Page 3 - CONTENTS
WARNINGS 4 BEFORE INSTALLATION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 Time/Temperature Relationships inScalds 8 INSTALLATION 9 Installation Codes 9 Equipment Base 9 Stacking 9 C...
Page 4 - WARNING - CALIFORNIA PROPOSITION; WARNINGS; Pay Attention to These Terms
4 DANGER: 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 causesevere personal injury, death or substantial property damage if ignored. CA...
Page 5 - BEFORE INSTALLATION; Product Receipt; Altering any Raypak pressure vessel
5 BEFORE INSTALLATION Raypak strongly recommends that this manual be re-viewed thoroughly before installing your Hi Deltaheater. Please review the General Safety informationbefore installing the heater. Factory warranty does notapply to heaters that have been improperly installed oroperated. (Refer ...
Page 6 - Component Locations
6 Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front
Page 7 - General Information; Valve; Table B: Manifold Data; per Valve
7 General Information Quantity of Vent Size (in.) Model No. Burners Gas Valves Blowers Flue Intake 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 # Burners per Valve Stages % Fire at Stage Model No. 1 2 3 1 2 1 2 302B 6 1 100 402B 8 1 100 502B 5 5 1 1, ...
Page 8 - GENERAL SAFETY; Feel water before bathing or showering.; Relationships in Scalds; Water; Table D: Time to Produce Serious Burn
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...
Page 9 - Installation Codes; Installations must follow these codes:; Equipment Base; The heaters should be located in an
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) • ...
Page 10 - Clearances; Indoor Installations; Table E: Clearances – Indoor Installations; Fig. 6: Minimum Clearances from Combustible; Outdoor Installations; Table F: Clearances – Outdoor Installations
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 Clearance fr...
Page 11 - Table G: Vent/Air Inlet Termination Clearances
11 U.S. Installations 1 Canadian Installations 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 be opened 4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) C Clearance to permanently closed w...
Page 12 - Combustion and Ventilation Air; Indoor Units
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...
Page 13 - TruSealTM Combustion Air; Conventional Combustion Air; All Air from Inside the Building; TWO; All Air from Outdoors; Two permanent openings
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...
Page 14 - Water Piping; General
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 negativepressure conditions or the equipment is commonvented with other gas-fired appliances. 1. Ventilation of the space occupied by...
Page 16 - Cold Water Starts; Temperature & Pressure Gauge; Hydronic Heating; Pump Selection; Table H: Heater Rates of Flow and Pressure Drops; Individual and multi-boiler Cold Water Start
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...
Page 17 - Piping; Primary/Secondary Piping; with Primary/Secondary Piping
17 Pressure Drop in Feet of Head Feedwater Regulator Raypak recommends that a feedwater regulator be in-stalled and set at 12 psi minimum pressure at thehighest point of the system. Install a check valve orback flow device upstream of the regulator, with amanual shut-off valve as required by local c...
Page 18 - Potable Water and Space Heating; All piping materials and components connected to; Fig. 13: Single Domestic Hot Water Heater and Storage; When the system requires water for space heating
18 Potable Water and Space Heating 1. All piping materials and components connected to the 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 h...
Page 19 - Automatic Chlorinators and Chemical
19 A thermostatically controlled mixing valve is used tomix the outlet water with the pool water. This mixedwater is supplied as the inlet water to the pool heater.The proper configuration is shown in Fig. 15. Theactive element of the valve adjusts the mixing ratio tomaintain the inlet water above 1...
Page 20 - Table J: Water Chemistry; Fiberglass Pools; Water Temperature
20 Raypak water heaters can operate lime/scale-freeusing potable water with a hardness not exceeding 25grains per gallon. Proper operation is achieved by set-ting the temperature rise/water flow per the guidelinesin the installation instructions. If the hardness of thewater exceeds the maximum level...
Page 21 - FAILURE TO FOLLOW; Reversing Gas Supply Connection; Gas Supply; Gas Supply Connection; Model; Table K: Maximum Equivalent Pipe Length
at test pressures equal to or less than 1/2 psi (3.45kPa). Relieve test pressure in the gas supply line priorto reconnecting the heater and its manual shut-offvalve to the gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GASVALVES . Over pressurized gas valves are not cov- ered by wa...
Page 22 - Gas Supply Pressure; Electrical Power Connections; DO; Field-Connected Controllers
22 6. Reinstall the pipe cap on the left-hand end of the main gas line. 7. Remove plastic cap from the right-hand side panel and reinstall into the standard main gas openinglocated on the left-hand side of the heater. 8. Remove the rubber grommet from the left-hand- side panel and reinstall into the...
Page 23 - Field Wiring Connection
Check the Power Source 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 withother stage terminals jumpered. To field-connect a...
