Raypak H-1262BE Installation Manual

INSTALLATION & OPERATING

LLC

INSTRUCTIONS

Models 992B–2342B

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 combustable 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. 1000.511K Effective: 04-30-14 Replaces: 01-18-13 P/N 241259 Rev. 12

Rev. 12 reflects the following: Changes to: Model Types on page 1, Fig. 5 on page 9, “System Design” on page 16, Fig. 13 on page 18, “Changing the

Flue Outlet” on page 29, Table S on page 48, carbon dioxide levels and igniter amperage on page 62.

Additions: Fig. 28 on page 29, Wiring Diagrams on pages 53-54 Deletions: None

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 16 Pool Heating 18 Gas Supply 22 Electrical Power Connections 24 Field Wiring Connection 25 Venting 27 Changing the Flue Outlet 29

Venting Installation Tips 29 Venting Configurations 30 Outdoor Installation 35 Controls 35 Heater Sequence of Operation 36 87%-Efficiency Boilers – Special Instructions 48 Wiring Diagrams 53

START-UP 55

Pre Start-up 55 Start-up 56

OPERATION 59

Lighting Instructions 59 To Turn Off Gas To Appliance 59

TROUBLESHOOTING 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 Important Instructions for the Commonwealth of Massachusetts 66 Start-up Checklist 67

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 - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the

State of California to cause cancer, birth defects or other reproductive harm.

WARNING: To minimize the possibility of improper operation, serious personal injury, fire, or damage 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.

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.

• 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.

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.

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.

number will have the form H9 1262B 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 (DHW), P = Pool). The number which fol-

ows identifies the firing mode (1 or 4 = on-off, 3 =

l 2-stage, 8 = 3-stage and 9 = 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. An “E” suffix indicates 87% efficiency (Category II or IV venting) (“H” stamped boilers only).

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.

Ratings and Certifications

Standards:

• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Hot Water Boilers

• CAN 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.

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

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.

OPTIONAL FLUE CONNECTION

2 LINE x 20 CHARACTER LCD STATUS DISPLAY

Component Locations

Fig. 1: Component Locations – Back

Fig. 2: Component Locations – Left Side

Panels removed for clarity

Fig. 3: Component Locations – Front

General Information

Quantity of Vent Size (in.)

Model

No.

Burners

Valves

Blowers Flue Intake

992B 11 2 + 1* 2 10 10

1262B 14 3 + 1* 2 12 10

1532B 17 4 2 12 10

1802B 20 4 2 14 10

2002B 23 5 3 14 10

2072B 23 5 3 14 10

2342B 26 5 3 16 10

Burners per Valve Stages % Fire at Stage

Model

No.

1 1A 2 3 4 1 2 3 4 1 2 3 4

992B 6

3 2 1 1, 2 1, 2, 3 54 82 100

1262B 5 3 3 3 1 1,2 1, 2, 3 1, 2, 3, 4 36 57 79 100

1532B 6 4 4 3 1 1,2 1, 2, 3 1, 2, 3, 4 35 59 82 100

1802B 6 4 5 5 1 1,2 1, 2, 3 1, 2, 3, 4 30 50 75 100

2002B 4 5 5 5 4 1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 39 61 83 100

2072B 4 5 5 5 4 1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 39 61 83 100

2342B 5 6 5 5 5 1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 42 62 81 100

*Hidden solenoid valve located inside of air plenum.

Table A: Basic Data

Table B: Manifold Data

GENERAL SAFETY

Water temperature over 125°F can cau s e i nsta n t s e v er e b u r ns or d eath 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

The temperature of the water in the heater can be reg-

2 PER NATIONAL FUEL GAS CODE (NFGC).

ulated by using an optional temperature controller. To comply with safety regulations, the temperature controller is set at the lowest setting when shipped from the factory. Raypak heaters are manufactured using either mechanical or digital controllers (sales order “B” options).

To adjust the water temperature of a mechanical controller, insert a small straight screwdriver into the adjustment screw on the front of temperature controller and turn the wheel to the desired setting (See Fig. 4.). To adjust the water temperature of a digital controller, consult your controller’s operating manual.

Equipment Base

he heater should be mounted on a level, structurally

T sound surface. The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed

n enclosed parking garages must be located at least

i 18 in. above the floor.

Stacking

Hi Delta units can be stacked two units high with an optional stacking rack. A stacking kit (sales order 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.

Fig. 4: Temperature Controller (Mechanical)

CAUTION: Hotter water increases the risk of scalding! There is a hot water scald potential if the thermostat is set too high.

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 - 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)

Fig. 5: Typical Stacked Installation

U.S. Installations

Canadian Installations

Clearance above grade, veranda, porch, deck, or balcony

1 ft (30 cm) 1 ft (30 cm)

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 * *

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) *

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)

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)

Clearance above paved sidewalk or paved driveway located on public property

7 ft (2.13m)

7 ft (2.13m) t

Clearance under veranda, porch, deck or balcony

* 12 in. (30 cm) TT

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code

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. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table D: Vent/Air Inlet Termination Clearances

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”

TOP VIEW

FRONT VIEW

Venting not shown for clarity. Heater must be vented

per instructions in this manual

Heater

Side

Min. C learance

from C ombustible

Surfaces

Recommended

Service

Clearance

Front Open 24”

Rear 12” 24”

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. 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.

Fig. 7: Minimum Clearances from Combustible

Surfaces – Indoor Installations

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.

. 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.

. 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

Fig. 8: 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.)

NOTE: It is recommended that the intake vent be insulated to minimize sweating.

Reversing Air Filter

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 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.

3. In cold climates, and to mitigate potential freezeup, 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

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

Follow these instructions to change the air duct connection from the left-hand side (standard) to the right-hand side:

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 TrueSeal 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:

992B to 1802B Left side – standard

Right side – optional

2002B to 2342B Right side only

space shall be considered in making this determination. Each opening shall have a minimum free area of

in.

er 1,000 BTUH (2,225 mm

er kW) of the total

input rating of all gas utilization equipment in the con-

fined space, but not less than 100 in.

pening shall commence within 12 in. (305 mm) of the

(645 cm2). One

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.

per 4,000 BTUH (550 mm2per kW) of total input rating of all equipment in the enclosure.

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

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.

Canadian Installations

f not less than 1 in.

o per kW) of total rated input of the burner(s), and

he location of the opening(s) shall not interfere

t 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

m) nor less than 6 in. (152 mm) above the floor

m 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.

or each 30,000 BTUH mm

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).

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.

4. Refer to B149 Installation code for additional information.

Water Piping

NOTE: For 87%-efficiency boilers, see special

instructions on page 48.

General

The heater should be located so that any water leaks

will not cause damage to the adjacent area or structures.

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.

1. Disconnect all electrical power from the heater (if applicable).

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

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.

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.

7. Remove the eight flange nuts and the in/out header 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 re-

uire hydrostatic testing prior to being placed in

q 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. 9 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 Operation

CAUTION: Damaging internal condensation may

occur if the heater inlet water temperature does not exceed 105ºF (41ºC) within 7 minutes of start-up.

NOTE: See Raypak Catalog No. 1000.57 for information on Cold Water Protection.

Fig. 9: 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 heater operated with an inlet temperature of less than 105ºF (41ºC) must have a manual bypass or an approved low-temperature operation system to prevent problems with condensation. A manual bypass, shown in Fig. 15, must be piped into the system at the time of installation. This piping is like a primary/secondary boiler installation with a bypass acting as the secondary boiler piping. Raypak strongly recommends that thermometer(s) be placed into the heater piping next to the in/out header to facilitate temperature adjustment. Inlet water temperatures below 105ºF (41ºC) can excessively cool the products of combustion, resulting in condensation on the heat exchanger and in the flue.

Failure to exceed 105ºF (41ºC) within 7 minutes may result in the premature failure of the hot surface igniter, remote flame sensor, burners and heat exchanger. It can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the vent system. The bypass allows part of the heater discharge water to be mixed with the cooler heater return water to increase the heater inlet temperature above 105ºF (41ºC). This precautionary measure should prevent the products of combustion from condensing in most installations. Warranty claims will be

denied when condensation occurs.

(41ºC) or higher. An injector pump arrangement may also be utilized to keep the heater loop at or above

05ºF (41ºC). An injector pump approach has the

1 added value of being able to adjust to changes in the

ystem water coming back to the heater take-off.

OTE: To ensure proper operation, use 20°F ∆T

boiler flow rates when designing the heating system loop pump.

Temperature & Pressure Gauge

Cold water operation issues are applicable to both cold water start and cold water run applications. Cold water operation for 7 minutes or less on start-up is acceptable. Where cold water starts will last longer than 7 minutes or where cold water operation is continuous, provisions must be made to mix higher temperature outlet water with the colder inlet water and thereby raise the inlet temperature to at least 105ºF (41ºC) within the 7-minute time limit.

Cold Water Starts

Frequent (more than once a week) cold water starts, wherein the inlet water temperature remains below 105ºF (41ºC) for more than 7 minutes, must have cold water start protection. Known protection methods consist of mixing heated outlet water with the inlet water with a bypass to raise the inlet to 105ºF (41ºC) or higher. Once the system is heated up and has return water temperatures of 105ºF (41ºC) 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 actuate the high limit, thereby shutting down the heater. Thus an automatic valve system, such as a three-way proportional valve or a modulating two-way valve to control the bypass, should be utilized.

The temperature and pressure gauge is factorymounted in the in/out header.

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 Raypak heating 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/De-coupler 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 sytem design assistance to avoid these issues.

Pump Selection

NOTE: Individual and multi-boiler Cold Water Start systems require the use of a 20°F ∆T boiler pump.

Cold Water Run

Cold water run differs from cold water start in that the system water entering the heater remains below 105ºF (41ºC) continuously. Typically, this is the case in swimming pool heating and water source heat pump applications as well as some others. If the system water is kept in a narrow temperature range, a permanent manual bypass can be employed and manually adjusted to achieve an inlet temperature of 105ºF

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 and Table H for flow rate requirements.

20°F

30°F T 40°F T

Min. Flow Max Flow

Model

No.

gpm

P (ft)

gpm

P (ft)

gpm

P (ft)

gpm

P (ft) T

gpm

P (ft) T

992B 83 5.2 55 2.3 42 1.3 42 1.3 40 132 13.1 13

1262B 106 9.6 71 4.3 53 2.4 53 2.4 40 132 14.8 16

1532B 129 15.7 86 7.1 64 4.0 64 4.0 40 132 16.5 19

1802B N/A N/A 101 10.7 76 6.0 76 6.0 40 132 18.3 23

002B N/A N/A 112 13.8 84 7.9 84 7.9 40 132 19.0 25

2072B N/A N/A 116 14.8 87 8.5 87 8.5 40 132 19.0 26

2342B N/A N/A 132 21.1 98 12.1 98 12.1 40 132 21.4 30

Notes: 1. Basis for minimum flow is 40°F ∆T. Basis for maximum flow is 132 GPM.

NOTE: BYPASS FOR LOW TEMP SYSTEMS ONLY

SYSTEM SENSOR (HEAT PUMP)

12” MAX OR MIN FEASIBLE

5’ MAX

SYSTEM SENSOR (4:1 TURNDOWN OR GREATER)

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

Feedwater Regulator

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.

Piping

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, must be installed so that the chilled medium is piped in parallel with the heater with appropriate valves to prevent the chilled medium from entering the heater.

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 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.

Raypak offers a full line of electronic sequencers that produce direct reset of heater water temperature. (Refer to the Controls section of the Raypak Catalog.)

Fig. 10: Air-Separation/Expansion Tank

Air-Separation/Expansion Tank

All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig. 10.

Three-Way Valves

Valves designed to blend water temperatures or 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.

Fig. 11: Single Heater - Space Heating Application

with Primary/Secondary Piping

Fig. 13: Single Domestic Hot Water Heater and Storage

12” MAX OR MIN FEASIBLE

SYSTEM SENSOR

(LESS THAN

4:1 TURNDOWN)

5’ MAX

’ MAX

SYSTEM SENSOR (4:1 TURNDOWN OR GREATER)

Tank

Pool Heating

Fig. 12: 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. Water softened as low as 0 to 3 grains per gallon is known to be aggressive and corrosive.

Potable Water and Space Heating

CAUTION: When this heater is used for both

potable water and space heating, observe the 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.

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 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.

The Hi Delta pool heater is equipped with an external pump and bypass arrangement as standard equipment. This arrangement blends 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 the installation of the pool heater, the pool thermostat needs to be installed in the main return water line, upstream of the heater. This will ensure that

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, a means such as a mixing valve shall be installed to temper the water in order to reduce scald hazard potential.

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Fig. 14: Single Pool Heater Application

Model

No.

oft* (3-4 grains per gallon)

edium (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

92B

3.3

3213.12½23.6

1262B 30 72 4.4 2½ 7.9 19 115 11.3 2½ 19.4 16 132 14.8 2½ 25.3

1532B 30 86 7.1 2½ 11.9 22 120 13.7 2½ 22.5 20 132 16.5 2½ 27.0

1802B 30 102 10.9 2½ 17.4 26 120 15.1 2½ 23.9 23 132 18.3 2½ 28.7

2002B 30 112 13.9 2½ 21.6 26 132 19.0 2½ 29.5 26 132 19.0 2½ 29.5

2072B 31 117 15.1 2½ 23.4 27 132 19.0 2½ 29.5 27 132 19.0 2½ 29.5

2342B 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

the heater will be energized at the right time. If the main water line is too far away from the heater and the capillary bulb will not reach it, locate the pool thermostat adjacent to the main line and run wires back to the

5. If this process does not raise the inlet water temperature to 105°F and Valve A is fully open, then slowly throttle Valve B closed to increase the inlet water temperature to 105°F.

heater.

Adjustment of the manual bypass valve is critical to proper operation of the heater. The manual bypass valve should be adjusted to achieve a minimum inlet water temperature of 105°F and an outlet water temperature below 140°F. When starting with a cold pool, make initial adjustments. Make final adjustments when pool water approaches desired temperature.

The use of a bypass is required for proper operation in a pool heating application. Use the following instructions to set the manual bypass:

1. Set Valve A (the bypass) to

⁄2 open position, and

Valve B to fully open position.

2. Turn on pump.

3. Turn on heater and wait until heater goes to full fire.

4. Adjust Valve A until the inlet water temperature is 105°F. NOTE: Opening the valve will increase the temperature and closing the valve will decrease the temperature.

Fig. 15: “H” Bypass Setting

FROM FILTE R

TO POOL

CHEMICAL FEED

OUTLET THERMOSTAT/LIMIT

POOLSTAT/ CONTROLLER

DRAIN VALVE

SOLATION

VALVES

EATER PUMP

(MAY BE REAR-MOUNTED)

HEATER LIMIT

(INSIDE HEADER OUTLET)

ADJUSTMENT

VALVE

5’ MAX

Automatic Chlorinators and Chemical

eeders

CAUTION: Combustion air must not be

contaminated by corrosive chemical fumes which

an damage the heater and void the warranty.

All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place chlorine tablets or bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (e.g. overnight).

Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical back-up into the heater when the pump is shut off.

NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid corrosion of the heat exchanger in the heater. Such damage is not covered under the warranty.

ing application, ensure that all the following installation requirements are met:

ypass information

B Piping information Outlet thermostat/limit Heater limit Pool thermostat

To complete the installation of the heater, the poolstat must be installed in the return water line from the pool, upstream of the heater. A factory-supplied operating control is configured to operate as the pool thermostat. A separate auto limit is shipped loose to be installed in the system piping downstream of the heater as the outlet thermostat. See Fig. 16 for details.

Pool Heating - P Models

All Raypak pool heaters are certified to ANSI Z21.56, which is the nationally recognized standard for swimming 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.

Some Raypak P 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. In such systems, the heater must be plumbed in a primary/secondary arrangement, wherein only a small portion of the water flowing in the piping system is pulled off, heated, and then returned to the system. In such systems, the water coming out of the heater is mixed with the filtered water in the main pipe and thus tempered before returning to the pool. This arrangement permits operation of the heater at a temperature range that has been optimized both to avoid damaging condensation on the heat exchanger and to mitigate the formation of scale in the heat exchanger tubes.

When a boiler or water heater is used in a pool heat-

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Fig. 16: Component Locations - WHP Models

NOTE: The recommended setting for the outlet thermostat is 110°F.

Winterizing Your Heater

Heaters installed outdoors in freezing climate areas should be shut down for the winter. To shut down heater, turn off manual main gas valve and main gas shut-off. Close isolation valves and remove water piping from the in/out header on the heater. Drain the heater and any piping of all water that may experience below-freezing temperatures.

Pool/Spa Water Chemistry

OTE: Chemical imbalance can cause severe

damage to your heater and associated equipment.

Water Hardness

Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in the water. The concentration of these salts is expressed in mg/l, ppm or grains per gallon, as a measure of relative hardness of water. Grains per gallon is the common reference measurement used in the U.S. water heater industry. Hardness expressed as mg/L or ppm may be divided by 17.1 to convert to grains per gallon. Water may be classified as very soft, slightly hard, moderately hard or hard based on its hardness number. The salts in water will precipitate out when the water is heated and will cause accelerated lime and scale accumulation on a heat transfer surface.

Raypak water heaters can operate lime/scale-free using potable water with a hardness not exceeding 25 grains per gallon. Proper operation is achieved by setting the temperature rise/water flow per the guidelines in the installation instructions. If the hardness of the water exceeds the maximum level of 25 grains per gallon special measures must be taken to adjust flow and temperature rise. Water should be softened to a hardness level no lower than 5 grains per gallon. Water softened below 3 grains per gallon may be under-sat-

urated with respect to calcium carbonate resulting in water that is aggressive and corrosive.

pH of Water

pH is a measure of relative acidity, neutrality or alkalinity. Dissolved minerals and gases affect water’s pH. The pH scale ranges from 0 to 14. Water with a pH of

7.0 is considered neutral. Water with a pH lower than 7 is considered acidic. Water with a pH higher than 7 is considered alkaline. A neutral pH (around 7) is desirable for most potable water applications. Corrosion damage and water heater failures resulting from water pH levels of lower than 6 or higher than 8 are non-warrantable. The ideal pH range for water used in a storage tank or a copper water heater system is 7.2 to

7.8.

Total Dissolved Solids

Total dissolved solids (TDS) is the measure of all minerals and solids that are dissolved in the water. The concentration of total dissolved solids is usually expressed in parts per million (ppm) as measured in a water sample. Water with a high TDS concentration will greatly accelerate lime and scale formation in the hot water system. Most high TDS concentrations will precipitate out of the water when heated. This can generate a scale accumulation on the heat transfer surface that will greatly reduce the service life of a water heater. This scale accumulation can also impede adequate flow of water and may totally block

Recommended Level(s) Fiberglass Pools Fiberglass Spas

Other Pool and Spa

Types

Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)

pH 7.3-7.4 7.3-7.4 7.6-7.8

Total Alkalinity (ppm) 120-150 120-150 80-120

Calcium Hardness (ppm) 200-300 150-200 200-400

Salt (ppm) 3000 Maximum 3000 Maximum 3000 Maximum

Free Chlorine (ppm)* 2-3 2-3 2-3

Total Dissolved Solids

(ppm)

*Free Chlorine MUST NOT EXCEED 5 ppm! **In salt water chlorinated pools, the total TDS can be as high as 4500ppm

1500 Maximum** 1500 Maximum** 1500 Maximum**

NOTE: The allowable concentrations of salt and of the Total Dissolved Solids are lower for the Hi Delta than for a typical residential pool heater, due to the higher water temperatures at which a Hi Delta operates.

Table I: Water Chemistry

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