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Raypak HD101 User's Manual

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1. TOP VIEW ZZ Fig 7 Minimum Installed Service Clearances Indoor Closet Installations hang Roof water drainage must be diverted away from heaters installed under overhangs CAUTION Service clearances less than the minimums may require removal of the heater to service either the heat exchanger or the burners H id Minimum Installed The heater must be installed in a manner that will eater Side Service Clearance enable the heater to be serviced without removing any Outdoor Installations These heaters are design certified for outdoor installa Other Side tion Heaters must not be installed under an overhang unless clearances are in accordance with local instal Water Side lation codes and the requirements of the gas supplier Three sides must be open in the area under the over Table D Clearances Outdoor Installations Fig 8 Minimum Installed Service Clearance Outdoor Installations 10 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 job site Combustion and Ventilation Air Combustion Air Filter This heater is supplied wit
2. 6 x ya ve ya al ms a 18 40078 TWNINSEL w e n a i aaa e a 98 4 C aE T I nate arate H l Z n l l a 34 HD Troubleshooting Step 1 Is temperature controller Step 2 No installed Step 3 Check and correct power connections at main terminal Step 4 block ignition module circuit breaker panel or blower relay YES Step 5 Step 6 Is 24VAC at PS on ignition module Is connecting plug secure Is the flame sensor signal to the z atap x ial sos ie aiii ignition module greater than 1 uA DC correct YES XES Correct inlet gas supply pressure Is manifold gas pressure NO Step 8 correct Replace gas valve Call our Technical Service Department 1 800 947 2975 Outside California 1 800 627 2975 Inside California YES NO The unit is okay Step 9 Adjust manifold gas pressure 35 PRE START UP Filling System Heating Heaters Fill system with water Purge all air from the system using purge valve sequence After system is purged of air lower system pressure Open valves for normal system operation fill system through feed pressu
3. For Canada only CAN CGA B149 Installation Code B149 and C S A C22 1 C E C Part 1 C22 1 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 CAUTION The heater should be located in an area where water leakage will not result in damage to the area adjacent to the appliance 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 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 WARNING This product must be installed by a licensed plumber or gas fitter when installed within the Commonweatlh of Massachusetts Clearances Indoor Closet Installations Heater Side Minimum Installed Service Clearance re r nm s DO NOT install on carpeting When water connections are on other side Table C Clearances Indoor Closet Installations WATER SIDE 24 sa ee p FRONT VIEW lt
4. ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimen tal to the operation of regulators relief valves or other equipment Where local experience indi cates that condensate is a problem with Category and IIl appliances this provision shall also apply Locate and guard vent termination to prevent acci dental contact by people or pets DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations Locate or guard vent to prevent condensate from damaging exterior finishes Use a rust resistant sheet metal backing plate against brick or mason ry surfaces DO NOT extend exposed vent pipe outside of building Condensate could freeze and block vent pipe US Installations Refer to latest edition of the National Fuel Gas Code Vent termination requirements are as follows a Vent must terminate at least four 4 feet below four 4 feet horizontally or one 1 foot above any door window or gravity air inlet to the building The vent must not be less than seven 7 feet above grade when located adjacent to public walk ways Terminate vent at least three 3 feet above any forced air inlet located within ten 10 feet Vent must terminate at least four 4 feet horizon tally and in n
5. Hot Water DANGER SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts external connections to the unit Solid conductors should not be used because they can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones on the unit or larger Installer action is required to electrically enable your Hi Delta heater to operate after making the power con nections You must make a connection on Terminal Block 3 for temperature control connections This will be done based on the controller option selected with your heater order For operation with a Temp Tracker controller refer to the Temp Tracker Installation and Operating Instructions Raypak Catalog number 5000 66 P N 241177 Consult the wiring diagram shipped with the heater in the instruction packet The Stage 1 connections are for the remote tank control through the heaters 24 volt transformer DO NOT attach line voltage to the Stage 1 connection Before starting heater check to ensure proper voltage to heater and pump 20 SINGLE
6. Fig 2 Component Locations Left Side FLUE EXHAUST TUBE PANEL REMOVED BLOCKED FLUE VENT SWITCH OPTIONAL FOR CLARITY HIGH LIMITS GAS VALVE STATUS LIGHT FLAME SENSOR ON OFF SWITCH 3 3 BLOWER AIR SWITCH N F RELAY z le g COMBUSTION AIR SWITCH AIR INTAKE lt i j ira TRANSFORMER o o odo o ECONOMASTER FILTER BOX lt IGNITION MODULE J J ALARM RELAY CONTROLS TRAY CONTROL ASSY IGNITER GAS TRAIN BLOWER BURNERS Fig 3 Component Locations Front Panels removed for clarity 6 General Information Quantity of Burners Neue ve no Flue Intake A ee i F a oes Ed Table A Basic Data SUPPLY GAS PRESSURE TAP HI amp LO MANIFOLD ADJUSTMENT CAP WHITE RODGERS GAS VALVE HI amp LO SUPPLY GAS PRESSURE TAP CAP MANIFOLD GAS PRESSURE TAP INVENSYS GAS VALVE Fig 5 MANIFOLD ADJUSTMENT HI amp LO MANIFOLD ADJUSTMENT MANIFOLD GAS PRESSURE TAP SUPPLY GAS PRESSURE TAP HONEYWELL GAS VALVE Gas Valves GENERAL SAFETY To meet commercial hot water use needs the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 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
7. Hot Ground 120 VAC Common Ground lt 1 VAC WARNING If Common Ground is gt 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 Attach Manometers to Measure Pressures Attach 16 scale manometer to the main gas shut off valve supply pressure tapping Attach one 12 scale manometer to the manifold gas pressure tapping See gas valve detail on page 7 Attach one 12 scale manometer to the tee near the blower housing EIHGIGEFI IAIIIIIWIGIAIAIAIIIYIA YOUR SAFETY READ BEFORE OPERATING W WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device C Use only your hand to push in or turn the gas control knob Never use which automatically lights the burner Do not try to light the burner by hand tools If the knob will not push in or turn by hand do not try to repair it B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell Cala qualified service technician Force or attempted repair may result next to the floor because some gas is heavier than air and will settle on the floor in a fire or explosion WHAT TO DO IF YOU SMELL GAS D Do not use this appliance if any part has been under
8. STAGE TANKSTAT a STAGE 1 CONNECTION _ ATTACH STAGE 1 CONNECTIONS ON HEATER TO THE SINGLE STAGE TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE Fig 15 Single Stage Tankstat 2 STAGE TANKSTAT ee STAGE 2 CONNECTION OR ae STAGE 1 CONNECTION OF HEATER 2 50 0 LP gt 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 AS SHOWN IN THE DIAGRAM Fig 16 2 Stage Tankstat Heater must be electrically grounded in accordance with NEC and C22 1 in Canada NOTES 1 Field installed ground to inside of junction box 2 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 Venting General CAUTION Proper installation of flue venting is critical for the safe and efficient operation of the heater Definition of 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 posi tive vent static pressure and with a vent gas temperature that avoids excessive condensate pro duction in the vent Category Il A heater which operates with a non posi tive vent static pressure and with a vent gas temperature that may cause excessive co
9. 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 and other similar products Areas causing contaminated combustion air dry cleaning laundry areas and establishments metal fabrication plants beauty shops e refrigeration repair shops photo processing plants auto body shops plastic manufacturing plants furniture refinishing areas and establishments new building construction remodeling areas Check for areas and products as listed above before installing heater If found remove products permanently OR provide outdoor combustion air 44 45 46 47 7 2 eu v Onn oF Vie U j Registered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A
