INSTALLATION & OPERATING
LLC
®
INSTRUCTIONS
Models 992C–2342C
Types H, WH & P
WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.
CATALOG NO. 1000.512A Effective: 06-15 -18 Replaces: 02-15-17 P/N 241664 Rev. 2
Revision 2 reflects the following changes:
Removed California Proposition 65 warning on page 4.
2
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 in
Scalds 8
INSTALLATION 9
Installation Codes 9
Equipment Base 9
Stacking 9
Clearances 11
Combustion and Ventilation Air 12
Conventional Combustion Air Supply 13
Water Piping 14
Hydronic Heating 17
Domestic Hot Water 20
Pool Heating 22
Gas Supply 25
Electrical Power Connections 26
Field Wiring Connection 28
Venting 32
Changing the Flue Outlet 34
Venting Installation Tips 34
Venting Configurations 35
Sequence of Operation 40
Controls 44
Wiring Diagrams 992C-1262C 54
Wiring Diagram 1532C-2342C 55
START-UP 56
Pre Start-up 56
Start-up 57
OPERATION 60
Lighting Instructions 60
To Turn Off Gas To Appliance 60
MAINTENANCE 61
Suggested Minimum
Maintenance Schedule 61
Preventative Maintenance Schedule 61
APPENDIX 63
Inside Air Contamination 63
WARRANTIES 64
Type H and WH 64
Type P 65
Start-up Checklist 67
Important Instructions for the
Commonwealth of Massachusetts 68
3
WARNINGS
Pay Attention to These Terms
ndicates the presence of immediate hazards which will cause severe person-
DANGER:
I
al injury, death or substantial property damage if ignored.
WARNING:
CAUTION:
NOTE:
DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.
WARNING: All venting types must be of the same
material or product throughout the entire exhaust
installation to ensure proper securing and sealing.
Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
WARNING: Both natural gas and propane have an
odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.
WARNING: UL recognized fuel gas detectors are
recommended in all enclosed propane and natural
gas applications wherein there is a potential for an
explosive mixture of fuel gas to accumulate and their
installation should be in accordance with the
detector manufacturer's recommendations and/or
local laws, rules, regulations, or customs.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to deenergize the
equipment before servicing.
CAUTION: Operation of this heater in lowtemperature systems requires special piping.
Harmful internal condensation will occur if the inlet
water temperature does not exceed 105°F. Warranty
claims will be denied when condensation occurs.
CAUTION: If this heater is to be installed above
radiation level, it must be provided with a low water
cut-off device at the time of heater installation.
CAUTION: If this heater is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
4
BEFORE INSTALLATION
Raypak strongly recommends that this manual be reviewed thoroughly before installing your Hi Delta
heater. Please review the General Safety information
before installing the heater. Factory warranty does not
pply to heaters that have been improperly installed or
a
operated. (Refer to the warranty at the back of this
manual.) Installation and service must be performed
by a qualified installer, service agency or gas supplier.
If, after reviewing this manual, you still have questions
which this manual does not answer, please contact the
manufacturer or your local Raypak representative.
Thank you for purchasing a Raypak product. We hope
you will be satisfied with the high quality and durability
of our equipment.
Product Receipt
On receipt of your heater it is suggested that you visually check for external damage to the shipping crate. If
the crate is damaged, make a note to that effect on the
Bill of Lading when signing for the shipment. Remove
the heater from the shipping packaging. Report any
damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that
you receive the correct number of packages as indicated on the Bill of Lading.
Claims for shortages and damages must be filed with
the carrier by consignee. Permission to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.
When ordering parts, you must specify the model and
serial number of the heater. When ordering under warranty conditions, you must also specify the date of
installation.
Purchased parts are subject to replacement only
under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted and will be
replaced in kind only per Raypak’s standard warranties.
Model Identification
The model identification number and heater serial
number are found on the heater rating plate located on
the lower right outside jacket of the heater. The model
number will have the form H9-1262C or similar
epending on the heater size and configuration. The
d
letter(s) in the first group of characters identifies the
application (H = Hydronic Heating, WH = Domestic
®
Hot Water, P = Pool). The number which follows iden-
ifies the firing mode ( 3 = 2-stage, 8 = 3-stage and 9
t
= 4-stage). The second group of characters identifies
the size of the heater (four numbers representing the
approximate MBTUH input), and, where applicable, a
letter, indicating the manufacturing series.
Ratings and Certifications
Standards:
• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired
Hot Water Boilers
• CAN1 3.1 - latest edition, Industrial and
Commercial Gas-Fired Package Boilers
• ANSI Z21.56 · CSA 4.7 - latest edition Gas-Fired
Pool Heaters
• ANSI Z21.10.3 · CSA 4.3 - latest edition Gas
Water Heaters
• CSA certified compliance with California AB1953
and Vermont Legislative Act 193 requirements.
All Raypak heaters are National Board registered, and
design-certified and tested by the Canadian Standards
Association (CSA) for the U.S. and Canada. Each
heater is constructed in accordance with Section IV of
the American Society of Mechanical Engineers
(ASME) Heater Pressure Vessel Code and bears the
ASME stamp. The heater also complies with the latest
edition of ASHRAE 90.1 Standard.
WARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube
bundle headers, or any ASME parts not
manufactured and/or approved by Raypak will
instantly void the ASME and CSA ratings of the
vessel and any Raypak warranty on the vessel.
Altering the ASME or CSA ratings of the vessel also
violates national, state, and local approval codes.
Installations at Elevation
Rated inputs are suitable for up to 4,500 ft elevation
without de-rating. Consult the factory for installations
at altitudes over 4,500 ft above sea level. Orifices are
not affected.
5
Component Locations
Fig. 1: Component Locations – Back
Fig. 2: Component Locations – Left Side
Panels removed for clarity
Fig. 3: Component Locations – Front
6
General Information
Model
No.
M
odel
No.
Burners
Quantity of Vent Size (in.)
Gas
Valves
Blowers Flue Intake
992C 11 2 + 1* 2 10 10
1262C 14 3 + 1* 2 12 10
1532C 17 4 2 12 10
1802C 20 4 2 14 10
2002C 23 5 3 14 10
2072C 23 5 3 14 10
2342C 26 5 3 16 10
*Hidden solenoid valve located inside of air plenum.
Table A: Basic Data
Burners per Valve Stages % Fire at Stages
1 1A 2 3 4 1 2 3 4 1 2 3 4
992C 6 3 2 1 1, 2 1, 2, 3 54 82 100
1262C 5 3 3 3 1 1, 2 1, 2, 3 1, 2, 3, 4 36 57 79 100
1532C 6 4 4 3 1 1, 2 1, 2, 3 1, 2, 3, 4 35 59 82 100
1802C 6 4 5 5 1 1, 2 1, 2, 3 1, 2, 3, 4 30 50 75 100
2002C 4 5 5 5 4 1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 39 61 83 100
2072C 4 5 5 5 4 1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 39 61 83 100
2342C 5 6 5 5 5 1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 42 62 81 100
Table B: Manifold Data
7
GENERAL SAFETY
Water temperature over 125°F can
c a us e i ns t a nt se v e re bu r n s o r d e a th
from scalds.
Children, disabled, and elderly are
at highest risk of being scalded.
See instruction manual before setting temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are
available, see manual.
Water
Temp.
Time to Produce Serious
Burn
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About 1 second
Table courtesy of The Shriners Burn Institute
To 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 recommended initial setting for the temperature control is
125°F.
Safety and energy conservation are factors to be considered when setting the water temperature on the
thermostat. The most energy-efficient operation will
result when the temperature setting is the lowest that
satisfies the needs of the application.
Water temperature over 125°F can cause instant
severe burns or death from scalds. Children, disabled
and elderly are at highest risk of being scalded.
• Feel water before bathing or showering.
• Temperature limiting valves are available.
NOTE: When this water heater is supplying general
purpose hot water for use by individuals, a
thermostatically controlled mixing valve for reducing
point of use water temperature is recommended to
reduce the risk of scald injury. Contact a licensed
plumber or the local plumbing authority for further
information.
Maximum water temperatures occur just after the
heater’s burner has shut off. To determine the water
temperature being delivered, turn on a hot water
faucet and place a thermometer in the hot water
stream and read the thermometer.
Time/Temperature
Relationships in Scalds
The following chart details the relationship of water
temperature and time with regard to scald injury and
may be used as a guide in determining the safest
water temperature for your applications.
Table C: Time to Produce Serious Burn
8
The temperature of the water in the heater can be regulated by adjusting the setpoint, this process is fully
escribed in the manual in the “Controls” section (see
d
page 47).
For accurate control of water temperature, the sensors
must be properly installed according with the piping
configuration, see “Applications & Modes” section for
detailed information (see page 19).
CAUTION: Hotter water increases the risk of scalding! There is a hot water scald potential if the
thermostat is set too high.
Temperature & Pressure Gauge
The temperature and pressure gauge is factorymounted in the in/out header.
INSTALLATION
Stacking
Hi Delta units can be stacked two units high with an
ptional stacking rack. A stacking kit (sales order
o
option X-1) is available from Raypak for this type of
installation. For installations above grade, a reinforcing kit (sales order option X-2) may also be required.
CAUTION: The heaters should be located in an
area where water leakage will not result in damage
to the area adjacent to the appliances or to the
structure. When such locations cannot be avoided, it
is recommended that a suitable catch pan,
adequately drained, be installed under the
appliance. The pan must not restrict air flow.
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 - latest
edition (NEC)
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1,
when required (CSD-1)
• For Canada only: CAN/CSA B149 Installation
Code (B149) and CSA C22.1 C.E.C. Part 1
(C22.1)
Equipment Base
The heater should be mounted on a level, structurally
sound surface. The heater is approved for installation
on a combustible surface but must NEVER be
installed on carpeting. Gas-fueled equipment installed
in enclosed parking garages must be located at least
18 in. above the floor.
