Raypak CHX-1000-10 Installation Manual
INSTALLATION & OPERATING
L
W
INSTRUCTIONS
Condensing Heat Exchanger (CHX)
Models 500, 750, 1000, & 1500
FFoorr HHii DDeellttaa MMooddeellss
440022BB––22000022BB
WARNING: If the information in 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 a safe place for future
reference.
CATALOG NO. 1000.56C Effective: 02-19-10 Replaces: 09-28-07 P/N 241007 Rev. 4
Rev. 4 reflects the following:
Changes to: Figures 3-8 on pages 8-11, Figures 11-19 on pages 15-19, Table D on page 20, Table E on page 24, Table F
on page 30.
Additions: California low-lead requirements on page 6, Replacement Parts information on pages 34 and 35.
2
CONTENTS
WARNINGS 4
GENERAL SAFETY 5
Time/Temperature Relationships in
Scalds 5
INTRODUCTION 6
Unpacking 6
INSTALLATION 6
Installation Codes 6
Equipment Base 6
Clearances 7
Combustion and Ventilation Air 7
CONNECTING THE CHX 7
VENTING CONNECTIONS 12
Appliance Categories 12
Support of Vent Stack 13
Vent Terminal Location 13
U.S. Installations 14
Installations in Canada 14
Venting Installation Tips 14
Venting Configurations 14
CONTROLS 19
Optional CHX Flow Switch 20
PVC/CPVC Vent Switch 20
WATER CONNECTIONS 20
Relief Valve Piping 21
Hydrostatic Test 21
Hydronic Heating 21
Domestic Hot Water 24
POOL HEATING 26
Automatic Chlorinators and Chemical
Feeders 26
Winterizing Your Heater 26
Pool and Spa Water Chemistry 27
OPERATION 29
Pre Start-Up 29
Start-Up 29
Post Start-Up Check 30
MAINTENANCE 30
Daily 30
Monthly 30
Periodically 31
Yearly 31
Cleaning the CHX Heating Surface 31
APPENDIX 33
Inside Air Contamination 33
REPLACEMENT PARTS 34
3
WARNINGS
Pay Attention to These Terms
ndicates the presence of immediate hazards which will cause severe
DANGER:
I
personal injury, death or substantial property damage if ignored.
WARNING:
CAUTION:
NOTE:
WARNING: Do not use this heater that this CHX is
attached to 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: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
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.
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.
4
GENERAL SAFETY
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.
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.
This section applies to Hot Water Supply Boilers and
Hot Water Heaters ONLY. For sanitary rinse applications where outlet temperatures of 180°F to 195°F are
required, a boiler is recommended since the 210°F
limit on water heaters will NOT allow the heater to
maintain these desired sanitary rinse temperatures.
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. Consult the Hi
Delta Installation and Operation Instructions (Catalog
Numbers 1000.501 or 1000.511) for control and hot
water requirements.
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 A: Time to Produce Serious Burn
5
INTRODUCTION
anties. Altering the agency ratings of the vessel also
r
violates national, state, and local approval codes.
Raypak strongly recommends that this manual be
reviewed thoroughly before installing your Raypak
heater. Please review the Safety section before
installing the heater. The factory warranty does not
apply to heaters that have been improperly installed or
operated; refer to the Warranty section.
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 your local
Raypak representative or Raypak corporate headquarters.
Thank you for purchasing a Raypak product. We hope
you will be pleased with the high quality and durability
of our equipment.
This manual applies only to CHX systems in conjunction with a Hi Delta heater, sizes 402B-2002B. It does
not cover either the installation or operation of a Hi
Delta heater that is not CHX-equipped. For those units
refer to the manual shipped with the heater.
INSTALLATION
WARNING: Improper installation, adjustment,
alteration, service or maintenance may damage the
equipment, create a hazard resulting in
asphyxiation, explosion or fire, and will void the
warranty.
These instructions are intended only for use by qualified personnel, specifically trained and experienced in
the installation of this type of heating equipment and
related system components. Installation and service
personnel may be required by some states to be
licensed. If your state is such, be sure your contractor
bears the appropriate license.
Persons not qualified shall not attempt to fix this equipment nor attempt repairs according to these
instructions.
Installation Codes
Unpacking
On receipt of your CHX 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 CHX 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 only to replacement
under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted and will
only be replaced in kind per Raypak’s standard war-
Installations must follow these codes:
• Local, state, provincial, and national codes, laws,
regulations and ordinances
• National Fuel Gas Code (NFGC), ANSI Z223.1latest edition
• For Canada only: CAN/CGA B149.1 and .2
Installation Code and C.S.A. C22. 1 C.E.C. Part 1
• CSA verified compliance with California AB1953
and Vermont Legislative Act 193 requirements.