10. and air separator fitting as shown in the piping diagrams Fig 10 12 Soft 0 4 grains per gallon Soft 0 4 grains per gallon grains per gallon Medium 5 15 grains per gallon Hard 16 25 grains per gallon Model Input Output ve worn woven Tr T amm or rs om ot oom ae ws sme or f omm ap wrs sh pom oo s s 2 s foolmal os 2 lt ea ne 0 s rj S G S s sns aa sates ea oa a AE io ve se sz e s 4 ENG AT Temperature rise F 10 3 1 1 2 AP Pressure drop through heat exchanger ft SHL System head loss ft System head loss is based on the heater and tank placed no more than 5 feet apart and 50 feet equivalent length of tubing and fittings gpm Gallons per minute flow rate MTS Minimum tubing size Must utilize optional cupro nickel tubes With Hard Water 16 25 grains per gallon the operating control must be set no higher than 130 F for scale free operation For operating tem peratures above 130 F a water softener must be utilized Table F Domestic Water Heater Flow Rate Requirements 16 HOT WATER SUPPLY Soib AL A WATER HEATER MOUNJED PRESSURE RELIEF VALVE Se RELIEF VALVE A THERMOMETER EXPANSION TANK X HEATER PUMP TANKSTAT DRAIN RECIRCULATION PUM bos BY OTHERS NOTES RECIRCULATION 1 PLUMB SWING CHECK VALVE IN GRAVITY CLOSED POSITION AN PIPE ALL RELIEF VALVES TO DRAIN OR AS L
11. before servicing CAUTION Risk of electric shock More than one 1 disconnect switch may be required to de energize the equipment before servicing Ignition Control Module The interrupted proved ignition device conserves ener gy When additional heat is needed the combustion air blower starts to purge all air from the combustion chamber for about 15 seconds On proof of air flow the air proving switch closes and the igniter is ener gized eliminating the fuel costs of maintaining a constant pilot To ensure safe operation the gas valve cannot open until the igniter is verified as capable of igniting the gas The ignition module is an electronic device which closes the main gas valve within 8 10 of a second whenever the flame is interrupted The main burner is automatically lit when the device is powered and pre purged The unit performs its own safety check Fig 22 Ignition Module 32 Modulating Temperature Control Optional This heater can be equipped with a Raypak modulat ing temperature control For operation with this control refer to the Temp Tracker Installation and Operating Instructions Raypak Catalog number 5000 66 P N 241177 o2 2 Fig 23 Modulating Temperature Control High Limit Manual Reset The heater is equipped with a manual reset high limit temperature device If the optional adjustable limit is used push the reset button and adjust the setting to 30 F or 40 F a
12. com mon venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common vent sys tem Turn on any exhaust fans such as range hoods and bathroom exhausts so they will oper ate at maximum speed Do not operate summer exhaust fan Close fireplace dampers Place in operation the appliances being inspected Follow the manufacturers instructions for lighting INSULATED EXHAUST VENTING BOILER UNIT 12 MIN FLUE EXHAUST VENT CAP 12 MIN Z Z Z7 7 Fig 19 Horizontal Thru Wall Venting Category Ill each appliance Adjust thermostat so appliance will operate continuously 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 01 to 08 in WC After it has been determined that each appliance remaining connected to the common venting sys tem 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 Certified Venting Material Appliance Category Stainless Steel Gas Tight 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 commo
13. corner 6 ft 1 83m F Clearance to each side of center line ex 9 ft 91 cm within a height H 15 ft above the me tended above meter regulator assembly ter regulator assembly J Clearance to window or door that may be opened Clearance to service regulator vent outlet 6 ft 1 83m Clearance to non mechanical air supply inlet 4 ft 1 2m below or to side to building or the combustion air inlet to any of opening 1 ft 30 cm 3 ft 91 cm other appliance above opening z 3 ft 91 cm above if within K Clearance to mechanical air supply inlet 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved 7 ft 2 13m 7 ft 2 13m t driveway located on public property Clearance under veranda porch deck or 42 in 30 cm TT balcony In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code In accordance with the current CAN CGA B149 Installation Codes 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 veranda 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 2 Table I Vent Air Inlet Termination Clearances 23 10 11 12
14. 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 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 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 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 A D 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 set ting temperature at water heater Feel water before bathing or show ering Temperature limiting valves are available see manual Time Temperature Relationships in Scalds The followin
15. leaks one more time POST START UP CHECK Check off steps as completed 1 Heater and heat distribution units or storage tank filled with water Automatic air vent if used open two full turns dur ing venting procedure Air purged from system Air purged from gas piping Piping checked for leaks Followed start up procedure for proper start up Is burner flame visible 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 con trols are tested When safety devices are restored burners should reignite after pre purge time delay Test limit control While burner is operating move indicator on high limit control below actual heater water temperature Burner should go off while blower and circulator continue to operate Raise setting on limit control above heater water temper ature and burner should reignite after pre purge time delay NOTE This test doesn t apply to fixed setting high limits Test ignition system safety device 40 Turn on manual gas valve Turn power on Set thermostat to call for heat When the unit is in operation Disconnect combustion 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
16. r Lt VOLT OHM METER BLACK CIRCUIT BREAKER WHITE GREEN i GROUND AC 108 Volts AC Minimum 132 Volts AC MAX AB 108 Volts AC Minimum 132 Volts AC MAX BC lt 1 Volt AC Fig 14 Check Power Source Making the Electrical Connections Refer to Fig 14 and the Wiring Diagram 1 Verify circuit breaker is properly sized by referring to heater rating plate A dedicated circuit breaker should be provided Turn off all power to the heater Verify that power has been turned off by testing with a volt ohm meter prior to working with any electrical connec tions or components 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 Provide an external surge suppressor capable of maintaining system integrity Provide overload protection and a disconnect means for equipment serviceability as required by local and state code Install heater controls thermostats or building management systems in accordance with the applicable manufacturer s instructions Conduit should not be used as the ground There must be a solidly wired ground 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 Electrical Connections Domestic
17. shall be at least 10 of the CAUTION This heater requires forced water area required in 2 and 3 but in no case shall circulation when the burner is operating See Table E the cross sectional area be less than 10 in 2 6500 and Table F for minimum and maximum flow rates mm2 and water pump selection The pump must be interlocked with the heater to prevent heater 2 For heaters using a barometric damper in the vent operation without water circulation system and when air supply is provided by natu 12 Reversing Water Connections Follow these instructions to change the water connec tions from the left hand side standard to the right hand side 1 10 11 12 13 14 Disconnect all electrical power from the heater if applicable Label all electrical connections and conduit lines This may include the flow switch low water cut off probe and or pump Disconnect or isolate the main gas pipe from the heater if applicable Remove both in out and return header access panels by removing all sheet metal screws 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 Remove limits control bulbs and or sensors Remove the six flange nuts and the in out header from the left hand side Remove the six flange nuts and the return header from the right hand side Remove the header stud bolts from each