Fig. 4: Typical Stacked Installation
9
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 window * *
D
Vertical clearance to ventilated soffit located
above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the
terminal
5 ft (1.5m) *
E Clearance to unventilated soffit * *
F Clearance to outside corner * *
G Clearance to inside corner 6 ft (1.83m) *
H
Clearance to each side of center line extended above meter/regulator assembly
*
3 ft (91 cm) within a height
15 ft above the me-
ter/regulator assembly
I Clearance to service regulator vent outlet * 6 ft (1.83m)
J
Clearance to non-mechanical air supply inlet
to building or the combustion air inlet to any
other appliance
4 ft (1.2m) below or to side
of opening; 1 ft (30 cm)
above opening
3 ft (91 cm)
K Clearance to mechanical air supply inlet
3 ft (91 cm) above if within
10 ft (3m) horizontally
6 ft (1.83m)
L
Clearance above paved sidewalk or paved
driveway located on public property
7 ft (2.13m)
7 ft (2.13m) t
M
Clearance under veranda, porch, deck or
balcony
* 12 in. (30 cm) TT
1
In accordance with the current ANSI Z223.1/NFPA 54 N ational Fuel Gas Code
2
In accordance with the current CAN/CSA-B149 Installation Codes
t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that se rves
both dwellings
TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of term inal and
underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)
* Clearances in accordance with local installation codes and the requirements of the gas supplier
Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table D: Vent/Air Inlet Termination Clearances
10
In addition, the heater shall be installed such that the
Heater
Side
Minimum Clearance
from Combustible
Surfaces
Recommended
Service
Clearance
Floor* 0” 0”
Rear 1” 6”
Water Side 12” 24”
Other Side 1” 24”
Top 1” 6”
Front Open 24”
Vent 2” 2”
Heater
Side
Min. C learance
from C ombustible
Surfaces
Recommended
Service
Clearance
Front Open 24”
Rear 12” 6”
Water Side 36” 36”
Other Side 36” 36”
Top Unobstructed 36”
Vent N/A N/A
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
* DO NOT install on carpeting.
Table E: Clearances – Indoor Installations
When installed according to the listed minimum clearances from combustible construction, these heaters
can still be serviced without removing permanent
structural construction around the heater. Combustible
clearances can be reduced per the NFGC; see paragraph 10.2.3. However, for ease of servicing, we
recommend a clearance of at least 24 in. in front, and
at least 12 in. on the water connection side. This will
allow the heater to be serviced in its installed location
without movement or removal of the heater.
Service clearances less than the minimums may
require removal of the heater to service either the heat
exchanger or the burner tray. In either case, 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 installation. Heaters must not be installed under an overhang
that is less than 3 ft from the top of the heater. Three
sides must be open in the area under the overhang.
Roof water drainage must be diverted away from
heaters installed under overhangs.
Top View
Fig. 6: Minimum Clearances from Combustible
Surfaces – Indoor Installations
Front View
Table F: Clearances – Outdoor Installations
These clearances are required when the outdoor
vent cap is used. If installing the heater outdoors
with a vent stack, the indoor clearances may be
utilized.
The combustion air intake hood MUST be used for
outdoor installations. The hood is shipped loose and
installed on the side of the heater over the filter box at
the jobsite.
11
1. Remove the four screws and the dust cover from
the right-hand side of the heater.
2. Remove the four screws and the air filter bracket
from the left-hand side of the heater.
Front View
Side View
Fig. 7: Minimum Clearances from Combustible
Surfaces – Outdoor Installations
Combustion and Ventilation Air
NOTE: Use of the heater in construction areas
where fine particulate matter, such as concrete or
dry-wall dust, is present may result in damage to the
heater that is not covered by the warranty. If
operated in a construction environment, a clean
source of combustion air must be provided directly to
the heater.
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 supplied via conventional means where combustion air is
drawn from the area immediately surrounding the
heater, or via direct vent, where combustion air is
drawn directly from outside. All installations must comply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty. (See
the Appendix.)
3. Reverse the components and reattach in the new
location, making sure that the air filter locking
bracket is on the bottom. (The air filter locking
bracket is reversible.)
Direct Vent
If outside air is drawn through the intake pipe directly
to the unit for combustion:
1. Install combustion air direct vent in accordance
with Fig. 31 (horizontal) or Fig. 32 (vertical) of this
manual (pages 33 and 34, respectively).
2. Ventilation of the space occupied by the heater(s)
is recommended and can be provided by an opening(s) for ventilation air at within 12” of the ceiling
or the highest practical point communicating with
the outdoors. The total cross-sectional area
should be at least 1 in.2of free area per 20,000
BTUH (111 mm2per kW) of total input rating of all
equipment in the room when the opening is communicating directly with the outdoors or through
vertical duct(s). The total cross-sectional area
should be at least 1 in.2of free area per 10,000
BTUH (222 mm2per kW) of total input rating of all
equipment in the room when the opening is communicating with the outdoors through horizontal
duct(s). Damage to the equipment due to inadequate ventilation of the space is not a warrantable
failure.
NOTE: In cold climates, and to mitigate potential
freeze-up, Raypak highly recommends the installation of a motorized sealed damper to prevent the
circulation of cold air through the heater during the
non-operating hours.
Direct-Ducted Combustion Air
NOTE: It is recommended that the intake vent be
insulated to minimize sweating.
