>DG ID G:8DCC:8I>C< I=: =:6I:G 6C9 >IH B6CJ6A H=JID;; K 6AK: ID I=: <6H HJEE AN A>C: F AILURE T [...]

  -:>CHI6AA I=: E>E: 86E DC I=: A:;I=6C9 :C9 D; I=: B6>C <6H A>C:  -:BDK:EA6HI>8 86E;GDB I=:G><=I=6C9H>9: E6C:A 6 C9 G:>CHI6AA >CID I=: HI6C96G9 B6>C <6H DE:C>C< AD86I:9 DC I=: A:;I=6C9 H&[...]

Check the P ower Sour ce =:8@ I=: EDL:G HDJG8:    1  (>C>BJB  1  (3    1  (>C>BJB  1  (3    1  (6M>BJB $; I=: =:6I:G 9D:H CDI =6K: 6 ;[...]

 $CHI6AA:G 68I>DC >H G:FJ>G:9 ID :A:8IG>86AAN :C67A: NDJG =:6I:GIDDE:G6I:6;I:GB6@>C<I=:EDL:G8DCC:8I>DCH 4 DJ BJHI B6@: 68ADH:9 8DCI68I 8DCC:8I>DC DC .I6<:  8D CC:8IDG D; I=: :CIG6A +D>CI 2>G>C< +2 [...]

 S INGLE ST A GE TA NKST A T ST A GE 1 CONNECTION AT TA CH ST A GE 1 CO N NECTIONS O N HEA T ER TO T HE SINGLE ST A GE TA N K S TAT A S SHOWN IN THE DIAG R A M A BOV E. Fig. 23: Single-Stage T ankstat DCHJAI I=: L> G>C< 9>6<G6B H=>EE:9 L>I= I=: =:6I:G >C I=:>CHIGJ8I>DCE68@:IDG?[...]

 Combustion Ai r Suppl y Exh a ust Configuration Hea ter Vent ing Catego r y Certified Mate r ials Co mb u st i on A ir Inl et Ma terial Ve rtical Nat ur al D raf t Vent ing I “B ” Vent Fro m I ns id e Bu i ldi n g (N on -D ire c t V e nti n g ) H ori zont a l T hro ugh- th e-Wall Ventin g III St a in les s S tee l (G as T ig ht) Ve rtica[...]

  'D86I:6C9 <J6G9K:CI I:GB>C6I>DCID EG:K:CI688> 9:CI6A 8DCI68I 7N E:DEA: DG E:IH  * )*/ I:GB>C6I: K:CI >C L>C9DL L:AA HI6>GL:AA 6A8DK: 8DJGIN6G9 DG DI=:G G:8:HH:9 6G:6  * )*/  I:GB>C6I: [...]

  -:BDK:I=:H8G:LH G:I6>C>C<G>C<6C9G6>C <6H@:I ;GDB IDE D; =:6I:G   -:BDK: I=: H8G:LH ;AJ: 8DAA6G 6C9 <6H@:I ;GDB I=: GJC H>9: D; I=: I:: AD86I:9 >C I=: ;AJ: 7DM DC IDE D; I=: =:6I:G   -:K:GH:[...]

 T er mination / =:K:CI I:GB>C6A H=DJA9 7:K:GI>86A 6C9 H=DJA9 I:GB> C6I:DJIH>9: I=:7J>A9>C< 6IA:6HI ;I 67DK:I=: =><=:HI E D>CI D; I=: GDD; I=6I >H L>I=>C  ;I /=: K:CI 86E H=DJA9 =6K: 6 B>C>[...]

 HE::9DCDIDE:G6I:HJBB:G:M=6JHI ;6CADH: ;>G:EA68: 96BE:GH  +A68:>C DE:G6I>DC I=:6EEA>6C8:H 7:>C<>CHE:8I:9 !DAADL I=: B6CJ;68IJG:G YH >CHIGJ8I>DCH ;DG A><=I>C< :68= 6EEA>6C8: 9?JHI I=:GBDHI6I HD 6EEA>[...]

