Raypak 302A-902A - Manual

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 Quantity of Vent Size (in.) Model No. Burners Gas Valves Blowers Flue 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 Valve Stages % Fire at Stage Model No. 1 2 3 1 2 1 2 302A 6 1 100 402A 8 1 100 502A 5 5 1 1,...

8 GENERAL SAFETY To meet commercial hot water use needs, the highlimit safety control on this water heater is adjustable upto 210°F. However, water temperatures over 125°Fcan cause instant severe burns or death from scalds.When supplying general purpose hot water, the rec-ommended initial setting fo...

9 INSTALLATION INSTALLATION Installation Codes Installations must follow these codes: • Local, state, provincial, and national codes, laws,regulations and ordinances • National Fuel Gas Code, ANSI Z223.1/NFPA 54 –latest edition (NFGC) • National Electrical Code, ANSI/NFPA 70 - latestedition (NEC) • ...

10 In addition, the heater shall be installed such that thegas ignition system components are protected fromwater (dripping, spraying, rain, etc.) during applianceoperation or service (circulator replacement, controlreplacement, etc.). Clearances Indoor Installations Heater Side Minimum Clear- ance ...

12 Fig. 8: Minimum Clearances from Combustible Surfaces – Outdoor Installations Combustion and Ventilation Air Indoor Units The heater must be supplied with sufficient quantitiesof non-contaminated air to support proper combustionand equipment ventilation. Combustion air can be sup-plied via convent...

13 three or four sheet metal screws (not supplied) equal-ly distributed around the circumference of the duct. Allducting should be self-supported. The filter housing isnot designed to support the air duct. TruSeal™ Combustion Air In certain applications it may be necessary to utilizethe TruSeal opti...

14 b. Not less than the sum of the areas of all ventconnectors in the confined space. WARNING: Do not use one permanent opening method if the equipment room is under negativepressure conditions or the equipment is commonvented with other gas-fired appliances. 1. Ventilation of the space occupied by ...

16 Failure to exceed 105ºF (41ºC) within 7 minutes mayresult 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 ofthe vent system. The bypass allow...

18 Potable Water and Space Heating 1. All piping materials and components connected tothe water heater for the space heating applicationshall be suitable for use with potable water. 2. Toxic chemicals, such as used for boiler treatment,shall not be introduced into the potable water usedfor space hea...

20 shut-off. Close isolation valves and remove water pip-ing from the in/out header on the heater. Drain theheater and any piping of all water that may experiencebelow-freezing temperatures. Pool/Spa Water Chemistr y Water Hardness Water hardness is mainly due to the presence of cal-cium and magnesi...

21 Gas Supply Connection The heater must be isolated from the gas supply pip-ing system by closing the manual shut-off valve duringany pressure testing of the gas supply piping systemat test pressures equal to or less than 1/2 psi (3.45kPa). Relieve test pressure in the gas supply line priorto recon...

22 8. Remove the rubber grommet from the left-hand-side panel and reinstall into the standard main gasopening, located on the right-hand side of theheater. 9. Install a coupling, nipple, union and sediment traponto the right-hand end of the main gas line andthen install the gas line, making sure tha...

23 CIRCUIT BREAKER WHITE GROUND BLACK GREEN A B C Fig. 18: Wiring Connections Check the power source: AC = 108 VAC Minimum, 132 VAC MAXAB = 108 VAC Minimum, 132 VAC MAXBC = <1 VAC Maximum If the heater does not have a factory-wired stage con-troller, it is factory-wired in an on-off configuration...

25 Installer action is required to electrically enable yourheater to operate after making the power connections.You must make a closed contact connection on Stage1 connector of the Central Point Wiring (CPW) boardfor temperature control connections. This will be donebased on the controller option se...

26 Combustion Air Supply Exhaust Configuration Heater Venting Category Certified Materials Combustion Air Inlet Material Vertical Natural Draft Venting I “B” Vent From Inside Building(Non-Direct Venting) Horizontal Through- the-Wall Venting III Stainless Steel (Gas Tight) Vertical Natural Draft Vent...

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, causingice formations. 11....

28 5. Remove the screws, retaining ring and rain gasketfrom top of heater. 6. Remove the screws, flue collar and gasket fromthe run side of the tee located in the flue box ontop of the heater. 7. Reverse the components and reattach in the newlocation. 8. Make sure that the stainless steel cover, now...

29 Ter 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 capshould have a minimum clearance of 4 ft horizontallyfrom and in no case above or below (unless a 4 ft hori-zontal dista...

31 Air Inlet Max. Length Model No. Certified Venting Material Vent Size Maximum Equivalent Vent Length* Combustion Air Intake Pipe Material 6” 8” 302A 5” 402A 100’ N/A 502A 6” 75’ 652A 752A 40’ 100’ 902A Category III 8” 70’ Room Air 40’ Ducted Combustion Air Galvanized Steel, 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 upwardslope 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 ...

33 Flues supported only by flashing and extended abovethe roof more than 5 ft should be securely guyed orbraced to withstand snow and wind loads. The air inlet opening MUST be installed 1 ft above theroof line or above normal snow levels that might ob-struct combustion air flow. This dimension is cr...

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 mainpower switch. This black toggle switch is locatedat the middle front of the control compartment. 2. When the main power switch is pl...

Ignition Module When additional heat is needed, the combustion airblower 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. Toensure safe operation, the gas valve cannot open untilthe igniter is ve...

39 87%-Efficiency Boilers – Special Instructions Water Piping An 87%-efficiency boiler requires a minimum inletwater temperature of 120ºF (49ºC) to prevent exces-sive condensation in the combustion chamber. An87%-efficiency boiler operated with an inlet tempera-ture of less than 120ºF (49ºC) must ha...

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 propertydamage. Vent Ter minal Location 1....

45 START-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 untilwater appears, then close vent. ...

46 Preparation Check Power Supply With multi-meter at incoming power, check voltagebetween: Hot - Common (≈120 VAC) Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) Attach Manometers to Measure Pressures 1. Turn off main gas valve. 2. Attach 24” scale manometer to the first main gasshut-off valv...

49 10. To restart system, follow lighting instructions in the Operation section. 11. Check to see that the high limit control is set above the design temperature requirements of thesystem. For multiple zones: Check to make sure the flow isadjusted as required in each zone. 12. Check that the heater ...

50 TROUBLESHOOTING Step 7 Step 6 Step 5 Step 1 Step 2 Step 3 Step 4 Is there a Call For Heat? Is Disable jumper intact? (J1) Is there 120VAC at J8 Connector 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 modul...

51 MAINTENANCE Suggested MinimumMaintenance Schedule Regular service by a qualified service agency andmaintenance must be performed to ensure maximumoperating efficiency. Maintenance as outlined below may be performed bythe owner. Daily 1. Check that the area where the heater is installedis free fro...

52 Weekly For low-pressure heaters, test low-water cut-offdevice. (With at least one stage of the appliance on,depress the low water cut-off test button, applianceshould shut-off and ignition fault light should come on.Depress reset button to reset). 1. Check igniter. (Resistance reading should be 4...

53 APPENDIX Inside Air Contamination All heaters experience some condensation duringstart-up. The condensate from flue gas is acidic.Combustion air can be contaminated by certain vaporsin the air which raise the acidity of the condensate.Higher acidity levels attack many materials includingstainless...