Raypak Hi Delta 302A-902A, Hi Delta 302A, Hi Delta 402A, Hi Delta 502A, Hi Delta 652A Installation And Operating Instructions Manual

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INSTALLATION AND OPERATING

INSTRUCTIONS

CATALOG NO. 1000.501B Effective: 09-08-06 Replaces: 01-01-05 P/N 240757 Rev. 1

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.

Models

302A-902A Types H, WH & P

WARNINGS 4 BEFORE INSTALLATION 5

Product Receipt 5 Model Identification 5 Ratings and Certifications 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 20 Electrical Power Connections 22 Field Wiring Connection 23 Venting 25 Changing the Flue Outlet 27 Venting Installation Tips 28 Venting Configurations 28 Controls 33 Outdoor Installation 33 Heater Sequence of Operations 34 87%-Efficiency Boilers – Special Instructions 39 Water Piping 39 Wiring Diagram 44

START-UP 45

Pre Start-up 45 Start-Up 46

OPERATION 49

Lighting Instructions 49 To Turn Of Gas To Appliance 49

TROUBLESHOOTING 50 MAINTENANCE 51

Suggested Minimum Maintenance Schedule 51 Preventative Maintenance Schedule 51

APPENDIX 53

Inside Air Contamination 53

WARRANTIES 54

Type H and WH 54 Type P 55

CONTENTS

DANGER:

Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored.

WARNING:

Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored.

CAUTION:

Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.

NOTE:

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

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: 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: To minimize the possibility of improper operation, serious personal injury, fire, or damage to the heater:

• Always keep the area around the heater free of combustible materials, gasoline, and other flammable liquids and vapors.

• Heater should never be covered or have any blockage to the flow of fresh air to the heater.

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

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

WARNING: Risk of electrical shock. More than one disconnect switch may be required to de-energize the equipment before servicing.

CAUTION: Operation of this heater in low-temperature 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.

WARNINGS

Pay Attention to These Terms

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.

Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.

Product Receipt

On receipt of your heater it is suggested that you visually check for external damage to the shipping crate. If the crate is damaged, make a note to that effect on the Bill of Lading when signing for the shipment. Remove the heater from the shipping packaging. Report any damage to the carrier immediately.

On occasion, items are shipped loose. Be sure that you receive the correct number of packages as indicated on the Bill of Lading.

Claims for shortages and damages must be filed with the carrier by consignee. Permission to return goods must be received from the factory prior to shipping. Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted. All returned goods are subject to a restocking charge.

When ordering parts, you must specify the model and serial number of the heater. When ordering under warranty conditions, you must also specify the date of installation.

Purchased parts are subject to replacement only under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted and will be replaced in kind only per Raypak’s standard warranties.

Model Identification

The model identification number and heater serial number are found on the heater rating plate located on the lower right outside jacket of the heater. The model

number will have the form H9 1262A 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. An “E” suffix indicates 87% efficiency (Category II or IV venting) (“H” stamped boilers only).

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

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.

Rated inputs are suitable for up to 5,000 ft elevation without de-rating. Consult the factory for installations at altitudes over 5,000 ft above sea level.

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.

Component Locations

Fig. 1: Component Locations – Back

Fig. 2: Component Locations – Left Side

Panels removed for clarity

Fig. 3: Component Locations – Front

General Information

Table A: Basic Data

Table B: Manifold Data

Table C: 2-Stage Design Option

* Valve 2 is inside the air plenum on H3/WH3 302A-402A

Model

No.

Burners

Quantity of

Gas

Valves

Blowers Flue Intake

302A 6 1 1 5 6

402A 8 1 1 6 6

502A 10 2 1 6 6

652A 13 2 1 8 6

752A 15 2 1 8 6

902A 18 3 1 8 6

Vent Size

(in.)

Model

No.

# Burners per

Valve

Stages

% Fire at

Stage

123 1 2 12

302A 6

1 100

402A 8 1 100

502A 5 5 11, 250100

652A 7 6 11,254100

752A 8 7 11,253100

902A 6 6 6 1, 1A 1, 1A, 2 66 100

Model

No.

# Burners

per Valve

Valve

Staging

% Firing at Stage

12*1 2 1 2

302A 4 2 1 1, 2 66 100

402A 5 3 1 1, 2 63 100

GENERAL SAFETY

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.

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.

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.

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

Water temperature over 125°F can cause instant severe burns or death from scalds.

Children, disabled, and elderly are at highest risk of being scalded.

See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available, see manual.

Water

Temp.

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

Time to Produce Serious

Burn

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/CGA B149.1 installation Code (B149.1) and CSA C22.1 C.E.C. Part 1 (C22.1)

The temperature of the water in the heater can be regulated 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.).

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

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 seismic-certified stacking kit is available from Raypak for this type of installation.

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. 5: Typical Stacked Installation

In addition, the heater shall be installed such that the 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

Table E: Clearances – Indoor Installations

Fig. 6: Minimum Clearances from Combustible

Surfaces – 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.

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.

* DO NOT install on carpeting.

Heater

Side

Floor* 0” 0”

Rear 1” 24”

Water Side 12” 24”

Other Side 1” 24”

Top 1” 1”

Front Open 24”

Vent 2” 2”

Minimum Clear-

ance

from Combustible

Surfaces

Recommended

Service

Clearance

Heater

Side

Front Open 24”

Rear 12” 24”

Water Side 36” 36”

Other Side 36” 36”

Top Unobstructed Unobstructed

Vent N/A N/A

Min. Clearance

from Combustible

Surfaces

Recommended

Service

Clearance

TOP VIEW

FRONT VIEW

Venting not shown for clarity. Heater must be vented

per instructions in this manual

Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table G: Vent/Air Inlet Termination Clearances

U.S. Installations

Clearance above grade, veranda, porch,

deck, or balcony

Clearance to window or door that may be

opened

4 ft (1.2m) below or to side

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

of opening; 1 foot (30 cm)

above opening

Canadian Installations

3 ft (91 cm)

C Clearance to permanently closed window **

Vertical clearance to ventilated soffit located above the terminal within a horizontal dis-

tance of 2 ft (61cm) from the centerline of the

5 ft (1.5m) *

terminal

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 ex-

tended 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

K Clearance to mechanical air supply inlet

Clearance above paved sidewalk or paved

driveway located on public property

Clearance under veranda, porch, deck or

balcony

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

In accordance with the current CAN/CG A-B149 Installation C odes

t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves

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 terminal and

underside of ver anda, porch, deck or balcony is greater than 1 ft (30cm)

* Clearances in accordance with local installation codes and the requirements of the gas supplier

4 ft (1.2m) below or to side

of opening; 1 ft (30 cm)

above opening

3 ft (91 cm) above if within

10 ft (3m) horizontally

7 ft (2.13m)

* 12 in. (30 cm) TT

3 ft (91 cm)

6 ft (1.83m)

7 ft (2.13m) t

Fig. 8: Minimum Clearances from Combustible

Surfaces – Outdoor Installations

Combustion and Ventilation Air

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 B149.1 (Canada), and all local codes.

Reversing Air Filter

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

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:

1. Install combustion air direct vent in accordance with Fig. 26 (horizontal) or Fig. 27 (vertical) of this manual (pages 31 and 32, respectively).

2. Provide adequate ventilation of the space occupied by the heater(s) by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area shall be at least 1 in.

of free area per 20,000

BTUH (111 mm

per 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 shall be at least 1 in.

of free area per 10,000

BTUH (222 mm

per kW) of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct(s).

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 nonoperating 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

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.

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.

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.

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:

302A & 402A Right side only

502A to 902A Left side - standard

Right side - optional

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

CAUTION: Use TrueSeal combustion air if damaging airborne contaminants are or will be present in the heater area. See the Appendix regarding air contamination.

space shall be considered in making this determination. Each opening shall have a minimum free area of 1 in.

per 1,000 BTUH (2,225 mm2per kW) of the total input rating of all gas utilization equipment in the confined space, but not less than 100 in.

(645 cm2). One opening shall commence within 12 in. (305 mm) of the top, and one opening shall commence within 12 in. (305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 in. (76 mm) in any direction.

All Air from Outdoors

The confined space shall communicate with the outdoors in accordance with one of the methods below. The minimum dimension of air openings shall not be less than 3 in. (76 mm) in any direction. Where ducts are used, they shall be of the same cross-sectional area as the net free area of the openings to which they connect.

1. Two permanent openings, one commencing

within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

a. Where directly communicating with the out-

doors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.

per

4,000 BTUH (550 mm

per kW) of total input

rating of all equipment in the enclosure.

b. Where communicating with the outdoors

through horizontal ducts, each opening shall have a minimum free area of 1 in.

per 2,000

BTUH (1,100 mm

per kW) of total input rat-

ing 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.

per 3,000 BTUH (740 mm2per kW) of the total input rating of all equipment located in the enclosure, and

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.

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.

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.

per 7,000 BTUH (320 mm2per kW) up

to and including 1 million BTUH, plus 1 in.

per

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).

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

CAUTION: All combustion air must be drawn from the air outside of the building; the mechanical equipment room must communicate directly with the outdoors.

of not less than 1 in.2for each 30,000 BTUH mm

per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere with the intended purpose of the opening(s) for ventilation air referred to in (1). This opening(s) can be ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down 18 in. (450 mm) from the floor, but not near piping.

4. Refer to B149.1 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.

Reversing Water Connections

Follow these instructions to change the water connections from the left-hand side (standard) to the righthand side.

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.

WARNING: Care must be taken to ensure that the equipment room is not under negative pressure conditions or that the equipment is not common-vented with other gas-fired appliances.

NOTE: For 87%-efficiency boilers, see special instructions on page 39.

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 ΔT as instructed in this manual.

Canadian Installations

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.

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.

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.

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 factorytested 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.

3. Check for leaks. Repair if found.

Cold Water Operation

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.

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

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

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.

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.

Temperature & Pressure Gauge

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

Hydronic Heating

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 ΔT as design ΔT. (ΔT is the temperature difference between the inlet and outlet water when the heater is firing at full rate). If a ΔT of larger than 20°F is necessary, see Table H and Table I for flow rate requirements.