Equipment Base
The CHX should be mounted on a level, structurally
sound surface. The CHX is approved for and can be
installed 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.
CAUTION: The cap should be located in an area
where water leakage will not result in damage to the
area adjacent to the heater or to the structure. when
such locations cannot be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the CHX.
The CHX must be mounted on a rack for connection to
the Hi Delta heaters. The following racks will allow
6
nstallation of the CHX either directly behind the Hi
i
Delta heater OR above the Hi Delta heater. These
racks are shown throughout this manual.
009528 - CHX Rack Kit for 402B - 902B Hi Delta
•
• 009529 - CHX Rack Kit for 992B - 2002B Hi Deltas
NOTE: The CHX does not require air for
combustion. Consult the Hi Delta Installation and
Operation Instructions (Catalog Number 1000.501 or
1000.511) for combustion air requirements for the
eater itself.
h
In addition to the racks noted above, an integral rack
is available factory-mounted to the appropriate CHX.
These are available using the following part numbers:
• 011640 - CHX/Rack Kit Short 402B/502B
• 011641 - CHX/Rack Kit Short 652B
• 011642 - CHX/Rack Kit Short 752B/902B
• 011643 - CHX/Rack Kit Short 992B
• 011644 - CHX/Rack Kit Short 1262B
• 011645 - CHX/Rack Kit Short 1532B
• 011646 - CHX/Rack Kit Short 1802B/2002B
Dimensional data for the CHX can be found on the
submittal sheets, Cat. No. 1000.81.
Clearances
Heater Side Min. Clearance
from Combustible
Surfaces
Floor* 0" 0"
Rear 0" 0"
Right
(Water Inlet)
Left (Water
Outlet)
Top 0" 36"
Vent 1" 1"
0" 12"
0" 12"
Recommended
Service
Clearance
and equipment ventilation. All installations must comply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
NOTE: In calculating free area, the required size of
openings for combustion, ventilation, and dilution air
shall be based on net free area of each opening. If
the free area through a design of louver or grill is
known, it shall be used in calculating the size
opening required to provide the free area specified.
For additional information, refer to the latest NFGC
requirements.
CONNECTING THE CHX
NOTE: Connect the vent before connecting the
water piping.
Install unions on water inlet and outlet of CHX for ease
of maintenance. The CHX requires cleaning as often
as once per year.
Typical Hi Delta connections to CHX are shown in
Figures 1 through 8. Hi Temp RTV (GE 106 or equivalent) is required to seal the vents as shown in Figures
9 and 10.
NOTE: Assembly instructions for racks are included
with rack kits.
*Do not install on carpeting.
Table B: Clearances - Indoor, Alcove and Outdoor
Installations.
Raypak CHXs are design certified by ANSI/CSA for
outdoor installation. Roof water drainage must be
diverted away from heaters installed under overhangs.
WARNING: Do not install the CHX outdoors if
freezing conditions are typical. The condensate will
freeze and back up the flue system.
Combustion and Ventilation Air
This heater must be supplied with sufficient quantities
of non-contaminated air to support proper combustion
NOTE: It is reccomended that the vent adapters be
preassembled without RTV to ensure proper
orientation and fit.
NOTE: Refer to the Heatfab Saf-T Vent CI Plus
Installation and Maintenance Instructions (PI-CCINS
020607) for specific vent assembly instructions.
Connecting the CHX to the heater:
1. Apply a bead of high temp RTV within approximately 1/4 in. of the edge of the CHX Vent Inlet
Adapter, then assemble it to the Heater Vent
Outlet Adapter ensuring that the band clamp tabs
are aligned (see Fig. 1). Attach and tighten the
band clamp.
7
Apply RTV
Here
Band Clamp Tabs
(D-27)
(D-28)
NOTE 1 - FIELD-SUPPLIED TRANSITION ADAPTER MAY BE REQUIRED
NOTE 2 - LOCKABLE BALANCING OR BLAST BAFFLE MAY BE REQUIRED
BETWEEN THE BAROMETRIC DAMPER AND POWER VENTER/EXTRACTOR
TO CONTROL EXCESS DRAFT.
NOTE 3 - NOT APPROVED FOR SYSTEMS WITH RETURN TEMPERATURES
BETWEEN 120°F AND 140°F.