Reversing Air Filter
Follow these instructions to change the air duct connection from the left-hand side (standard) to the
right-hand side:
In certain applications it may be desirable to duct the
combustion air directly to the heater. This should be
done with PVC, CPVC or single-wall galvanized ducting. The duct will attach directly to the collar on the air
filter housing located on the side of the heater. The
ducting is attached to the air filter housing collar using
12
three or four sheet metal screws (not supplied) equally distributed around the circumference of the duct. All
ducting should be self-supported. The filter housing is
not designed to support the air duct.
CAUTION: Use TruSeal combustion air if
damaging airborne contaminants are or will be
present in the heater area. See the Appendix
regarding air contamination.
TruSeal®Combustion Air
In certain applications it may be necessary to utilize
the TruSeal option (sales order option D-21 or D-22)
and duct the combustion air directly to the blower.
Combustion air may be ducted directly to the heater by
using PVC, CPVC or sealed single-wall galvanized
ducting. The duct will attach directly to the air collar located on the side of the heater, using three or four
sheet metal screws (not supplied) equally positioned
around the circumference of the duct. The screws and
duct connection point must be sealed with RTV (not
supplied). An in-line intake air filter kit (sales order
option D-17) must be installed in the combustion air
duct. TruSeal is generally used when damaging contaminants are present in the mechanical room.
TruSeal heater connection points are available as follows:
992C to 1802C Left side – standard
Right side – optional
2002C to 2342C Right side only
space shall be considered in making this determination. Each opening shall have a minimum free area of
1 in.2 per 1,000 BTUH (2,225 mm2per kW) of the total
input rating of all gas utilization equipment in the confined space, but not less than 100 in.2(645 cm2). One
opening shall commence within 12 in. (305 mm) of the
top, and one opening shall commence within 12 in.
(305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than
3 in. (76 mm) in any direction.
All Air from Outdoors
The confined space shall communicate with the outdoors in accordance with one of the methods below.
The minimum dimension of air openings shall not be
less than 3 in. (76 mm) in any direction. Where ducts
are used, they shall be of the same cross-sectional
area as the net free area of the openings to which they
connect.
1. Two permanent openings, one commencing
within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of
the enclosure, shall be provided. The openings
shall communicate directly, or by ducts, with the
outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
a. Where directly communicating with the out-
doors or where communicating to the
outdoors through vertical ducts, each opening
shall have a minimum free area of 1 in.
4,000 BTUH (550 mm2per kW) of total input
rating of all equipment in the enclosure.
2
per
CAUTION: This type of installation is
recommended if damaging airborne contaminants
are or will be present in the heater area. See the
Appendix regarding air contamination.
Conventional Combustion Air
Supply
U.S. Installations
All Air from Inside the Building
The confined space shall be provided with TWO permanent openings communicating directly with an
additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for a
room large in comparison (NFGC). The total input of all
gas utilization equipment installed in the combined
b. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in.2per 2,000
BTUH (1,100 mm2per kW) of total input rating of all equipment in the enclosure.
2. One permanent opening, commencing within 12
in. (305 mm) of the top of the enclosure, shall be
permitted where the equipment has clearances of
at least 1 in. (25 mm) from the sides and back and
6 in. (152 mm) from the front of the appliance. The
opening shall directly communicate with the outdoors or shall communicate through a vertical or
horizontal duct to the outdoors or spaces that
freely communicate with the outdoors, and shall
have a minimum free area of:
a. 1 in.2per 3,000 BTUH (740 mm2per kW) of
the total input rating of all equipment located in
the enclosure, and
13
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
ented with other gas-fired appliances.
v
Canadian Installations
of not less than 1 in.2for each 30,000 BTUH mm
per kW) of total rated input of the burner(s), and
the location of the opening(s) shall not interfere
with the intended purpose of the opening(s) for
ventilation air referred to in (1). This opening(s)
can be ducted to a point not more than 18 in. (450
mm) nor less than 6 in. (152 mm) above the floor
level. The duct can also “goose neck” through the
roof. The duct is preferred to be straight down 18
in. (450 mm) from the floor, but not near piping.
2
CAUTION: All combustion air must be drawn from
the air outside of the building; the mechanical equipment room must communicate directly with the
outdoors.
1. Ventilation of the space occupied by the heater
shall be provided by an opening(s) for ventilation
air at the highest practical point communicating
with the outdoors. The total cross-sectional area of
such an opening(s) shall be at least 10% of the
area required in 2. and 3. (below), but in no case
shall the cross-sectional area be less than 10 in.
(65 cm2).
2. For heaters using a barometric damper in the vent
system there shall be a permanent air supply
opening(s) having a cross section area of not less
than 1 in.2per 7,000 BTUH (320 mm2per kW) up
to and including 1 million BTUH, plus 1 in.2per
14,000 BTUH (160 mm2per kW) in excess of 1
million BTUH. This opening(s) shall be either
located at or ducted to a point not more than 18 in.
(450 mm) nor less than 6 in. (152 mm) above the
floor level. The duct can also “goose neck” through
the roof. The duct is preferred to be straight down
and terminated 18 in. (450 mm) from the floor, but
not near piping. This air supply opening requirement shall be in addition to the air opening for
ventilation air required in 1. (above).