Table H: Heater Rates of Flow and Pressure Drops

Notes: 1. Basis for minimum flow is 20 gpm or 40°F ΔT. 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.

Model

No.

10°F T 20°F T 30°F T 40°F T

gpm

P (ft)

gpm

P (ft)

gpm

P (ft)

gpm

P (ft)

Min. Flow Max Flow

gpm

P (ft) T

gpm

302A 50 3.1 25 0.8 N/A N/A N/A N/A 20 0.5 25 90 9.8 6

402A 67 5.5 34 1.4 22 0.6 N/A N/A 20 0.5 34 90 10.0 7

502A 84 9.1 42 2.3 28 1.1 21 0.6 21 0.6 40 90 10.4 9

652A N/A N/A 55 4.1 36 1.8 27 1.1 27 1.1 40 90 10.8 12

752A N/A N/A 63 5.7 42 2.6 32 1.5 32 1.5 40 90 11.3 14

902A N/A N/A 76 8.3 50 3.8 38 2.2 38 2.2 40 90 11.7 17

P (ft) T

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 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.

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

Fig. 10: Air-Separation/Expansion Tank

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.)

Domestic Hot Water

When designing the water piping system for domestic hot water applications, water hardness should be considered. Table I indicates the suggested flow rates for soft, medium and hard water. Water hardness is expressed in grains per gallon.

Fig. 11: Single Heater - Low-Temperature (Heat Pump)

Application with Primary/Secondary Piping

Fig. 12: Dual Heaters (Reverse/Return)

with Primary/Secondary Piping

Potable Water and Space Heating

1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water.

2. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating.

3. If the heater will be used to supply potable water, it shall not be connected to any heating system or components previously used with a non-potable water heating appliance.

4. When the system requires water for space heating at temperatures higher than 140°F, a means such as a mixing valve shall be installed to temper the water in order to reduce scald hazard potential.

CAUTION: When this heater is used for both potable water and space heating, observe the following to ensure proper operation.

Fig. 13: Single Domestic Hot Water Heater and Storage

Tank

Table I: Domestic Water Heater Flow Rate Requirements

Pool Heating

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

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.

ΔT = Temperature rise, °F ΔP = Pressure drop through heat exchanger, ft SHL = System head loss, ft (based on heater and tank placed no more than 5 ft apart and equivalent length pipe/fittings of 2” tube = 25 ft) gpm = Gallons per minute, flow rate MTS = Minimum tubing size

* Must use optional cupro-nickel tubes. If over 25 grains per gallon, a water softening system must also be used

Model

No.

Soft (0-4 grains per gallon) Medium (5-15 grains per gallon) Hard* (16+ grains per gallon)

gpm

MTS SHL

gpm

MTS SHL

gpm

302A 13 40 2.0 2 4.3 10 52 3.3 2 7.1 6 90 9.8 2 20.3

402A 17 40 2.0 2 4.4 13 52 3.4 2 7.2 8 90 10.0 2 20.5

502A 21 40 2.1 2 4.5 16 52 3.5 2 7.4 9 90 10.4 2 20.9

652A 28 40 2.2 2 4.6 20 55 4.1 2 8.4 12 90 10.8 2 21.3

MTS SHL

752A 30 42 2.6 2 5.2 20 63 5.7 2 11.1 14 90 11.3 2 21.8

902A 30 51 3.9 2 7.6 20 76 8.4 2 16.1 17 90 11.7 2 22.2

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 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 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.

5. If this process does not raise the inlet water tem-

Fig. 14: Single Pool Heater Application

perature to 105°F and Valve A is fully open, then slowly throttle Valve B closed to increase the inlet water temperature to 105°F.

Automatic Chlorinators and Chemical Feeders

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.

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

Fig. 15: “H” Bypass Setting

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty.

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.

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

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 as low as 0 to 1 grain per gallon may be under-saturated 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.

NOTE: Chemical imbalance can cause severe damage to your heater and associated equipment.

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 the water passages in the tubes of the heat exchanger. A heat exchanger that is damaged or blocked by lime/scale accumulation must be replaced. Failure of a water heater due to lime scale build up on the heating surface is non-warrantable. The manufacturer of the water heater has no control of the water quality, especially the TDS levels in your system. Total dissolved solids in excess of 2,500 ppm will accelerate lime and scale formation in the heat exchanger. Heat exchanger failure due to total dissolved solids in excess of 2,500 ppm is a non-warrantable condition. Raypak offers basic temperature guidelines for operation of a potable water heater on normal to moderate levels of hardness and solids but levels of hardness and total dissolved solids beyond normal limits for operation will require special setup and operation.

Gas Supply

Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. It is recommended that a union be installed in the gas supply piping adjacent to the heater for servicing. A pounds-to-inches regulator must be installed to reduce the gas supply pressure to a maximum of 10.5 in. WC for natural gas and 13.0 in. WC for propane gas. The regulator should be placed a minimum distance of 10 times the pipe diameter up-stream of the heater gas controls. Refer to Table J for maximum pipe lengths.

NOTE: Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH or other chemical imbalance is non-warrantable.

DANGER: Make sure the gas on which the heater will operate is the same type as specified on the heater’s rating plate.

Gas Supply Connection

The heater must be isolated from the gas supply piping system by closing the manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa). Relieve test pressure in the gas supply line prior to reconnecting the heater and its manual shut-off valve to the gas supply line. FAILURE TO FOLLOW

THIS PROCEDURE MAY DAMAGE THE GAS VALVES. Over pressurized gas valves are not cov-

ered by warranty. The heater and its gas connections shall be leak-tested before placing the appliance in operation. Use soapy water for leak test. DO NOT use an open flame.

CAUTION: The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa).

Fig. 16: Gas Supply Connection

CAUTION: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.

CAUTION: Support gas supply piping with hangers, not by the heater or its accessories. Make sure the gas piping is protected from physical damage and freezing, where required.

Reversing Gas Supply Connection

Reversing the standard fuel connection from the lefthand to the right-hand side is a simple field operation.

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

2. Disconnect the main gas pipe from the heater (if applicable).

3. Remove the left and right front panels from the heater.

4. Locate the main gas line that traverses across the heater above the manifold risers.

5. Remove the pipe cap from the right-hand end of the main gas line.

6. Reinstall the pipe cap on the left-hand end of the main gas line.

7. Remove plastic cap from the right-hand side panel and reinstall into the standard main gas opening located on the left-hand side of the heater.

CAUTION: Do not use Teflon tape on main gas line pipe thread. A pipe compound rated for natural and propane gases is recommended. Apply sparingly only on male pipe ends leaving the two end threads bare.

Table J: Maximum Equivalent Pipe Length

Natural gas – 1,000 BTU per ft3, .60 specific gravity at 0.5 in. WC pressure drop Propane gas – 2,500 BTU per ft

, 1.53 specific gravity at 0.6 in. WC pressure drop

Model

No.

3/4" 1” 1-1/4” 1-1/2” 2” 2-1/2”

NPNPNPNPNPNP

302A 15 25 35 85 150 380 360 -- -- -- -- --

402A -- 15 25 60 100 260 250 -- -- -- -- --

502A -- -- -- -- 65 150 130 360 500 -- -- --

652A -- -- -- -- 45 100 95 250 340 -- -- --

752A -- -- -- -- 35 80 75 180 260 600 -- --

902A -- -- -- -- 20 45 45 110 150 360 400 --

8. Remove the rubber grommet from the left-handside panel and reinstall into the standard main gas opening, located on the right-hand side of the heater.

9. Install a coupling, nipple, union and sediment trap onto the right-hand end of the main gas line and then install the gas line, making sure that a manual shut-off valve has been installed within 10 ft of the heater.

10. Replace the left and right front panels on the heater.

Gas Supply Pressure

A minimum of 5.0 in. WC and a maximum of 10.5 in. WC upstream gas pressure is required under load and no-load conditions for natural gas. A minimum of 11.0 in. WC and a maximum of 13.0 in. WC is required for propane gas. The gas pressure regulator(s) supplied on the heater is for low-pressure service. If upstream pressure exceeds 14.0 in. WC, an intermediate gas pressure regulator, of the lockup type, must be installed.

When connecting additional gas utilization equipment to the gas piping system, the existing piping must be checked to determine if it has adequate capacity for the combined load.

The gas valve pressure regulator(s) on the heater are nominally preset at 3.5 in. WC for natural gas, and

10.5 in. WC for propane gas. The pressure at the gas

valve outlet tap, measured with a manometer, while in operation should be 3.5 ± 0.1 in. WC for natural gas and 10.5 in. ± 0.1 in. WC for propane gas. If an adjustment is needed, remove the adjustment screw cover and turn the adjustment screw clockwise to increase pressure or counter-clockwise to lower pressure.

Fig. 17: Gas Valve

Electrical Power Connections

Installations must follow these codes:

• National Electrical Code and any other national, state, provincial or local codes or regulations having jurisdiction.

• Safety wiring must be NEC Class 1.

• Heater must be electrically grounded as required by the NEC.

• In Canada, CSA C22. 1 C.E.C. Part 1.

The heater is wired for 120 VAC, 8 amps. The voltage is indicated on the tie-in leads. Consult the wiring diagram shipped with the heater in the instruction packet. The remote tank control stat, thermostat, or electronic heater control (as applicable) may be connected to the stage selector terminal (See wiring diagram). 24 VAC is supplied to this connection through the heater transformer. DO NOT attach any voltage to the stage se- lector terminals. Before starting the heater check to ensure proper voltage to the heater and pump.

Install a separate disconnect means for each load. Use appropriately sized wire as defined by NEC, CSA and/or local code. All primary wiring should be 125% of minimum rating.

If any of the original wire as supplied with the heater must be replaced, it must be replaced with 105°C wire or its equivalent.

Field-Connected Controllers

It is strongly recommended that all individually-powered control modules and the heater should be supplied from the same power source.