 Ai r Inl et Ma x . L ength Mode l No. Certified Vent in g Mate r ial Ve nt Si ze Max i mum Eq uiv a le nt Vent Le n gt h * Combustion Air Int ake Pipe Mate r ial 6” 8” 302B 5” 402B 100’ N/A 502B 6” 75’ 652B 752B 40’ 100’ 902B Cate gor y I II 8” 70’ Ro om Ai r 40’ Ducted Combustion Air Galvanized Ste el , PVC , ABS, CPVC[...]

 !DG >CHI6AA6I>DCH >C :MIG:B:AN 8DA9 8A>B6I: >I >H G: FJ>G:9 I=6I  /=: K:CI BJHI 7: >CHI6AA:9 L>I= 6 HA><=I JEL6G9 H ADE: D; CDI BDG: I=6C  >C8= E:G ;DDI D; =DG> ODCI6A GJC ID I=: K:CI?[...]

 !AJ:H HJEEDGI:9 DCAN 7N ;A6H=>C< 6C9 :MI:C9:9 67DK: I=: GDD; BDG: I=6C  ;I H=DJA9 7: H:8JG:AN <JN:9 DG 7G68:9 ID L>I=HI6C9 HCDL 6C9 L>C9 AD69H /=:6>G>CA:I DE:C>C<(0./7: >CHI6AA:9 ;I67DK:I=: GDD; A>C:[...]

 Fig. 28: Status LED Indicator Decal Heater Sequence of Oper ation Models 302B-902B  /=:7A68@=DI L>G:A:69<D:H 9>G:8IANIDI=: B6>C EDL:G HL>I8= /=>H 7A68@ ID<<A: HL>I8= >H AD86I:9 6I I=: B>99A: ;GDCI D; I=: 8DCIGDA 8DBE6GIB:CI[...]

 Ext er n al L ig ht s L i g h t C o l o r I n d i c a t i o n P o w e r B l u e M a i n p o w er is on Cal l For Heat Yel low Th ermo stat i s cl osed S a f e t y R e d O ne or m ore s a fe ti es is inoperativ e Ign i tion R ed Ign i tion m odu l e is i no p e rat ive F l o w G r e e n Flow is p rese nt Blo w er 1 Gr e e n B l o w er 1 is o [...]

Ignition Module 2=:C 699>I>DC6A =:6I >H C::9:9 I=: 8DB7JHI>DC 6>G 7ADL:G HI6GIH ID EJG<: 6>G ;GDB I=: 8DB7JHI>DC 8=6B 7 :G ;DG 67DJI  H:8DC9H *C EGDD;D;6>G ;ADL  I=: 6>GEGDK>C< HL>I8= 8ADH:H 6C9 I=: &[...]

 High Limit (Manual Reset) /=: =:6I:G >H :FJ>EE:9 L>I= 6 B6CJ6A G:H:I =><= A>B>I I:BE:G6IJG: 9:K>8: +JH= I=: G:H:I 7JIIDC 6C9 69?JHI I =: H:II>C< ID   P! 67DK: 9:H>G:9 DE:G6I>C< I:B E:G6IJG: Flow Switch /=&[...]

 Fig. 34: Fan-Proving Switch Fig. 35: Blocked V ent Switch UDB Dia gnostic Boar d /=>H =:6I:G >H :FJ>EE:9 L>I= 6 9>6<CDHI>8 7D6G9 L=>8= L>AA>C9>86I:;6JAIH6HI=:N D88JG  -:;:GIDI=:;DAADL>C< H:8I>DC ;DG >CHIGJ8I>DCH DC 688:HH>C<[...]

 Detection D elay Fault Flow Switch Blower Switch Factory Option External Interlock CWS/CWR Ignition Lockout *T oggles Between / H i Delta PVC V ent Limit-CHX M anual High Limit Auto High Limit L ow W ater Cut-o ff V ent Pressure L ow Gas Pressure High Gas Pressure Controller A l a rm Power On / No CFH System Normal Standby / Web Si te* Power[...]

