Raypak HI DELTA 302B, 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...

Page 2: ...n page 5 Table J on page 20 Electrical Power Connections on page 22 Table T on page 40 Wiring Diagram on page 45 Igniter check As Required Item 4 on page 53 Warranty on page 56 Fax number in Start Up...

Page 3: ...ield 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 Efficien...

Page 4: ...defects or other reproductive harm WARNING Risk of electrical shock More than one disconnect switch may be required to deenergize the equipment before servicing CAUTION Operation of this heater in lo...

Page 5: ...s standard war ranties 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 mo...

Page 6: ...6 Component Locations Fig 1 Component Locations Back Fig 2 Component Locations Left Side Panels removed for clarity Fig 3 Component Locations Front...

Page 7: ...ve Stages Fire at Stage Model No 1 2 3 1 2 1 2 302B 6 1 100 402B 8 1 100 502B 5 5 1 1 2 50 100 652B 7 6 1 1 2 54 100 752B 8 7 1 1 2 53 100 902B 6 6 6 1 2 1 2 3 66 100 Table A Basic Data Table B Manifo...

Page 8: ...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 te...

Page 9: ...etting 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 shoul...

Page 10: ...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 t...

Page 11: ...t 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...

Page 12: ...oint com municating with the outdoors The total cross sectional area shall be at least 1 in 2 of free area per 20 000 BTUH 111 mm2 per kW of total input rating of all equipment in the room when the op...

Page 13: ...100 in 2 645 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 mini mum dimension of air openings sha...

Page 14: ...must be drawn from the air outside of the building the mechanical equip ment room must communicate directly with the outdoors of not less than 1 in 2 for each 30 000 BTUH mm2 per kW of total rated in...

Page 15: ...s to the heater and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based anti freeze Raypak recommends conducting the hydrostatic test...

Page 16: ...d Water Run Cold water run differs from cold water start in that the system water entering the heater remains below 105 F 41 C continuously Typically this is the case in swim ming pool heating and wat...

Page 17: ...s highly recommend ed 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...

Page 18: ...he 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 thermo st...

Page 19: ...e 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 p...

Page 20: ...tion 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...

Page 21: ...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 K for maximum...

Page 22: ...e adjustment screw clockwise to increase pressure or counter clockwise to lower pressure Electrical Power Connections Installations must follow these codes National Electrical Code and any other natio...

Page 23: ...ections 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 equi...

Page 24: ...er 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 set point at which you want the heater to maintain Ensure that t...

Page 25: ...nting is criti cal for the safe and efficient operation of the heater Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of...

Page 26: ...ombination with below freez ing 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...

Page 27: ...e a 4 ft clearance between the ends of vent caps located on the same horizontal plane Canadian Installations Refer to latest edition of the B149 Installation code A vent shall not terminate 1 Directly...

Page 28: ...test agency CAUTION The silicone vent gaskets must be prop erly reinstalled to prevent flue gas leakage Replace any torn or worn vent gaskets WARNING Examine the venting system at least once a year C...

Page 29: ...eration 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 block age restriction leakage corrosion...

Page 30: ...t in length If horizontal run exceeds 70 equivalent ft an appropri ately sized extractor must be used Each elbow used is equal to 10 ft of straight pipe This will allow installa tion in one of the fou...

Page 31: ...ontal 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 ins...

Page 32: ...ted for use with Category III gas burning heaters such as the AL29 4C stainless steel vents offered by Heat Fab Inc 800 772 0739 Protech System Inc 800 766 3473 Z Flex 800 654 5600 or American Metal P...

Page 33: ...Do not locate adjacent to any window door walk way 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 level...

Page 34: ...rified to ensure that it is safe to operate the heater The safety compo nents wired into the diagnostic board are low water cut off optional blocked vent switch man ual vent temp switch optional manua...

Page 35: ...at J14 on the cir cuit board 33 The 120 VAC signal continues to the coil of the blower relay K 3 N O 34 The 120 VAC signal continues to the 120 VAC safety terminals located at J13 on the circuit board...

Page 36: ...ntrol Fig 29 Ignition Module Table Q Ignition Module Diagnostic LED Codes 36 45 The stage 1 LED on the status display board is now illuminated 46 The coil of relay K 2 is now energized with the N O co...

Page 37: ...elow 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 32 Low Water Cut Off High and Low Gas Pre...

Page 38: ...old both the UP and DOWN buttons for 5 seconds while the power is on Diagnostic information is provided any time a fault is recorded This information is intended to assist in locating the problem with...

Page 39: ...wer Check Filter Check Air Sw Hose 1 Ignition Lockout Display actual Fault Flash Code Recycle Reset Control Push Reset Button See Table Below 90 Field Interlock Err Check Louvers Check Comb Damper Che...

Page 40: ...requirements for the 87 efficiency Hi Delta CAUTION Proper installation of flue venting is criti cal for the safe and efficient operation of the boiler NOTE For additional information on appliance cat...

Page 41: ...ves or other equipment 8 Locate and guard vent termination to prevent acci dental contact by people or pets 9 DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area unl...

Page 42: ...CPVC 30 80 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 o...

Page 43: ...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 ac c...

Page 44: ...n vertical height exceeds 25 ft consult factory prior to installation Fig 41 Direct Vent Vertical Table V Category II or IV Vertical Venting Vent lengths are based on a lateral length of 2 ft Refer to...

Page 45: ...45 Wiring Diagram...

Page 46: ...ier from a neigh bor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas con trol knob Never...

Page 47: ...ailure 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 connec...

Page 48: ...ed pilot to light the burner sections on either side of it The burn er sections on either side of the supervised section pilot are electrically interlocked with the supervised ignition system so as th...

Page 49: ...restore electrical power to heater Fig 42 Leak Test This completes leak testing for a single Hi Delta mani fold riser Repeat steps 1 8 for each riser Post Start Up Check Check off steps as completed 1...

Page 50: ...rn 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 informa tion on the front cover...

Page 51: ...hnical Service Department 1 805 278 5300 Replace gas valve Are the gas valve settings correct Replace fan relay Replace fan Replace air pressure switch Correct the air settings or you may have to clea...

Page 52: ...e 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 I...

Page 53: ...t Up Check page 49 3 Check flame sensors 4 Conduct a combustion test at full fire Carbon di oxide should be 7 5 to 8 5 at full fire for natural gas and between 9 2 to 9 8 for propane gas Carbon monoxi...

Page 54: ...ontaminated ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners ch...

Page 55: ...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...

Page 56: ...ted pools 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...

Page 57: ...ght _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size _________...

Page 58: ...wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth...

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Page 60: ...60 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A...