Check the Power Source

NOTE: Field-supplied isolation relays should be

installed when field-connected controllers are mounted more than 50 equivalent feet (18 Ga) from heater.

WARNING: Using a multi-meter, check the following voltages at the circuit breaker panel prior to connecting any equipment. Make sure proper polarity is followed and house ground is proven. (See Fig. 18.)

BLACK

Fig. 18: Wiring Connections

Check the power source:

AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum

If the heater does not have a factory-wired stage controller, it is factory-wired in an on-off configuration with other stage terminals jumpered.

To field-connect a stage controller, remove factoryinstalled jumper and wire stage controller as shown in Fig. 21.

Making the Electrical Connections

Refer to Fig. 18-23.

1. Verify that circuit breaker is properly sized by referring to heater rating plate. A dedicated circuit breaker should be provided.

2. Turn off all power to the heater. Verify that power has been turned off by testing with a multi-meter

Fig. 19: Multi-meter

prior to working with any electrical connections or

components.

3. Observe proper wire colors while making electrical connections. Many electronic controls are polarity sensitive. Components damaged by improper electrical installation are not covered by warranty.

4. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code.

5. Install heater controls, thermostats, or building management systems in accordance with the applicable manufacturers’ instructions.

6. Conduit should not be used as the earth ground.

Field Wiring Connection

NOTE: A grounding electrode conductor shall be

used to connect the equipment grounding conductors, the equipment enclosures, and the grounded service conductor to the grounding electrode.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

Fig. 20: Wiring Location

CIRCUIT

BREAKER

WHITE

GREEN

GROUND

AB C

DANGER: SHOCK HAZARD

Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components.

Fig. 21: Wiring Connections

Installer action is required to electrically enable your heater to operate after making the power connections. You must make a closed contact connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connections. This will be done based on the controller option selected with your heater order.

1. For Pool and Closed-Loop Water-Source Heat Pump applications, your heater should be configured to operate in an on-off firing mode. This means that you will connect a single-pole control to stage one of the CPW board. Then jumper the remaining firing stages. For example, if your heater is a Model 1532A, you will jumper stages two, three and four. Then your heater will either be on at full fire, or it will be off.

2. For 2-stage controller connections, connect each stage of the control to the corresponding stage of the CPW board in the heater, i.e., stage 1 of the heater to stage 1 of the control; stage 2 of the heater to stage 2 of the control, as shown in Fig. 21 and 22. Set the operating control to the setpoint at which you want the heater to maintain. Ensure that the sensing bulb of the control is at the point in the system that will best maintain the temperature you want. For example, when you are heating a tank of water, you want the operating control sensor bulb in the tank.

3. For single-stage controller connections, attach the stage 1 connections on heater 1 to the tankstat per Fig. 23.

Heater must be electrically grounded in accordance with the NEC, and CSA C22.1 C.E.C. Part 1 in Canada.

Fig. 22: 2-Stage Tankstat

Fig. 23: Single-Stage Tankstat

Consult the wiring diagram shipped with the heater in the instruction packet or at the end of this section. The stage-selector terminals are for the remote tank control through the heater’s 24 VAC transformer. DO NOT

attach any voltage to the stage-selector terminals.

Before starting the heater, check to ensure proper voltage to the heater and pump.

Venting

General

Appliance Categories

Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent.

Category I – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category II – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

NOTE: If any of the original wire supplied with the heater must be replaced, it must be replaced with similar sized 105°C wire or its equivalent.

NOTE: For 87%-efficiency boilers, see special instructions on page 39.

CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the heater.

SINGLE

STAGE

TANKSTAT

STAGE 1

CONNECTION

ATTACH STAGE 1 CONNECTIONS

ON HEATER TO THE SINGLE STAGE

TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.

STAGE 1

CONNECTION

ATTACH STAGE 1 CONNECTIONS ON HEATER

TO STAGE 1 CONNECTION ON TANKSTAT.

ATTACH STAGE 2 CONNECTIONS OR STAGE 1 CONNECTION OF HEATER 2

TO STAGE 2 CONNECTIONON TANKSTAT

2-STAGE

TANKSTAT

STAGE 2 CONNECTION OR

AS SHOWN IN THE DIAGRAM.

STAGE 1 CONNECTION

OF HEATER 2

Category III – A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category IV – A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

See Table K for appliance category requirements.

Support of Vent Stack

The weight of the vent stack or chimney must not rest on the heater vent connection. Support must be provided in compliance with applicable codes. The vent should also be installed to maintain proper clearances from combustible materials.

Use insulated vent pipe spacers where the vent passes through combustible roofs and walls.

Vent Terminal Location

1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.

2. Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury.

3. Gases may form a white vapor plume in winter. The plume could obstruct a window view if the termination is installed near windows.

4. Prevailing winds, in combination with below-freezing temperatures, can cause freezing of condensate and water/ice build-up on buildings, plants or roofs.

5. The bottom of the vent terminal and the air intake shall be located at least 12 in. above grade, including normal snow line.

6. Un-insulated single-wall metal vent pipe shall not be used outdoors in cold climates for venting gasfired equipment.

7. Through-the-wall vents for Category II and IV appliances and non-categorized condensing appliances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. Where local experience indicates that condensate is a problem with Category I and III appliances, this provision shall also apply.

NOTE: For additional information on appliance categorization, see appropriate ANSI Z21 Standard and the NFGC (U.S.), or B149.1 (Canada), or applicable provisions of local building codes.

CAUTION: When condensate traps are installed, condensate must be routed to an appropriate container for neutralization before disposal, as required by local codes.

WARNING: Contact the manufacturer of the vent material if there is any question about the appliance categorization and suitability of a vent material for application on a Category III or IV vent system. Using improper venting materials can result in personal injury, death or property damage.

NOTE: During winter months check the vent cap and make sure no blockage occurs from build-up of snow or ice.

Table K: Venting Category Requirements

Combustion

Air Supply

Exhaust

Configuration

Heater Venting

Category

Certified

Materials

Combustion Air

Inlet Material

Vertical Natural

From Inside Building (Non-Direct Venting)

From Outside Building

(Direct Venting)

Draft Venting

Horizontal Through-

the-Wall Venting

Vertical Natural

Draft Venting

Horizontal Through-

the-Wall Venting

I “B” Vent

III

I “B” Vent

III

Stainless Steel

(Gas Tight)

Stainless Steel

(Gas Tight)

Galvanized Steel

PVC ABS

CPVC

8. Locate and guard vent termination to prevent accidental contact by people or pets.

9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area.

10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations.

11. Locate or guard vent to prevent condensate from damaging exterior finishes. Use a rust-resistant sheet metal backing plate against brick or masonry surfaces.

12. DO NOT extend exposed vent pipe outside of building. Condensate could freeze and block vent pipe.

U.S. Installations

Refer to the latest edition of the National Fuel Gas Code.

Vent termination requirements are as follows:

1. Vent must terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, window or gravity air inlet to the building.

2. The vent must not be less than 7 ft above grade when located adjacent to public walkways.

3. Terminate vent at least 3 ft above any forced air inlet located within 10 ft.

4. Vent must terminate at least 4 ft horizontally, and in no case above or below unless 4 ft horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment.

5. Terminate vent at least 6 ft away from adjacent walls.

6. DO NOT terminate vent closer than 5 ft below roof overhang.

7. The vent terminal requires a 12 in. vent terminal clearance from the wall.

8. Terminate vent at least 1 ft above grade, including normal snow line.

9. Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane.

Canadian Installations

Refer to latest edition of B149.1.

A vent shall not terminate:

1. Directly above a paved sidewalk or driveway which is located between two single-family dwellings and serves both dwellings.

2. Less than 7 ft (2.13 m) above a paved sidewalk or paved driveway located on public property.

3. Within 6 ft (1.8 m) of a mechanical air supply inlet to any building.

4. Above a meter/regulator assembly within 3 ft (915 mm) horizontally of the vertical centre-line of the regulator.

5. Within 6 ft (1.8 m) of any gas service regulator vent outlet.

6. Less than 1 ft (305 mm) above grade level.

7. Within the 3 ft (915 mm) of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building or the combustion air inlet of any other appliance.

8. Underneath a verandah, porch or deck, unless the verandah, porch or deck is fully open on a minimum of two sides beneath the floor, and the distance between the top of the vent termination and the underside of the verandah, porch or deck is greater than 1 ft (305 mm).

Changing the Flue Outlet

Follow these instructions to change the flue connection from the standard top location to the rear of the heater.

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

2. Disconnect or isolate the main gas pipe from the heater (if applicable).

3. Remove the screws, gasket and dustcover from the rear of the heater.

4. Remove the screws, stainless steel flue cover and gasket from the branch side of the tee located in the flue box at the rear of the heater.

5. Remove the screws, retaining ring and rain gasket from top of heater.

6. Remove the screws, flue collar and gasket from the run side of the tee located in the flue box on top of the heater.

7. Reverse the components and reattach in the new location.

8. Make sure that the stainless steel cover, now located on the run side of the tee, is sealed to avoid any flue gas spillage.

Venting Installation Tips

Support piping:

• horizontal runs - at least every 5 ft

• vertical runs - use braces

• under or near elbows

Venting Configurations

For heaters connected to gas vents or chimneys, vent installations shall be in accordance with the NFGC (U.S.), or B149.1 (Canada), or applicable provisions of local building codes.

Natural Draft Vertical Venting (Category I)

Installation

Natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The negative draft must be within the range of -.01 to -.08 in. WC as measured 12 in. above the appliance flue outlet to ensure proper operation. Vent material must be listed by a nationally recognized test agency.

CAUTION: The silicone vent gaskets must be properly reinstalled to prevent flue gas leakage. Replace any torn or worn vent gaskets.

WARNING: Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness, corrosion or deterioration.

The maximum and minimum venting length for Category I appliances shall be determined per the NFGC (U.S.) or B149.1 (Canada).

The diameter of vent flue pipe should be sized according to the NFGC (U.S.) and B149.1 (Canada). The minimum flue pipe diameter for conventional negative draft venting using double-wall Type B vent is: 5 in. for Model 302A, 6 in. for Models 402A and 502A, and 8 in. for Models 652A, 752A and 902A.

