Raypak 122, Installation & Operating Instructions Manual

Page 1: ... 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 i...

Page 2: ... The text in the BEFORE INSTALLATION section on page 5 the text in paragraph one of the GENERAL SAFETY section on page 8 the text in paragraph one of the Outdoor Installations section on page 10 Table E on page 10 the wiring diagram on page 35 ...

Page 3: ...tions 19 Venting 21 Outdoor Installation 32 High Limit Manual Reset 33 Flow Switch 33 CONTROLS 33 Ignition Control Module 33 Low Water Cut Off Optional 34 Operating Control 34 WIRING DIAGRAM MODELS 122 322 35 PRE START UP 36 Filling System Heating Heaters 36 Domestic Hot Water Heaters 36 Inspect Venting System 36 For Your Safety Read Before Lighting 36 Pre Start Up Check 36 INITIAL START UP 36 Too...

Page 4: ...e required to deenergize 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 d...

Page 5: ...der the manufacturer s warranty Debits for defec tive replacement parts will not be accepted Parts will be replaced in kind only per Raypak s standard war ranties Model Identification The model identification number and heater serial number are found on the heater data plate located on the left inside jacket of the heater The model number will have the form H3 0162 or similar depending on the heat...

Page 6: ... GAS CONNECTION VIEW PORT PRESSURE RELIEF CONNECTION FLUE EXHAUST COMBUSTION AIR INTAKE Component Locations Fig 1 Component Locations Back Fig 2 Component Locations Left Side Panels removed for clarity Fig 3 Component Locations Front 6 HI LIMITS ...

Page 7: ...Intake 122 3 2 1 4 5 162 4 2 1 5 5 202 5 2 1 5 5 242 6 2 1 5 5 322 8 2 1 6 5 Model No Burners per Valve Stages Fire at Stage A B 1 2 1 2 122 2 1 A AB 66 100 162 3 1 A AB 75 100 202 3 2 A AB 60 100 242 4 2 A AB 66 100 322 5 3 A AB 63 100 7 Second valve located inside air plenum Fig 4 Gas Valve Detail Fig 5 Air Shutter Adjustment ...

Page 8: ...rmometer 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 Water temperature over 125 F can...

Page 9: ...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 CAUTION The heater should be located in an area where water leakage will not result in damage to the area adjacent to the...

Page 10: ... 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 Heater Side Min Clearance from Combustible Surfaces Recommended Service Clearance Front Open 24 Rear 12 24 Water Side 36 36 Other Side 36 36 Top Unobstructed 36 Vent N A N A Table E Clearances Outdoor Installations TOP VIEW FRONT VIEW Fig 8 Minim...

Page 11: ...equipment in the enclosure b Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 sq in per 2000 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 sup plied via conventional means where combu...

Page 12: ...r 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 sup ply opening s having a total cross sectional area of not less than 1 sq in for each 30 000 BTUH 70 sq mm per kW of total rated input of the burn er s and the location of the opening s shall not in...

Page 13: ...1 3 10 1 0 40 44 11 8 9 322 27 4 70 18 2 2 14 1 4 40 44 12 2 12 Table F Heater Rates of Flow and Pressure Drops Flow switch when used will not activate at less than 12 gpm NOTE Basis for minimum flow 10 gpm or 40 Delta T maximum flow 44 gpm except for 1 25 header Hydrostatic Test Unlike many other types of heaters Raypak heaters do not require hydrostatic testing prior to being placed in operation...

Page 14: ...14 Fig 9 Single Boiler Low Temperature Application Heat Pump Primary Secondary Piping Fig 10 Dual Boiler Primary Secondary Piping ...

Page 15: ... be provided with a low water cut off device The boiler when used in connec tion with a refrigeration system must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be expos...

Page 16: ...16 Fig 11 Single Heater Domestic Hot Water with One Storage Tank ...

Page 17: ...mpletely dilut ed 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 concen trations will result when the pump is not running i e overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical backup into the heater when the pump is shut off CAUTION Power...

Page 18: ... 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 turn the adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure CAUTION The heater and its manual shutoff valve must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1 2 PSIG 3 45 kPa The heater mus...

Page 19: ...ire as supplied with the heater must be replaced it must be replaced with 105 C wire or its equivalent Check the Power Source AC 108 Volts AC Minimum 132 Volts AC MAX AB 108 Volts AC Minimum 132 Volts AC MAX BC 1 Volt AC Making the Electrical Connections Refer to Fig 14 Wiring Connection and the Wiring Diagram 1 Verify circuit breaker is properly sized by referring to heater rating plate A dedicat...

Page 20: ...rol at the setpoint in which you want the heater to maintain Ensure that the sens ing 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 Consult the wiring diagram shipped with the heater in the instruction packet The Stage 1 connections are for th...

Page 21: ...oids excessive condensate pro duction in the vent Category II A heater which operates with a non posi tive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent 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...

Page 22: ...ns for proper opera tion Support of Vent Stack The weight of the vent stack or chimney must not rest on the heater vent connection Support must be pro vided in compliance with applicable codes The vent should also be supported to maintain proper clear ances from combustible materials Use insulated vent pipe spacers where the vent pass es through combustible roofs and walls Vent Terminal Location G...

