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CATALOG NO. 1000.50K
Effective: 08-01-03
Replaces: 01-15-03
INSTALLATION
AND OPERATING
INSTRUCTIONS
Models 302-902
Type H, WH, & P
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of
this or any other appliance. To do so may result in an explosion or fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage,
personal injury or loss of life. Refer to the users inf
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TABLE OF CONTENTS PAGE NO. 4 SECTION A: BEFORE INSTALLING THE BOILER 8 SECTION B: BOILER INSTALLATION 11 SECTION C: COMBUSTION AND VENTILATION AIR 13 SECTION D: WATER PIPING - GENERAL 14 SECTION E: HYDRONIC HEATING PIPING 16 SECTION F: DOMESTIC HOT WATER PIPING 17 SECTION G: POOL HEATING 19 SECTION H: GAS SUPPLY CONNECTIONS 21 SECTION I: ELECTRICAL POWER CONNECTIONS 24 SECTION J: VENTING CONNECTIONS 28 J-1: Natural Draft Vertical Venting 31 J-2: Horizontal Thru-Wall V enting 34 J-3: Horizont
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DANGER: Make sure the gas on which the boiler will operate is the same type as that specified on the boiler model and 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 boiler. Instead, shut off the gas supply at a location external to the appliance. WARNING: Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace an
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Pay attention to these terms: 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. NOTICE: indicates special ins
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MODEL IDENTIFICATION The model identification number and boiler serial number are found on the boiler data plate located on the left inside jacket of the boiler. The model number will have the form H3 0752 or similar depending on the boiler size and configuration. The first character of the model number identifies application (H = Hydronic Heating System, W = Hot Water Supply System, P = Pool Application). The second character identifies the firing mode (3-two stage firing). The next four p
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HIGH DELTA COMPONENT LOCATION Flue Exhaust Combustion Air Filter (Inlet) Optional Combustion Air (Inlet) Alternate Flue Connection BACK Electrical Connection Gas Supply Connection Pressure Relief Connection Water Inlet View Port Water Outlet Temperature and Pressure Gauge LEFT-SIDE Gas Train Operational Center Control Combustion Air Blower Pressure Relief Valve Igniter Heat Exchanger Remote Sensor Burner Group FRONT Fig. #9220 6
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General Information 7
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SECTION B: BOILER INSTALLATION INSTALLATION CODES Installations must follow these codes: · Local, state, provincial, and national codes, laws, regulations and ordinances. · National Fuel Gas Code (NFGC), ANSI Z223.1- latest edition. · National Electrical Code (NEC), ANSI/NFPA 70 - latest edition. · Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required. · For Canada only: CAN/CGA B149.1 and .2 Installation Code and C.S.A. C22. 1 C.E.C. Part 1. EQ
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CLEARANCES TABLE 1 INDOOR INSTALLATION MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES Boiler Size Boiler Side 302-902 Floor See Note 1 Rear 1" Water Side 12 Other Side 1" Top 1" Front 1" Vent 2" Note 1. Do not install on carpeting. 12" 1" 1" 1" TOP VIEW Fig. #9221.1 FRONT VIEW When installed according to the listed minimum clearances from combustible construction mate- rials, the Raypak heaters can still be serviced without removing permanent structural construc- tion around the heater. However,
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OUTDOOR INSTALLATIONS Raypak Hi Delta Boilers are design certified for outdoor installation. Boilers must not be installed under an overhang that is less than three (3) feet from the top of the boiler. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from boilers installed under overhangs. TABLE 2 OUTDOOR INSTALLATION MINIMUM CLEARANCES Boiler Size Boiler Side 302-902 Rear 12" Right 36 Left 36" Top Unobstructed Vent N/A These clearances requ
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SECTION C: COMBUSTION AND VENTILATION AIR COMBUSTION AND VENTILATION AIR (Indoor Units) The boiler must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation. Combustion air can be supplied via conventional venting, where combustion air is drawn from the area immedi- ately surrounding the boiler, or via direct vent, where combustion air is drawn directly from outside. All installations must comply with the requirements of NFGC for
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COMBUSTION AND VENTILATION AIR SUPPLY (FOR CANADA INSTALLATION) CAUTION: All combustion air has to be drawn from the air outside the building (the mechanical equipment room directly communicates with the outdoors). 1. Ventilation of the space occupied by the boiler shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors. The total cross-sectional area of such an opening(s) shall be at least 10% of the area required in (2) and (3), but in
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SECTION D: WATER PIPING - GENERAL The boiler should be located so that any water leaks will not cause damage to the adjacent area or structures. CAUTION: This boiler requires forced water circulation when the burner is operating. See Table D-1 for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the boiler toprevent boiler operation without water circulation. RELIEF VALVE PIPING WARNING: Pressure relief valve discharge piping must be piped near the flo
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SECTION E: HYDRONIC HEATING PIPING PUMP SELECTION In order to insure proper performance of your boiler system, you must install a properly sized pump. Raypak recommends using a 20°F Delta T as design Delta T. (Delta T is the temperature difference between the inlet and outlet water when the boiler is firing at full rate). If a Delta T larger than 20°F is necessary, see Table D-1 for minimum flow rate requirements. PRESSURE DROP IN FEET OF HEAD FEEDWATER REGULATOR Raypak recommends that a feedwat
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SINGLE BOILER - LOW TEMPERATURE APPLICATION (HEAT PUMP) PRIMARY/SECONDARY PIPING 12 Fig. #9223 DUAL BOILER PRIMARY/SECONDARY PIPING Fig. #9232.2 15
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SECTION F: DOMESTIC HOT WATER PIPING When designing the water piping system for domestic water applications, water hardness should be considered. Table F-1 indicates the suggested flow rates for soft, medium and hard water. Hardness is specified as grains per gallon. TABLE F-1 DOMESTIC WATER HEATER FLOW RATE REQUIREMENTS DT = Temperature rise, degrees F DP = Pressure drop, ft, through heat exchanger SHL = System head loss, ft. GPM = Gallons/minute, flow rate MPS = Minimum pipe size
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SECTION G: POOL HEATING CAUTIO CAUTION: Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation. Improper flow control can damage the heater. Uncontrolled flow (too high) or restricted flow (too low) can seriously damage the heater. Follow these instructions to make sure your heater is properly installed. The Hi-Delta pool heater is equipped with an external pump and bypass arrangement that blends outle
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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 (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. NOTE: High chemical con
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SECTION H: GAS SUPPLY CONNECTIONS DANGER: Make sure the gas on which the boiler will operate is the same type as specified on the boiler model and rating plate. Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve located outside the heater jacket. A pounds to inches regulator must be installed to reduce to gas supply pressure to under 14" W.C. The regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the boiler gas
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GAS PRESSURE REGULATOR The gas valve pressure regulator(s) on the boiler are nominally preset at 3.5" W.C. for Natural gas, and 10.5" W.C. for Propane gas manifold pressure. The pressure at the gas valve outlet tap, measured with a manometer,while in operation should be 3.5 ± 0.1" W.C. for Natural gas and 10.5" ± 0.1" W.C. for Propane gas. If an adjustment is needed, turn the adjustment screw clockwise to increase pressure or counter-clockwise to lower pressure. 20
