CATALOG NO. 1000.50K Effective: 08-01-03 Replaces: 01-15-03 INSTALLATION AND OPERATING INSTRUCTIONS Models 302-902 Type H, WH, & P FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
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DANGER: Make sure the gas on which the boiler will operate is the same type as that specified on the boiler model and rating plate. WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the boiler. Instead, shut off the gas supply at a location external to the appliance. WARNING: Do not use this boiler if any part has been under water.
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.
MODEL IDENTIFICATION The model identification number and boiler serial number are found on the boiler data plate located on the left inside jacket of the boiler. The model number will have the form H3 0752 or similar depending on the boiler size and configuration. The first character of the model number identifies application (H = Hydronic Heating System, W = Hot Water Supply System, P = Pool Application). The second character identifies the firing mode (3-two stage firing).
HIGH DELTA COMPONENT LOCATION Flue Exhaust Combustion Air Filter (Inlet) Optional Combustion Air (Inlet) Alternate Flue Connection BACK Electrical Connection Gas Supply Connection Pressure Relief Connection Water Inlet View Port Water Outlet Temperature and Pressure Gauge LEFT-SIDE Gas Train Operational Center Control Combustion Air Blower Pressure Relief Valve Igniter Heat Exchanger FRONT Remote Sensor Burner Group 6 Fig.
General Information 7
SECTION B: BOILER INSTALLATION INSTALLATION CODES Installations must follow these codes: · Local, state, provincial, and national codes, laws, regulations and ordinances. · National Fuel Gas Code (NFGC), ANSI Z223.1- latest edition. · National Electrical Code (NEC), ANSI/NFPA 70 - latest edition. · Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required. · For Canada only: CAN/CGA B149.1 and .2 Installation Code and C.S.A. C22. 1 C.E.C. Part 1.
CLEARANCES TABLE 1 INDOOR INSTALLATION MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES Boiler Side Floor Rear Water Side Other Side Top Front Vent Boiler Size 302-902 See Note 1 1" 12” 1" 1" 1" 2" Note 1. Do not install on carpeting. 12" 1" 1" 1" TOP VIEW Fig. #9221.1 FRONT VIEW When installed according to the listed minimum clearances from combustible construction materials, the Raypak heaters can still be serviced without removing permanent structural construction around the heater.
OUTDOOR INSTALLATIONS Raypak Hi Delta Boilers are design certified for outdoor installation. Boilers must not be installed under an overhang that is less than three (3) feet from the top of the boiler. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from boilers installed under overhangs.
SECTION C: COMBUSTION AND VENTILATION AIR COMBUSTION AND VENTILATION AIR (Indoor Units) The boiler must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation. Combustion air can be supplied via conventional venting, where combustion air is drawn from the area immediately surrounding the boiler, or via direct vent, where combustion air is drawn directly from outside. All installations must comply with the requirements of NFGC for U.S.
COMBUSTION AND VENTILATION AIR SUPPLY (FOR CANADA INSTALLATION) CAUTION: 1. 2. 3. 4. All combustion air has to be drawn from the air outside the building (the mechanical equipment room directly communicates with the outdoors). Ventilation of the space occupied by the boiler shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors.
SECTION D: WATER PIPING - GENERAL The boiler should be located so that any water leaks will not cause damage to the adjacent area or structures. CAUTION: This boiler requires forced water circulation when the burner is operating. See Table D-1 for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the boiler toprevent boiler operation without water circulation.
SECTION E: HYDRONIC HEATING PIPING PUMP SELECTION In order to insure proper performance of your boiler system, you must install a properly sized pump. Raypak recommends using a 20°F Delta T as design Delta T. (Delta T is the temperature difference between the inlet and outlet water when the boiler is firing at full rate). If a Delta T larger than 20°F is necessary, see Table D-1 for minimum flow rate requirements.
SINGLE BOILER - LOW TEMPERATURE APPLICATION (HEAT PUMP) PRIMARY/SECONDARY PIPING 12 Fig. #9223 DUAL BOILER PRIMARY/SECONDARY PIPING Fig. #9232.
SECTION F: DOMESTIC HOT WATER PIPING When designing the water piping system for domestic water applications, water hardness should be considered. Table F-1 indicates the suggested flow rates for soft, medium and hard water. Hardness is specified as grains per gallon. TABLE F-1 DOMESTIC WATER HEATER FLOW RATE REQUIREMENTS DT = Temperature rise, degrees F GPM = Gallons/minute, flow rate DP = Pressure drop, ft, through heat exchanger MPS = Minimum pipe size, NPT SHL = System head loss, ft.