4. Refer to B149 Installation code for additional information.
Water Piping
General
The heater should be located so that any water leaks
will not cause damage to the adjacent area or struc-
tures.
2
CAUTION: This heater requires forced water
circulation when the burner is operating. See Table
G and Table H for minimum and maximum flow rates
and water pump selection. The pump must be
interlocked with the heater to prevent heater
operation without water circulation.
NOTE: Minimum pipe size for in/out connections is
2 1⁄2 NPT. Verify proper flow rates and ∆T as instruct-
ed in this manual.
Reversing Water Connections
Follow these instructions to change the water connections from the left-hand side (standard) to the
right-hand side.
WARNING: Care must be taken to ensure that the
equipment room is not under negative pressure
conditions or that the equipment is not commonvented with other gas-fired appliances.
3. For heaters not using a barometric damper in the
vent system, and when air supply is provided by
natural air flow from outdoors for a power burner
and there is no draft regulator, drafthood or similar
flue gas dilution device installed in the same
space, in addition to the opening for ventilation air
required in 1., there shall be a permanent air supply opening(s) having a total cross-sectional area
1. Disconnect all electrical power from the heater (if
applicable).
2. Label all electrical connections and conduit lines.
This may include the flow switch, low water cut-off
probe and/or pump.
3. Disconnect or isolate the main gas pipe from the
heater (if applicable).
4. Remove both in/out and return header access
panels by removing all sheet metal screws.
14
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 thermocouples.
. Remove the eight flange nuts and the in/out head-
7
er from the left-hand side.
8. Remove the eight flange nuts and the return header from the right-hand side.
9. Reverse the headers to the new location.
10. Install NEW red beveled O-rings flush against both
tube sheets with the bevel facing outward.
Hydrostatic Test
Unlike many types of heaters, this heater does not require hydrostatic testing prior to being placed in
operation. The heat exchanger has already been factory-tested and is rated for 160 psi operating pressure.
However, Raypak does recommend hydrostatic test-
ng of the piping connections to the heater and the rest
i
of the system prior to operation. This is particularly
true for hydronic systems using expensive glycolbased anti-freeze. Raypak recommends conducting
the hydrostatic test before connecting gas piping or
electrical supply.
Leaks must be repaired at once to prevent damage to
the heater. NEVER use petroleum-based stop-leak
compounds.
11. Push the header firmly against the O-rings. Install
and tighten the flange nuts onto the stud bolts until
finger tight.
12. Slowly tighten the flange nuts, starting from the
center nut (number 1) in Fig. 8 and working sequentially around the header as indicated. Torque
all nuts to 25 ft/lb. DO NOT OVER-TIGHTEN.
13. Re-route the capillary(s), wiring etc. to the new
location, adding thermal paste and shim to the
capillary well.
To perform hydrostatic test:
1. Connect fill water supply. With bleed valve open,
fill heater with water. When water flows from bleed
valve, shut off water. Close bleed valve. Carefully
fill the rest of the system, making sure to eliminate
any entrapped air by using high-point vents. Close
feed valve. Test at standard operating pressure for
at least 24 hours.
2. Make sure constant gauge pressure has been
maintained throughout test.
3. Check for leaks. Repair if found.
Cold Water Protection (CWP)
This heater must operate with a stable inlet temperature of 105°F (41°C), long periods of operation with
temperatures below 105°F (41°C) can excessively
cool the products of combustion, resulting in collection
of condensate in the heat exchanger, damaging the
heat exchanger, combustion chamber, significantly
reducing the life of the equipment. The following applications are approved configurations supported by
Raypak for CWP systems.
Fig. 8: Torque Sequence
Relief Valve Piping
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.
A bypass allows part of the heater discharge water to
be mixed with the cooler water returning to the heater
inlet, to increase the heater inlet temperature above
105°F (41°C). This precautionary measure should prevent the products of combustion from condensing in
most installations.
15
AUTION: Damage due to internal condensation
C
may occur if the heater inlet water temperature does
ot exceed 105°F (41°C) within 7 minutes of start-
n
up. Warranty claims will be denied for damage or
failures caused by condensation.
models: MIX TYPE = VALVE
H
Heating Systems, where the inlet water temperature
remains below 105°F (41°C) must
have cold water
protection. Known protection methods consist of mix-
ing heated outlet water with the inlet water using a
bypass to raise the inlet to 105°F (41°C) or higher.
Once the system is heated up and has return water
temperatures of 105°F (41°C) or higher, the mixing of
outlet water with inlet water is no longer needed and
the bypass can be shut off. If the bypass is not shut off
as the system heats up, the outlet temperature may
continue to climb and trip the high limit, thereby shutting down the heater. Thus an automatic valve system,
such as a three-way proportional valve to control the
bypass, should be used. The integrated VERSA IC
control system provides automatic functionality to control a proportional 3-way valve to provide Cold Water
Protection for Single or Cascade configurations. See
Fig. 9.
models: MIX TYPE = PUMP
H
models include a second option for individual Cold
H
Water Protection method (“PUMP”). MIX TYPE =
UMP uses a Variable Speed Pump as a CWP mech-
P
anism recommended for those systems that require
low-lead/non-ferrous plumbing. Applications that
require a working setpoint over 150°F must use an H
model with a storage tank. See Figs.10,11 and 12.