The connection from the appliance vent to the stack must be as direct as possible and shall be the same diameter as, or larger than, the vent outlet. The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot from the heater to the vent terminal. The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints.

NOTE: A vent adapter (field-supplied) must be used to connect Type B vent to the unit.

Fig. 24: Natural Draft Vertical Venting

(Category I)

Termination

The vent terminal should be vertical and should terminate outside the building at least 2 ft above the highest point of the roof that is within 10 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft horizontal distance is maintained) electric meters, gas meters, regulators and relief equipment. The distance of the vent terminal from adjacent public walkways, adjacent buildings, open windows and building openings must be consistent with the NFGC (U.S.) or B149.1 (Canada). Gas vents supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads.

Common Venting System

Manifolds that connect more than one heater to a common chimney must be sized to handle the combined load. Consult available guides for proper sizing of the manifold and the chimney. At no time should the area of the common vent be less than the area of the largest heater exhaust outlet.

Common venting systems may be too large once an existing unit is removed. At the time of removal of an existing appliance, the following steps must be fol- lowed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

1. Seal any unused opening in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and verify there is no blockage, restriction, leakage, corrosion or other unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common vent system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum

CAUTION: A listed vent cap terminal, adequately sized, must be used to evacuate the flue products from the heaters.

WARNING: Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure.

CAUTION: Vent connectors for natural draft venting systems must be Type B or better.

Table L: Category I Vertical Venting

* Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. When vertical height exceeds 25 ft, consult factory prior to installation.

** Subtract 10 ft per elbow. Max. 3 elbows.

Maximum combustion air duct length terminated at 100 equivalent ft.

Vertical Venting

Min. Max.

Model

Certified

Venting Material

Vent Size

302A 5”

402A

502A

652A

752A

Cat. I

(Type B

Equivalent)

6”

5’ 25’

8”

Height*

Combustion Air

Intake Pipe

Material

Air Inlet

Max. Length**

6” 8”

100’ N/A

Galvanized Steel,

PVC,

75’

ABS,

CPVC

100’

40’

902A

speed. Do not operate summer exhaust fan. Close

fireplace dampers.

4. Place in operation the appliances being inspected. Follow the manufacturer’s instructions for lighting each appliance. Adjust thermostat so appliance will operate continuously.

5. Check the pressure at a pressure tap located 12 in. above the bottom joint of the first vertical vent pipe. Pressure should be anywhere between -0.01 and -0.08 in. WC.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances to their previous conditions of use.

7. Any improper operation of the common venting system should be corrected so that the installation conforms with the NFGC (U.S.) or B149.1 (Canada). When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in Appendix G in the NFGC (U.S.) or B149.1 (Canada).

Horizontal Through-the-Wall Venting (Category III)

Installation

These installations utilize the heater-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the outdoors. Adequate combustion and ventilation air must be supplied to the equipment room in accordance with the NFGC (U.S.) or B149.1 (Canada).

Fig. 25: Horizontal Through-the-Wall Venting

(Category III)

The total length of the horizontal through-the-wall flue system should not exceed 70 equivalent ft in length. If horizontal run exceeds 70 equivalent ft, an appropriately sized extractor must be used. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in one of the four following arrangements:

• 70’ of straight flue pipe

• 60’ of straight flue pipe and one elbow

• 50’ of straight flue pipe and two elbows

• 40’ of straight pipe and three elbows

The vent cap is not considered in the overall length of the venting system.

The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight. The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that:

1. The vent must be installed with a slight downward slope of not more than 1/4 inch per foot of horizontal run to the vent terminal.

2. The vent must be insulated through the length of the horizontal run.

For installations in extremely cold climate, it is required that:

1. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of horizontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes.

2. The vent must be insulated through the length of the horizontal run.

Termination

The flue direct vent cap MUST be mounted on the exterior of the building. The direct vent cap cannot be installed in a well or below grade. The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved stainless steel flue direct vent cap must be used (sales order option D-15).

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Model

Table M: Category III Horizontal and Direct Venting

Use only the special gas vent pipes listed for use with Category III gas burning heaters, such as the AL29-4C stainless steel vents offered by Heat Fab Inc. (800772-0739), Protech System, Inc. (800-766-3473) or ZFlex (800-654-5600). Pipe joints must be positively sealed. Follow the vent manufacturer’s installation instructions carefully.

Direct Vent - Horizontal Throughthe-Wall

Installation

These installations utilize the heater-mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors.

Fig. 26: Direct Vent - Horizontal Through-the-Wall

The total length of the through-the-wall flue cannot exceed 40 equivalent ft in length for the flue outlet. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in one of the three following arrangements:

• 40’ of straight flue pipe

• 30’ of straight flue pipe and one elbow

• 20’ of straight flue pipe and two elbows.

The total length of air supply pipe cannot exceed the distances listed in Table M. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in any arrangement that does not exceed the lengths shown in Table M.

The flue direct vent cap is not considered in the overall length of the venting system.

Care must be taken during assembly that all joints are sealed properly and are airtight.

The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that:

1. The vent must be installed with a slight downward slope of not more than 1/4 inch per foot of horizontal run to the vent terminal.

2. The vent must be insulated through the length of the horizontal run.

* Subtract 10 ft per elbow. Max. 3 elbows.

Maximum combustion air duct length terminated at 100 equivalent ft.

No.

Certified

Venting Material

Vent Size

Maximum

Equivalent

Vent Length*

Combustion

Air

Intake Pipe

Material

Air Inlet

Max. Length

6” 8”

302A 5”

402A

6”

502A

Category III

652A

752A

8”

902A

70’

Room Air

40’

Ducted

Combustion

Galvanized

Steel,

PVC, ABS,

CPVC

100’ N/A

75’

100’

40’

Air

30’ 80’

Note: When vertical height exceeds 25 ft,

consult factory prior to installation.

For installations in extremely cold climate, it is required that:

2. The intake vent must be insulated through the length of the horizontal run.

Termination

The direct vent cap MUST NOT be installed with any combustion air inlet directly above a direct vent cap. This vertical spacing would allow the flue products from the direct vent cap to be pulled into the combustion air intake installed above.

This type of installation can cause non-warrantable problems with components and poor operation of the heater due to the recirculation of flue products. Multiple direct vent caps should be installed in the same horizontal plane with a 4 ft clearance from the side of one vent cap to the side of the adjacent vent cap(s).

Combustion air supplied from outdoors must be free of particulate and chemical contaminants. To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.

The stainless steel flue direct vent cap must be furnished by the heater manufacturer in accordance with its listing (sales order option D-15).

Use only the special gas vent pipes listed for use with Category III gas burning heaters, such as the AL29-4C stainless steel vents offered by Heat Fab Inc. (800772-0739), Protech System, Inc. (800-766-3473) or ZFlex (800-654-5600). Pipe joints must be positively sealed. Follow carefully the vent manufacturer’s installation instructions.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Direct Vent - Vertical

Installation

These installations utilize the heater-mounted blower to draw combustion air from outdoors and force the heated flue products through the vent pipe under positive pressure. The vent material must be in accordance with the above instructions for vent materials. Vent material must be listed by a nationally recognized test agency.

The connection from the appliance flue to the stack must be as direct as possible and should be the same size or larger than the vent outlet.

See Table L for Category I venting guidelines.

It is recommended that in colder climates, the intake vent be insulated.

Termination

The flue terminal should be vertical and should terminate outside the building at least 2 ft above the highest point of the roof within 10 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft horizontal distance is maintained) electric meters, gas meters, regulators and relief equipment. The distance of the vent terminal from adjacent public walkways, adjacent buildings, open windows and building openings must be consistent with the NFGC (U.S.) or B149.1 (Canada).

Note: When vertical height exceeds 25 ft, consult

factory prior to installation.

Fig. 27: Direct Vent - Vertical

Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads.

The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that might obstruct combustion air flow. This dimension is critical to the correct operation of the heater and venting system and reduces the chance of blockage from snow. The vent cap must have a minimum 3 ft vertical clearance from the air inlet opening.

Outdoor Installation

Outdoor models are self-venting when installed with the optional factory-supplied outdoor vent kit and require no additional vent piping. A special vent cap, flow switch cover and air intake hood are provided in accordance with CSA requirements, which must be installed directly on the heater. Correct clearances can be found earlier in this section.

Care must be taken when locating the heater outdoors, because the flue gases discharged from the vent cap can condense as they leave the cap. Improper location can result in damage to adjacent structures or building finish. For maximum efficiency and safety, the following precautions must be observed:

1. Outdoor models must be installed outdoors and must use the outdoor vent cap, flow switch cover and air intake hood available from the manufacturer (sales order option D-11).

2. Periodically check venting system. The heater’s venting areas must never be obstructed in any way and minimum clearances must be observed to prevent restriction of combustion and ventilation air. Keep area clear and free of combustible and flammable materials.

3. Do not locate adjacent to any window, door walkway, or gravity air intake. The vent must be located a minimum of 4 ft horizontally from such areas.

4. Install above grade level and above normal snow levels.

5. Vent terminal must be at least 3 ft above any forced air inlet located within 10 ft.

6. Adjacent brick or masonry surfaces must be protected with a rust-resistant sheet metal plate.

Freeze Protection

When installing this heater in an outdoor location that is susceptible to freezing, sales order option B-22 must be ordered. The B-22 option energizes the heater pump at a preset temperature drop to circulate water and reduces the possibility of freezing and damaging the heat exchanger or headers.

Controls

NOTE: Condensate can freeze on the vent cap.

Frozen condensate on the vent cap can result in a blocked flue condition.

NOTE: The vent cap, flow switch cover and air intake hood must be furnished by the heater manufacturer in accordance with its listing (sales order option D-11).

WARNING: Installation, adjustment and service of heater controls, including timing of various operating functions, must be performed by a qualified installer, service agency or the gas supplier. Failure to do so may result in control damage, heater malfunction, property damage, personal injury, or death.

