INSTALLATION & OPERATING INSTRUCTIONS Models 122–322 L W Types H, WH & P 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.
Rev. 9 reflects the following: Changes to: The text in the BEFORE INSTALLATION section on page 5; the text in paragraph one of the GENERAL SAFETY section on page 8; the text in paragraph one of the Outdoor Installations section on page 10; Table E on page 10; the wiring diagram on page 35. California Hot Water Supply, Inc.
CONTENTS WARNINGS 4 Pay Attention to These Terms 4 BEFORE INSTALLATION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 Time/Temperature Relationships in Scalds 8 GENERAL SAFETY 8 Clearances 9 Equipment Base 9 INSTALLATION 9 Installation Codes 9 Combustion and Ventilation Air 11 Conventional Combustion Air Supply 11 Water Piping 12 Hydronic Heating 13 Domestic Hot Water Piping 15 Pool Heating 17 Gas Supply 17 Ele
WARNINGS - Pay Attention to These Terms DANGER: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
BEFORE INSTALLATION Raypak strongly recommends that this manual be reviewed 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 manual). Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Component Locations COMBUSTION AIR INTAKE FLUE EXHAUST Fig. 1: Component Locations—Back PRESSURE RELIEF CONNECTION WATER OUTLET GAS CONNECTION WATER INLET VIEW PORT Fig. 2: Component Locations—Left Side HI LIMITS HI-LIMITS Fig# 9399 Panels removed for clarity Fig. 3: Component Locations—Front California Hot Water Supply, Inc.
General Information Model No. Quantity of Vent Size (in.) Burners Gas Valves Blowers Flue Intake 122 3 2* 1 4 5 162 4 2* 1 5 5 202 5 2* 1 5 5 242 6 2* 1 5 5 322 8 2* 1 6 5 *Second valve located inside air plenum Table A: Basic Data Model Burners per Valve No. A B Stages % Fire at Stage 1 2 1 2 122 2 1 A AB 66 100 162 3 1 A AB 75 100 202 3 2 A AB 60 100 242 4 2 A AB 66 100 322 5 3 A AB 63 100 Table B: Manifold Data Fig.
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 recommended initial setting for the temperature control is 125°F. Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat.
The temperature of the water in the heater can be regulated by using the temperature control. To comply with safety regulations, the temperature control is 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). Equipment Base The heater should be mounted on a level, structurally sound surface.
FRONT VIEW TOP VIEW Fig. 7: Minimum Clearances from Combustible Surfaces—Indoor Installations When installed according to the listed minimum clearances from combustible construction, these heaters can still be serviced without removing permanent structural construction around the heater. However, for ease of servicing, we recommend a clearance of at least 24 in. in front, and at least 36 in. on the water connection side.
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 Indoor Units The heater must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation.
Btu per hr (11 cm2 per kW) of total input rating of all equipment in the enclosure. 2. 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 of the appliance.
Hydrostatic Test Low Temperature System 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 operating pressure. However, Raypak does recommend hydrostatically testing 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.
Fig. 9: Single Boiler—Low Temperature Application (Heat Pump) Primary/Secondary Piping Fig. 10: Dual Boiler—Primary/Secondary Piping California Hot Water Supply, Inc.
Piping—Heating Boilers Three-Way Valves All high points should be vented. Purge 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 connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler.
Fig. 11: Single Heater—Domestic Hot Water with One Storage Tank California Hot Water Supply, Inc.
Pool Heating Winterizing Your Heater When heaters installed outdoors in freezing climate areas are to be shut down for the winter, please observe the following procedure: CAUTION: Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation. Improper flow control can damage the heater. Uncontrolled flow (too high) or restricted flow (too low) can seriously damage the heater.
GAS FLOW MANUAL SHUT OFF VALVE SUPPLIED BY OTHERS SEDIMENT TRAP EXTENTS OF UNIT ENCLOSURE MANUAL SHUT OFF VALVE GAS FLOW SUPPLIED BY OTHERS EXTENTS OF UNIT ENCLOSURE SEDIMENT TRAP UNION TO BURNERS TO BURNERS Fig. 12: Sediment Trap Orientation Gas Supply Connection CAUTION: The heater and its manual shutoff valve must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 PSIG (3.45 kPa).
Electrical Power Connections Installations must follow these codes: · · · · National Electrical Code and any other national, state, provincial or local codes or regulations having 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 The heater is wired for 120 VAC, 12 AMPS. The voltage is indicated on the tie-in leads. Consult the wiring diagram shipped with the heater in the instruction packet.
Fig. 14: Single Stage and 2-Stage Tankstat Electrical Connections—Domestic Hot Water 1. For Pool and Closed Loop Water Source Heat Pump applications, your heater should be configured to operate in an ON/OFF firing mode. This means that you will connect a single-pole control to stage one of stage selector (Terminals 4 & 5). Then jumper the remaining firing stages. For example, if your heater is a 162, you will jumper stage two. Then your heater will either be on at full fire, or it will be off.
Venting SINGLE STAGE TANKSTAT 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. 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 Category I.