®
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 9: CWP-Hydronic Single-Boiler (BOIL 3-way)
Mode 1
Fig. 10: H - Hydronic - Single Boiler with CWP (VS
Pump - MIX TYPE = 2)
Fig. 11: Low Temp Process - Open Loop: H model,
Single with Storage Tank
16
Fig. 12: Low Temp Process - Open Loop: H model, Cascade with Storage Tank
Cold Water Protection: WH models
Direct DHW heating systems utilize a variable speed
pump arrangement (MIX TYPE = PUMP) to keep the
heater inlet at or above 105°F (41°C). The integrated
VERSA IC control system provides functionality to
control a single variable speed injection pump via an
added inverter drive to provide Cold Water Protection
to the system.
See Fig. 13 as an example of a single heater application. For more information regarding this function see
VERSA IC manual, catalog 5000.72.
Hydronic Heating
System Design
Hot water heating systems all have unique levels of
operating diversity. Raypak equipment design utilizes
as little water mass as possible to ensure maximum
operating efficiency. Primary / Secondary piping
arrangement is the method recommended and the
only method supported by Raypak for installation of Hi
Delta equipment. Proper system design should
always include system flow in excess of the connected
boiler flow for proper operation (Boiler Flow + 15% =
Min. System Flow). When appropriate, a Buffer/Decoupler Tank can be used where system flow may be
reduced below the connected boiler flow. Failure to
design for adequate system flow (i.e. bypasses, 3-way
control valves, flow limiting balance devices, buffer
tanks, etc.) will result in boiler short-cycling and poor
system performance. Always contact your local
Raypak representative for system design assistance
to avoid these issues.
Pump Selection
Fig. 13: WH Direct DHW - Single Heater with CWP (VS
Pump - MIX TYPE = 2)
In order to ensure proper performance of your heater
system, you must install a correctly sized pump. Raypak recommends using a 20°F ∆T as design ∆T. (∆T is
the temperature difference between the inlet and outlet
water when the heater is firing at full rate). If a ∆T of
larger than 20°F is necessary, see Table G for flow rate
requirements.
17
Model
o.
N
0ºF∆T
2
gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) ∆T gpm ∆P (ft) ∆T
0ºF∆T
3
9ºF∆T
3
in. Flow
M
ax. Flow
M
992C 83 5.2 55 2.3 43 1.4 43 1.4 39 132 13.1 13
1262C 106 9.6 71 4.3 54 2.5 54 2.5 39 132 14.8 16
1532C 129 15.7 86 7.1 66 4.2 66 4.2 39 132 16.5 19
1802C N/A N/A 101 10.7 78 6.3 78 6.3 39 132 18.3 23
2002C N/A N/A 112 13.8 86 8.3 86 8.3 39 132 19.0 25
2072C N/A N/A 116 14.8 89 8.9 89 8.9 39 132 19.0 26
2342C N/A N/A 132 21.1 101 12.7 101 12.7 39 132 21.4 30
Notes: 1. Basis for minimum flow is 40°F ∆T. Basis for maximum flow is 132 GPM.
Feedwater Regulator
2. Rear-mounted pumps may provide higher flow rates on smaller models than the system requirements
Table G: Heater Rates of Flow and Pressure Drops
an external source such as the Temp Tracker MOD+
Hybrid sequencer (sales option B-36). Proper place-
Raypak recommends that a feedwater regulator be installed 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.
ment and method of installation are critical for proper
operation of the system. (See Fig. 7) The sensor must
be installed in a drywell in conjunction with heat conductive compound as shown in the following images.
The drywell must be installed no more than 5 equivalent feet of pipe/tubing downstream of the de-coupler
Piping
and installed in such a way that ensures the sensor
bulb is in the flow path.
All high points should be vented. Purge valves and a
bypass valve should be installed. A heater installed
above radiation level must be provided with a low water cut-off device (sales order option F-10). The heater,
when used in connection with a refrigeration system,
CAUTION: Be careful when installing the drywell
not to over-tighten the well as this can damage the
well and may prevent the sensor from fitting
property.
must be installed so that the chilled medium is piped in
parallel with the heater with appropriate valves to pre-
Three-Way Valves
vent the chilled medium from entering the heater.
Valves designed to blend water temperatures or
The piping system of a hot water heater connected to
heating coils located in air handling units where they
may be exposed to circulating refrigerated air, must be
reduce water circulation through the heater should not
be used. Raypak heaters are high-recovery, low-mass
heaters which are not subject to thermal shock.
equipped with flow control valves or other automatic
means to prevent gravity circulation of the heater
water during the cooling cycle. It is highly recommended that the piping be insulated.
Air-Separation/Expansion Tank
All heaters should be equipped with a properly sized
expansion tank and air separator fitting as shown in
Fig. 14.