WARNING: Turn off the power to the heater before installation, adjustment or service of the CPW board or any heater controls. Failure to do so may result in board damage, heater malfunction, property damage, personal injury, or death.

CAUTION: This appliance has provisions to be connected to more than one supply source. To reduce the risk of electric shock, disconnect all such connections before servicing.

CAUTION: Risk of electric shock: More than one disconnect switch may be required to de-energize the equipment before servicing.

Fig. 28: External LED Indicator Decal

Heater Sequence of Operation

Models 302A, 402A, 502A, 652A, 752A and 902A

1. The black (hot) wire lead goes directly to the main power switch. This black toggle switch is located at the middle front of the control compartment.

2. When the main power switch is placed in the “ON” position, 120 VAC is applied to the 120 VAC terminal block on the circuit board and the 120/24 VAC transformer is powered.

3. 120 VAC is waiting at the N.O. contacts of the Economaster II pump delay.

4. Terminals L1 and F1 of the ignition module are powered with 120VAC.

5. 120 VAC power is also applied to the control power connector on the circuit board.

6. 120 VAC power is waiting at relay contacts K-3 to energize the heater blower.

7. The 120/24 VAC transformer outputs 24 VAC.

8. 24 VAC is sent to the low water cut-off (optional) and the red power light is energized.

9. 24 VAC is applied to the blue power light located on the diagnostic display board.

10. 24 VAC is also applied to the red LED safety shutdown light on the front diagnostic board.

11. 24 VAC is applied to the alarm circuit (optional). If the E-5 sales option (Alarm) is included a 5 second time delay relay will not allow the alarm to so-

und unless the circuit stays energized for more than 5 seconds.

12. Power is applied to terminal P1-1 of the U-2 Board. All safeties are verified to ensure that it is safe to operate the heater. The safety components wired into the diagnostic board are: low water cut-off (optional), blocked vent switch, manual vent temp switch (optional), manual reset high limit, low gas pressure switch (optional), high gas pressure switch (optional), and auto-reset high limit (optional).

13. Power is applied to terminal TP-1 of the Economaster II pump delay to energize the circuit board.

14. Once all safeties have been verified to be closed, a 24 VAC signal is output from pin P3-16 of the U2 Board.

15. Relay K-1 (N.C.) will now be energized, and opens the N.C. contacts to disable the alarm (optional) and turns off the red safety shutdown light.

16. Pin P1-4 on the diagnostic board will now output a 24 VAC signal to pin 1 of the “standby switch”.

17. The “standby switch” (rocker switch) located at the lower left front of the control compartment is now powered. If the switch is “ON” and there is no call for heat (CFH), the heater is in standby mode.

18. After the standby switch is placed into the “ON” position, a 24 VAC signal is sent to the “enable/disable” connection (normally jumpered).

19. 24 VAC switched power is applied to the S24V terminal on the ignition module.

20. When the “enable/disable” contacts are closed, the 24 VAC signal travels to pin 1 of the stage 1 connection and waits for a CFH.

21. When a CFH occurs, a 24 VAC signal is sent to the CFH light on the diagnostics panel located on the lower left front of the control compartment.

22. Power is now sent to terminal TP4 of the Economaster II to energize the relay and close the contacts.

23. The heater pump is energized upon relay closure of the Economaster II.

External Lights

Table N: LED Indicators

24. Upon sufficient flow from the heater pump, the flow switch contacts will close.

25. The flow light is energized; located on the diagnostics panel.

26. A 24 VAC signal is also sent to the “TH” terminal located on the ignition module.

27. Once the 24 VAC “TH” signal is received at the ignition module, a 120 VAC signal is sent from F2 on the ignition module to the 120 VAC pilot duty terminals, located at J-14 on the circuit board.

28. The 120 VAC signal continues to the coil of the blower relay K-3 (N.O.).

29. The 120 VAC signal continues to the 120 VAC safety terminals located at J-13 on the circuit board.

30. When the coil on relay K-3 (N.O.) is powered, the relay contacts (K-3) close and energizes the blower from the J-8 connections on the CPW board.

31. After proper air pressure is received in the air plenum, the air pressure switch will close.

32. A 24 VAC signal is now sent to the blower LED on the diagnostics board.

33. Power is applied to the optional equipment interlock connection (normally jumpered).

34. The 24 VAC signal is then sent to the 24 VAC safety connector.

35. 24 VAC is now sent to the pressure switch (P.S.) terminal on the ignition module.

Light Color Indication

Power Blue Main power is on

Call For Heat Yellow Thermostat is closed

Safety Red

Ignition Red Ignition module is inoperative

Flow Green Flow is present

Blower 1 Green Blower 1 is on

Stage 1 Green Stage 1 is on

Stage 2 Green Stage 2 is on

Light Color Indication

Board Power Yellow Board power is on

Low Water Cut-Off Red Low water cut-off is open

Blocked Vent Red Vent is blocked

Manual Reset Hi-Limit Red Manual reset is open

Low Gas Pressure Switch

High Gas Pressure Switch

(Not Used) Red

PVC Vent Limit Red

Auto Reset High Limit Red Auto reset option

One or more safeties is inopera-

tive

Internal Lights

Red Low gas pressure

Red High gas pressure

Vent temperature exceeds

limits

Ignition Module

When additional heat is needed, the combustion air blower starts to purge air from the combustion chamber for about 15 seconds. On proof-of-air flow, the air-

proving switch closes and the igniter is energized. To ensure safe operation, the gas valve cannot open until the igniter is verified. The main burner is automatically lit when the device is powered and pre-purged. The heater performs its own safety check and opens the main valve only after the igniter is proven to be capable of ignition.

The standard ignition module will attempt to light three times before locking out. To reset it, turn off power to the heater, wait 30 seconds and re-apply power.

Fig. 29: Ignition Module

Table O: Ignition Module

Diagnostic LED Codes

36. Once the pressure switch signal is received at the ignition module the hot surface igniter is energized by a 120 VAC signal from S-1 on the ignition module. (The hot surface igniter must draw greater than 3.1 amps while being energized or ignition lockout will occur after three tries.)

37. Once the ignition module determines that the hot surface igniter amp draw is within specs and operating properly, a 24 VAC signal is output from pin GV on the module.

38. 24 VAC signal is received to gas valve 1 thus energizing it.

39. The stage 1 LED on the diagnostics display board is now illuminated.

40. The coil of relay K-2 (N.O.) is now energized with the (K-2) contacts closing downstream of the stage 2 connections.

41. The gas coming through the burners should ignite from the heat of the hot surface igniter and the flame should carry over from one burner to the other burners of stage 1. The remote sensor is now trying to sense the flame. If the flame is not sensed within 4 seconds, the ignition module will shut down the gas valve and retry the hot surface igniter. During ignition retry the heater must perform a 15-second pre-purge and an approximately 30-second igniter warm-up before opening gas valve 1 again. The standard ignition module will attempt ignition a maximum of three times prior to ignition lockout.

42. (Models 302A-402A only) 24 VAC is now waiting at pin 3 of the stage 2 connection on the CPW board.

43. (Models 502A-902A only) After gas valve 1 opens and flame rectification is received, time delay relay 1 (TD-1) starts a 5-second countdown.

44. (Models 502A-902A only) After the 5 second countdown from TD-1, 24 VAC is waiting at pin 3 of the stage 2 connection on the CPW board.

45. After closure of the stage 2 contacts Gas valve 2 in energized.

46. The stage 2 LED on the diagnostics display board is now illuminated.

47. The heater is now operating at full fire.

Code Condition

Off

1 Flash

Low air pressure, brief flash-

System OK;

No faults present

Possible control fault;

Check power

ing normal on start-up

2 Flashes

3 Flashes Ignition lockout

4 Flashes Low igniter current

5 Flashes

6 Flashes

Flame in combustion

chamber; No call for heat

Low 24VAC, check control

supply voltage

Internal fault;

Replace control

The optional single-try ignition module will lock out after failing to light one time. To reset it, press and release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case. Turning off the power to the heater WILL NOT reset the ignition module.

High Limit (Manual Reset)

The heater is equipped with a manual reset high limit temperature device. Push the reset button and adjust the setting to 40 - 50°F above desired operating temperature.

Flow Switch

This dual-purpose control, mounted and wired in series with the main gas valve, shuts off heater in case of pump failure or low water flow.

Operating Control

The heater may be equipped with different types of operating controls. Consult the individual control data sheets supplied with your heater paperwork. See the

Fig. 30: High Limit (Manual Reset)

Fig. 31: Flow Switch

Fig. 32: Operating Control

Low Water Cut-Off (Optional)

The low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets.

Fig. 33: Low Water Cut-Off

High and Low Gas Pressure Switches

The low gas pressure switch (standard) connection mounts upstream of the gas valve to ensure that sufficient gas pressure is present for proper regulator performance. The low gas pressure switch automatically shuts down the heater if gas supply drops below the factory setting of 5.0 in. WC for natural gas, and 10.0 in. WC for propane gas.

The high gas pressure switch (optional) connection mounts down-stream of the stage-1 gas valve. If the gas pressure regulator fails, the high gas pressure switch automatically shuts down the burner.

General Safety Section for safety precautions concerning domestic hot water applications.

Fig. 34: High/Low Gas Pressure Switch

Fig. 35: Fan-Proving Switch

Fig. 36: Blocked Vent Switch

87%-Efficiency Boilers – Special Instructions

Water Piping

An 87%-efficiency boiler requires a minimum inlet water temperature of 120ºF (49ºC) to prevent excessive condensation in the combustion chamber. An 87%-efficiency boiler operated with an inlet temperature of less than 120ºF (49ºC) 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 in the secondary boiler piping. Raypak strongly recomm-

NOTE: The constructions of the 84%- (standard) and 87%-efficiency (optional) boilers are very similar, and they are installed to the same requirements, except as noted in this section.

ends that a thermometer be placed into the boiler inlet piping next to the in/out header to facilitate temperature adjustment. Inlet water temperatures below 120ºF (49ºC) can excessively cool the products of combustion, resulting in condensation on the heat exchanger.

