INSTALLATION & OPERATING INSTRUCTIONS ® Models HD101–HD401 Types H & WH L W WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance.
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 GENERAL SAFETY 8 Time/Temperature Relationships in Scalds 8 INSTALLATION 9 Installation Codes 9 Equipment Base 9 Clearances 9 Combustion and Ventilation Air 11 Conventional Combustion Air Supply 11 Water Piping 12 Hydronic Heating 14 Domestic Hot Water Piping 16 Gas Supply 17 Electrical Power Co
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 Model Identification 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 Fig. 1: Component Locations — Angle View Fig. 2: Component Locations — Left Side Fig.
General Information Vent Size (in.) Model No. Quantity of Burners HD101 2 4 HD151 3 4 HD201 4 5 HD251 5 5 HD301 6 5 HD401 8 6 Flue Intake 4 Table A: Basic Data Fig. 4: Air Shutter Adjustment 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.
Equipment Base The temperature of the water in the heater can be regulated by using the optional temperature control. To comply with safety regulations, the optional temperature control will be set at the lowest setting when shipped from the factory. 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.
FRONT VIEW 2 TOP VIEW 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. The heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater.
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 outdoors 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). These clearances are required when the outdoor vent cap is used.
a. Where directly communicating with the outdoors 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 rating of all equipment in the enclosure. ral air flow from the outdoors for natural draft, partial 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.
Reversing Water Connections Follow these instructions to change the water connections from the left-hand side (standard) to the right-hand side. 1. Disconnect all electrical power from the heater (if applicable). 2. Label all electrical connections and conduit lines. This may include the flow switch, low water cut-off probe and/or pump. 3. Disconnect or isolate the main gas pipe from the heater (if applicable). Fig. 9: Torque Sequence 4.
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.
*Maximum 4 times the pipe diameter or 12”, whichever is less. Fig. 10: Single Boiler — Low Temperature Application (Heat Pump) Primary/Secondary Piping *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig.
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. 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 heater’s rating plate. 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).
Fig. 13: Sediment Trap Orientation pressure exceeds 14 in. WC, an intermediate gas pressure regulator, of the lockup type, must be installed. 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. When connecting additional gas utilization equipment to the gas piping system, the existing piping must be checked to determine if it has adequate capacity.
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, less than 12 AMPS. The voltage is indicated on the tie-in leads. Consult the wiring diagram shipped with the heater in the instruction packet.
Electrical Connections — Domestic Hot Water SINGLE STAGE TANKSTAT 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.
Heater must be electrically grounded in accordance with NEC and C22.1(in Canada). See Table H for appliance category requirements for the Hi Delta. NOTES: 1. Field installed ground to inside of junction box. 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. 2.
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 any Category I Venting System* Horizontal Thru-wall Venting III Stainless Steel (Gas Tight) Vertical Venting I Type B or any 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.
ances shall not terminate over public walkways or 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 BTUH 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 Follow items listed below to avoid personal injury or property damage. · · · · 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 –0.01 in. to –0.08 in. WC as measured 12 in. from the appliance flue outlet to ensure proper operation.
Fig. 19: Horizontal Thru-Wall Venting (Category III) each appliance. Adjust thermostat so appliance will operate continuously. 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).
Horizontal Thru-wall Venting System (Category III) Installation b) The vent be insulated through the length of the horizontal run. 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 supplied in accordance with the NFGC or, in Canada, the B149 Installation Code.
Fig. 20: Direct Vent Horizontal Thru-Wall Venting (Category III) Model No. Appliance Category Certified Venting Material Vent Size (inches) HD101 HD151 HD201 HD251 HD301 HD401 Max. Venting Length (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) 100, 4 Elbows Max.
Fig. 21: Direct Vent—Vertical Venting (Category I) Model No. Appliance Category Certified Venting Material HD101 HD151 HD201 HD251 HD301 HD401 I Type B Equivalent Vent Size (inches) Min./Max. Vertical Venting Height (feet) Min. 4 6 5 (HD201) 6 (HD251) 6 (HD301) 11 6 8 Max. 25* Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) Galvanized Steel PVC ABS CPVC 4 100 *Over 25 feet, use single acting barometric damper.
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 Modulating Temperature Control (Optional) 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. This heater can be equipped with a Raypak modulating temperature control.
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 temperature. cient gas pressure is present for proper regulator performance. 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.
WIRING DIAGRAM—MODELS HD101–HD401 34
HD Troubleshooting Does the main power switch provide power to the green power LED? Step 1 YES Check the switch, transformer and/or line voltage NO NO Is Disable connection intact? Reattach. YES Step 2 Is there a Call For Heat? Is temperature controller installed? NO Install. NO YES Step 3 Does the Pump come on? NO Is there 120VAC at the pump or pump relay contacts? NO Check and correct power connections at main terminal block, circuit breaker panel or pump relay.
PRE-START-UP NOTE: Digital manometers are not recommended. Filling System-Heating Heaters Preparation for Start-Up 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. WARNING: Do not turn on gas at this time.
Check the Gas Supply Pressure 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. 1. Slowly turn on main gas shut-off valve. 2. Read the gas supply pressure from the manometer; minimum supply pressure is 4 in. WC, recommended supply is 7 in. WC for natural gas (minimum 11.0 in. WC for LP gas). 6. If the pressure reading differs by more than the tolerance given, adjust the gas valve accordingly.
3. Carefully remove 2-stage solenoid. 1. Turn off gas supply at the appliance service level. 4. Skip to Step 9 for LO-fire adjustment only. 2. Remove the pressure regulator cover assembly. 5. Locate and remove Lo-fire adjustment cap. 3. Remove the existing stem/spring assembly. 6. Carefully remove the spring & weight. 4. Insert the replacement stem/spring assembly. 7. Using an allen wrench, turn clockwise to increase and counterclockwise to decrease the HI-fire 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: • • • • • 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.
Heat Exchanger Removal 3. Remove the (4) screws holding the panel in place. 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 relief valve. Remove side inspection panels. 2. Remove screw behind inspection panels holding the jacket top down. 3. Remove the front panel. Remove two additional screws holding the jacket top to the top support. 4.
JACKET TOP REMOVAL FLUE COLLECTOR REMOVAL ACCESS PANEL REMOVAL ACCESS PANEL REMOVAL Fig. 35: Heat Exchanger Removal MAINTENANCE heater operating efficiency. Maintenance as outlined below may be performed by the owner. Suggested Minimum Maintenance Schedule: Yearly (Beginning of each heating season): Regular service by a qualified service agency and maintenance must be performed to ensure maximum 1. Annual service call by qualified service agency.
2. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal. 2. Visually inspect burner flame. 3. Visually inspect venting system for proper function, deterioration or leakage. 3. Visually inspect venting system for proper function, deterioration or leakage. 4. Check air vents for leakage. Quarterly: 4. Check that heater area is free from combustible materials, gasoline, and other flammable vapors and liquids. 1. Check relief valve.
• • • • • • 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.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