System Sensor Installation
The System Sensor (S3) is required for all selectable
mode unless the unit’s firing rate will be controlled by
Fig. 14: Air-Separation/Expansion Tank
18
PT
N
itting
F
hermal
T
Paste
Fig. 15: System Sensor Installation
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 16: Single Heater - Space Heating Application
with Primary/Secondary Piping
Drywell
ystem
S
Sensor (S3)
Fig. 17: MODE 1 - Single Boiler with
Primary/Secondary Piping
Mode 1 (Type H Units Only)
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4). The system temperature is
controlled by the System sensor (S3). The Boiler
Pump (P1) runs during any call for heat. The System
Pump (P2) runs whenever the system is enabled for
heating and the outdoor air temperature is lower than
the warm weather shut down (WWSD) temperature
setting (if utilized). The Boiler Pump is delayed “off” as
user-defined in the BOILER menu and System Pump
is delayed “off” as user-defined in the ADJUST menu.
Applications & Modes
The VERSA IC Control system is designed for a wide
range of applications. The installer/design engineer
should refer to the following Modes to determine which
best fits the intended application and functionality for
the unit being installed.
Type H models of Hi Delta have three modes available
to them to address the various applications the units
can be applied to. Type WH and P units will only have
one configuration available to them.
For detailed information on the Versa IC control system, see Catalog 5000.72. This manual can be found
in the document library at www.raypak.com
S1 - Outlet Sensor
S2 – Inlet Sensor
Fig. 18: MODE 1 - Boiler Cascade with
Primary/Secondary Piping
NOTE: MODE 1 can also be used for process heating applications in conjunction with a buffer/storage
tank when operating temperatures above 150°F are
.
required. Care must be given to ensure water hardness is no more than 15 grains per gallon for scale
free operation.
19
Fig. 19: MODE 2 - Single Boiler with Indirect
on System Loop
Mode 2 (Type H Units Only)
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4) with indirect DHW on the system loop (with or without priority). The system
temperature is controlled by the System sensor (S3).
The Indirect DHW sensor (S5) determines the indirect
call/tank setpoint. The system temperature is boosted
to Target Max when using the Indirect DHW sensor
(S5) during an indirect call for heat. Priority mode toggles off the System Pump (P2) when an indirect call for
heat is present. The Boiler Pump (P1) runs during any
call for heat. The Indirect DHW Pump (P3) runs during
an indirect call for heat with no “off” delay. The Boiler
Pump (P1) is delayed “off” as user-defined in the
BOILER menu and System Pump (P2) delay “off” as
user-defined in the ADJUST menu. The System Pump
(P2) runs whenever the system is enabled for heating
and the outdoor air temperature is lower than the
WWSD temperature setting (if utilized) unless an indirect call for heat is present with priority.
Mode 3 (Type H Units Only)
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4) with indirect DHW on the boiler
oop (with priority). The system temperature is con-
l
trolled by the Supply sensor (S3) whenever the
indirect call for heat is not active. The DHW Supply
sensor (S5) determines the indirect call/tank setpoint.
During an indirect call for heat the boiler firing rate is
determined by the water temperature at the Indirect
Supply sensor (S6) and the Target Max setting when
using the Indirect DHW sensor (S5). The Boiler Pump
(P1) runs during all heat calls regardless of priority.
The Indirect DHW Pump (P3) runs during an indirect
call for heat with no “off” delay. The Boiler Pump (P1)
is delayed “off” as user-defined in the BOILER menu
and System Pump (P2) delay “off” as user-defined in
the ADJUST menu. The system pump (P2) runs
whenever the system is enabled for heating and the
outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect call for
heat is present.
NOTE: A Tank Aquastat can be used in lieu of the
Indirect DHW Sensor (S5). See the Versa IC manual
for additional details.
Fig. 20: MODE 3 - Single Boiler with Indirect
on Boiler Loop
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 21: Dual Heaters (Reverse/Return)
with Primary/Secondary Piping
Domestic Hot Water
When designing the water piping system for domestic
hot water applications, water hardness should be considered. Table H indicates the suggested flow rates for
soft, medium and hard water. Water hardness is expressed in grains per gallon.
20
Fig. 22: Single Domestic Hot Water Heater and Storage
Tank
WH – Direct DHW Configuration
When the unit is ordered as a “WH” configuration the
only application available to it is direct DHW with single or multiple heaters (Maximum 4 heaters). The tank
temperature is controlled by the System sensor (S3).
The Boiler Pump (P1) runs during any call for heat.
The System Pump (P2) output is active whenever the
system is enabled. The Boiler Pump is delayed “off”
after the Tank Target temperature is achieved and as
user defined in the BOILER menu.
Potable Water and Space Heating
CAUTION: When this heater is used for both
otable water and space heating, observe the
p
following to ensure proper operation.
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. Toxic 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 supply potable water,
it shall not be connected to any heating system or
components previously used with a non-potable
water heating appliance.
4. When the system requires water for space heating
at temperatures higher than 140°F (60°C), a
means such as a mixing valve shall be installed to
temper the water in order to reduce scald hazard
potential.