 87%-Ef ficiency Boiler s – Special Instr uctions Wa ter Piping C :;;>8>:C8N 7D>A:G G:FJ>G:H 6 B>C>BJB >CA:I L6I:G I:BE:G6IJG: D; S! S ID EG:K:CI :M8:H H>K: 8DC9:CH6I>DC >C I=: 8DB7JHI>DC 8=6B7:G  C ?[...]

 W ARNING: DCI68I I=: K:CIB6I:G>6A B6CJ;68IJG:G >; I=:G: 6G: 6CN FJ:HI>DCH 67DJI I=: 6EEA>6C8: 8 6I:<DGNDGHJ>I67>A>IND;6K:CIB6I:G>6A ;DG6I:<DGN $$ $$$ DG $1 6EEA>86I>DCH 0H>C< >BEGDE:G K:CI>C< B6I:G>6[...]

 Horizontal T hr ough-the-Wall V enting (Categor y IV) WARNING: 1 :CI 8DCC:8IDGH H:GK>C< 6EEA>6C8:H K:CI:9 7N C6IJG6A 9G6;I H=6AA CDI 7: 8DCC:8I:9 >CID 6CN EDGI>DC D; B:8=6C>86A 9G6;I HNHI:BH DE:G6I>C< J C9:G 6 EDH>I>K: EG:HHJG: Fig. 39: Horizontal Th[...]

 /=: HI6>CA :HH HI::A 9>G:8I K:CI 86E BJHI 7: ;JGC>H=:9 7N I=: 7D>A:G B6CJ;68IJG:G >C 688DG96C8: L>I= >IH A>HI >C< H6A:H DG9:G DEI>DC  0H: DCAN 9DJ7A:L6AA K:CI E>E: 6C9 I=: HE:8>6A <6H K:CI?[...]

 Direct V ent - V er tical Ve rtical V enti n g Height* Ai r Inl et Max. Length ** Mode l Certified Vent in g Mate r ial Ve nt Si ze Min. Max . Co mb u st i on A ir Int ake Pipe Mate r ial 6” 8” 302B 5” 402B 100’ N/A 502B 6” 75’ 652B 752B 902B Cate gor y I I or I V 8” 5’ 25’ Gal vani zed Stee l , PVC , ABS, CPVC 40’ 100’[...]

 W iring Dia g r am[...]

 ST ART -UP Pre Star t-up Filling System (Heating Boiler s) !>AA HNHI:B L>I= L6I:G  +JG<: 6AA 6>G ;GDB I=: HNHI:B 'DL:G HNHI:B EG:HHJG: *E:C K6AK:H ;DG CDGB6A HNH I:B DE:G6I>DC 6C9  ;>AA HNHI:B I=GDJ<= ;::9 EG:HHJG: (6CJ6AAN DE:[...]

 Prepar ation Check Po wer Suppl y 2>I= BJAI>B:I:G 6I >C8DB>C< EDL:G  8=:8@ KDAI6<: 7:IL::C #DI  DBBDC T 1  #DI  "GDJC9 T 1  DBBDC  "GDJC9   1  Attach Manometer s to Measure P[...]

 Safety Inspection  =:8@ 6AA I=:GBDHI6IH 6C9 =><= A>B>I H:II>C<H  JG>C<I=: ;DAADL>C<H6;:IN 8=:8@HA:6K: B6CDB: I:GH =DD@:9 JE 8=:8@ 6C9 G:8DG9   $; DI=:G<6H;>G:9 6EEA>6C8:H>C I=: GDDB6G: DC[...]

  (6CJ6AAN 8ADH: I=: 9DLCHIG:6B A:6@ I:HI K6AK:  *E:C I:HI ED>CI  6C9 8DCC:8I 6 B6CDB:I:G ID >I 1 :G>;NI=6II=:G: >H<6HEG:HHJG:6C9I=6I>I>HL>I= >CI=: EGDE:G G6C<: )*/  BJHI CDI :M8::9 [...]