18. the carrier immediately On occasion items are shipped loose Be sure that you receive the correct number of packages as indi cated 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 war ranty conditions you must also specify the date of installation Purchased parts are subject to replacement only under 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 right side jacket of the heater The model number will have the form H3 HD101 or similar depending on the heater size and configuration The first character of the model number identifies application H Hydronic Heating System WH Hot Water Supply System The second character identifies the firing mode 3 two stage firing 4 On Off firing The next three places identify the size of the heater Ratings and Certifications Standards Gas
19. tube sheet Reverse the headers and stud bolts to the new location Install NEW red beveled O rings flush against both tube sheets with the bevel facing outward Push the header firmly against the O rings Install and tighten the flange nuts onto the stud bolts until finger tight 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 TIGHT EN Re route the capillary s wiring etc to the new location adding thermal paste and shim to the capillary well 13 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 other types of heaters Raypak heaters do not require hydrostatic testing prior to being placed in operation The heat exchanger has already been factory tested and is rated for 160 PSI maximum oper Low Temperature System Heater requires minimum inlet temperature of 105 F Consult the following sections for piping details Temperature amp Pressure Gauge ating pressure However Raypak does recommend hydrostatically tes
20. turn clockwise to increase and counterclockwise to decrease manifold pres sure See nominal gas valve manifold settings above 4 Replace cap s when pressure is set Invensys Model HD401 Natural Only 1 Turn heater off 2 Locate and remove the Torx tamper resistant screw Shown in Fig 30 Carefully remove 2 stage solenoid 4 Skip to Step 9 for LO fire adjustment only 5 Locate and remove Lo fire adjustment cap 6 Carefully remove the spring amp weight 7 Using an allen wrench turn clockwise to increase and counterclockwise to decrease the HI fire man ifold pressure Heater will not run while adjusting HI fire pressure 8 Carefully place the spring amp weight back in before replacing LO fire adjustment cap 9 ForLO fire adjustment tighten the cap to increase the pressure loosen to decrease 10 When correct settings are set replace the sole noid and tamper screw in place B 10 TORX TAMPER S RESISTANT SCREW y d z 2 STAGE SOLENOID LO FIRE ADJUSTMENT CAP ji WEIGHT e BA SPRING b WAS l HI FIRE ADJUSTMENT USE 3 16 ALLEN WRENCH Fig 30 Gas Valve Adjustment Invensys Valve Gas Type Conversion on Valve WARNING Burner orifices must be changed when changing gas type NOTE Model HD401 valve requires replacement of 39 Turn off gas supply at the appliance service level 2 Remove the pressure regulator cover assembly 3 Remove the ex
21. used and sized adequately to evacuate the flue products from the heaters 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 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 heater exhaust outlet 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 26 CAUTION Vent connectors for natural draft venting systems must be type B vent or better Common venting systems may be too large when 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 a Seal any unused opening in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the
22. valves and a bypass valve should be installed A boiler installed above radiation level must 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 Three Way Valves Valves designed to blend water temperatures or reduce water circulation through the boiler should not be used Raypak boilers are high recovery low mass boilers not subject to thermal shock Raypak offers a full line of electric sequencers that produce direct reset of boiler water temperature Refer to the Controls Section in our Complete Catalog from entering the boiler Domestic Hot Water Piping The boiler piping system of a hot water heating boiler 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 boiler water during the cooling cycle It is highly recom mended that the piping be insulated When designing the water piping system for domestic water applications water hardness should be consid ered Table E indicates the suggested flow rates for soft medium and hard water Hardness is specified as grains per gallon Air Separation Expansion Tank All boilers should be equipped with a properly sized expansion tank
23. Fired Low Pressure Steam and Hot Water Heaters ANSI 221 13 CSA 4 9 latest edition Industrial and Commercial Gas Fired Package Heaters CAN 3 1 latest edition Gas Water Heaters ANSI Z21 10 3 CSA 4 3 lat est edition 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 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 Installations at Elevation Rated inputs are suitable for up to 2000 feet elevation without de rate Consult the Factory for installations at any altitude in excess of 2000 feet Component Locations FLUE EXHAUST WATER INLET PRESSURE RELIEF CONNECTION GAS CONNECTION WATER OUTLET AIR INTAKE AIR FILTER VIEW PORT HIGH VOLTAGE CONNECTION LOW VOLTAGE CONNECTION FIELD WIRING J BOX
24. HD251 and HD301 and 6 for HD401 NOTE Vent Adapter will have to be used to connect B vent to the unit 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 hori zontal 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 Natural Draft Vertical Vent Termination The vent terminal should be vertical and should termi nate outside the building at least two 2 feet above the highest point of the roof that is within 10 feet The vent cap should have a minimum clearance of four 4 feet horizontally from and in no case above or below unless a four 4 foot horizontal distance is main tained 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 consis tent with the NFGC or in Canada the 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 CAUTION Listed vent cap terminal must be
25. INSTALLATION amp OPERATING INSTRUCTIONS Models HD101 HD401 Types H amp WH 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 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 D D A Rheem Company CATALOG NO 1000 52 Effective 06 11 09 Replaces NEW P N 241356 Rev 1 WARNINGS Pay Attention to These Terms BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information GENERAL SAFETY Time Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Co
26. Material Galvanized Stainless 100 Steel Steel 4 Elbows PVC Gas Tight Max ABS CPVC Table L Horizontal Thru Wall Venting 29 36 MIN j 12 MIN ZZ A ZZ 1 VENT PIPE INTAKE P VENT COMBUSTION AIR FILTER BOILER UNIT T L A A F SSE Fig 21 Direct Vent Vertical Venting Category l I Certified Min Max Vertical Combustion Air Inlet Appliance Venting Venting Height feet Air Intake Size Category Pipe Material Material inches Galvanized Steel PVC ABS CPVC HD201 6 Equivalent HD251 6 Over 25 feet use single acting barometric damper Consult the factory for additional information Table M Vertical Venting 30 Vertical Direct Vent System Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and 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 0 01 to 0 08 in WC as measured 12 in from the appliance outlet to ensure proper operation 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 maximum and minimum venting length for Category appliance shall be determined per the lat est edition of the NFGC U S a
27. OCAL CODES REQUIRE Fig 12 Single Heater Domestic Hot Water with One Storage Tank Gas Supply Gas Supply Connection DANGER Make sure the gas on which the heater will operate is the same type as specified on the 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 psi 3 45 kPa The heater n must be isolated from the gas supply piping system Gas piping must have a sediment trap ahead of the by closing the manual shutoff valve during any heater gas controls and a manual shut off valve locat pressure testing of the gas supply piping system at ed outside the heater jacket A pounds to inches test pressures equal to or less than 1 2 psi Relieve regulator must be installed to reduce the natural gas tact pressure in the gas supply line before supply pressure to under 10 5 in WC 13 0 in WC for reconnecting the heater and its manual shut off valve propane gas The regulator should be placed a mini to the gas supply line FAILURE TO FOLLOW THIS mum distance of 10 times the pipe diameter upstream PROCEDURE MAY DAMAGE THE GAS VALVES of the heater gas controls All gas piping must be test over pressurized gas valves are not covered by ed after installation in accordance with local codes warranty The heater and its gas connections shall The heater and its gas connection must be leak tested be leak tested
