Raypak Hi Delta Hot Water Boiler- 9 HP Mfg: Raypak Stock No. SPPP289B.6 Model: H3-302A Serial No. 9904158613 Raypak Hi Delta Hot Water Boiler- 9 HP. Model: H3-302A. S/N: 9904158613. Low pressure boiler. Capacity: 51 gpm. MAWP (water): 160 psi. Input: 300,00 Btu/hr. Output: 252,000 Btu/hr. Minimum relief valve capacity: 400 lbs/hr. Heating surface area: 40 sq. ft. Maximum water temperature: 250 °F. Ideal for hydronic heating in commercial and industrial environments.
CATALOG NO. Effective: Replaces: 1000.501A 4-1-05 3-15-05 INSTALLATION AND OPERATING INSTRUCTIONS Models 302A-902A Types H, WH, & P FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.
Table of Contents WARNINGS................................................................4 SECTION D Start-up..............................................45 SECTION A Before Installation ..............................5 Pre Start-up............................................................45 Product Receipt .......................................................5 Start-Up .................................................................46 Model Identification ......................................
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.
SECTION A Before Installation Raypak strongly recommends that this manual be reviewed thoroughly before installing your Hi Delta heater. Please review the General Safety information in Section B 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 gas supplier.
SECTION A: Before Installation Ratings and Certifications Component Locations Standards: • • • • ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Hot Water Boilers CAN 3.1 - latest edition, Industrial and Commercial Gas-Fired Package Boilers ANSI Z21.56 · CSA 4.7 - latest edition Gas-Fired Pool Heaters ANSI Z21.10.3 · CSA 4.3 - latest edition Gas Water Heaters All Raypak heaters are National Board Approved, and design-certified and tested by the Canadian Standards Association (CSA) for the U.S.
SECTION A: Before Installation General Information Quantity of Vent Size (in.) Model No. Burners Gas Valves Blowers Flue Intake 302A 6 1 1 5 6 402A 8 1 1 6 6 502A 10 2 1 6 6 652A 13 2 1 8 6 752A 15 2 1 8 6 902A 18 3 1 8 6 Table A: Basic Data Model No.
SECTION A: Before Installation 8
SECTION B General Safety To meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the recommended initial setting for the control is 125°F. Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat.
SECTION B: General Safety Time/Temperature Relationships in Scalds The following 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 Temp.
SECTION C Installation 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. Installation Codes Installations must follow these codes: • • • • • Local, state, provincial, and national codes, laws, regulations and ordinances National Fuel Gas Code, ANSI Z223.
SECTION C: Installation operation or service (circulator replacement, control replacement, etc.). 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 12 in. on the water connection side.
SECTION C: Installation 1. Remove the four screws and the dust cover from the right-hand side of the heater. 2. Remove the four screws and the air filter bracket from the left-hand side of the heater. 3. Reverse the components and reattach in the new location, making sure that the air filter locking bracket is on the bottom. (The air filter locking bracket is reversible.) Direct Vent If outside air is drawn through the intake pipe directly to the unit for combustion: Fig.
SECTION C: Installation heater area. See Section H of this manual regarding air contamination. All Air from Outdoors The confined space shall communicate with the outdoors in accordance with one of the methods below. The minimum dimension of air openings shall not be less than 3 in. (76 mm) in any direction. Where ducts are used, they shall be of the same cross-sectional area as the net free area of the openings to which they connect.
SECTION C: Installation straight down 18 in. (450 mm) from the floor, but not near piping. Canadian Installations CAUTION: All combustion air must be drawn from the air outside of the building; the mechanical equipment room must communicate directly with the outdoors. 1. 2. 4. Water Piping Ventilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practical point communicating with the outdoors.
SECTION C: Installation 10. Install NEW red beveled O-rings flush against both tube sheets with the bevel facing outward. 1. Connect fill water supply. With bleed valve open, fill heater with water. When water flows from bleed valve, shut off water. Close bleed valve. Carefully fill the rest of the system, making sure to eliminate any entrapped air by using high-point vents. Close feed valve. Test at standard operating pressure for at least 24 hours. 2.