Page 25 - Venting; Flue Exhaust Tee; Table L: Flue Exhaust Tee Kits
25 SINGLE STAGE TANKSTAT STAGE 1 CONNECTION ATTACH STAGE 1 CONNECTIONS ON HEATER TO THE SINGLE STAGE TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE. Fig. 23: Single-Stage Tankstat Consult the wiring diagram shipped with the heater inthe instruction packet or at the end of this section. Thestage-selector ter...
Page 26 - Table M: Venting Category Requirements
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...
Page 27 - Canadian Installations; Changing the Flue Outlet
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. 1...
Page 28 - Natural Draft Vertical Venting; Installation
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 ontop of the heater. 7. Reverse the components and reattach in the new location. 8. Make sure that the stainless steel cover, ...
Page 29 - the following steps must be fol-; CPVC
29 Termination The vent terminal should be vertical and should termi-nate outside the building at least 2 ft above the highestpoint 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 distance...
Page 31 - Table O: Category III Horizontal and Direct Venting; 0’ of straight flue pipe
31 Air Inlet Max. Length Model No. Certified Venting Material Vent Size Maximum Equivalent Vent Length* Combustion Air Intake Pipe Material 6” 8” 302B 5” 402B 100’ N/A 502B 6” 75’ 652B 752B 40’ 100’ 902B Category III 8” 70’ Room Air 40’ Ducted Combustion Air Galvanized Steel, PVC, ABS, CPVC 30’ 80’ ...
Page 32 - Direct Vent - Vertical
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, anapproved condensate trap must be installed perapplicable codes. 2. The intake ven...
Page 33 - Outdoor Installation; Freeze Protection; Controls
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...
Page 34 - Heater Sequence of Operation
34 Fig. 28: Status LED Indicator Decal Heater Sequence of Operation Models 302B-902B 1. The black (hot) wire lead goes directly to the main power switch. This black toggle switch is locatedat the middle front of the control compartment. 2. When the main power switch is placed in the “ON” position, 1...
Page 35 - Table P: Status LED Indicators
35 External Lights Light Color Indication Power Blue Main power is on Call For Heat Yellow Thermostat is closed Safety Red One or more safeties is inoperative Ignition Red Ignition module is inoperative Flow Green Flow is present Blower 1 Green Blower 1 is on Stage 1 Green Stage 1 is on Stage 2 Gree...
Page 36 - Ignition Module; Table Q: Ignition Module
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.To ensure safe operation, the gas valve cannot openuntil the igniter is ver...
Page 38 - Pump Time Delay
38 Fig. 34: Fan-Proving Switch Fig. 35: Blocked Vent Switch UDB Diagnostic Board This heater is equipped with a diagnostic board whichwill indicate faults as they occur. Refer to the followingsection for instructions on accessing, reviewing andclearing these faults. UDB Fault History To view the fau...
Page 39 - Table R: UDB Fault Messages
39 Detection Delay Fault Flow Switch Blower Switch Factory Option External Interlock CWS/CWR Ignition Lockout *Toggles Between / Hi Delta PVC Vent Limit-CHX Manual High Limit Auto High Limit Low Water Cut-off Vent Pressure Low Gas Pressure High Gas Pressure Controller Alarm Power On / No CFH System ...
Page 40 - Special Instructions; Proper installation of flue venting is criti-; Table S: Heater Rate of Flow and Pressure Drop
40 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...
Page 42 - Table U: Category II and IV Venting
42 Horizontal Through-the-Wall Venting (Category IV) WARNING: Vent connectors serving appliances vented by natural draft shall not be connected intoany portion of mechanical draft systems operatingunder a positive pressure. Fig. 39: Horizontal Through-the-Wall Venting (Category IV) Installation Thes...
Page 44 - Category II; Table V: Category II or IV Vertical Venting
44 Direct Vent - Vertical Vertical Venting Height* Air Inlet Max. Length** Model Certified Venting Material Vent Size Min. Max. Combustion Air Intake Pipe Material 6” 8” 302B 5” 402B 100’ N/A 502B 6” 75’ 652B 752B 902B Category II or IV 8” 5’ 25’ Galvanized Steel, PVC, ABS, CPVC 40’ 100’ Note: When ...
Page 45 - Wiring Diagram
Page 46 - WHAT TO DO IF YOU SMELL GAS:
46 START-UP Pre Start-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. A...
Page 47 - Blower Adjustment
47 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 gas shut-off val...
Page 50 - OPERATION; Lighting Instructions
50 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 ...
Page 51 - TROUBLESHOOTING
51 TROUBLESHOOTING 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 ignit...
Page 52 - MAINTENANCE; Suggested Minimum; Preventive Maintenance; Daily
52 MAINTENANCE Suggested Minimum Maintenance 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 installed is free f...
Page 54 - APPENDIX; Inside Air Contamination
54 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...
Page 57 - RAYPAK PRODUCTS
57 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. Additi...
Page 58 - Important Instructions for the Commonwealth of Massachusetts
58 (b) EXEMPTIONS: The following equipment is exempt from248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "EquipmentNot Required To Be Vented" in the most current edition ofNFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas...