28. ate on the vent cap can result in a blocked flue condition Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury Gases may form a white vapor plume in winter The plume could obstruct a window view if the ter mination is installed in close proximity to windows Prevailing winds in combination with below freez ing temperatures can cause freezing of condensate and water ice build up on buildings plants or roofs The bottom of the vent terminal and the air intake shall be located at least 12 in above grade includ ing normal snow line Un insulated single wall metal vent pipe shall not be used outdoors on cold climates for venting gas utilization equipment Through the wall vents for Category Il and IV appliances and non categorized condensing appli INSIDE CORNER DETAIL d E lt wy FIXED cLoseD MMMM SL v LLL GY Fig 17 Minimum Clearances from Vent Air Inlet Terminations Indoor and Outdoor Installations U S Installations Canadian Installations Clearance above grade veranda porch deck or balcony 1 ft 30 cm 1 ft 30 cm 4 ft 1 2m below or to side of opening 1 foot 30 cm 3 ft 91 cm above opening Vertical clearance to ventilated soffit located above the terminal within a horizontal dis 5 ft 1 5m tance of 2 ft 61cm from the centerline of the terminal Clearance to inside
29. before placing the appliance in before placing it in operation operation Use soapy water for leak test DO NOT use open flame heater s rating plate 17 MANUAL SHUT OFF VALVE ND HEATER JACKET GAS VALVE Po 3 MIN l l TYPICAL 1 UNION fl Fig 13 Sediment Trap Orientation CAUTION Do not use Teflon tape on gas line pipe thread A pipe compound rated for use with gas systems is recommended Apply sparingly only on male pipe ends CAUTION Support gas supply piping with hangers not by the heater or its accessories Ensure the gas piping is protected from physical damage and freezing where required Gas Supply Pressure A minimum of 4 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 in WC and a maximum of 13 in WC is required for propane gas The gas pressure regulator supplied on the heater is for low pressure service If upstream 3 4 Model Input se e pressure exceeds 14 in WC an intermediate gas pressure regulator of the lockup type must be installed When connecting addi
30. bove desired operating temperature kaa Fig 24 Manual Reset High Limit High Limit Auto Reset Optional This heater may be equipped with an optional adjust able auto reset high limit temperature device The optional adjustable auto reset high limit is located behind the front panel see Fig 3 Adjust the setting to approx 20 F 10 C above desired outlet tempera ture O Fig 25 High Limit Auto Reset Optional 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 NOTE Flow switch will not operate if flow is less than 12 gpm Ss S24 Fig 26 Flow Switch High and Low Gas Pressure Switches Optional The low gas pressure switch optional connection mounts upstream of the gas valve to ensure that suffi 33 cient gas pressure is present for proper regulator per formance The low gas pressure switch automatically shuts down the heater if gas supply drops below the recommended setting of 4 0 in WC for natural gas and 9 0 in WC for propane gas The high gas pressure switch optional connection mounts down stream of the gas valve If the gas pres sure regulator fails the high gas pressure switch automatically shuts down the burner The high gas pressure switch automatically shuts down the heater if gas manifold pressure rises above the recommended s
31. ck 3 Check for leaks Repair if found flow device upstream of the regulator with a manual shut off valve as required by local codes 10 F AT F AT 20 F AT 30 F AT SO era ae ae a fe CE T T Te er ele ss z wej eo me z 29 o e or a ss e froze eo ver 2 z s e s ee m e zo 2 2 er a oo e o7 mw 52 wo sor ee 2 so o oe e s w moj ee oe se ss 2 2 m ole oo Flow switch will not activate at less than 12 gpm NOTE Basis for minimum flow 13 gpm or 40 F AT maximum flow gpm except for header Table E Heater Rates of Flow and Pressure Drops 14 Maximum 4 times the pipe diameter or 12 whichever is less Fig 10 Single Boiler Low Temperature Application Heat Pump Primary Secondary Piping CONTROLLER TEMPERATURE GAUGES Q P 27 EXPANSION SYSTEM TANK g SUPPLY CJ S UO Cm P Q SYSTEM NI 2X BOILER PUMP PUMP 7 0 tg ral 6X ISOLATION VALVE CITY WATER om INLET WATER PRESSURE REGULATOR gt MAIN TEMPERATURE SENSOR b ae NOTES SYSTEM RETURN 1 PLUMB SWING CHECK VALVE IN GRAVITY CLOSED POSITION 2 PIPE ALL RELIEF VALVES TO DRAIN OR AS LOCAL CODES REQUIRE Maximum 4 times the pipe diameter or 12 whichever is less Fig 11 Dual Boiler Primary Secondary Piping 15 Piping Heating Boilers All high points should be vented Purge
32. e 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 in 2 for each 30 000 BTUH 70 mm per kW of total rated input of the burner s and the location of the opening s shall not inter fere with the intended purpose of the opening s for ventilation air referred to 1 This opening s can be ducted to a point not more than 18 in 450 mm nor less than 6 in 150 mm above the floor level The duct can also Goose Neck through the roof The duct is preferred to be straight down 18 from floor but do not place near piping 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 4 Refer to the latest version of the B149 for addition Installations in Canada al information CAUTION All combustion air must be drawn from Water Piping the air outside of the building the mechanical equipment room must communicate directly with the outdoors General _ I The heater should be located so that any water leaks 1 Ventilation of the space occupied by the heater will not cause damage to the adjacent area or struc shall be provided by an opening s for ventilation tures air at the highest practical point communicating with outdoors The total cross sectional area of such an opening s
33. e heater is wired for 120 VAC less than 12 AMPS The voltage is indicated on the tie in leads Consult the wiring diagram shipped with the heater in the instruc tion packet The remote tank control stat thermostat or electronic heater control as applicable may be con nected to stage selector terminal See wiring diagram 24 Volts are supplied to this connection through the heater transformer DO NOT attach line voltage to the TH leads Before starting the heater check to ensure proper voltage to the heater and pump Install a separate disconnect means for each load Use appropriate sized wire as defined by NEC CSA and or local code All primary wiring should be 125 of minimum rating It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source Surge Protection Microprocessor based and solid state controls are vul nerable to damage from voltage and amperage fluctuations in the power supply All sensitive control components should be protected by a suitable com mercial grade surge protection device 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 Check the Power Source WARNING Using a volt ohm meter VOM check the following voltages at the terminal block inside the unit Make sure proper polarity is followed and house ground is proven 19 rini
34. em Stainless Steel Gas Tight Type B or any Category Venting System Galvanized Steel PVC ABS Stainless Steel CPVC Gas Tight Table H Venting Category Requirements Barometric Damper A barometric damper may be required when vent heights exceed 25 feet or when the draft is greater than 0 08 in WC In these installations a barometric damper single acting is required The damper should be installed NO CLOSER than 18 in from the discharge of the unit and no closer than 18 in from a combustible ceiling The damper can be installed in horizontal or vertical runs of vent pipe as necessary Installation in a bull head tee is acceptable as shown in the NFGC The weights on the damper should be adjusted per the damper manufacturer s instructions for proper opera tion to maintain 0 01 to 0 08 in WC 12 in from the heater outlet at all firing conditions 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 22 Vent Terminal Location NOTE During winter months check the vent cap and make sure no blockage occurs from build up of snow Condensate can freeze on the vent cap Frozen condens