SECTION C: Installation Cold Water Starts Temperature & Pressure Gauge Frequent (more than once a week) cold water starts, wherein the inlet water temperature remains below 105ºF (41ºC) for more than 7 minutes, must have cold water start protection. Known protection methods consist of mixing heated outlet water with the inlet water with a bypass to raise the inlet to 105ºF (41ºC) or higher.
SECTION C: Installation The piping system of a hot water heater 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 heater water during the cooling cycle. It is highly recommended that the piping be insulated.
SECTION C: Installation Domestic Hot Water When designing the water piping system for domestic hot water applications, water hardness should be considered. Table H indicates the suggested flow rates for soft, medium and hard water. Water hardness is expressed in grains per gallon. Potable Water and Space Heating CAUTION: When this heater is used for both potable water and space heating, observe the following to ensure proper operation. 1. 2.
SECTION C: Installation slowly throttle Valve B closed to increase the inlet water temperature to 105°F. heat exchanger. The pump also serves to circulate water through the heater from the main system piping. To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return water line, upstream of the heater. This will ensure that the heater will be energized at the right time.
SECTION C: Installation heater and any piping of all water that may experience below-freezing temperatures. pH of Water pH is a measure of relative acidity, neutrality or alkalinity. Dissolved minerals and gases affect water’s pH. The pH scale ranges from 0 to 14. Water with a pH of 7.0 is considered neutral. Water with a pH lower than 7 is considered acidic. Water with a pH higher than 7 is considered alkaline. A neutral pH (around 7) is desirable for most potable water applications.
SECTION C: Installation formation in the heat exchanger. Heat exchanger failure due to total dissolved solids in excess of 2,500 ppm is a non-warrantable condition. Raypak offers basic temperature guidelines for operation of a potable water heater on normal to moderate levels of hardness and solids but levels of hardness and total dissolved solids beyond normal limits for operation will require special setup and operation.
SECTION C: Installation 9. Install a coupling, union and sediment trap onto the right-hand end of the main gas line and then install the gas line, making sure that a manual shut-off valve has been installed within 10 ft of the heater. Electrical Power Connections Installations must follow these codes: • 10. Replace the left and right front panels on the heater. • • Gas Supply Pressure A minimum of 5.0 in. WC and a maximum of 10.5 in.
SECTION C: Installation BLACK prior to working with any electrical connections or components. CIRCUIT BREAKER 3. 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. 4. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code. 5.
SECTION C: Installation Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components. Installer action is required to electrically enable your heater to operate after making the power connections. You must make a connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connections. This will be done based on the controller option selected with your heater order. 1.
SECTION C: Installation 3. For single-stage controller connections, attach the stage 1 connections on heater 1 to the tankstat per Fig. 23. Venting NOTE: For 87%-efficiency boilers, see special instructions on page 39. SINGLE STAGE TANKSTAT CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the heater.
SECTION C: Installation ate 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. CAUTION: When condensate traps are installed, condensate must be routed to an appropriate container for neutralization before disposal, as required by local codes.
SECTION C: Installation 9. Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane. 5. Remove the screws, retaining ring and rain gasket from top of heater. 6. Remove the 12 screws, flue collar and gasket from the run side of the tee located in the flue box on top of the heater. 7. Reverse the components and reattach in the new location.
SECTION C: Installation pendix B of B149.1 and .2 (Canada). The minimum flue pipe diameter for conventional negative draft venting using double-wall Type B vent is 5 in. for Model 302A, 6 in. for Models 402A and 502A, and 8 in. for Models 652A, 752A and 902A. NOTICE: A vent adapter (field-supplied) must be used to connect Type 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.
SECTION C: Installation dampers and other gas burning appliances to their previous conditions of use. Common Venting System Manifolds that connect more than one heater to a common 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 common vent be less than the area of the largest heater exhaust outlet. 7.
