Raypak 992B manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.51 1F Effective: 06-23-09 Replaces: 08-21-08 P/N 241259 Rev . 7 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 liq[...]

2 Rev . 7 reflects the following: Changes to: Fig. 3 on page 6; the UDB Diagnostic Board and UDB Fault History sections on page 44; the Wiring Diagrams on pages 50 and 51.[...]

WARNINGS 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 Stacking 9 Clearances 1 1 Combustion and V entilation A[...]

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 OPTIONAL FLUE CONNECTION 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 Qua nt it y o f Vent Size (i n.) Mode l No. Bur ne rs Gas Va lve s Blowers Flue Intake 992B 11 2 + 1* 2 10 10 1262B 14 3 + 1* 2 12 10 1532B 17 4 2 12 10 1802B 20 4 2 14 10 2002B 23 5 3 14 10 2072B 23 5 3 14 10 2342B 26 5 3 16 10 Bur ne r s p er Va lv e St age s % F ire at St ag e Mode l No. 1 1A 2 3 4 1 2 3 4 1 2 3 4 992B 6 3[...]

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 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 low or to sid e of openin g; 1 foot (30 c m) above op ening 3 ft (91 c m) C Clearance to per manently closed wind ow ** D Ver tical clearan [...]

11 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 Clea ranc e fr om Comb us tibl e Surf a c es Recom mend[...]

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 Dr op in F eet of Head F eedwater R e gulator Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the highest 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 Wa ter 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 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 installed within 10 ft of the heater . 10. Replace the left and right front panels on the heater . Gas Supply Pr essur e A minimum of 5.0 in. WC and a maximum of 10[...]

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: On-Off Wiring Connections Fig. 22: 2-Stage Wiring Connections Fig. 23: 3-Stage Wiring Connections Fig. 24: 4-Stage Wiring Connection Installer action is required to electrically enable your heater t[...]

25 ured to operate in an on-off firing mode. This means that you will connect a single-pole control to stage one of the CPW board. Then jumper the remaining firing stages. For example, if your heater is a Model 1532B, you will jumper stages two, three and four . Then your heater will either be on at full fire, or it will be off. 2. For 2-stage cont[...]

26 Combustion Air Su p ply Exh a ust Configuration Heater Venting Category Certified Mate r ials Combustion Air Inlet M ater ial Ver ti ca l N atu r a l Draft Ventin g I “B” Ven t From Ins ide Bu ilding (Non-Direct Venting) Horizontal Through- the-Wall Venting II I Stainless Stee l (Gas Tight) Ver ti ca l N atu r a l Draft Ventin g I “B” Ve[...]

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 highest 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 meters[...]

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 I nlet Max . Len gth* Mode l No. Certified Vent in g Mate r ial Vent Size Max i mum Eq uiv a le n t Vent Le ngt h* Combustion Air Intake Pipe Mate r ial 10” 12” 992B 10” 1262B 1532B 12” 75’ 100’ 1802B 2002B 2072B 14” 2342B Category I II 16” 70’ Room Air 40’ Ducted Combustion Air Galvanized Ste el , PVC , ABS, CPVC 40’ 7[...]

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 approved condensate trap must be installed per applicable codes. 2. The intake vent must be insulated through the length of the [...]

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. 31: Status LED Indicator Decal Heater Sequence of Operation Models 992B-1262B 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 applied to the 120 V AC termi- na[...]

35 Ext er n al L ig ht s Li ght Co lor I ndi cati on Power Blue Main power is on Call For H eat Yellow Thermostat is closed Sa fety Re d One or more safe ties is inopera- tiv e Ign i tion Re d Ign i tion m od ul e is ino per at iv e Flow Green Flow is prese nt Blower 1 Green Blower 1 is on Blower 2 Green Blower 2 is on Blower 3 Green Blower 3 is on[...]

36 gized by a 120 V AC signal from S-1 on the ignition module for approximately 30 seconds. (The hot surface igniter must draw greater than 3.1 amps while being energized or ignition lockout will occur after three tries.) 43. Once the ignition module determines that the hot surface igniter has heated up and operating prop- erly , a 24 V AC signal i[...]

37 9. 24 V AC is applied to the blue power light located on the status display board. 10. 24 V AC is also applied to the red LED safety shut- down light on the front status board until the safeties have been proven. 1 1. 24 V AC is applied to the alarm circuit (optional). If the E-5 sales option (Alarm) is included a 5-sec- ond time delay relay wil[...]

38 36. After proper air pressure is received in the air plenum, the air pressure switches will close. 37. If there is insufficient air pressure and the air pres- sure switch does not close, a 24 V AC signal is sent to the Universal Diagnostics Board to indicate the fault. 38. A 24 V AC signal is now sent to the blower LED’s on the status board. 3[...]