35. em for proper func tion deterioration or leakage 4 Check that heater area is free from combustible materials gasoline and other flammable vapors and liquids 5 Check for and remove any obstruction to the flow of combustion or ventilation air to heater 6 Follow pre start up check in the Initial Start up section 7 Visually inspect burner flame Should see light blue flame Visually inspect hot surface igniter for damage cracking or debris build up 8 Check operation of safety devices Refer to manu facturer s instructions 9 Follow oil lubricating instructions on circulator if required Over oiling will damage circulator Water lubricated circulators do not need oiling 10 To avoid potential of severe burn DO NOT REST HANDS ON OR GRASP PIPES Use a light touch return piping will heat up quickly 11 Check blower and blower motor Clean and oil as necessary 12 Check for piping leaks around circulators relief valves and other fittings Repair if found DO NOT use petroleum based stop leak 13 Check air filter and replace if necessary Daily 1 Check that heater area 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 ba
36. etting of 4 0 in WC for natural gas and 10 5 in WC for propane gas Fig 27 Gas Pressure Switch 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 28 Low Water Cut Off sn LON NaH L AYT30 dnd 9 HIHI A t JHL AS A kag L pe DODOOOD0000G Ww 9 1 TT Take ae SALON wiano WA ara I Ya aha re i r t I I whe I t I I Aa 1 oso ae L mete ane ra nr a BOY O Huo 0086 NOL INS waa M 39MM m lt A T a N l ul A O lt fa lt a JOULNOD ONIOWIS MVdAVS omy ony 1 9
37. for Gas Burning Appliances and Equipment or applicable pro visions of local building codes 10 FEET OR LESS I 2 MIN T a VENT CAP VENT PIPE bS COMBUSTION AIR FILTER BOILER UNIT Fig 18 Natural Draft Vertical Venting Category l Air Inlet Max Length feet HD201 6 HD251 6 Vent lengths are based on a lateral length of 2 feet Refer to the latest edition of the NFGC for further details ANSI 2223 1 Table J Natural Draft Vertical Venting 25 Natural Draft Vertical Venting System 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 neg ative draft must be within the range of 0 01 in to 0 08 in WC as measured 12 in from the appliance flue outlet to ensure proper operation Vent material must be listed by a nationally recognized test agency The maximum and minimum venting length for Category appliance shall be determined per the lat est edition of the NFGC U S or B149 Installation Code Canada The diameter of vent flue pipe should be sized accord ing to Part 11 of the latest edition of the NFGC U S and part 7 and appendix B of the B149 Installation Code Canada The minimum flue pipe diameter for conventional negative draft venting using double wall B type vent is 4 for HD101 and HD151 5 for HD201
38. for details CAUTION This heater requires forced water circulation when the burner is operating See minimum and maximum flow rates Severe damage will occur if the heater is operated without proper water flow circulation BEFORE INSTALLATION Raypak strongly recommends that this manual be re viewed 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 man ual Installation and service must be performed by a qualified installer service agency or the gas supplier If after reviewing this manual you still have questions which this manual does not answer please contact your local Raypak representative or visit our website at www raypak com Thank you for purchasing a Raypak product We hope you will be satisfied with the high quality and durability of our equipment Product Receipt WARNING Pump motors should NOT be supported by any type of stand or support from above due to possible misalignment of pump and motor which may occur On receipt of your heater it is suggested that you visu ally 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 Next remove the heater from the shipping packaging Report any damage to
39. g 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 Water Time to Produce Serious Temp Burn 120 F More than 5 minutes 125 F 1 1 2 to 2 minutes 130 F About 30 seconds Table courtesy of The Shriners Burn Institute Table B Time to Produce Serious Burn The temperature of the water in the heater can be reg ulated by using the optional temperature control To comply with safety regulations the optional tempera ture control will be 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 control and turn the wheel to the desired setting See Fig 6 lt l _ ADJUSTMENT SCREW Fig 6 Temperature Control CAUTION Hotter water increases the risk of scald ing There is a hot water scald potential if the thermostat is set too high 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 latest edi tion NFGC National Electrical Code ANSI NFPA 70 latest edition NEC Standard for Controls and Safety Devices for Automatically Fired Heaters ANSI ASME CSD 1 when required CSD 1
40. h an integral combustion air filter This filter will reduce the amount of particulates passed through the combustion system and heat exchanger but will not protect against chemical inside air contamination See Appendix The filter must be checked periodically to verify that adequate combus tion air is being supplied to the heater See the Maintenance section of this manual for information on checking the filter and establishing service intervals 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 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 com ply with the requirements of the NFGC U S and B149 Canada and all local codes CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty See the Appendix Direct Combustion Air If outside air is drawn through the intake pipe directly to the unit for combustion 1 Install combustion air direct vent in accordance with the venting section of this manual Provide adequate ventilation of the space occu pied by the heater s by an opening s for ventilation air at the highest practical point com municating with the outdoors The
41. he instructions To Turn Off GAS INLET q Gas To Appliance and call your service technician or gas supplier B WI IGIISIZIIGCUGIUII IrorunNoFF GAS TO APPLIANCE aes 1 Set the thermostat to the lowest setting 4 Turn gas control knob clockwise to OFF Or push switch to OFF 2 Turn off all electrical power to the appliance if service is to be performed 5 Replace heater door panel 3 Remove heater door panel ITE RODGERS 37 Check the Gas Supply Pressure 1 Slowly turn on main gas shut off valve 2 Read the gas supply pressure from the manome ter minimum supply pressure is 4 in WC recommended supply is 7 in WC for natural gas minimum 11 0 in WC for LP gas 3 If pressure is gt 14 in WC turn off the valve 4 Check if the service regulator is installed and or adjust the service regulator Start Up Blower Adjustment 1 Connect manometer to the plugged side of the tee 2 Close manual firing valve 3 Turn power on 4 Check manometers attached to fan pressure switch This LO speed pressure reading should be 0 2 in WC for models HD101 and HD151 0 3 in WC for models HD201 HD401 If not adjust the air shutter on the blower to attain the correct value See air shutter adjustment page 7 5 Turn power off 6 Reinstall rubber plug on tee Main Burner Adjust
42. ials Do not locate adjacent to any window door walk way or gravity air intake The vent must be located a minimum of four 4 feet horizontally or four 4 feet below or one 1 foot above such areas Install above grade level and above normal snow levels Vent must be at least 3 feet above any forced air inlet located within 10 feet Adjacent brick or masonry surfaces must be pro tected with a rust resistant sheet metal plate Multiple Outdoor Vent installations require a four 4 feet clearance between vent assemblies NOTE Condensate can freeze on the vent assembly Frozen condensate on the vent assembly can result in a blocked flue condition The vent assembly must be furnished by the heater manufacturer in accordance with its listing CONTROLS 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 heater controls Failure to do so may result in heater malfunction property damage personal injury or death CAUTION This appliance has provisions to be connected to more than one 1 supply source To reduce the risk of electric shock disconnect all such connections