Venting

Appliance Categories

See Table Q for appliance category requirements for the 87%-efficiency Hi Delta.

CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the boiler.

NOTE: For additional information on appliance categorization, see appropriate code NFGC (U.S.) and B149.1 (Canada), or applicable local building codes.

Table P: Heater Rate of Flow and Pressure Drop

Table Q: Category Determination for Venting Purpose and Venting Arrangement

Note: Basis for minimum flow is 20 gpm or 40°F ΔT. Basis for maximum flow is 90 gpm.

Model

No.

302AE 52 3.3 26 <1.0 N/A N/A 20 <1.0 26 90 9.8 6

402AE 69 6.0 35 1.5 23 <1.0 20 <1.0 35 90 10.0 8

502AE 87 9.7 44 2.5 29 1.1 22 <1.0 40 90 10.4 10

652AE N/A N/A 57 4.4 38 2.0 28 1.1 40 90 10.8 13

752AE N/A N/A 65 6.1 44 2.8 33 1.6 40 90 11.3 15

902AE N/A N/A 78 8.9 52 4.1 39 2.3 40 90 11.7 17

10°F T 20°F T 30°F T Min. Flow Max Flow

gpm

P (ft) gpm P (ft) gpm P (ft) gpm P (ft) Tgpm P (ft) T

Combustion

Air Supply

From Inside Building (Non-Direct Venting)

From Outside Building

(Direct Venting)

Exhaust

Configuration

Vertical Natural Draft

Venting

Horizontal Through-

the-Wall Venting

Vertical Natural Draft

Venting

Horizontal Through-

the-Wall Venting

Heater Venting

Category

IV AL29-4C

Certified

Materials

Stainless Steel

(Gas Tight)

Stainless Steel

(Gas Tight)

Combustion Air

Inlet Material

Galvanized Steel

PVC

ABS

CPVC

WARNING: Contact the vent material manufacturer if there are any questions about the appliance category or suitability of a vent material for Category II, III or IV applications. Using improper venting materials can result in personal injury, death or property damage.

Vent Terminal Location

1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.

2. Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury.

3. Gases may form a white vapor plume in winter. The plume could obstruct a window view if the termination is installed near windows.

4. Prevailing winds, in combination with below-freezing temperatures, can cause freezing of con-densate and water/ice build-up on building, plants or roof.

5. The bottom of the vent terminal and the air intake shall be located at least 12 in. above grade, including normal snow line.

6. Un-insulated single-wall metal vent pipe shall NOT be used outdoors in cold climates for venting gas utilization equipment.

7. Through-the-wall vents for Category II and IV appliances shall not terminate over public walkways or areas where condensate or vapor could create a nuisance or hazard, or be detrimental to the operation of regulators, relief valves or other equipment.

8. Locate and guard vent termination to prevent accidental contact by people or pets.

9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area, unless previously approved by local authority.

10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations.

11. Locate or guard vent to prevent condensate from damaging exterior finishes. Install a rust-resistant sheet metal backing plate against brick or masonry surfaces.

12. DO NOT extend exposed vent pipe outside of building. Condensate could freeze and block vent pipe.

Condensate Management

Condensate must be routed from the condensate trap to an appropriate container for neutralization before disposal, as required by local codes.

Vertical Venting (Category II)

Common Venting System

Manifolds that connect more than one boiler to a common chimney must be engineered to handle the combined load. Consult available guides for proper sizing of the manifold and the chimney. At no time should the area of the vent be less than the area of the largest boiler exhaust outlet.

NOTE: During winter months check the vent cap and make sure no blockage occurs from build-up of snow or ice.

CAUTION: A properly sized listed vent cap terminal must be used to evacuate the flue products from the boilers.

Fig. 37: Vertical Venting (Category II)

Note: When vertical height exceeds 25 ft,

consult factory prior to installation.

Horizontal Through-the-Wall Venting (Category IV)

WARNING: Vent connectors serving appliances

vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure.

Fig. 38: Horizontal Through-the-Wall Venting

(Category IV)

Installation

These installations utilize the boiler-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the outdoors. Adequate combustion and ventilation air must be supplied to the mechanical room in accordance with the NFGC (U.S.) and B149.1 (Canada).

The total length of the horizontal through-the-wall exhaust vent system should not exceed 70 ft in length. If horizontal run exceeds 70 ft, an appropriately sized extractor must be used. To maintain proper operation,

pressure reading must be between -0.01 and -0.1 in. WC as measured 12 in. from the appliance flue outlet. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in one of the four following combinations:

• 70’ of straight flue pipe

• 60’ of straight flue pipe and one elbow

• 50’ of straight flue pipe and two elbows

• 40’ of straight pipe and three elbows

The vent cap is not considered in the overall length of the venting system.

1. The vent must be installed with a slight upward slope of not more than 1/4 in per foot of horizontal run to the vent terminal.

2. The vent must be insulated through the length of the horizontal run.

Common Venting System

Common venting of Category IV systems is not allowed.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Table R: Category II and IV Venting

* Subtract 10 ft per elbow. Max. 3 elbows. Maximum combustion air duct length terminated at 100 equivalent ft.

Model

302AE 5”

402AE

502AE

652AE

752AE

902AE

Certified

Venting Material

Category II

or IV

Maximum

Vent Size

6”

8”

Equivalent

Vent Length

70’

Room Air

40’

Ducted

Combustion

Air

Combustion Air

Intake Pipe

Galvanized Steel,

Material

PVC, ABS,

CPVC

Air Inlet

Max. Length*

6” 8”

100’ N/A

75’

100’

40’

30’ 80’

The stainless steel direct vent cap must be furnished by the boiler manufacturer in accordance with its listing (sales order option D-15).

Use only double-wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burning boilers, such as the stainless steel Saf-T vent by Heat Fab Inc. (800-772-0739), Protech Systems Inc. (800-766-3473), or Z-Flex (800-654-5600). Pipe joints must be positively sealed. Follow the vent manufacturer’s installation instructions carefully.

Direct Vent - Horizontal Throughthe-Wall

Installation

These installations utilize the boiler-mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors.

The total length of the direct vent through-the-wall exhaust vent cannot exceed 40 ft in length for the flue outlet. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in one of the three following combinations:

• 40’ of straight flue pipe

• 30’ of straight flue pipe and one elbow

• 20’ of straight flue pipe and two elbows

The total length air supply duct cannot exceed the distances listed. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in one of the three following combinations:

• 40’ of straight combustion air pipe

• 30’ of straight combustion air pipe and one elbow

• 20’ of straight combustion air pipe and two elbows

The flue exhaust direct vent cap is not considered in the overall length of the venting system.

Care must be taken during assembly that all joints are sealed properly and are airtight.

The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is recommended that:

1. The vent must be installed with a slight downward slope of not more than 1/4 inch per foot of horizontal run to the vent terminal.

2. The vent must be insulated through the length of the horizontal run.

For installations in extremely cold climate, it is recommended that:

2. The intake vent must be insulated through the length of the horizontal run.

Common Venting System

Common venting of Category IV systems is not allowed.

The stainless steel flue exhaust direct vent cap must be furnished by the boiler manufacturer in accordance with its listing (sales order option D-15).

Fig. 39: Direct Vent - Horizontal Through-the-Wall

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Direct Vent - Vertical

Note: When vertical height exceeds 25 ft, consult

factory prior to installation.

Fig. 40: Direct Vent - Vertical

Table S: Category II or IV Vertical Venting

* Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. When vertical height exceeds 25 ft, consult factory prior to installation.

** Subtract 10 ft per elbow. Max. 3 elbows.

Maximum combustion air duct length terminated at 100 equivalent ft.

Certified

Model

Venting

Vent Size

Material

302A 5”

402A

502A

652A

Category II

or IV

752A

Vertical Venting

Height*

Min. Max.

6”

5’ 25’

8”

Combustion Air

Intake Pipe

Material

Galvanized Steel,

PVC,

ABS,

CPVC

Air Inlet

Max. Length**

6” 8”

100’ N/A

75’

40’

902A

100’

Wiring Diagram

START-UP

Pre Start-up

Filling System (Heating Boilers)

Fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal system operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent.

Air Purge (Domestic Hot Water Heaters)

Purge all air from system before lighting heater. This can be normally accomplished by opening a downstream valve.

Venting System Inspection

1. Check all vent pipe connections and flue pipe material.

2. Make sure vent terminations are installed per code and are clear of all debris or blockage.

For Your Safety

This appliance has a hot surface igniter. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand.

BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell near the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any telephone in your building.

• Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

• If you cannot reach your gas supplier, call the fire department.

• Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not turn by hand, do not try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion.

• Do not use this appliance if any part has been under water, immediately call a qualified service techni-cian to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

• Check around unit for debris and remove combustible products, i.e. gasoline, etc.

Pre Start-up Check

1. Verify heater is filled with water.

2. Check system piping for leaks. If found, repair immediately.

3. Vent air from system. Air in system can interfere with water circulation.

4. Purge air from gas line up to heater.

Initial Start-up

Tools Needed

• (1) 12-0-12, 24” scale U-tube manometer

• (4) 6-0-6, 12” scale U-tube manometers (minimum)

• (1) Screwdriver

• (1) Multi-meter

• (1) 3/16” Allen wrench

NOTE: Digital manometers are not recommended.

Preparation

Check Power Supply

With multi-meter at incoming power, check voltage between:

Hot - Common (≈120 VAC)

Hot - Ground (≈120 VAC)

Common - Ground (< 1 VAC)

Attach Manometers to Measure Pressures

1. Turn off main gas valve.

2. Attach 24” scale manometer to the first main gas shut-off valve pressure tapping.

3. Attach (1) 12” scale manometer to the outlet side of the second main gas shut-off valve pressure tapping.

4. Attach (1) 12” scale manometer near the fan-proving switch. Pull black cap from air pressure switch tee and connect the manometer. NOTE: Retain caps for reinstallation later.