39 60. If ignition module two locks out, a signal will be sent to the Universal Diagnostics Board and to the status display board to indicate an ignition fault. 61. The coil of relay K-5 (N.O.) is now energized with the (K-5) contacts closing downstream of the stage 4 connections. 62. Power is now applied to time delay relay 3 and the contacts of T[...]

40 23. When a CFH occurs, a 24 V AC signal is sent to the CFH light on the status panel located on the lower left front of the control compartment. 24. Power is also sent from pin 2 of the stage 1 con- nection to pin P1-3 of the universal diagnostic board. 25 . Power is now sent to terminal TP4 of the Economaster II to energize the relay and close [...]

41 49. When power is sent to gas valve 1 it is also sent to time delay relay 1 (TD-1) which starts a 5-second countdown. 50. After the 5-second countdown from TD-1 and the internal contacts close, time delay relay 2 (TD-2 ) receives 24 V AC. 51. Gas valve 1a is energized allowing the remainder of stage 1 to fire. 52. After the 5-second countdown fr[...]

42 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 [...]

43 Fig. 35: Operating Control Low W ater Cut-Off (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. 36: Low W ater Cut-Off High and Low Gas Pr[...]

UDB F ault Histor y T o view the fault codes in the UDB history file: 1. Press the UP or DOWN buttons on the membrane switch for 2 seconds to access the fault history . 2. Press either button to scroll through the recorded faults in history . 3. The most recent fault recorded will be the first fault displayed (the last 16 faults are stored in the h[...]

45 87%-Ef ficiency Boilers – 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 lo[...]

46 WARNING: Contact the vent material manufacturer if there are any questions about the appliance category or suitability of a vent material for Category II, III or IV applications. Using improper venting materials can result in personal injury , death or property damage. V ent T er minal Location 1. Condensate can freeze on the vent cap. Frozen co[...]

47 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. 43: Horizontal Through-the-W all V enting (Category IV) Installation These installations utilize the boiler-mounted[...]

48 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[...]

49 Direct V ent - V er tical Vert ica l Ve nt in g Height* Air I nlet Max . Len gth** Mode l Certified Vent in g Mate r ial Vent Size Min. Max . Combustion Air Intake Pipe Mate r ial 10” 12” 992BE 10” 1262BE 1532BE 12” 75’ 100’ 1802BE 2002BE 2072BE 14” 2342BE Category I I or IV 16” 5’ 25’ Galvanized Steel, PVC , ABS, CPVC 40’ [...]

50 W iring Dia g r am—Models 992B–1262B SEE PAGE 24 FOR ST AGING OPTIONS[...]

51 W iring Dia g r am—Models 1532B–2342B[...]

52 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 Wa ter Heaters) Pu[...]

53 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 essur es 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)[...]

54 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 [...]

55 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[...]

56 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 [...]

57 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[...]

58 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[...]

59 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). Monthly 1. Check flue, vent, stack, or outlet dampers. 2. T est fan air pressure. (See “Blo[...]

60 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- [...]

61 LIMITED PARTS WARRANTY HI DELTA – TYPES H AND WH MODELS 992B–2342B SCOP E Ray pak, I nc. ( “Ray pak ”) w arr ants to th e or ig inal ow ner th at al l par ts o f th is h ea ter w hic h a re ac tu al ly m an uf ac tur ed by R ay pak will b e free fro m f ai lur e un der n orm al use a nd s ervic e for t he s p ec if ie d wa rra nt y per i[...]

62 LIMI TED P ARTS WA RRANTY HI DELTA – TYPE P MODELS 992B–2342B SCOP E Ray pak, Inc. (“ Ray pak” ) w ar r ants to th e o rig in al ow ner th at al l par ts o f th is h ea ter w hic h ar e ac tu al ly m anuf ac tur ed by R ay pak w il l be fre e fro m f ai lur e un der n orm al use a nd s erv ice for th e sp ec if ie d wa rr a nty per iods [...]

63 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This s tart- u p ch ec k lis t is to b e c o mp l ete ly fill e d o ut by th e s e rv ic e tec hn ici an s ta r tin g up th e R ay p ak Boi ler o r H eate r for the first time. All in formation may be used for warranty p urposes an d to ensure that the ins tallation is c orrec t. Addi ti o na l[...]

64 NOTES: _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ _____[...]

65 NOTES: _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ _____[...]

66 NOTES: _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ ____________ ___________ ______________ ____________ ____________ ______ _ _____________ ____________ _____[...]

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