43. instructions in the Operation section 11 High limit control set to design temperature requirements of system For multiple zones flow adjusted as required in each zone 12 Heater cycled with thermostat Raise to highest setting and verify heater goes through normal start up cycle Reduce to lowest setting and verify heater goes off 13 Observed several operating cycles for proper operation 14 Set room thermostat or tankstat to desired temper ature 15 Reviewed all instructions shipped with this heater with owner or maintenance person returned to envelope and given to owner Air Filter Inspection Removal 1 Turn power off 2 Locate the Air Filter panel below the air intake duct Fig 32 Locate the Air Filter Panel 3 Remove the 4 screws holding the panel in place Fig 33 Remove the Screws and Panel 4 Pull the air filter out for inspection Replace if nec essary Fig 34 Inspect the Air Filter 5 When replacing note the direction of the air flow defined on the side of the filter The arrow should be pointing downward 6 Replace the panel and screws before operating 41 Heat Exchanger Removal Refer to Fig 35 for the following procedure 1 Before beginning make sure the heater is cool to the touch Shut water gas and electricity off close valves and relieve pressure then remove the
44. 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 31 blockage from snow The vent cap must have a mini mum 3 foot clearance from the air inlet opening Outdoor Installation Outdoor models are self venting when installed with the factory supplied vent assembly and air intake cover and require no additional vent piping This spe cial vent assembly is provided with the heater in accordance with CSA requirements It must be installed directly on the heater See the Venting sec tion for correct clearances Care must be taken when locating the outdoor unit because the flue gases discharged from the vent assembly can condense as they leave the assembly Improper location can result in damage to adjacent structures or building finish For maximum efficiency and safety the following precautions must be observed a Outdoor models must be installed outdoors and must use the outdoor vent assembly and air intake cover supplied by the manufacturer 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 mater
45. isting stem spring assembly 4 Insert the replacement stem spring assembly 5 Replace the pressure regulator cover assembly and tighten screws 6 Mount conversion labels on the gas valve 9 Fig 31 Gas Type Conversion on Honeywell Valve Safety Inspection Replace main gas manifold adjustment screw cap Check all thermostats and high limit settings During the following safety checks leave manome ters hooked up check and record Ifother gas fired equipment are in the room and on same gas main check all pressures on the Hi Delta SS with all other equipment running Check thermostats for ON OFF operation Check High limits for ON OFF operation While in operation check flow switch operation Check the low gas pressure switches For proper adjustment if available use the attached manometers to set pressure The scales on the switch are approximate only Low gas pressure switch optional must be set at 3 5 in WC for nat ural gas and 10 5 in WC for LP gas High gas pressure switch optional at 1 in WC above manifold pressure Insert ignition control lockout tests as safety check Follow Up Safety checks must be recorded as performed Turn unit on After main burner ignition Check Manometer s for proper reading s Cycle unit several times and recheck readings Re analyze with unit running record or print results Remove all Manometers and replace hose replace all gas pressure caps Check for gas
46. mbustion Air Supply Water Piping Hydronic Heating Domestic Hot Water Piping Gas Supply Electrical Power Connections Venting Outdoor Installation CONTROLS Ignition Control Module Modulating Temperature Control Optional High Limit Manual Reset High Limit Auto Reset Optional co cO O O 1 t Ot O QI A CONTENTS Flow Switch High and Low Gas Pressure Switches Optional Low Water Cut Off Optional WIRING DIAGRAM MODELS HD101 HD401 HD TROUBLESHOOTING PRE START UP Filling System Heating Heaters Domestic Hot Water Heaters Inspect Venting System Pre Start Up Check INITIAL START UP Tools Needed Preparation for Start Up Start Up Main Burner Adjustment Gas Valve Adjustment Gas Type Conversion on Valve Safety Inspection Follow Up POST START UP CHECK Air Filter Inspection Removal Heat Exchanger Removal MAINTENANCE Suggested Minimum Maintenance Schedule APPENDIX Inside Combustion Air Contamination WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe personal injury death or substantial property damage if ignored Indicates the presence of hazards or unsafe practices which could cause severe personal injury death or substantial property damage if ignored Indicates special instructions on installation operation or maintenance which Indicates the presence of hazards or unsafe practices which could ca
47. ment 1 Turn off unit 2 Open manual firing valve 3 Turn on the unit wait 15 seconds and the igniter should glow There s a 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 tap See gas valve details on page 7 This should read 3 0 in 0 3 in WC HI and 1 0 in 0 1 in WC LO for natural gas or 10 0 in 0 1 in WC HI and 3 5 in 0 1 in WC LO for propane gas If the pressure reading differs by more than the tol erance given adjust the gas valve accordingly See gas valve adjustment section below for instructions Gas Valve Adjustment HI or ON OFF 2 9 3 1 in WC 9 9 10 1 in WC 38 0 9 1 1 in WC 3 4 3 6 in WC Table N Manifold Pressures Honeywell Gas Valve 1 While the heater is running remove plastic cap located behind ON OFF knob 2 Locate the HI or LO screw to adjust 3 Using a small flat screwdriver turn clockwise to increase and counterclockwise to decrease mani fold pressure See nominal gas valve manifold settings in Table N above 4 Replace plastic cap when pressure is set White Rodgers Gas Valve 1 While the heater is running locate the HI or LO cap located adjacent to ON OFF switch 2 Remove the appropriate cap 3 Using a flat screwdriver
48. n venting sys tem the common venting system should be re sized to approach the minimum size as deter mined using the appropriate tables in Appendix G in the NFGC US and Appendix B of the B149 Installation Code Canada Vent Size inches Max Venting Length feet Table K Horizontal Thru Wall Venting Category III Horizontal Thru wall Venting System Category III Installation These installations utilize the heater mounted blower to vent the combustion products to the outdoors Combustion air is taken from the space and the vent is installed horizontally through the wall to the outdoors Adequate combustion and ventilation air must be sup plied in accordance with the NFGC or in Canada the B149 Installation Code The total length of the horizontal thru wall exhaust vent system should not exceed one hundred 100 feet in length If horizontal run exceeds 100 feet an appro priately sized extractor must be used Each elbow used is equal to ten 10 feet of straight pipe This will allow installation in one of the four following combina tions 100 of straight flue pipe 90 of straight flue pipe and one elbow 80 of straight flue pipe and two elbows 70 of straight pipe and three elbows 60 of straight pipe and four elbows The vent cap is not considered in the overall length of the venting system The vent must be installed to pre vent the flue gas leakage Care must be taken during assembly to en
49. nd B149 Installation Code Canada The connection from the appliance exhaust vent to the stack must be as direct as possible and should be the same as or larger than the vent outlet The vent must be installed to prevent accumulation of condensate and where necessary have means provided for drainage of condensate 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 termi nal 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 phys ical damage or separation of joints Vertical Direct Vent Termination The exhaust vent terminal should be vertical and should terminate outside the building at least two 2 feet above the highest point of the roof within 10 feet The vent cap should have a minimum clearance of four 4 feet horizontally from and in no case above or below unless a four 4 foot 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 consis tent with the NFGC or in Canada the B149 Installation Code Gas vents supported only by flash ing and extended above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads The vertical direct vent cap