Combustion Air Supply From Inside Building (Non-Direct Venting) From Outside Building (Direct Venting) Exhaust Configuration Venting Category Certified Appliance Material Vertical Natural Draft Venting I Type B or and Category I Venting System* Horizontal Thru-wall Venting III Stainless Steel (Gas Tight) Vertical Venting I Type B or and Category I Venting System* Horizontal Thru-wall Venting III Stainless Steel (Gas Tight) Combustion Air Inlet Material Galvanized Steel PVC ABS CPVC *As d
Fig. 17: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 1 2 t TT * 2 U.S. Installations Canadian Installations A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 ft (1.
f) over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. Where local experience indicates that condensate is a problem with Category I and III appliances, this provision shall also apply. g) The vent terminal of a direct vent appliance with an input over 50,000 Btu per hour shall require a 12-inch vent terminal clearance.
Venting Installation Tips on, Venting of Equipment, of the latest edition of NFGC, or in Canada, B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of local building codes. Support piping: · · · horizontal runs- at least every five (5) feet. vertical runs - use braces: under or near elbows 10 FEET OR LESS Follow items listed below to avoid personal injury or property damage. · · · · 2' MIN. 2' MIN. Cut nonmetallic intake pipe with fine-toothed hacksaw.
Natural Draft Vertical Venting System Installation CAUTION: Listed vent cap terminal must be used and sized adequately to evacuate the flue products from the heaters. 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 negative draft must be within the range of -.01 in. to -.08 in. WC as measured 12 in. from the appliance flue outlet to ensure proper operation.
12" MIN INSULATED EXHAUST VENTING FLUE EXHAUST VENT CAP COMBUSTION AIR FILTER 12" MIN BOILER UNIT Fig. 19: Horizontal Thru-Wall Venting (Category III) each appliance. Adjust thermostat so appliance will operate continuously. e) 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.
Horizontal Thru-wall Venting System (Category III) Installation Horizontal Thru-wall Direct Vent Termination These installations utilize the heater-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the outdoors. Adequate combustion and ventilation air must be supplied to the mechanical room in accordance with the NFGC or, in Canada, the B149 Installation Code.
12" VENT PIPE VENT CAP INTAKE VENT 36" MIN. INTAKE VENT COMBUSTION AIR FILTER 6" 12" MIN. BOILER UNIT Fig. 20: Direct Vent Horizontal Thru-Wall Venting (Category III) Model No. Appliance Category Certified Venting Material 122 162 202 242 Vent Size (inches) 4 III Stainless Steel (Gas Tight) 322 5 6 Max. Venting Length (feet) Combustion Air Intake Pipe Material 40 Subtract 10 ft per elbow, Max. two elbows Galvanized Steel PVC ABS CPVC Air Inlet Size (inches) Max.
Horizontal Thru-wall Direct Vent System (Category III) Installation Horizontal Thru-wall Direct Vent Termination These installations utilize the heater mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors. 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.
36" VENT CAP 36" MIN. 12" MIN. VENT PIPE INTAKE VENT COMBUSTION AIR FILTER BOILER UNIT Fig. 21: Direct Vent—Vertical Venting (Category I) Model No. Appliance Category Certified Venting Material 122 162 202 242 Vent Size (inches) Min./Max. Vertical Venting Height (feet) Combustion Air Intake Pipe Material 5/25 Galvanized Steel PVC ABS CPVC Air Inlet Size (inches) Max. Air Intake Length (feet) 5 40 Subtract 10 ft per elbow, Max.
Vertical Direct Vent System Installation blockage from snow. The vent cap must have a minimum 3 foot clearance from the air inlet opening. 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.
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.
Flow Switch Low Water Cut Off (Optional) Dual-purpose control shuts off heater in case of pump failure or low water flow. Mounted and wired in series with the main gas valve. Check with Manufacturer for proper paddle size. Utilize correct paddle size for proper operation. The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe.
WIRING DIAGRAM—MODELS 122–322 California Hot Water Supply, Inc.
PRE-START-UP 4. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not turn by hand, do not try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion. 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 pressure.
6. Reconnect fan pressure switch tubing to original position. WARNING: If Common - Ground is > 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. Main Burner Adjustment 1. Turn off unit. Attach Manometers to Measure Pressures • • • 2. Open manual firing valve. Attach 24" scale manometer to the first main gas shut-off valve pressure tapping.
Follow-Up • • · · Safety checks must be recorded as performed. Turn unit on. 10. To restart system, follow lighting instructions in the Operation section. After main burner ignition: • • • • • off immediately. Wait 5 minutes. Reconnect combustion air pressure switch, burner should reignite after pre-purge time delay. Check Manometer for proper reading. Cycle unit several times and recheck readings Re-analyze with unit running record or print results.
8. Turn on all electric power to the appliance. 9. Set thermostat to desired setting. The appliance will operate. The igniter will glow after the prepurge time delay (15 seconds). After igniter reaches temperature (45 seconds) the main valve will open. System will try for ignition three (3) times. If ignition is not sensed, lockout will commence. 10. If the appliance will not operate, follow the instruction "To Turn Off Gas To Appliance", and call your service technician or gas supplier. 11.
Monthly: Products causing contaminated combustion air: 1. Check for piping leaks around circulators, mixing valves, relief valves, and other fittings. If found, repair at once. DO NOT use petroleum-based stop leak compounds. • • • • • • • • • • • • 2. Visually inspect burner flame. 3. Visually inspect venting system for proper function, deterioration or leakage. 4. Check air vents for leakage. Quarterly: 1. Check relief valve. Refer to manufacturer’s instructions on valve. 2.
LIMITED PARTS WARRANTY COMMERCIAL BOILERS TYPE HI-DELTA SIZES 122 TO 322 MODELS H AND WH SCOPE: Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A. California Hot Water Supply, Inc.