SECTION G: POOL HEATING CAUTIO CAUTION: Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation. Improper flow control can damage the heater. Uncontrolled flow (too high) or restricted flow (too low) can seriously damage the heater. Follow these instructions to make sure your heater is properly installed.
AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place chlorine tablets or bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (i.e. overnight). Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the heater when the pump is shut off.
SECTION H: GAS SUPPLY CONNECTIONS DANGER: Make sure the gas on which the boiler will operate is the same type as specified on the boiler model and rating plate. Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve located outside the heater jacket. A pounds to inches regulator must be installed to reduce to gas supply pressure to under 14" W.C. The regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the boiler gas controls.
GAS PRESSURE REGULATOR The gas valve pressure regulator(s) on the boiler are nominally preset at 3.5" W.C. for Natural gas, and 10.5" W.C. for Propane gas manifold pressure. The pressure at the gas valve outlet tap, measured with a manometer,while in operation should be 3.5 ± 0.1" W.C. for Natural gas and 10.5" ± 0.1" W.C. for Propane gas. If an adjustment is needed, turn the adjustment screw clockwise to increase pressure or counter-clockwise to lower pressure.
SECTION I: 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. Boiler must be electrically grounded as required by N.E.C. ANSI/NFPA 70-latest edition. In Canada, C.S.A. C22. 1 C.E.C. Part 1. The boiler is wired for 120 Volts, 12 AMPS. The voltage is indicated on the tie-in leads.
MAKING THE ELECTRICAL CONNECTIONS Refer to Fig. #9227 Wiring Connection, and Fig. #9233 or Fig. #9234 Wiring Diagram. 1. 2. 3. 4. 5. 6. 7. Verify circuit breaker is properly sized by referring to boiler rating plate. A dedicated circuit breaker should be provided. Turn off all power to the boiler. Verify that power has been turned off by testing with a volt-ohm meter prior to working with any electrical connections or components. Observe proper wire colors while making electrical connections.
ELECTRICAL CONNECTIONS - DOMESTIC HOT WATER CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. DANGER - SHOCK HAZARD 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 Hi-Delta boiler to operate after making the power conections.
SECTION J: VENTING CONNECTIONS GENERAL CAUTION: Proper installation of flue exhaust venting is critical for the safe and efficient operation of the boiler. Definition of Appliance Categories Boilers 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 boiler which operates with a non-positive vent static pressure and with a vent gas tempera ture that avoids excessive condensate production in the vent.
Category Determination for Venting Purpose and Venting Arrangement 25 * As defined in the latest edition of the National Fuel Gas Code, or in Canada, the latest edition of the CAN/CGA B149.1 and B149.2.
Support of Vent Stack The weight of the vent stack or chimney must not rest on the boiler vent connection. Support must be provided in compliance with applicable codes. The vent should also be supported to maintain proper clearances from combustible materials. Use insulated vent pipe spacers where the vent passes through combustible roofs and walls. Vent Terminal Location NOTICE: During winter months check the vent cap and make sure no blockage occurs from build up of snow.
Canada Installations - Refer to latest edition of CAN/CGA-B149.1 and .2 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 b) Less than 7 ft.(2.13m)above a paved sidewalk or paved driveway located on public property c) Within 6 ft(1.
SECTION J-1 Natural Draft Vertical Venting (Category I) 10' OR LESS VENT CAP 2' MIN 2' MIN VENT PIPE COMBUSTION AIR FILTER BOILER UNIT Fig. #9228 NATURAL DRAFT VERTICAL VENT NOTE: **Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the National Fuel Gas Code for further details. (ANSI Z223.
• 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 negative draft must be within the range of -.01” to -.10” negative W.C. as measured 12 inches from the appliance flue outlet to insure proper operation. Vent material must be listed by a nationally recognized test agency.
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 followed 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.
SECTION J-2 Horizontal Thru-Wall Venting (Category III) OPTIONAL FLUE EXHAUST VENTING COMBUSTION AIR FILTER 9" MIN. FLUE EXHAUST VENT CAP BOILER UNIT CONDENSATE TRAP INSULATED EXHAUST VENTING 12" MIN. Fig. #9229.1 HORIZONTAL THRU-WALL VENTING (CATEGORY III) TABLE • Horizontal Thru-wall Venting System (Category III) Installation These installations utilize the boiler-mounted blower to vent the combustion products to the outdoors.
The total length of the horizontal thru-wall exhaust vent system should not exceed seventy (70) feet in length. If horizontal run exceeds 70 feet, an appropriately sized extractor must be used. To maintain proper operation pressure reading must be between -.01 to -.1 W.C. as measured 12 inches from the appliance flue outlet. Each elbow used is equal to ten (10) feet of straight pipe. This will allow installation in one of the four following combinations. · · · · 70’ of straight flue pipe.