50. ndensate production in the vent Category Ill 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 21 See Table H for appliance category requirements for the Hi Delta NOTE For additional information on appliance categorization see appropriate ANSI Z21 Standard and the NFGC U S or B149 Canada or applicable provisions of local building codes Determination of Appliance Category for Venting Purposes and Venting Arrangements 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 Ill or IV vent system Using improper venting materials can result in personal injury death or property damage Exhaust Configuration Combustion Air Supply Vertical Natural Draft Venting From Inside Building Non Direct Venting Horizontal Thru wall Venting Vertical Venting From Outside Building Direct Venting Horizontal Thru wall Venting Venting Category As defined in the latest edition of the NFGC or in Canada the B149 Certified Appliance Material Combustion Air Inlet Material Type B or any Category Venting Syst
51. ntake installed above This type of installation can cause non warrantable problems with components and poor operation of the unit due to the recirculation of flue products Multiple direct vent caps should be installed in the same horizontal plane with a three 3 foot 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 WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would 28 jeopardize the safety and health of inhabitants The flue exhaust direct vent cap must be furnished by the heater manufacturer in accordance with its listing Use only the special gas vent pipes listed for use with Category IIl gas burning heaters such as the stainless steel 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 manufacturers installation instructions carefully Z y INTAKE Z VENT 36 MIN COMBUSTION AIR FILTER 12 MIN f 7 f Fig 20 Direct Vent Horizontal Thru Wall Venting Category III i Max Combustion Appliance eomitied Vent Size Venting Air Intake Air Inlet Category Size inches Venting Material inches Length Pipe feet
52. o case above or below unless four 4 feet horizontal distance is maintained from elec tric meters gas meters regulators and relief equipment Terminate vent at least six 6 feet away from adja cent walls DO NOT terminate vent closer than five 5 feet below roof overhang 24 The vent terminal of a direct vent appliance with an input over 50 000 BTUH per hour shall require a 12 inch vent terminal clearance Terminate vent at least one 1 foot above grade including normal snow line Multiple direct vent installations require a four 4 foot clearance between vent caps Installations in Canada Refer to latest edition of CAN CGA B149 A vent shall not terminate a Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings Less than 7 ft 2 1m above a paved sidewalk or paved driveway located on public property Within 6 ft 1 8m of a mechanical air supply inlet to any building Above a meter regulator assembly within 3 ft 914mm horizontally of the vertical center line of the regulator Within 6 ft 1 8m of any gas service regulator vent outlet Less than 1 ft 305mm above grade level Within the 3 ft 914mm of a window or door which can be opened in any building any non mechani cal air supply inlet to any building or the combustion air inlet of any other appliance Underneath a verandah porch or deck unless i the
53. of the appliance The opening shall directly communicate with the out doors or shall communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors and shall have a minimum free area of a 1 in 2 per 3000 BTUH 7 cm2 per kW of the total input rating of all equipment located in the enclosure and b Not less than the sum of the areas of all vent connectors in the confined space ral air flow from the outdoors for natural draft par tial fan assisted fan assisted or power draft assisted burners there shall be a permanent air supply opening s having a cross section area of not less than 1 in 2 per 7000 BTUH 310 mm2 per kW up to and including 1 million BTUH plus 1 in 2 per 14000 BTUH 155 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 150 mm above the floor level The duct can also Goose Neck through the roof The duct is preferred straight down 18 from floor but do not place near piping This air supply opening requirement shall be in addition to the air opening for ventilation air required in 1 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 sam
54. ottom of the enclosure The minimum dimension of air openings shall be not less than 3 in 8 cm in any direction All Air from Outdoors The confined space shall communicate with the out doors in accordance with methods 1 or 2 below The minimum dimension of air openings shall not be less than 3 in 8 cm in any direction Where ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect 1 Two permanent openings one commencing within 12 in 30 cm of the top and one commenc ing within 12 in 30 cm of the bottom of the enclosure shall be provided The openings shall communicate directly or by ducts with the out doors 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 2 per 4000 BTUH 5 5 cm2 per kW of total input rat ing 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 2 per 2000 BTUH 11 cm2 per kW of total input rating of all equipment in the enclosure One permanent opening commencing within 12 in 30 cm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 2 5 cm from the sides and back and 6 in 16 cm from the front
55. re Manually open air vent on the compression tank until water appears then close vent Domestic Hot Water Heaters Purge all air from system before lighting heater This can be normally be accomplished by opening a down stream valve Inspect Venting System 1 Check all vent pipe connections and flue pipe material 2 Ensure vent terminations are installed per code and are clear of all debris or blockage 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 One 8 0 8 16 scale manometer Two 6 0 6 12 scale manometers 7 16 open end wrench e 1 2 open end wrench Screwdriver Standard amp Phillips 3 8 open end wrench Multi meter 3 16 Allen wrench 93 32 Allen wrench Honeywell gas valve 5 32 Allen wrench Invensys gas valve 10 Torx driver w center hole Invensys gas valve NOTE Digital manometers are not recommended Preparation for Start Up WARNING Do not turn on gas at this time Check Power Supply ANAM M Wu VOLT OHM METER BLACK ciRcUIT BREAKER WHITE GREEN I GROUND ABC Fig 29 Check Power Source With volt meter at incoming power check voltage between Hot Common 120 VAC
56. relief valve Remove side inspection panels Remove screw behind inspection panels holding the jacket top down Remove the front panel Remove two additional screws holding the jacket top to the top support Disconnect vent pipe from the flue exhaust and set aside Remove jacket top then disconnect vent switch hose Remove two rows of screws holding the flue col lector to the combustion chamber Remove two additional screws located on the front combustion panel Cut any silicone holding the flue collector and heat exchanger in place Carefully lift and remove the flue collector Lift heat exchanger straight up being careful not to damage the refractory Reverse the above procedure to re install Make sure sufficient high temperature silicone sealant RTV is placed along the vertical sides of the tube sheet and flue collector FLUE COLLECTOR REMOVAL ACCESS I ACCESS PANEL REMOVAL Fig 35 Heat Exchanger Removal MAINTENAN CE heater operating efficiency Maintenance as outlined below may be performed by the owner Suggested Minimum Yearly Beginning of each heating Maintenance Schedule season Regular service by a qualified service agency and 1 Annual service call by qualified service agency maintenance must be performed to ensure maximum 42 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 syst
57. sed stop leak compounds 43 Visually inspect burner flame 3 Visually inspect venting system for proper func tion deterioration or leakage 4 Check air vents for leakage Quarterly 1 Check relief valve Refer to manufacturer s instructions on valve 2 Test low water cut off if used Refer to manufac turer s instructions 3 Check the air filter replace if necessary APPENDIX Inside Combustion Air Contamination All heaters experience some condensation during start up The condensate from flue gas is slightly acidic In most cases the pH level is not harmful to vents or drains When combustion air is contaminated by vapors from products in areas listed below the acidic levels in the condensate increase Higher acidic levels attack many materials including stainless steel commonly used in high efficiency systems The heater can use special corrosion resistant non metallic intake vent material You may however choose to use outside combustion air for one or more of these reasons installation is in an area containing 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