Page 23: ...ce 4 ft 1 2m below or to side of opening 1 ft 30 cm above opening 3 ft 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t M Clearance under veranda porch deck or balcony 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 Na...

Page 24: ...above or below unless four 4 feet horizontal distance is maintained from elec tric meters gas meters regulators and relief equipment e Terminate vent at least six 6 feet away from adja cent walls f DO NOT terminate vent closer than five 5 feet below roof overhang g The vent terminal of a direct vent appliance with an input over 50 000 Btu per hour shall require a 12 inch vent terminal clearance h ...

Page 25: ...ll be in accordance with the section on Venting of Equipment of the latest edition of NFGC or in Canada B149 Installation Code for Gas Burning Appliances and Equipment or applicable pro visions of local building codes WARNING Examine the venting system at least once a year Check all joints and vent pipe connections for tightness corrosion or deterioration NOTE The words Flue Exhaust Flue and Exhau...

Page 26: ...he B149 Installation Code for Gas Burning Appliances and Equipment Gas vents supported only by flashing and extended above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads Natural Draft Vertical Venting with Common Venting System Category I Appliance Only Manifolds that connect more than one heater to a com mon chimney must be sized to handle the com...

Page 27: ...STION AIR FILTER BOILER UNIT Fig 19 Horizontal Thru Wall Venting Category III g Any improper operation of the common venting system should be corrected so that the installation conforms with the latest edition of the NFGC US and the B149 Installation Code Canada When re sizing any portion of the common venting sys tem the common venting system should be re sized to approach the minimum size as det...

Page 28: ...on of condensate in the vent pipes It is rec ommended that a The vent be installed with a slight downward slope of not more than 1 4 per foot of horizontal run to the vent terminal b The vent be insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that a The vent be installed with a slight upward slope of not more than 1 4 per foot o...

Page 29: ...nce Category Certified Venting Material Vent Size inches Max Venting Length feet Combustion Air Intake Pipe Material Air Inlet Size inches Max Air Intake Length feet 122 III Stainless Steel Gas Tight 4 40 Subtract 10 ft per elbow Max two elbows Galvanized Steel PVC ABS CPVC 5 40 Subtract 10 ft per elbow Max two elbows 162 202 242 5 322 6 Table L Horizontal Thru Wall Venting ...

Page 30: ...erminal In this case an approved conden sate trap must be installed per applicable codes b The vent be insulated through the length of the horizontal run Horizontal Thru wall Direct Vent Termination The flue exhaust 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 one 1 fo...

Page 31: ...al Vent Size inches Min Max Vertical Venting Height feet Combustion Air Intake Pipe Material Air Inlet Size inches Max Air Intake Length feet 122 I Type B Equivalent 4 5 25 Galvanized Steel PVC ABS CPVC 5 40 Subtract 10 ft per elbow Max two elbows 162 202 242 5 322 6 Table M Vertical Venting Fig 21 Direct Vent Vertical Venting Category I ...

Page 32: ...ed to withstand snow and wind loads The vertical direct vent cap is designed for roof top mounting only The air inlet opening MUST be installed one 1 foot 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 mi...

Page 33: ...heater is equipped with a manual reset high limit temperature device Push the reset button and adjust the setting to 30 F or 40 F above desired operating temperature 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...

Page 34: ...temporary conditions such as power fluctuations or air pockets Fig 24 Flow Switch Fig 25 Low Water Cut Off Flow Switch Dual purpose control shuts off heater in case of pump failure or low water flow Mounted and wired in series with the main gas valve Check with Manufacturer for proper paddle size Utilize correct paddle size for prop er operation NOTE Flow switch will not operate if flow is less th...

Page 35: ...35 WIRING DIAGRAM MODELS 122 322 ...

Page 36: ... neigh bor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department 4 Use only your hand to push in or turn the gas con trol knob Never use tools If the knob will not turn by hand do not try to repair it call a qualified serv ice technician Forced or attempted repair may result in a fire or explosion 5 Do not use this appliance if any part h...

Page 37: ...to original position Main Burner Adjustment 1 Turn off unit 2 Open manual firing valve 3 Turn on the unit wait 15 seconds and the igniter should glow Sight glass to check igniter at both ends of the heater Gas valve should be open after 45 seconds 4 If burner does not light on first trial It will retry up to 3 times 5 Main burner ignition check manifold gas pres sure at gas valve manifold pressure...

Page 38: ...ce Turn on manual gas valve Turn power on Set thermostat to call for heat When the unit is in operation Disconnect combus tion air blower pressure switch burner should go off immediately Wait 5 minutes Reconnect combustion air pressure switch burner should reignite after pre purge time delay 10 To restart system follow lighting instructions in the Operation section 11 High limit control set to des...

Page 39: ...may be performed by the owner Yearly Beginning of each heating season 1 Annual service call by qualified service agency 2 Visually check top of vent for soot Call service person to clean Some sediment at bottom of vent is normal 3 Visually inspect venting system for proper func tion deterioration or leakage 4 Check that heater area is free from combustible materials gasoline and other flammable va...

Page 40: ...ng contaminants listed below which will induce acidic condensation you want to reduce infiltration into your building through openings around windows and doors 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 can...

Page 41: ... all applicable warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original warranty 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 n...

Page 42: ...42 ...

Page 43: ...43 ...

Page 44: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...