  / DG:HI6GIHNHI:B;DAADL A><=I>C<>CHIGJ8I>DCH>CI=: *E:G6I>DC H:8I>DC   =:8@ ID H:: I=6I I=: =><= A>B>I 8DCIGDA >H H:I 67DK:I=:9:H><CI:BE:G6IJG:G:FJ>G:B:CIHD; I=: HNHI:B !DGBJAI>EA: ODC:[...]

 TR OUBLESHOO TING Ste p 7 Ste p 6 Ste p 5 S tep 1 S tep 2 S tep 3 S tep 4 Is there a Call For H eat? I s Disable j um p e r intact? ( J1 ) I s there 120VAC at J8 C onnecto r o n the CPW board? D o the combustion air b lowers come on? I s 24VAC at pr ese nt at TH (J3 & J12 on C PW board and orange wire on ignition module)? C heck flow swi[...]

 MAINTENANCE Suggested Minimum Maintenance Schedule -:<JA6G H:GK>8: 7N 6 FJ6A>;>:9 H:GK>8: 6<:C8N 6C9 B6>CI:C6C8: BJHI 7: E:G;DGB:9 ID :CHJG: B6M>BJB DE:G6I>C< :;;>8>:C8N  (6>CI:C6C8: 6H DJIA>C:9 7:ADL B6N 7: E:G;DGB:9 7N I=: DLC:G ?[...]

 W eekl y !D G  A D L E G : H HJ G :  = : 6I : G H   I: H I  A D L L 6 I :G  8 J I  D; ; 9 :K>8: 2>I= 6I A:6HI DC: HI6<: D; I=: 6EEA>6C8: DC 9:EG:HH I=: ADL L6I:G 8JID;; I:HI 7JIIDC 6EEA>6C8: H=DJA9H=JID;;6C9 ><C>I>[...]

 APPENDIX Inside Air Contamination AA =:6I:GH :ME:G>:C8: HDB: 8DC9:CH6I>DC 9JG>C< HI6GIJE /=: 8DC9:CH6I: ;GDB ;AJ: <6H >H 68>9>8  DB7JHI>DC 6>G86C 7:8DCI6B>C6I:9 7N 8:GI6>CK6EDGH >C I=: 6>G L=>8= G6>H: I=: [...]

 L IMIT ED P ART S W A RR AN TY HI DE LT A – T YP ES H A ND WH M OD ELS 302 B–902 B SCOP E R aypak, Inc. (“Ray pak”) w arr ants to th e orig inal ow ner th at al l parts of th is h eater w hic h a re ac tual ly m anuf actur ed by R aypak wil l be free f rom f ailur e un der n orm al use a nd s ervice for the s pec ifie d warr anty per[...]

 LIMIT E D P AR TS W A RRAN TY HI DELT A – TY PE P MO DELS 302 B–90 2B S CO P E Ray pa k, I nc. (“ Ray pak”) w arr an ts to the or igi nal ow ner t ha t a ll pa r ts o f t his hea ter w hi c h are actu ally man ufac tured by R ay pak will b e fr ee from f ailur e un de r n orm al use a nd serv ice for th e sp ecif ied wa rr ant y pe r[...]

 START-UP CHECKLIST FOR FA N-ASSISTED RAYPAK PRODUC TS This s t ar t-u p c heck li st is t o be c o mpl e te ly f illed o ut b y the s er vic e te ch n ic ia n s tar ti ng u p t he Ra ypak B oil er or H eater fo r the first time. All in fo rm a ti on ma y b e us ed f or warr a nty p u rp o se s an d to ens ure that t he ins tal la t i on is c[...]

 7 3 (+/$*). /=: ;DAADL>C< :FJ>EB:CI >H :M: BEI ;GDB   (-6 I=GDJ<=   /=: :FJ>EB:CI A>HI:9 >C =6EI:G  :CI>IA:9  FJ>EB:CI )DI -:FJ>G:9 / D : 1 :CI:9 >C I=[...]

[...]

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