SECTION C: Installation The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight. The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that: 1. The vent must be installed with a slight downward slope of not more than 1/4 inch per foot of horizontal run to the vent terminal. 2. The vent must be insulated through the length of the horizontal run.
SECTION C: Installation This type of installation can cause non-warrantable problems with components and poor operation of the heater due to the recirculation of flue products. Multiple direct vent caps should be installed in the same horizontal plane with a 4 ft clearance from the side of one vent cap to the side of the adjacent vent cap(s). The total length of the through-the-wall flue cannot exceed 40 equivalent ft in length for the flue outlet. Each elbow used is equal to 10 ft of straight pipe.
SECTION C: Installation tive pressure. 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. 1. Outdoor models must be installed outdoors and must use the outdoor vent cap, flow switch cover and air intake hood available from the manufacturer (sales order option D-11).
SECTION C: Installation board damage, heater malfunction, property damage, personal injury, or death. CAUTION: This appliance has provisions to be connected to more than one supply source. To reduce the risk of electric shock, disconnect all such connections before servicing. CAUTION: Risk of electric shock: More than one disconnect switch may be required to de-energize the equipment before servicing. Fig.
SECTION C: Installation pump, and to the common connection of the flow switch. Heater Sequence of Operations 1. 2. 3. The black (hot) wire lead goes directly to the main power switch. This black toggle switch is located at the middle front of the control compartment. When the main power switch is placed in the “ON” position, the 120 VAC terminal block on the circuit board, the 120/24 VAC transformer and terminals L1 and F1 of the ignition module are powered.
SECTION C: Installation 15. After gas valve 1 opens and flame rectification is received, relay K2 (N.O.) contacts (K2a) close downstream of the stage 2 connections and then time delay relay 1 (TD1) starts a 5-second countdown.
SECTION C: Installation Fig. 31: Flow Switch Fig. 33: Low Water Cut-Off Operating Control High and Low Gas Pressure Switches The heater may be equipped with different types of operating controls. Consult the individual control data sheets supplied with your heater paperwork. See Section B for safety precautions concerning domestic hot water applications.
SECTION C: Installation Fig. 35: Fan-Proving Switch Fig.
SECTION C: Installation that a thermometer be placed into the boiler inlet piping next to the in/out header to facilitate temperature adjustment. Inlet water temperatures below 120ºF (49ºC) can excessively cool the products of combustion, resulting in condensation on the heat exchanger. 87%-Efficiency Boilers – Special Instructions NOTE: The 84%- (standard) and 87%-efficiency (optional) boilers are identical and are installed to the same requirements, except as noted in this section.
SECTION C: Installation suitability of a vent material for Category II, III or IV applications. Using improper venting materials can result in personal injury, death or property damage. 12. DO NOT extend exposed vent pipe outside of building. Condensate could freeze and block vent pipe. Vent Terminal Location Condensate Management NOTICE: During winter months check the vent cap and make sure no blockage occurs from build-up of snow or ice.
SECTION C: Installation portion of mechanical draft systems operating under a positive pressure. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in one of the four following combinations: Horizontal Through-the-Wall Venting (Category IV) • • • • 70’ of straight flue pipe 60’ of straight flue pipe and one elbow 50’ of straight flue pipe and two elbows 40’ of straight pipe and three elbows The vent cap is not considered in the overall length of the venting system.
SECTION C: Installation Use only double-wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burning boilers, such as the stainless steel Saf-T vent by Heat Fab Inc. (800-772-0739), Protech Systems Inc. (800766-3473), or Z-Flex (800-654-5600). Pipe joints must be positively sealed. Follow the vent manufacturer’s installation instructions carefully. The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is recommended that: 1.
SECTION C: Installation Direct Vent - Vertical Note: When vertical height exceeds 25 ft, consult factory prior to installation. Fig. 40: Direct Vent - Vertical Model Certified Venting Material 302A 652A 752A Vertical Venting Height* Min. Max. Combustion Air Intake Pipe Material 5” 402A 502A Vent Size 6” Category II or IV 5’ 25’ 8” Galvanized Steel, PVC, ABS, CPVC Air Inlet Max. Length** 6” 8” 100’ N/A 75’ 40’ 100’ 902A * Vent lengths are based on a lateral length of 2 ft.