(SEE NOTE 2)
(SEE NOTES 1 & 3)
CHX/Heater Vent
dapter Assembly
A
(D-27/D-28)
Hi Delta Exhaust
utlet
O
Apply RTV
Here
Fig. 1: Connect the CHX Vent Inlet Adapter to the
Heater Vent Outlet Adapter
2. Apply a bead of high temp RTV within approximately 1/4 inch of the edge of the CHX Exhaust
Inlet. Install the CHX/Heater Vent Adapter
Assembly, created in step 1, onto the CHX
Exhaust Inlet (vent adapter must overlap onto
exhaust inlet/outlet by at least 1/2 in.) and secure
by tightening the hose clamp provided. Refer to
the bottom of Fig. 2.
3. Position the CHX so that the CHX/Heater Vent
Adapter Assembly aligns with the Hi Delta Exhaust
Outlet and install as described in step 2. See top
of Fig. 2.
CHX Outlet Vent
dapter (D-18)
A
CHX/Heater Vent
Adapter Assembly
(D-27/D-28)
Apply RTV
Here
Fig. 2: Proper Orientation of Vent Adapters for
Installation, Hi Delta Exhaust Outlet (Top) and CHX
Inlet/Outlet (Bottom)
4. Install the CHX Outlet Vent Adapter (see Fig. 2)
and then install venting and water piping according to your installation. See Fig. 3 through 10 for
more information about various CHX configurations. Refer to the following sections for specific
information about venting and water piping.
Fig. 3: Hi Delta with Top-Mounted CHX and Power Venter
8
N
OTE 1 - FIELD-SUPPLIED TRANSITION ADAPTER MAY BE REQUIRED
NOTE 2 - LOCKABLE BALANCING OR BLAST BAFFLE MAY BE REQUIRED
BETWEEN THE BAROMETRIC DAMPER AND POWER VENTER/EXTRACTOR
TO CONTROL EXCESS DRAFT.
NOTE 3 - NOT APPROVED FOR SYSTEMS WITH RETURN TEMPERATURES
BETWEEN 120°F AND 140°F.
(SEE NOTE 2)
(SEE NOTES 1 & 3)
Fig. 4: Hi Delta with Rear-Mounted CHX and Power Venter
NOTE 1 - FIELD-SUPPLIED TRANSITION ADAPTER MAY BE REQUIRED
NOTE 2 - LOCKABLE BALANCING OR BLAST BAFFLE MAY BE REQUIRED
BETWEEN THE BAROMETRIC DAMPER AND POWER VENTER/EXTRACTOR
TO CONTROL EXCESS DRAFT.
NOTE 3 - NOT APPROVED FOR SYSTEMS WITH RETURN TEMPERATURES
BETWEEN 120°F AND 140°F.
(SEE NOTE 2)
(SEE NOTES
1 & 3)
(SEE NOTES 1 & 3)
Fig. 5: Stacked Hi Deltas with Rear-Mounted CHXs and Power Venters
9
1
NOTE 1 - FIELD-SUPPLIED TRANSITION ADAPTER MAY BE REQUIRED
NOTE 2 - LOCKABLE BALANCING OR BLAST BAFFLE MAY BE REQUIRED
BETWEEN THE BAROMETRIC DAMPER AND POWER VENTER/EXTRACTOR
TO CONTROL EXCESS DRAFT.
(SEE NOTE 2)
1
NOTE 1 - FIELD-SUPPLIED TRANSITION ADAPTER MAY BE REQUIRED
NOTE 2 - LOCKABLE BALANCING OR BLAST BAFFLE MAY BE REQUIRED
BETWEEN THE BAROMETRIC DAMPER AND POWER VENTER/EXTRACTOR
TO CONTROL EXCESS DRAFT.
(SEE NOTE 2)
Fig. 6: Hi Delta with Top-Mounted CHX and Extractor
Fig. 7: Hi Delta with Rear-Mounted CHX and Extractor
10
1
NOTE 1 - FIELD-SUPPLIED TRANSITION ADAPTER MAY BE REQUIRED
NOTE 2 - LOCKABLE BALANCING OR BLAST BAFFLE MAY BE REQUIRED
BETWEEN THE BAROMETRIC DAMPER AND POWER VENTER/EXTRACTOR
TO CONTROL EXCESS DRAFT.
(SEE NOTE 2)
Fig. 8: Stacked Hi Deltas with Rear-Mounted CHXs and Extractors
CONDENSATE DRAIN
ADJUST AS NECESSARY
HI TEMP RTV THIS JOINT
HI TEMP RTV THIS JOINT
HI TEMP RTV THIS JOINT
TIGHTEN LOCKING STRAP
FOLD FLAPS
NOTE: CHX flue in/out may be different for different models based on:
• Vertical location
• General appearance
• With or without added extensions
Fig. 9: Sealing Rear-Mounted CHX on the Hi Delta
11
Loading...