Automatic Chemical Feeders
Fig. 23: WH Units - Single Water Heater with Tank
H Units - Single Boiler with Process Tank
NOTE: WH units will operate to a maximum tank
temperature of 150°F. For temperatures required
above 150°F, an “H” model boiler must be used and
great care must be given to ensure water hardness
is no more than 15 grains per gallon for scale free
operation. MODE 1 should be used and configured
for setpoint operation for process heating applications.
NOTE: If local codes require a vacuum relief valve,
acquire one locally and install per valve
manufacturer’s instructions.
All chemicals must be introduced and completely diluted into the water before being circulated through the
heater. High chemical concentrations will result when
the pump is not running (e.g. overnight).
NOTE: High chemical concentrates from feeders
that are out of adjustment will cause rapid corrosion
to the heat exchanger. Such damage is not covered
under the warranty.
NOTE: Failure of a heat exchanger due to lime
scale build-up on the heating surface, low pH or
other chemical imbalance is non-warrantable.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty.
21
Model
No.
Soft* (3-4 grains per gallon) Medium (5-15 grains per gallon) Hard* (16+** grains per gallon)
∆T GPM ∆P MTS SHL ∆T GPM ∆P MTS SHL ∆T GPM ∆P MTS SHL
992C 29 60 2.7 2½ 5.2 17 98 7.3 2½ 13.3 13 132 13.1 2½ 23.6
262C29
1
2
.4
½
7
4
2
.9
7
9
1
1511.3
1
½
1
9.4
2
6
1
3214.82½25.3
1
1532C 29 86 7.1 2½ 11.9 22 120 13.7 2½ 22.5 20 132 16.5 2½ 27.0
1802C 29 102 10.9 2½ 17.4 26 120 15.1 2½ 23.9 23 132 18.3 2½ 28.7
2002C 29 112 13.9 2½ 21.6 26 132 19.0 2½ 29.5 26 132 19.0 2½ 29.5
2072C 31 117 15.1 2½ 23.4 27 132 19.0 2½ 29.5 27 132 19.0 2½ 29.5
2342C 33 120 17.8 2½ 26.5 30 132 21.4 2½ 31.8 30 132 21.4 2½ 31.8
∆T = Temperature rise, °F
∆P = Pressure drop through heat exchanger, ft
SHL = System head loss, ft. Includes 50 eq ft of tubing each way (total 100 eq ft).
GPM = Gallons per minute, flow rate
MTS = Minimum tubing size
*Must utilize optional cupro-nickel tubes.
**If over 25 grains per gallon, a water softener/treatment system must be utilized.
Caution: For scale free operation with "Hard Water" (16-25 grains per gallon of total hardness), the operating control must NOT be set
higher than 130 °F. For higher than 130 °F operation, a water softener/treatment system must be utilized.
Caution: Water softened below 3 grains per gallon is known to be aggressive and corrosive.
Table H: Domestic Water Heater Flow Rate Requirements
Pool Heating
CAUTION: Power to the heater should be
interlocked with the main system pump to make sure
the heater does not fire without the main system
pool. This arrangement permits operation of the heater
at a temperature range that has been optimized both
to avoid forming condensation on the heat exchanger
and to mitigate the formation of scale in the heat
exchanger tubes.
pump in operation. Improper flow control can
damage the heater. Uncontrolled flow (too high) or
restricted flow (too low) can seriously damage the
heater. Follow these instructions to make sure your
heater is properly installed.
All Raypak pool heaters are certified to ANSI Z21.56,
which is the nationally recognized standard for swim-
For a Pool heating application, always verify that the
Hi Delta unit has been ordered as a pool heater. To
avoid issues related to high temperatures not appropriate to a pool application.
NOTE: The recommended setting for the outlet
thermostat is 110°F.
ming pools. Some heaters being sold in the
marketplace for heating commercial swimming pools
are often certified as hot water boilers or water
heaters. Regardless of which standard they are certified to, they are generally trimmed out either by the
manufacturer or the installer with controls that are suitable for maintaining normal swimming pool
temperatures and water conditions.
The P-992C-2342C models are configured to accommodate locating the outlet temperature controller in the
pool system piping that supplies the heated water to
the pool. This arrangement facilitates controlling or
limiting the temperature of the water supplied to the
pool. The heater must be plumbed in a primary/secondary arrangement, wherein only a portion of the
water flowing in the piping system is pulled off, heated,
and then returned to the system. The water coming out
of the heater is mixed with the filtered water in the
main pipe and thus tempered before returning to the
The Hi Delta pool heater is offered with bypass
options: manual H-Bypass, or automatic Cold Water
Run (CWR) bypass made of CPVC. These arrangements both blend outlet water with the inlet water to
increase the inlet water temperature, thereby reducing
the likelihood of condensation forming on the heat
exchanger. The pump also serves to circulate water
through the heater from the main system piping.
To complete installation of the heater, the system sensor (S3) must be installed in the return water line,
upstream of the heater. The supplied electronic operating control is configured to operate as the poolstat. A
separate sensor (S6) is shipped loose to be installed
in the system piping downstream of the heater outlet.
WARNING: To ensure safe operation of the Hi
Delta heater, all plumbing from the heater to the
main loop must be CPVC, copper or brass.
22
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