SECTION C: Installation Wiring Diagram 44
SECTION D Start-up Pre Start-up WHAT TO DO IF YOU SMELL GAS: Filling System (Boilers) • • Fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal system operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. • • • Air Purge (Water Heaters) Purge all air from system before lighting heater. This can normally be accomplished by opening a downstream valve.
SECTION D: Start-up Initial Start-up Start-Up Tools Needed Blower Adjustment • • • • • (1) 12-0-12, 24” scale U-tube manometer (2) 6-0-6, 12” scale U-tube manometers (1) Screwdriver (1) Multi-meter (1) 3/16” Allen wrench 1. Turn off power. 2. Unplug cap at pressure switches and connect manometer(s) to the tee. 3. Close all manual firing valves. NOTICE: Digital manometers are not recommended. 4. Turn power on. WARNING: Do not turn on gas at this time. 5.
SECTION D: Start-up 4. If other gas-fired appliances in the room are on the same gas main, check all pressures on the Hi Delta with all other equipment running. 5. Check thermostats for ON-OFF operation. 6. Check high limits for ON-OFF operation. 7. While in operation, check flow switch operation 8. Check the low gas pressure switch. (For proper adjustment, use the attached manometers, if available, to set pressure. The scales on the switch are approximate only.
SECTION D: Start-up A to test point B and open the upstream manual gas valve. Make sure that test points A & B have been opened so as to allow gas to flow. This will bring pressure to the second valve seat. 5. Open test point C and connect a second rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up of pressure. Increasing pressure indicates a leaking gas valve. 6. Remove rubber tube and manometers. Close each test point valve as the tubes are removed. 7.
SECTION E Operation 12. If heater fails to start, verify the following: Lighting Instructions 1. Before lighting, make sure you have read all of the safety information in this manual. a. There are no loose connections or that the service switch is off. 2. Set the thermostat to the lowest setting. b. High temperature limit switch is set above water temperature. 3. Turn off all electrical power to the appliance. c. Thermostat is set above room temperature. 4.
SECTION D: Start-up 50
SECTION F Troubleshooting Turn off gas supply. Turn thermostat (controller) to call-for-heat Is there 24 VAC nominal power to the module? No Check line voltage power, low-voltage transformer, limit controller, controller and wiring No Check AMP draw at ignition module. If less than 3.1 AMP, replace HSI. Yes Is the HSI glowing (120 VAC at S1)? Yes Turn gas supply on • Is the Stage 1 light on? No • • Verify that all manual gas valves are open, and supply tubing and pressures are good.
SECTION F: Troubleshooting 52
SECTION G Maintenance Suggested Minimum Maintenance Schedule 1. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal. Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. 2. Visually inspect venting system for proper function, deterioration or leakage. 3. Check that area is free from combustible materials, gasoline, and other flammable vapors and liquids. 4.
SECTION G: Maintenance Periodically Semi-Annually 1. Check relief valve. Refer to manufacturer’s instructions on valve. 1. Recalibrate all indicating and recording gauges. 2. 2. Test low water cut-off, if used. Refer to manufacturer’s instructions. Check flame failure detection system components. (See Pilot Turn-Down Test Procedure, page 47.) 3. 3. Clean screen and air filter in intake. Check firing rate control by checking the manifold pressure. (See “Main Burner Adjustment” on page 46.) 4.
SECTION H Appendix Inside Air Contamination • All heaters experience some condensation during startup. The condensate from flue gas is acidic. Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high efficiency systems. The heater can be supplied with corrosionresistant, non-metallic intake air vent material.
LIMITED PARTS WARRANTY HI DELTA – TYPES H AND WH MODELS 302A–902A SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater 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. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
LIMITED PARTS WARRANTY HI DELTA – TYPE P MODELS 302A–902A SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater 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. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A.