Check Gas Supply Pressure

1. Slowly turn on main gas shut-off valve.

2. Read the gas supply pressure from the manometer; minimum supply pressure for natural gas is 5.0 in. WC, recommended supply is 7.0 in. WC, minimum supply pressure for propane gas is 11.0 in. WC (dynamic readings, all stages firing).

3. If the pressure is > 14.0 in. WC, turn off the valve.

4. Check if the service regulator is installed and/or adjust the service regulator.

WARNING: Do not turn on gas at this time.

WARNING: If Common - Ground is > 1 VAC,

STOP: Contact electrician to correct ground failure. Failure to do this may burn out 120V-24V transformer, or may cause other safety control damage or failure.

Start-Up

Blower Adjustment

1. Turn off power.

2. Unplug cap at pressure switches and connect manometer(s) to the tee.

3. Close all manual firing valves.

4. Turn power on.

5. Check manometers attached to fan pressure switch. The reading should be 1.4 ± .1 in. WC for propane gas and natural gas. If not, adjust the air shutter on the blowers to attain the correct value.

6. Turn power off.

7. Reconnect this cap.

Main Burner Adjustment

1. Turn off unit.

2. Open manual firing valves.

3. Turn on the unit, wait 15 seconds, and the igniter should glow. Look into sight glass located at each end of the heater to check igniter operation. Gas valves should open in 45-60 seconds.

4. If burner does not light on first trial. It will retry, up to three times.

5. Main burner ignition: Check manifold gas pressure at gas valve outlet pressure tap. This should read

3.5 ± 0.1 in. WC for natural gas and 10.5 ± 0.1 in. WC for propane gas.

6. If the pressure reading differs by more than ± 0.1 in. WC, remove screw cover from the gas pressure regulator and adjust main burner manifold pressure. Replace the screw cover. Repeat steps 2 to 5 on other valves as necessary.

CAUTION: Special manifold and air settings may be required. Verify rating plate and blower housing.

Safety Inspection

1. Check all thermostats and high limit settings.

2. During the following safety checks leave manometers hooked up, check and record.

3. If other gas-fired appliances in the room are on the same gas main, check all pressures on the Hi Delta with all other equipment running.

4. Check thermostats for ON-OFF operation.

5. Check high limits for ON-OFF operation.

6. While in operation, check flow switch operation.

7. Check the low gas pressure switch. (For proper adjustment, use the attached manometers, if available, to set pressure. The scales on the switch are approximate only.) Low gas pressure switch must be set at 5.0 in. WC for natural gas and 10.0 in. WC for propane gas.

8. Make sure that the high gas pressure switch (optional) is set to 1.0 in. WC above manifold pressure.

Follow-Up

Safety checks must be recorded as performed.

Turn heater on. After main burner ignition:

1. Check manometer for proper reading.

2. Cycle heater several times and re-check readings.

3. Remove all manometers and replace caps and screws.

4. Replace all gas pressure caps.

5. Check for gas leaks one more time.

Pilot Turn-Down Test

The Hi Delta heaters, depending on their size, have one to three burner sections. Each burner section is supplied gas by gas valves incorporated into a single valve body. A maximum of three burner sections may be controlled by a single hot surface ignition system. The middle of the three burner sections is ignited directly with a hot surface ignition system.

The burner section that is ignited directly by the hot surface ignition system serves as a supervised pilot to light the burner sections on either side of it. The burner sections on either side of the supervised section (pilot) are electrically interlocked with the supervised ignition system so as they are not energized unless flame is proven on the center section which is acting as a pilot to light the right and left-hand sections.

The pilot turn-down test is conducted as follows:

1. Turn off manual valves on non-supervised burner sections.

2. Turn on electrical power and adjust thermostat to call for heat.

3. Wait for completion of ignition sequence to light burner section being utilized as a pilot for those turned off in step 1 above.

4. Gradually reduce manifold pressure (flame) on supervised burner section by slowly closing manual gas valve. Watch for shut-down due to loss of supervised flame signal as pressure is being reduced. Flame signal should be lost before manifold pressure goes below 2.0 in. WC for natural gas and 6.0 in. WC for propane gas.

Leak Test Procedure: Dual-Seat Gas Valves

Proper leak testing requires three pressure test points in the gas train.

Test point A is upstream of the automatic gas valve. On the first automatic valve, this is a bleedle valve. On the other valves, this is a plugged port. The bleedle valve on the first valve may be used for all the other valves as well.

Test point B is a bleedle valve located between the two automatic gas valve seats.

Test point C is located downstream of both automatic gas valve seats and upstream of the manual valve. On the manual valve, this is a bleedle valve. Identical readings will be found at the plugged port labeled as Alternate C.

Refer to Fig. 41. The numbers on the diagram refer to the steps below:

These tests are to be conducted with the electrical power to the heater turned off.

1. Manually close the downstream leak test valve.

2. Open test point A and connect a manometer to it. Verify that there is gas pressure and that it is within the proper range (NOTE: must not exceed 14.0 in. WC).

3. Open test point B and connect a rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up of pressure. Increasing pressure indicates a leaking gas valve.

4. Next, close the upstream manual gas valve and remove the manometer from test point A and from test point B. Connect a rubber tube from test point A to test point B and open the upstream manual gas valve. Make sure that test points A & B have been opened so as to allow gas to flow. This will bring pressure to the second valve seat.

5. Open test point C and connect a second rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up of pressure. Increasing pressure indicates a leaking gas valve.

6. Remove rubber tube and manometers. Close each test point valve as the tubes are removed.

7. Connect a manometer to each test point (one at a time) and look for a build-up of pressure. If a buildup of pressure is detected, check each test point valve to see if it is tightly closed. If leak persists, replace test point valve(s).

8. After no leakage has been verified at all valve seats and test valves, open downstream leak tests valve and restore electrical power to heater.

Fig. 41: Leak Test

This completes leak testing for a single Hi Delta manifold riser. Repeat steps 1-8 for each riser.

Post Start-Up Check

Check off steps as completed:

1. Verify that the heater and heat distribution units or storage tank are filled with water.

2. Confirm that the automatic air vent (if used) was opened two full turns during the venting procedure.

3. Verify that air has been purged from the system.

4. Verify that air has been purged from the gas piping, and that the piping has been checked for leaks.

5. Confirm that the proper start-up procedures were followed.

6. Inspect burner to verify flame.

7. Test safety controls: If heater is equipped with a low water cut-off or additional safety controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when controls are tested. When safety devices are restored, burners should re-ignite after pre-purge time delay.

8. Test limit control: While burner is operating, move indicator on high limit control below actual water temperature. Burner should go off while blower and circulator continue to operate. Raise setting on limit control above water temperature and burner should re-ignite after pre-purge time delay.

9. Test ignition system safety device:

a. Turn on manual gas valve. Turn power on.

b. Set thermostat to call for heat.

c. When the heater is in operation, pull cap off of

tee in air switch hose. The burner should go off immediately.

d. Wait 5 minutes.

e. Reattach cap on tee. Burner should re-ignite

after pre-purge time delay.

10. To restart system, follow lighting instructions in the Operation section.

11. Check to see that the high limit control is set above the design temperature requirements of the system.

For multiple zones: Check to make sure the flow is adjusted as required in each zone.

12. Check that the heater is cycled with the thermostat. Raise to the highest setting and verify that the heater goes through the normal start-up cycle. Reduce to the lowest setting and verify that the heater goes off.

13. Observe several operating cycles for proper operation.

14. Set the room thermostat or tankstat to desired temperature.

15. Review all instructions shipped with this heater with owner or maintenance person, return to envelope and give to owner or place the instructions inside front panel on heater.

OPERATION

Lighting Instructions

1. Before lighting, make sure you have read all of the safety information in this manual.

2. Set the thermostat to the lowest setting.

3. Turn off all electrical power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

5. Remove upper front panel.

6. Turn on main manual gas valve.

7. Wait 5 minutes to clear out any gas. Then smell for gas, especially near the floor. If you then smell gas, STOP! Follow the steps in the safety information on the front cover of this manual. If you do not smell gas, go to next step.

8. Turn on all electrical power to the appliance.

9. Set thermostat to desired setting. The appliance will operate. The igniter will glow after the prepurge time delay (15 seconds). After igniter reaches temperature (45 seconds) the main valve will open. System will try for ignition three times. If flame is not sensed, lockout will commence.

10. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance,” and call your service technician or gas supplier.

11. Replace access panel.

12. If heater fails to start, verify the following:

a. There are no loose connections or that the

service switch is off.

b. High temperature limit switch is set above wa-

ter temperature.

c. Thermostat is set above room temperature.

d. Gas is on at the meter and the heater.

e. Incoming gas pressure to the gas valve is

NOT less than 5.0 in. WC for natural gas, 11.0 in. WC for propane gas.

To Turn Off Gas To Appliance

1. Set the thermostat to lowest setting.

2. Turn off all electrical power to the appliance if service is to be performed.

3. Remove upper front panels.

4. Turn off main manual gas valve.

5. Replace access panel.

TROUBLESHOOTING

)

(

)

Step 1

Step 2

Step 3

Does the power switch

provide power to the

control panel?

YES

Is Disable jumper intact? (J1

YES

Do the combustion air

blowers come on?

Is there a Call For

Heat?

Reattach.

Is there 120VAC at J8

Connecto

on the CPW board?

YES

Check the switch

and/or line voltage

Replace ignition module

Unit is in standby mode.

Check all safety limit devices and voltage from the transformer to J10 on

CPW board.

Does F2 on ignition module

have 120VAC?

YES

Step 4

Step 5

Step 6

YES

Are the blower lights

illuminated?

YES

Is 24VAC at PS on ignition module? Is

connecting plug

secure?

Does igniterprove?

YES

Is the flame

sensor signal to

the ignition module greater than 1 uA DC?

YES

Is 24VAC at present at TH (J3 & J12 on CPW

board and orange wire on ignition module)?

YES

Check Amp draw during heat-up for greater than

3.1 Am

Is air pressure switch(s) and

J2 of CPW board (N.O.)

owered?

Does air pressure switch(s)

have correct pressure?

1.4” W.C.

