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.
Rev. 3 reflects the following: Changes to: Updated Table E on page 14, Table G on page 18, Troubleshooting flowchart on page 35, Table O on page 38.
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
WARNINGS — DANGER: WARNING: CAUTION: NOTE: 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 the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
BEFORE INSTALLATION 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 ).
Component Locations Fig. 1: Component Locations — Angle View Fig. 2: Component Locations — Left Side Fig.
General Information Model No. Quantity of Burners HD151 3 HD101 2 HD201 4 HD251 HD301 HD401 5 6 8 Table A: Basic Data Vent Size (in.) Flue 4 Intake 4 5 5 4 5 6 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.
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.
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. 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.
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.
Gas Supply Fig. 12: Single Heater — Domestic Hot Water with One Storage Tank 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 Gas Pressure Regulator 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. 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 pressure at the gas valve outlet tap, measured with a manometer, while in operation should be as indicated in Table G.
Input Model No. (KBTUH) HD151 150 HD101 HD201 HD251 HD301 HD401 3/4” N 1” P N P N 160 530 600 60 230 240 100 105 385 340 199 30 95 95 250 299 399 50 20 15 5 180 50 35 20 1-1/4” 45 25 355 170 80 1-1/2” P N 550 360 P 360 170 100 365 Table H: Maximum Equivalent Pipe Length 210 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.
5. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code. 1 6. Install heater controls, thermostats, or building management systems in accordance with the applicable manufacturer’s instructions.
2-STAGE TANKSTAT STAGE 1 CONNECTION Category II. A heater which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent. Category III. A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent. STAGE 2 CONNECTION OR STAGE 1 CONNECTION OF HEATER 2 Category IV.
Combustion Air Supply From Inside Building (Non-Direct Venting) From Outside Building (Direct Venting) Exhaust Configuration Venting Category Vertical Natural Draft Venting I Certified Appliance Material Type B or any Category I Venting System* Horizontal Thru-wall Venting III Vertical Venting I Horizontal Thru-wall Venting Type B or any Category I Venting System* III Stainless Steel (Gas Tight) Combustion Air Inlet Material Stainless Steel (Gas Tight) Galvanized Steel PVC ABS CPVC *As def
Fig. 18: 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 · Cut nonmetallic intake pipe with fine-toothed hacksaw. Do not use nonmetallic intake pipe or fittings that are cracked or damaged.
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. 20: 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. 21: Direct Vent Horizontal Thru-Wall Venting (Category III) Model No. HD101 HD151 HD201 HD251 HD301 HD401 Appliance Category III Certified Venting Material Vent Size (inches) Stainless Steel (Gas Tight) 4 5 6 Max. Venting Length (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) 100, 4 Elbows Max.
Fig. 22: Direct Vent—Vertical Venting (Category I) Model No. HD101 HD151 HD201 HD251 HD301 HD401 Appliance Category I Certified Venting Material Type B Equivalent Vent Size (inches) 4 5 6 Min./Max. Vertical Venting Height (feet) Min. 6 (HD201) 6 (HD251) 6 (HD301) 11 Max. 25* 8 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. Outdoor 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.
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
HD101-HD401 Troubleshooting Step 1 NO Does the main power switch provide power to the green power LED? YES Check the switch, transformer and/or line voltage NO Is Disable connection intact? Reattach. YES Step 2 NO Is there a Call For Heat? Is temperature controller installed? NO Install.
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 6. If the pressure reading differs by more than the tolerance given, adjust the gas valve accordingly. See gas valve adjustment section below for instructions. 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). Gas Valve Adjustment Firing Stage 3. If pressure is > 14 in. WC, turn off the valve. 4.
3. Carefully remove 2-stage solenoid. 2. Remove the pressure regulator cover assembly. 5. Locate and remove Lo-fire adjustment cap. 4. Insert the replacement stem/spring assembly. 4. Skip to Step 9 for LO-fire adjustment only. 3. Remove the existing stem/spring assembly. 6. Carefully remove the spring & weight. 5. Replace the pressure regulator cover assembly and tighten screws. 7. Using an allen wrench, turn clockwise to increase and counterclockwise to decrease the HI-fire manifold pressure.
· Follow-Up • • Safety checks must be recorded as performed. Turn unit on. • • • 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 leaks one more time. · · After main burner ignition: • • When the unit is in operation. Disconnect combustion air blower pressure switch, burner should go off immediately. Wait 5 minutes.
Heat Exchanger Removal 3. Remove the (4) screws holding the panel in place. Refer to Fig. 36 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 MAINTENANCE Fig. 36: Heat Exchanger Removal heater operating efficiency. Maintenance as outlined below may be performed by the owner. Suggested Minimum Maintenance Schedule: Yearly (Beginning of each heating season): 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.
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows: (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1.
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www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.