Raypak Hi Delta 302A-902A Installation And Operating Instructions Manual

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[Page 1] Raypak Hi Delta 302A-902A

INSTALLATION AND OPERATING INSTRUCTIONS CATALOG NO. 1000.501B Effective: 09-08-06 Replaces: 01-01-05 P/N 240757 Rev. 1 WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property dam- age, personal injur...

[Page 2] Raypak Hi Delta 302A-902A

2 ...

[Page 3] Raypak Hi Delta 302A-902A

WARNINGS 4 BEFORE INSTALLATION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 Time/Temperature Relationships in Scalds 8 INSTALLATION 9 Installation Codes 9 Equipme...

[Page 4] Raypak Hi Delta 302A-902A

4 DANGER: Indicates the presence of immediate hazards which will cause severe person- al injury, death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury,...

[Page 5] Raypak Hi Delta 302A-902A

5 BEFORE INSTALLATION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your Hi Delta heater. Please review the General Safety information before installing the heater. Factory warranty does not apply to heaters t...

[Page 6] Raypak Hi Delta 302A-902A

6 Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front ...

[Page 7] Raypak Hi Delta 302A-902A

7 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 # Burners per Valve Stages % Fire at Stage Model No. 12...

[Page 8] Raypak Hi Delta 302A-902A

8 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 genera...

[Page 9] Raypak Hi Delta 302A-902A

9 INSTALLATION INSTALLATION Installation Codes Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances • National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition (NFGC) • Nat...

[Page 10] Raypak Hi Delta 302A-902A

10 In addition, the heater shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation or service (circulator replacement, control replacement, etc.). Clearances...

[Page 11] Raypak Hi Delta 302A-902A

11 U.S. Installations 1 Canadian Installations 2 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 (1.2m) below or to side of opening; 1 foot (30 cm) above op...

[Page 12] Raypak Hi Delta 302A-902A

12 Fig. 8: Minimum Clearances from Combustible Surfaces – Outdoor Installations Combustion and Ventilation Air Indoor Units The heater must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ve...

[Page 13] Raypak Hi Delta 302A-902A

13 three or four sheet metal screws (not supplied) equal- ly distributed around the circumference of the duct. All ducting should be self-supported. The filter housing is not designed to support the air duct. TruSeal™ Combustion Air In certain appl...

[Page 14] Raypak Hi Delta 302A-902A

14 b. Not less than the sum of the areas of all vent connectors in the confined space. WARNING: Do not use one permanent opening method if the equipment room is under negative pressure conditions or the equipment is common vented with other gas-fired...

[Page 15] Raypak Hi Delta 302A-902A

15 5. Remove all plumbing fittings to the header. This will include both inlet and outlet water pipe unions and the pressure relief valve and drain piping. 6. Remove limits, control bulbs and/or thermocou- ples. 7. Remove the eight flange nuts and th...

[Page 16] Raypak Hi Delta 302A-902A

16 Failure to exceed 105ºF (41ºC) within 7 minutes may result in the premature failure of the hot surface ignit- er, remote flame sensor, burners and heat exchanger. It can cause operational problems, bad combustion, sooting, flue gas spillage and ...

[Page 17] Raypak Hi Delta 302A-902A

17 Pressure Drop in Feet of Head Feedwater Regulator Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the high- est point of the system. Install a check valve or back flow device upstream of the regula...

[Page 18] Raypak Hi Delta 302A-902A

18 Potable Water and Space Heating 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water. 2. Toxic chemicals, such as used for boiler treatment, shall not b...

[Page 19] Raypak Hi Delta 302A-902A

19 circulate water through the heater from the main sys- tem piping. To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return wa- ter line, upstream of the heater. This will ensure that the heater ...

[Page 20] Raypak Hi Delta 302A-902A

20 shut-off. Close isolation valves and remove water pip- ing from the in/out header on the heater. Drain the heater and any piping of all water that may experience below-freezing temperatures. Pool/Spa Water Chemistry Water Hardness Water hardness i...

[Page 21] Raypak Hi Delta 302A-902A

21 Gas Supply Connection The heater must be isolated from the gas supply pip- ing system by closing the manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa). Reli...

[Page 22] Raypak Hi Delta 302A-902A

22 8. Remove the rubber grommet from the left-hand- side panel and reinstall into the standard main gas opening, located on the right-hand side of the heater. 9. Install a coupling, nipple, union and sediment trap onto the right-hand end of the main ...

[Page 23] Raypak Hi Delta 302A-902A

23 CIRCUIT BREAKER WHITE GROUND BLACK GREEN AB C Fig. 18: Wiring Connections Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum If the heater does not have a factory-wired stage con- t...

[Page 24] Raypak Hi Delta 302A-902A

24 DANGER: SHOCK HAZARD Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. Fig. 21: Wiring Connections ...

[Page 25] Raypak Hi Delta 302A-902A

25 Installer action is required to electrically enable your heater to operate after making the power connections. You must make a closed contact connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connectio...

[Page 26] Raypak Hi Delta 302A-902A

26 Combustion Air Supply Exhaust Configuration Heater Venting Category Certified Materials Combustion Air Inlet Material Vertical Natural Draft Venting I “B” Vent From Inside Building (Non-Direct Venting) Horizontal Through- the-Wall Venting II...

[Page 27] Raypak Hi Delta 302A-902A

27 8. Locate and guard vent termination to prevent acci- dental contact by people or pets. 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. 10. DO NOT terminate above any door, window, or gravity air intak...

[Page 28] Raypak Hi Delta 302A-902A

28 5. Remove the screws, retaining ring and rain gasket from top of heater. 6. Remove the 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 loca...