YES

Replace HSI

Are the gas valve

settings correct?

YES

Check flow switch, all

connectors on CPW board

and controller.

Is there continuity from the

fan relay to fan(s)?

YES

Replace air

ressure switch

Is air switch

bouncing?

YES

Check the fan relay. Is there

120VAC at K3 relay?

YES

Replace fan

Correct the air settings or

you may have to clean

burners, heat exchanger

and/or air filter.

YES

Readjust to 3.5” W.C.

gas.

Is the unit running?

Replace fan rela

Step 7

Is the unit running?

Call our Technical Service Department

1-800-927-2975 Outside California

1-800-627-2975 Inside California

YES

Is static and dynamic inlet

manifold gas pressure correct?

Is downdraft present?

The unit is oka

YES

Clean or replace flame senso

Replace gas valve

MAINTENANCE

Suggested Minimum Maintenance Schedule

Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency.

Maintenance as outlined below may be performed by the owner.

Daily

1. Check that the area where the heater is installed is free from combustible materials, gasoline, and other flammable vapors and liquids.

2. Check for and remove any obstruction to the flow of combustion or ventilation air to heater.

Monthly

1. Check for piping leaks around circulators, mixing valves, relief valves, and other fittings. If found, repair at once. DO NOT use petroleum-based stop-leak compounds.

2. Visually inspect burner flame.

3. Visually inspect venting system for proper function, deterioration or leakage.

4. Check air vents for leakage.

Yearly (Beginning Of Each Heating Season)

Schedule annual service call by qualified service agency.

1. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal.

2. Visually inspect venting system for proper function, deterioration or leakage.

3. Check that area is free from combustible materials, gasoline, and other flammable vapors and liquids.

4. Check for and remove any obstruction to the flow of combustion or ventilation air to heater.

5. Follow pre-start-up check in the Start-up section.

6. Visually inspect burner flame. It should be light blue. Remove and visually inspect hot surface igniter and sensor for damage, cracking or debris build-up.

7. Check operation of safety devices. Refer to manufacturers’ instructions.

8. Follow oil-lubricating instructions on circulator if required. Over-oiling will damage circulator. Water-lubricated circulators do not need oiling.

9. To avoid potential of severe burn, DO NOT REST HANDS ON OR GRASP PIPES. Use a light touch; return piping will heat up quickly.

10. Check blower and blower motor.

11. Check for piping leaks around circulators, relief valves and other fittings. Repair, if found. DO NOT use petroleum-based stop-leak.

12. Clean air filter.

Periodically

1. Check relief valve. Refer to manufacturer’s instructions on valve.

2. Test low water cut-off, if used. Refer to manufacturer’s instructions.

3. Clean screen and air filter in intake.

Preventive Maintenance Schedule

The following is required procedure in CSD-1 states and good practice for all Hi Delta installations.

Daily

1. Check gauges, monitors and indicators.

2. Check instrument and equipment settings. (See “Post Start-Up Check” on page 48.)

3. Check burner flame. (Should see light blue flame).

Weekly

For low-pressure heaters, test low-water cut-off device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance should shut-off and ignition fault light should come on. Depress reset button to reset).

1. Check igniter. (Resistance reading should be 4270 ohms at ambient temperature.)

2. Check flame signal strength. (Flame signal should be greater than 1 microamp).

3. Check flame failure detection system. (See “Post Start-Up Check” on page 48.)

4. Check firing rate control by checking the manifold pressure. (See “Main Burner Adjustment” on page

46.)

5. Make auditory and visual check of main fuel valves.

Monthly

1. Check flue, vent, stack, or outlet dampers.

2. Test fan air pressure. (See “Blower Adjustment” on page 46.)

3. Test high and low gas pressure interlocks (if equipped). (See “Safety Inspection” on page 47.)

Semi-Annually

1. Recalibrate all indicating and recording gauges.

2. Check flame failure detection system components. (See “Pilot Turn-Down Test Procedure,” page 47.)

3. Check firing rate control by checking the manifold pressure. (See “Main Burner Adjustment” on page

46.)

4. Check piping and wiring of all interlocks and shutoff valves.

5. Inspect burners.

Annually

1. Test flame failure detection system and pilot turndown. (See “Pilot Turn-Down Test Procedure,” page 47.)

2. Test high limit and operating temperature. (See “Post Start-Up Check,” page 48.)

3. Check flame sensors.

4. Conduct a combustion test at full fire. Carbon dioxide should be 7.5 to 8.5% at full fire for natural gas, and between 9.2 to 9.8% for propane gas; Carbon monoxide should be < 150 ppm).

5. Check coils for 60 cycle hum or buzz. Check for leaks at all valve fittings using a soapy water solution. Test other operating parts of all safety shut-off and control valves and increase or decrease settings (depending on the type of control) until the safety circuit opens. Reset to original setting after each device is tested.

6. Perform leakage test on gas valves. (See Fig. 41.)

7. Test air switch in accordance with manufacturer’s instructions. (Turn panel switch to the “On” position until blower is proven, then turn the switch to “Off”.

As Required

1. Recondition or replace low water cut-off device (if equipped).

2. Check drip leg and gas strainers.

3. Perform flame failure detection and pilot turndown tests.

4. Test safety/safety relief valves in accordance with ASME Heater and Pressure Vessel Code Sections VI and VII.

APPENDIX

Inside Air Contamination

All heaters experience some condensation during start-up. The condensate from flue gas is acidic. Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high efficiency systems. The heater can be supplied with corrosion-resistant, non-metallic intake air vent material. You may, however, choose to use outside combustion air for one or more of these reasons:

1. Installation is in an area containing contaminants listed below which will induce acidic condensation.

2. You want to reduce infiltration into your building through openings around windows and doors.

3. You are using AL29-4C stainless steel vent pipe, which is more corrosion-resistant than standard metallic vent pipe. In extremely contaminated areas, this may also experience deterioration.

Products causing contaminated combustion air:

• spray cans containing chloro/fluorocarbons

• permanent wave solutions

• chlorinated waxes/cleaners

• chlorine-based swimming pool chemicals

• calcium chloride used for thawing

• sodium chloride used for water softening

• refrigerant leaks

• paint or varnish removers

• hydrochloric acid/muriatic acid

• cements and glues

• antistatic fabric softeners used in clothes dryers

• chloride-type bleaches, detergents, and cleaning solvents found in household laundry rooms

• adhesives used to fasten building products

• similar products

Areas where contaminated combustion air commonly exists:

• dry cleaning/laundry areas

• metal fabrication plants

• beauty shops

• refrigeration repair shops

• photo processing plants

• auto body shops

• plastic manufacturing plants

• furniture refinishing areas and establishments

• new building construction

• remodeling areas

• open pit skimmers

Check for areas and products listed above before installing heater. If found:

• remove products permanently, OR

• install TruSeal direct vent

LIMITED PARTS WARRANTY

HI DELTA – TYPES H AND WH

MODELS 302A–902A

SCOPE

Raypak, Inc. (“Raypak”) warr ants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.

HEAT EXCHANGER WARRANTY

Domestic Hot Water Five (5) years from date of heater installation. Includes copper heat exchanger with bronze and cast iron waterways. Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways. Space Heating (Closed Loop System) Ten (10) years from date of heater installation. Includes both c upro-nickel and copper heat exchanger with bronze or cast iron waterways. Thermal Shock Warranty Twenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large changes exceeding 150°F betw een the water temperature at intake and heater temperature, or operating at heater temperatures exceeding 230°F).

ANY OTHER PART MANUFACTURED BY RAYPAK

One (1) year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records, whichever comes first.

SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.

ADDITIONAL WARRANTY EXCLUSIONS

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accor dance with our printed instructions provided;

2. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding heater design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the heater system;

7. Failing to eliminate air from, or replenish water in, the connected water system;

8. Chemic al contamination of combustion air or use of chemical additives to water.

PARTS REPLACEMENT

Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be w arranted for only the unexpir ed portion of the original w arranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer.

TO MAKE WARRANTY CLAIM

Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service Manager, Raypak, Inc., 2151 E astman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be received from Raypak before replacement of any part.

EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY

This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or cons equential damages. So the above limitation or exclusion may not apply to you.

This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that you complete the infor mation below and retain this certificate in the event warranty s ervice is needed. Reasonable proof of the effective date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manufacture plus thirty (30) days.

Original Owner Model Number

Mailing Address Serial Number

Date of Installation

City State Zip Code Installation Site

Daytime Telephone Number Contractor/Installer

RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com

LIMITED PARTS WARRANTY

HI DELTA – TYPE P

MODELS 302A–902A

SCOPE

HEAT EXCHANGER WARRANTY

Five (5) years from date of heater installation. Includes cupo-nickel heat exchanger with bronze and cast iron waterways. Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways. Thermal Shock Warranty Twenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large changes exceeding 150°F betw een the water temperature at intake and heater temperature, or operating at heater temperatures exceeding 230°F).

ANY OTHER PART MANUFACTURED BY RAYPAK

One (1) Year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Ray pak’s records, whichever comes first.

SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.

ADDITIONAL WARRANTY EXCLUSIONS

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions pr ovided;

2. Abus e, alteration, accident, fire, flood and the like;

3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding heater design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the heater system;

7. Chemical contamination of combustion air or use of chemical additives to water .

8. Misuse or neglect, including but not limited to freeze-ups, operating the heater with cabinet door off, having flow restrictions or obstructions between the heater outlet and pool/spa or not maintaining proper chemical balance (pH level must be between 7.2 and 7.8 and total alkalinity between 100 and 150 PPM. Total Dissolved Solids (TDS) must be no greater than 2500 PPM).

PARTS REPLACEMENT

TO MAKE WARRANTY CLAIM

EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY

Original Owner Model Number

Mailing Address Serial Number

Date of Installation

City State Zip Code Installation Site

Daytime Telephone Number Contractor/Installer

RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468

Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036

Litho in U.S.A.

Raypak Hi Delta 302A-902A, Hi Delta 302A, Hi Delta 402A, Hi Delta 502A, Hi Delta 652A Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual