Raypak H3-302B Installation Manual
INSTALLATION & OPERATING
LLC
®
INSTRUCTIONS
Models 302B –902B
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. 1000.501M Effective: 07-01-16 Replaces: 04-30-14 P/N 240757 Rev. 14
Rev. 14 reflects the following:
Changes to: “Gas supply pressure” on page 22, wiring diagram on page 46
Additions: None
Deletions: Type “P” warranty on page 57
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 10
Combustion and Ventilation Air 12
Conventional Combustion Air Supply 13
Water Piping 14
Hydronic Heating 16
Gas Supply 21
Electrical Power Connections 23
Field Wiring Connection 24
Venting 25
Changing the Flue Outlet 28
Venting Installation Tips 28
Venting Configurations 28
Outdoor Installation 34
Controls 34
Heater Sequence of Operations 35
Wiring Diagram 41
START-UP 42
Pre Start-up 42
Start-Up 43
OPERATION 46
Lighting Instructions 46
To Turn Off Gas To Appliance 46
TROUBLESHOOTING 47
MAINTENANCE 48
Suggested Minimum
Maintenance Schedule 48
Preventative Maintenance Schedule 48
APPENDIX 50
Inside Air Contamination 50
WARRANTIES 52
Type H and WH 52
Start-Up Checklist 54
Important Instructions for the
Commonwealth of
Massachusetts 55
3
WARNINGS
Pay Attention to These Terms
DANGER:
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 immediate hazards which will cause severe personal injury, death or substantial property damage if ignored.
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.
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
apply to heaters that have been improperly installed or
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
depending on the heater size and configuration. The
letter(s) in the first group of characters identifies the
application (H = Hydronic Heating, WH = Domestic
®
Hot Water (DHW), P = Pool). The number which follows identifies the firing mode (1 or 4 = on-off, 3 =
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.
Ratings and Certifications
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.
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
• Low-lead content (<.25%) CSA-certified
All Raypak heaters are National Board Approved, 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.
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
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.
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
Quantity of
Vent Size
(in.)
Model
No.
Burners
Gas
Valves
Blowers Flue Intake
302B 6 1 1 5 6
402B 8 1 1 6 6
502B 10 2 1 6 6
652B 13 2 1 8 6
752B 15 2 1 8 6
902B 18 3 1 8 6
# Burners per
Valve
Stages
% Fire at
Stage
Model
No.
1231212
302B 6 1 100
402B 8 1 100
502B 5 5 11, 2 50100
652B 7 6 11, 2 54100
752B 8 7 11, 2 53100
902B 6 6 6 1, 2 1, 2, 3 66 100
# Burners
per Valve
Valve
Staging
% Firing
at Stage
Model
No.
12*1 2 1 2
302B 4 2 1 1, 2 66 100
402B 5 3 1 1, 2 63 100
Table A: Basic Data
Table B: Manifold Data
* Valve 2 is inside the air plenum on H3/WH3 302B-402B
Table C: 2-Stage Design Option
7
GENERAL SAFETY
Water temperature over 125°F can
c au se in s t an t s ev e r e b ur n s or de a t h
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 D: Time to Produce Serious Burn
8
The temperature of the water in the heater can be reg-
REQUIRES OPTIONAL VENT TEE.
REQUIRES OPTIONAL VENT TEE IF VENTED OUT BACK
OF HEATER.
4
4 PER NATIONAL FUEL GAS CODE (NFGC).
ulated by using the temperature controller. To comply
with safety regulations, the temperature controller is
set at the lowest setting when shipped from the factory.
To adjust the water temperature, 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.).
Fig. 4: Temperature Controller
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.
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.
CAUTION: Hotter water increases the risk of
INSTALLATION
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
9
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 Unobstructed
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.
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.
Table E: Clearances – Indoor Installations
Fig. 6: 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.
10
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 National 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. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table G: Vent/Air Inlet Termination Clearances
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.
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:
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
drywall 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
1. Install combustion air direct vent in accordance
with Fig. 27 (horizontal) or Fig. 28 (vertical) of this
manual (pages 31 and 32, 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.
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.
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.
2
of
2
of
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:
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 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:
302B & 402B Right side only
502B to 902B Left side - standard
Right side - optional
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 con-
2
fined space, but not less than 100 in.
(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
2
shall have a minimum free area of 1 in.
2
4,000 BTUH (550 mm
per kW) of total input
per
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
2
have a minimum free area of 1 in.
per 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:
2
a. 1 in.
per 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
vented with other gas-fired appliances.
Canadian Installations
2
of not less than 1 in.
for 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
2
than 1 in.
per 7,000 BTUH (320 mm2per kW) up
to and including 1 million BTUH, plus 1 in.2per
2
14,000 BTUH (160 mm
per 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 the 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 H
and Table I 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 in. Verify proper flow rates and ∆T as instructed 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.
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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 six flange nuts and the in/out header
from the left-hand side.
8. Remove the six flange nuts and the return header
from the right-hand side.
9. Remove the header stud bolts from each tube
sheet.
10. Reverse the headers and stud bolts to the new
location.
11. Install NEW red beveled O-rings flush against both
tube sheets with the bevel facing outward.
12. Push the header firmly against the O-rings. Install
and tighten the flange nuts onto the stud bolts until
finger tight.
13. 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.
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 testing of the piping connections to the heater and the rest
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.
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.
14. Re-route the capillary(s), wiring etc. to the new
location, adding thermal paste and shim to the
capillary well.
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.
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.
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.
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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.
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
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
(41ºC) or higher. An injector pump arrangement may
also be utilized to keep the heater loop at or above
105ºF (41ºC). An injector pump approach has the
added value of being able to adjust to changes in the
system water coming back to the heater take-off.
NOTE: To ensure proper operation, use 20°F ∆T
boiler flow rates when designing the heating system
loop pump.
Temperature & Pressure Gauge
The temperature and pressure gauge is factorymounted in the in/out header.
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.
NOTE: Individual and multi-boiler Cold Water Start
systems require the use of a 20°F ∆T boiler pump.
Hydronic Heating
System Design
How 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 installtion 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.
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10°F T 20°F T 30°F T 40°F T
Min. Flow Max Flow
Model
No.
gpm
P (ft)
gpm
P (ft)
gpm
P (ft)
gpm
P (ft)
gpm
P (ft) T
gpm
P (ft) T
302B 50 3.3 25 0.8 N/A N/A N/A N/A 20 0.5 25 90 9.8 6
402B 67 5.8 34 1.4 22 0.6 N/A N/A 20 0.5 34 90 10.0 7
502B 84 9.1 42 2.3 28 1.1 21 0.6 21 0.6 40 90 10.4 9
652B N/A N/A 55 4.1 36 1.8 27 1.1 27 1.1 40 90 10.8 12
752B N/A N/A 63 5.7 42 2.6 32 1.5 32 1.5 40 90 11.3 14
902B N/A N/A 76 8.3 50 3.8 38 2.2 38 2.2 40 90 11.7 17
Notes: 1. Basis for minimum flow is 20 gpm or 40°F ∆T. Basis for maximum flow is 90 gpm. Flow switch will not operate if flow is less
than 20 gpm.
2. Rear-mounted pumps may provide higher flow rates on smaller models than the system requirements.
Table H: Heater Rates of Flow and Pressure Drops
Pump Selection
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 H and Table I
for flow rate requirements.
Pressure Drop in Feet of Head
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
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.
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
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.
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