[Page 29] Raypak Hi Delta 302A-902A

29 Termination The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the high- est point of the roof that is within 10 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no...

[Page 30] Raypak Hi Delta 302A-902A

30 speed. Do not operate summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliances being inspected. Follow the manufacturer’s instructions for lighting each appliance. Adjust thermostat so appliance will operate continuously...

[Page 31] Raypak Hi Delta 302A-902A

31 Air Inlet Max. Length Model No. Certified Venting Material Vent Size Maximum Equivalent Vent Length* Combustion Air Intake Pipe Material 6” 8” 302A 5” 402A 100’ N/A 502A 6” 75’ 652A 752A 40’ 100’ 902A Category III 8” 70’ Ro...

[Page 32] Raypak Hi Delta 302A-902A

32 For installations in extremely cold climate, it is re- quired that: 1. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of hori- zontal run to the vent terminal. In this case, an ap- proved condensate trap m...

[Page 33] Raypak Hi Delta 302A-902A

33 Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that migh...

[Page 34] Raypak Hi Delta 302A-902A

34 Fig. 28: External LED Indicator Decal Heater Sequence of Operation Models 302A, 402A, 502A, 652A, 752A and 902A 1. The black (hot) wire lead goes directly to the main power switch. This black toggle switch is located at the middle front of the con...

[Page 35] Raypak Hi Delta 302A-902A

35 External Lights Light Color Indication Power Blue Main power is on Call For Heat Yellow Thermostat is closed Safety Red One or more safeties is inopera- tive Ignition Red Ignition module is inoperative Flow Green Flow is present Blower 1 Green Bl...

[Page 36] Raypak Hi Delta 302A-902A

Ignition Module When additional heat is needed, the combustion air blower starts to purge air from the combustion cham- ber for about 15 seconds. On proof-of-air flow, the air- proving switch closes and the igniter is energized. To ensure safe operat...

[Page 37] Raypak Hi Delta 302A-902A

37 The optional single-try ignition module will lock out after failing to light one time. To reset it, press and release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case. T...

[Page 38] Raypak Hi Delta 302A-902A

38 Fig. 34: High/Low Gas Pressure Switch Fig. 35: Fan-Proving Switch Fig. 36: Blocked Vent Switch ...

[Page 39] Raypak Hi Delta 302A-902A

39 87%-Efficiency Boilers – Special Instructions Water Piping An 87%-efficiency boiler requires a minimum inlet water temperature of 120ºF (49ºC) to prevent exces- sive condensation in the combustion chamber. An 87%-efficiency boiler operated wi...

[Page 40] Raypak Hi Delta 302A-902A

40 WARNING: Contact the vent material manufactur- er if there are any questions about the appliance cat- egory or suitability of a vent material for Category II, III or IV applications. Using improper venting materi- als can result in personal injury...

[Page 41] Raypak Hi Delta 302A-902A

41 Horizontal Through-the-Wall Venting (Category IV) WARNING: Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure. Fig. 38: Horizontal Thro...

[Page 42] Raypak Hi Delta 302A-902A

42 The stainless steel direct vent cap must be furnished by the boiler manufacturer in accordance with its list- ing (sales order option D-15). Use only double-wall vent pipe and the special gas vent pipes listed for use with category II or IV gas bu...

[Page 43] Raypak Hi Delta 302A-902A

43 Direct Vent - Vertical Vertical Venting Height* Air Inlet Max. Length** Model Certified Venting Material Vent Size Min. Max. Combustion Air Intake Pipe Material 6” 8” 302A 5” 402A 100’ N/A 502A 6” 75’ 652A 752A 902A Category II or I...

[Page 44] Raypak Hi Delta 302A-902A

44 Wiring Diagram ...

[Page 45] Raypak Hi Delta 302A-902A

45 START-UP Pre Start-up Filling System (Heating Boilers) Fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the c...

[Page 46] Raypak Hi Delta 302A-902A

46 Preparation Check Power Supply With multi-meter at incoming power, check voltage between: Hot - Common (≈120 VAC) Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) Attach Manometers to Measure Pressures 1. Turn off main gas valve. 2. Attach...

[Page 47] Raypak Hi Delta 302A-902A

47 Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record. 3. If other gas-fired appliances in the room are on the same gas main, check all pressures on...

[Page 48] Raypak Hi Delta 302A-902A

48 1. Manually close the downstream leak test valve. 2. Open test point A and connect a manometer to it. Verify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in. WC). 3. Open test point B and connect ...

[Page 49] Raypak Hi Delta 302A-902A

49 10. To restart system, follow lighting instructions in the Operation section. 11. Check to see that the high limit control is set above the design temperature requirements of the system. For multiple zones: Check to make sure the flow is adjusted ...

[Page 50] Raypak Hi Delta 302A-902A

50 TROUBLESHOOTING Ste p 7 Ste p 6 Ste p 5 Step 1 Step 2 Step 3 Step 4 Is there a Call For Heat? Is Disable j um p er intact? ( J1 ) Is there 120VAC at J8 Connecto r on the CPW board? Do the combustion air blowers come...

[Page 51] Raypak Hi Delta 302A-902A

51 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. Maintenance as outlined below may be performed by the owner. Daily 1. Check ...

[Page 52] Raypak Hi Delta 302A-902A

52 Weekly For low-pressure heaters, test low-water cut-off device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance should shut-off and ignition fault light should come on. Depress reset button to res...

[Page 53] Raypak Hi Delta 302A-902A

53 APPENDIX Inside Air Contamination All heaters experience some condensation during start-up. 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 a...

[Page 54] Raypak Hi Delta 302A-902A

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 ...

[Page 55] Raypak Hi Delta 302A-902A

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 ...

[Page 56] Raypak Hi Delta 302A-902A

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. ...