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INSTALLATION & OPERATING
INSTRUCTIONS
Models 302B –902B
L
Types H, WH & P
W
WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance.
To do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do
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Rev. 11 reflects the following: Changes to: “Installations at Elevation” and low-lead certification on 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 Checklist on page 57 Additions: Note on page 15, notes on page 16, Table R on page 39 Deletions: None 2
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CONTENTS WARNINGS 4 Controls 33 BEFORE INSTALLATION 5 Outdoor Installation 33 Product Receipt 5 Heater Sequence of Operations 34 Model Identification 5 87%-Efficiency Boilers – Ratings and Certifications 5 Special Instructions 40 Installations at Elevation 5 Water Piping 40 Component Locations 6 Wiring Diagram 45 General Information 7 START-UP 46 GENERAL SAFETY 8 Pre Start-up 46 Time/Temperature Relationships in Start-Up 47 Scalds 8 OPERATION 50 INSTALLATION 9 Lighting Instructions 50 Installat
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WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe person- DANGER: al injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. Indicates special
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number will have the form H9 1262B or similar BEFORE INSTALLATION depending on the heater size and configuration. The letter(s) in the first group of characters identifies the Raypak strongly recommends that this manual be re- application (H = Hydronic Heating, WH = Domestic viewed thoroughly before installing your Hi Delta Hot Water (DHW), P = Pool). The number which fol- heater. Please review the General Safety information lows identifies the firing mode (1 or 4 = on-off, 3 = before installin
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Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front 6
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General Information Vent Size Quantity of (in.) Model No. Gas Burners Blowers Flue Intake Valves 302B 6 1 1 5 6 402B 8 1 1 6 6 502B 10 2 1 6 6 652B 13 2 1 8 6 752B 15 2 1 8 6 902B 18 3 1 8 6 Table A: Basic Data # Burners per % Fire at Stages Model Valve Stage No. 123 1 2 1 2 302B 6 1 100 402B 8 1 100 502B 5 5 1 1, 2 50 100 652B 7 6 11,2 54 100 752B 8 7 11,2 53 100 902B 6 6 6 1, 2 1, 2, 3 66 100 Table B: Manifold Data # Burners Valve % Firing Model per Valve Staging at Stage No. 12* 1 2 1 2 302B
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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 rec- ommended initial setting for the temperature control is 125°F. Safety and energy conservation are factors to be con- sidered when setting the water temperature on the thermostat. The most energy-efficient operation will resu
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The temperature of the water in the heater can be reg- Equipment Base ulated by using the temperature controller. To comply with safety regulations, the temperature controller is The heater should be mounted on a level, structurally set at the lowest setting when shipped from the facto- sound surface. The heater is approved for installation ry. on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed To adjust the water temperature, insert a small straigh
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In addition, the heater shall be installed such that the When installed according to the listed minimum clear- gas ignition system components are protected from ances from combustible construction, these heaters water (dripping, spraying, rain, etc.) during appliance can still be serviced without removing permanent operation or service (circulator replacement, control structural construction around the heater. However, for replacement, etc.). ease of servicing, we recommend a clearance of at lea
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Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 2 U.S. Installations Canadian Installations Clearance above grade, veranda, porch, A 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be B of opening; 1 foot (30 cm) 3 ft (91 cm) opened above opening C Clearance to permanently closed window * * Vertical clearance to ventilated soffit located above the terminal within a horizo
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Reversing Air Filter Follow these instructions to change the air duct con- nection from the left-hand side (standard) to the right-hand 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
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three or four sheet metal screws (not supplied) equal- space shall be considered in making this determina- ly distributed around the circumference of the duct. All tion. Each opening shall have a minimum free area of 2 2 ducting should be self-supported. The filter housing is 1 in. per 1,000 BTUH (2,225 mm per kW) of the total not designed to support the air duct. input rating of all gas utilization equipment in the con- 2 2 fined space, but not less than 100 in. (645 cm ). One opening shall com
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2 2 b. Not less than the sum of the areas of all vent of not less than 1 in. for each 30,000 BTUH mm connectors in the confined space. 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 WARNING: Do not use one permanent opening ventilation air referred to in (1). This opening(s) method if the equipment room is under negative can be ducted to a point not more than 18 in. (450 pressure conditions or
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5. Remove all plumbing fittings to the header. This Hydrostatic Test will include both inlet and outlet water pipe unions and the pressure relief valve and drain piping. Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in 6. Remove limits, control bulbs and/or thermocou- operation. The heat exchanger has already been fac- ples. tory-tested and is rated for 160 psi operating pressure. However, Raypak does recommend hydrostatic test- 7. Remove
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Failure to exceed 105ºF (41ºC) within 7 minutes may NOTE: Individual and multi-boiler Cold Water Start result in the premature failure of the hot surface ignit- systems require the use of a 20°F ∆T boiler pump. er, remote flame sensor, burners and heat exchanger. Cold Water Run 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 Cold water run differs from cold water start in that the disc
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heaters which are not subject to thermal shock. Pressure Drop in Feet of Head Raypak offers a full line of electronic sequencers that Feedwater Regulator produce direct reset of heater water temperature. (Refer to the Controls section of the Raypak Catalog.) Raypak recommends that a feedwater regulator be in- stalled 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
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Potable Water and Space Heating 4. When the system requires water for space heating at temperatures higher than 140°F, a means such CAUTION: When this heater is used for both as a mixing valve shall be installed to temper the potable water and space heating, observe the water in order to reduce scald hazard potential. following to ensure proper operation. Pool Heating 1. All piping materials and components connected to CAUTION: Power to the heater should be the water heater for the space heating
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Automatic Chlorinators and Chemical Feeders CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty. All chemicals must be introduced and completely di- luted 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 (e.g. overnight). MIXING VALVE Chlorinators must feed downstrea
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concentration of total dissolved solids is usually ex- Raypak water heaters can operate lime/scale-free pressed in parts per million (ppm) as measured in a using potable water with a hardness not exceeding 25 water sample. Water with a high TDS concentration grains per gallon. Proper operation is achieved by set- will greatly accelerate lime and scale formation in the ting the temperature rise/water flow per the guidelines hot water system. Most high TDS concentrations will in the installation i
