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INSTALLATION & OPERATING
INSTRUCTIONS
®
Models HD101–HD401 L
W
Types H & WH
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.
• Do not to
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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. Additions: Commonwealth of Massachusetts information on page 45 Deletions: None 2
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CONTENTS WARNINGS 4 Flow Switch 33 Pay Attention to These Terms 4 High and Low Gas Pressure Switches BEFORE INSTALLATION 5 (Optional) 33 Product Receipt 5 Low Water Cut Off (Optional) 33 Model Identification 5 WIRING DIAGRAM—MODELS Ratings and Certifications 5 HD101–HD401 34 Installations at Elevation 5 HD TROUBLESHOOTING 35 Component Locations 6 PRE-START-UP 36 General Information 7 Filling System-Heating Heaters 36 GENERAL SAFETY 8 Domestic Hot Water Heaters 36 Time/Temperature Relationships i
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WARNINGS — Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. Indicates special i
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Model Identification BEFORE INSTALLATION The model identification number and heater serial Raypak strongly recommends that this manual be re- number are found on the heater data plate located on viewed thoroughly before installing your Hi Delta the right side jacket of the heater. The model number heater. Please review the General Safety information will have the form H3-HD101 or similar depending on before installing the heater. Factory warranty does not the heater size and configuration. The f
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Component Locations Fig. 1: Component Locations — Angle View Fig. 2: Component Locations — Left Side Fig. 3: Component Locations — Front (Panels removed for clarity) 6
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General Information Vent Size (in.) Model Quantity of Burners No. Flue Intake HD101 2 4 HD151 3 4 HD201 4 5 4 HD251 5 5 HD301 6 5 HD401 8 6 Table A: Basic Data Fig. 4: Air Shutter Adjustment Fig. 5: Gas Valves 7
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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 rec- ommended initial setting for the temperature control is 125°F. Safety and energy conservation are factors to be con- sidered when setting the water temperature on the Water
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The temperature of the water in the heater can be reg- Equipment Base ulated by using the optional temperature control. To comply with safety regulations, the optional tempera- The heater should be mounted on a level, structurally ture control will be set at the lowest setting when sound surface. The heater is approved for installation shipped from the factory. on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed To adjust the water temperature, inser
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Fig. 7: Minimum Installed Service Clearances — Indoor/Closet Installations hang. Roof water drainage must be diverted away CAUTION: Service clearances less than the from heaters installed under overhangs. minimums may require removal of the heater to service either the heat exchanger or the burners. Minimum Installed Heater Side The heater must be installed in a manner that will Service Clearance enable the heater to be serviced without removing any structure around the heater. Front 24” Rear 12
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2 These clearances are required when the outdoor area per 20,000 BTUH (111 mm per kW) of total vent cap is used. If installing the heater outdoors input rating of all equipment in the room when the with a vent stack, the indoor clearances may be opening is communicating directly with the out- utilized. doors or through vertical duct(s). The total 2 cross-sectional area shall be at least 1 in. of free 2 The combustion air intake hood MUST be used for area per 10,000 BTUH (222 mm per kW) of total
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a. Where directly communicating with the out- ral air flow from the outdoors for natural draft, par- doors or where communicating to the tial fan assisted, fan-assisted or power outdoors through vertical ducts, each opening draft-assisted burners, there shall be a permanent 2 shall have a minimum free area of 1 in. per air supply opening(s) having a cross section area 2 2 2 4000 BTUH (5.5 cm per kW) of total input rat- of not less than 1 in. per 7000 BTUH (310 mm ing of all equipment in the encl
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Reversing Water Connections Follow these instructions to change the water connec- tions 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. Remove both in/out and return header access panels by re
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Hydrostatic Test Low Temperature System Unlike many other types of heaters, Raypak heaters Heater requires minimum inlet temperature of 105°F. do not require hydrostatic testing prior to being placed Consult the following sections for piping details. in operation. The heat exchanger has already been factory-tested and is rated for 160 PSI maximum oper- Temperature & Pressure Gauge ating pressure. However, Raypak does recommend hydrostatically testing the piping connections to the The temperature
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*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. 11: Dual Boiler—Primary/Secondary Piping 15
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Piping—Heating Boilers Three-Way Valves All high points should be vented. Purge valves and a Valves designed to blend water temperatures or bypass valve should be installed. A boiler installed reduce water circulation through the boiler should not above radiation level must be provided with a low be used. Raypak boilers are high recovery low mass water cut-off device. The boiler, when used in connec- boilers not subject to thermal shock. Raypak offers a tion with a refrigeration system, must be
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Fig. 12: Single Heater — Domestic Hot Water with One Storage Tank Gas Supply Connection Gas Supply DANGER: Make sure the gas on which the heater CAUTION: The heater and its manual shutoff valve will operate is the same type as specified on the must be disconnected from the gas supply during heater’s rating plate. any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa). The heater must be isolated from the gas supply piping system Gas piping must have a sed
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Fig. 13: Sediment Trap Orientation CAUTION: Do not use Teflon tape on gas line pipe Gas Pressure Regulator thread. A pipe compound rated for use with gas systems is recommended. Apply sparingly only on The gas valve pressure regulator(s) on the heater are male pipe ends. nominally preset at 3 in. WC for natural gas, and 10.0 in. WC for propane gas manifold pressure. The pres- CAUTION: Support gas supply piping with sure at the gas valve outlet tap, measured with a hangers, not by the heater or i
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Input 3/4” 1” 1-1/4” 1-1/2” Model No. (KBTUH) N P N P N P N P HD101 100 105 385 340 HD151 150 50 180 160 530 600 HD201 199 30 95 95 355 360 HD251 250 20 50 60 230 240 HD301 299 15 35 45 170 170 550 360 HD401 399 5 20 25 80 100 365 210 Table H: Maximum Equivalent Pipe Length 3 Natural gas – 1,000 BTUH per ft , .60 specific gravity at 0.5 in. WC pressure drop 3 Propane gas – 2,500 BTUH per ft , 1.50 specific gravity at 0.5 in. WC pressure drop Install a separate disconnect means for each load. Use
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5. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code. 2 1 3 45 6 7 8 9 10 11 12 ENABLE / STAGE 1 STAGE 2 INTERLOCK / ALARM 24V 24VR DISABLE OR LOUVER SW DRY CWS / CWR 6. Install heater controls, thermostats, or building SEQUENCER CONTACTS FAN / DAMPER (PILOT DUTY) management systems in accordance with the JUMPERED (OPTIONAL) JUMPERED (OPTIONAL) WHEN NOT USED WHEN NOT USED applicable manufacturer’s instructions. 7. Conduit should n