58. sure that all joints are sealed properly and are airtight The horizontal portions of the vent shall also be sup ported for the design and weight of the material employed to maintain clearances and to prevent phys ical damage or separation of joints The vent must be installed to prevent the potential accumulation 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 of horizontal run to the vent terminal 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 foot above ground level and above normal snow levels Multiple direct vent caps MUST NOT be installed with one combustion air inlet directly above a direct vent cap This vertical spacing would allow the flue prod ucts from the direct vent cap to be pulled into the combustion air i
59. t Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust Wear appropriate personal protective equipment including gloves safety glasses with side shields and appropriate NIOSH certified respiratory protection to avoid inhalation of airborne dust and airborne fiber particles 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 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 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
60. ting the piping connections to the heater and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based antifreeze Raypak recom mends conducting the hydrostatic test before connecting gas piping or electrical supply The temperature and pressure gauge is shipped loose for field installation Hydronic Heating Pump Selection Leaks must be repaired at once to prevent damage to the heater NEVER use petroleum based stop leak compounds In order to ensure proper performance of your boiler system you must install a properly sized pump Raypak recommends using a 20 F AT as design AT AT is the temperature difference between the inlet and outlet water when the heater is firing at full rate If a AT other than 20 F is necessary see Table E for flow rate requirements 1 Connect fill water supply Fill heater with water be sure bleed valve is open When water flows from bleed valve shut off water Close bleed valve Carefully fill the rest of the system being sure to eliminate any entrapped air by using high point vents Close feed valve Test at standard operating pressure for at least 24 hours Pressure Drop in Feet of Head Feedwater Regulator 2 Make sure constant gauge pressure has been Raypak recommends that a feedwater regulator be maintained throughout test installed and set at 12 psi minimum pressure at the highest point of system Install a check valve or ba
61. tional gas utilization equipment to the gas piping system the existing piping must be checked to determine if it has adequate capacity Gas Pressure Regulator The gas valve pressure regulator s on the heater are nominally preset at 3 in WC for natural gas and 10 0 in WC for propane gas manifold pressure The pres sure at the gas valve outlet tap measured with a manometer while in operation should be 3 0 in 0 3 in WC HI and 1 0 in 0 1 WC LO for natural gas and 10 0 in 0 1 in WC HI and 3 5 in 0 1 in WC LO for propane gas If an adjustment is needed turn the adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure 1 1 4 1 1 2 so worm wT s s s s power o oss L mor eo so reo veo soo pow ee fo fe fs mor ao fo feo fo opal mor os we 70 o so moor e e me o oes ao Natural gas 1 000 BTUH per ft3 60 specific gravity at 0 5 in WC pressure drop Propane gas 2 500 BTUH per ft3 1 50 specific gravity at 0 5 in WC pressure drop Table G Maximum Equivalent Pipe Length 18 Electrical Power Connections Installations must follow these codes National Electrical Code and any other national state provincial or local codes or regulations hav ing jurisdiction Safety wiring must be N E C Class 1 Heater must be electrically grounded as required by N E C In Canada C22 1 Th
62. total cross sectional area shall be at least 1 in 2 of free 11 area per 20 000 BTUH 111 mm2 per kW of total input rating of all equipment in the room when the opening is communicating directly with the out doors or through vertical duct s The total cross sectional area shall be at least 1 in 2 of free area per 10 000 BTUH 222 mm2 per kW of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct s In cold climates and to mitigate potential freeze up Raypak highly recommends the installation of a motorized sealed damper to prevent the circula tion of cold air through the heater during non operating hours Conventional Combustion Air Supply U S Installations All Air from Inside the Building The confined space shall be provided with TWO per manent openings communicating directly with an additional room s of sufficient volume so that the com bined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each open ing shall have a minimum free area of 1 in 2 per 1 000 BTUH 22 cm per kW of the total input rating of all gas utilization equipment in the confined space but not less than 100 in 645 cm One opening shall commence within 6 3 4 in of the top and one opening shall commence within 6 3 4 in of the b
63. use minor personal injury or product or property damage if ignored 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 Risk of electrical shock More than one disconnect switch may be required to deenergize the equipment before servicing WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING This unit contains refractory ceramic fiber RCF insulation in the combustion chamber RCF as manufactured does not contain respirable crystalline silica However following sustained exposure to very high temperatures gt 2192F the RCF can transform into crystalline silica cristabolite The International Agency for Research on Cancer IARC has classified the inhalation of crystalline silica cristabolite as carcinogenic to humans When removing the burners or heat exchangers take precautions to avoid creating airborne dust and avoid inhaling airborne fibers When cleaning spills use wet sweeping or High Efficiency Particulate Air HEPA filtered vacuum to minimize airborne dus
64. verandah porch or deck is fully open on a minimum of two sides beneath the floor and ii the distance between the top of the vent termi nation and the underside of the verandah porch or deck is greater than 1 ft 30 cm Venting Installation Tips Support piping horizontal runs at least every five 5 feet vertical runs use braces under or near elbows Follow items listed below to avoid personal injury or property damage Cut nonmetallic intake pipe with fine toothed hack saw Do not use nonmetallic intake pipe or fittings that are cracked or damaged Do not use nonmetallic intake fittings if they are cut or altered Do not drill holes or use screws or rivets in non metallic intake pipe or fittings To make metallic vent joints Do not install seams of vent pipe on bottom of runs 100 Seal all joints and seams with high temper ature silicone sealant 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 Exhaust Vent are used interchangeably Venting Configurations For heaters connected to gas vents or chimneys vent installations shall be in accordance with the section Certified Minimum Venting Material Appliance Category Equivalent Recommended on Venting of Equipment of the latest edition of NFGC or in Canada B149 Installation Code
65. water Immediately Do not try to light any appliance call a qualified service to inspect the appliance and to replace any part Do not touch any electric switch do not use any phone in your building of the control system and any gas control which has been under water Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions Ifyou cannot reach your gas supplier call the fire department CS OPERATING INSTRUCTIONS Waw 1 STOP Read the safety information above on this label GAS CONTROL KNOB _ 2 Set the thermostal to the lowest setting SONI ZONE RESIN NDE 3 Turn off all electric power to the appliance 4 This appliance does not have a pilot It is equipped with an ignition device GAS INLET f which automatically lights the burner Do not try to light the burner by hand 5 Remove heater door panel INVENSYS 6 Turn gas control knob clockwise to OFF Or push switch to OFF 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step f f GAS CONTROL SWITCH KNOB 8 Turn gas control knob counter clockwise to ON Or push switch to ON al SHOWN IN ON POSITION 9 Replace heater door panel 10 Turn on all electric power to the appliance 11 Set thermostat to desired setting f 12 If the appliance will not operate follow t

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