• 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. The Raypak supplied flue exhaust direct vent cap must be utilized. WARNING: No substitutions of flue pipe or vent cap material are allowed.
SECTION J-3 DIRECT VENT Horizontal Thru-wall Venting (Category III) 9" MIN. EXHAUST VENT INTAKE VENT CONDENSATE TRAP 36" MIN. BOILER UNIT AIR FILTER 6" MIN. 12" MIN. Fig. #9230.
• Horizontal Thru-wall Direct Vent System (Category III) Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors. The total length of the thru-wall exhaust vent cannot exceed forty (40) feet in length for the flue outlet. Each elbow used is equal to ten (10) feet of straight pipe. This will allow installation in one of the three following combinations. · · · 40’ of straight combustion air pipe.
DIRECT VENT SECTION J-4 Vertical Venting (Category I) 3' MIN. VENT CAP 3' MIN. 1' MIN. INTAKE VENT EXHAUST VENT BOILER UNIT AIR FILTER Fig. #9231.
• Vertical Direct Vent System Installation These installations utilize the boiler 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- 0.10” negative W.C. as measured 12 inches from the appliance outlet to insure proper operation. The vent material must be in accordance with the above instructions for vent materials.
SECTION J-5 Outdoor Installation Outdoor models are self -venting when installed with the factory-supplied restricted direct vent cap and require no additional vent piping. This special vent cap is provided with the boiler in accordance with AGA/CGA requirements. It must be installed directly on the boiler. See Section B for correct clearances. Care must be taken when locating the outdoor unit because the flue gases discharged from the vent hood can condense as they leave the hood.
HI DELTA OUTDOOR VENT INSTRUCTIONS 1. Turn off the power and shut off the gas to heater. Heater as shipped 2. Slide the vent collar from kit over the collar on heater as shown in Fig. 1. 3. Drill a 3/16” pilot hole into the heater collar through each of the holes on the lower vent collar. See Fig. 1. Fig. 1 4. Take four of the self-tapping screws from the kit and screw into the holes as shown in Fig. 2. Fig. 2 5. Slide tinnerman clips over the small bracket as shown in Fig. 3. Fig.
HI DELTA OUTDOOR VENT INSTRUCTIONS CONTINUED 6. Slide the collector over vent collar, aligning the holes over the openings in the tinnerman clips as shown in Fig. 4. Fig. 4 7. Take four of the screws from the kit and screw into the holes as shown in Fig. 4. 8. Slide the vent cap down into the vent collar as shown in Fig. 5. Fig. 5 9. Drill a 3/16” pilot hole into the vent cap through each of the upper holes in the vent collar. See Fig. 6. Also see finished assembly below. Fig. 6 10.
HI DELTA FILTER BOX KIT NOTICE: These instructions are intended for use by qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel are required to be licensed in some states. Persons not qualified shall not attempt repairs according to these instructions.
HI DELTA FILTER BOX INSTRUCTIONS CONTINUED 11. Mark the four holes through filter box for screw locations. Air intake collar 12. Using a 1/16 drill bit, drill a pilot hole in each of the holes previously marked. 13. Mount the filter box to the unit using four screws provided in the kit. 14. Install filter under filter box on top of air intake. See Fig. 3. NOTE: The filter media fits loosely in the filter box.
SECTION K: CONTROLS WARNING: Installation, adjustment and service of boiler 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, boiler malfunction, property damage, personal injury, or death. WARNING: Turn off the power to the boiler before installation, adjustment or service of the Central Point Wiring board or any boiler controls.
Boiler Sequence of Operations HI-DELTA Model 302-402 The black (hot) wire leads you directly to the Main Power Switch. This switch is located at the bottom right-front corner of the control compartment. When the main power switch is placed in the “ON” position, both the 120 v and 24 v terminal blocks on the Main Circuit Board will be powered and the power light will turn on.
HI-DELTA Model 502-752 The black (hot) wire leads you directly to the Main Power Switch. This switch is located at the bottom right-front corner of the control compartment. When the main power switch is placed in the “ON” position, both the 120 v and 24 v terminal blocks on the Main Circuit Board will be powered and the power light will turn on.
HI-DELTA Model 902 The black (hot) wire leads you directly to the Main Power Switch. This switch is located at the bottom right-front corner of the control compartment. When the main power switch is placed in the “ON” position, both the 120 v and 24 v terminal blocks on the Main Circuit Board will be powered and the power light will turn on.
IGNITION CONTROL MODULE The interrupted proved ignition device conserves energy. 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 energized, eliminating the fuel costs of maintaining a constant pilot. To assure safe operation, the gas valve cannot open until the pilot igniter is verified.
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 3 second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Drw. #8996 Fig.# J-5 LOW WATER CUTOFF HIGH AND LOW GAS PRESSURE SWITCHES The low gas pressure switch (optional) mounts upstream of the gas valve to ensure that sufficient gas pressure is present for proper regulator performance.
WIRE DIAGRAM MODEL 302-402 Reference Drawing Number M152462-Rev.
WIRE DIAGRAM MODEL 302-402 Reference Drawing Number M152470-Rev.
WIRE DIAGRAM MODEL 502-752 Reference Drawing Number M152464-Rev R H3/HW3 51
WIRE DIAGRAM MODEL 902 Reference Drawing Number M152465 Rev-P H3/W3 52
SECTION L: GENERAL SAFETY PRECAUTIONS To meet commercial water use needs, the temperature Hi-Limt on this hot water boiler is adjustable up to 210°F. However, water temperatures over 125°F can cause severe burns instantly or death from scalds. The preferred starting point for setting the control for supplying general purpose hot water is 125°F. Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat.
SECTION M: PRE-START-UP FILLING SYSTEM-HEATING BOILERS 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. Manually open air vent on the compression tank until water appears, then close vent. DOMESTIC HOTWATER BOILERS Purge all air from system before lighting boiler. This can be normally be accomplished by opening a downstream valve.
SECTION N: HI-DELTA INITIAL START-UP 1.0 • • • • • • • • TOOLS NEEDED One 12-0-12, 24” scale manometer 6-0-6, 12” scale manometers 7/16” open end wrench 1/2” open end wrench Screwdriver Volt meter 3/16” Allen wrench Jumper cable 2.0 PREPARATION FOR START-UP WARNING: 2.
3.0 START-UP 3.1 Blower Adjustment 1. 2. 3. 4. 5. 6. Disconnect all fan pressure switch tubings at plenum and connect manometer using a tee. Close all manual firing valves. Turn power on; Check manometers attached to fan pressure switches. The readings should be 1.4 + .2"W.C. for propane and natural gas. If not, adjust the air shutter on the blowers to attain the correct value. Turn power off. Reconnect all fan pressure switch tubing to original positions. 3.2 Main Burner Adjustment 1. 2. 3. 4. 5. 6.
PILOT TURN DOWN TEST FOR RAYPAK HI DELTA BOILERS The Hi Delta boilers, depending on their size, have from two to five burner sections. Each burner section is supplied gas by dual gas valves incorporated in single valve body. A maximum of three burner sections may be controlled by a single hot surface ignition system. The middle of the three burner sections is lighted directly with a hot surface ignition system.
4) Next, close the upstream manual gas valve and remove the manometers from test point A and from test point B. Connect a rubber tube from test point 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.
SECTION O: POST START-UP CHECK Check off steps as completed: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
SECTION P: OPERATION OPERATING INSTRUCTIONS Lighting Instructions 1. 2. 3. 4. STOP! Read the safety information first. Set the thermostat to the lowest setting. Turn off all electric power to the appliance. This appliance is equipped with an ignition device which automatically lights the burner. Do Not try to light the burner by hand. 5. Remove upper front panel. 6. Turn on main manual gas valve. 7. Wait five (5) minutes to clear out any gas. Then smell for gas, especially near the floor.
SECTION Q: MAINTENANCE SUGGESTED MINIMUM MAINTENANCE SCHEDULE: Regular service by a qualified service agency and maintenance must be performed to assure maximum boiler operating efficiency. Maintenance as outlined below may be performed by the owner. Yearly (Beginning of each heating season): 1. 2. 3. 4. 5. 6. 7. Annual service call by qualified service agency. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal.
PREVENTIVE MAINTENANCE SCHEDULE Required procedure in CSD-1 States and good practice for all Hi-Delta installations. Daily 1. 2. 3. Check gages, monitors and indicators. (See page 6 of the Operating and Installation Instructions Manual). Check instrument and equipment settings. (See page 49-50 of the Operating and Installation Instructions Manual). Check burner flame. (Should see light blue flame). Weekly 1. 2. 3. 4. 5. 6. For low-pressure boilers, test low-water fuel cutoff device.
APPENDIX A INSIDE COMBUSTION AIR CONTAMINATION: All boilers 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.
LIMITED PARTS WARRANTY COMMERCIAL BOILERS TYPE HI-DELTA SIZES 302 TO 902 MODELS H AND W 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: (800) 872-9725 Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX: (905) 677-8036 6-99 Litho in U. S. A.