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INSTALLATION & OPERATING
INSTRUCTIONS
Models 992B–2342B
L
Types H, WH & P
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 combustable 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
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Rev. 7 reflects the following: Changes to: Fig. 3 on page 6; the UDB Diagnostic Board and UDB Fault History sections on page 44; the Wiring Diagrams on pages 50 and 51. 2
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CONTENTS WARNINGS 4 Venting Installation Tips 28 BEFORE INSTALLATION 5 Venting Configurations 28 Product Receipt 5 Outdoor Installation 33 Model Identification 5 Controls 33 Ratings and Certifications 5 Heater Sequence of Operation 34 Installations at Elevation 5 87%-Efficiency Boilers – Component Locations 6 Special Instructions 45 General Information 7 Wiring Diagrams 50 GENERAL SAFETY 8 START-UP 52 Time/Temperature Relationships in Pre Start-up 52 Scalds 8 Start-Up 53 INSTALLATION 9 OPERATIO
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WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe person- DANGER: al 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
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number will have the form H9 1262B or similar BEFORE INSTALLATION depending on the heater size and configuration. The letter(s) in the first group of characters identifies the Raypak strongly recommends that this manual be re- application (H = Hydronic Heating, WH = Domestic viewed thoroughly before installing your Hi Delta Hot Water (DHW), P = Pool). The number which fol- heater. Please review the General Safety information lows identifies the firing mode (1 or 4 = on-off, 3 = before installing
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Component Locations OPTIONAL FLUE CONNECTION Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front 6
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General Information Quantity of Vent Size (in.) Model Gas No. Burners Blowers Flue Intake Valves 992B 11 2 + 1* 2 10 10 1262B 14 3 + 1* 2 12 10 1532B 17 4 2 12 10 1802B 20 4 2 14 10 2002B 23 5 3 14 10 2072B 23 5 3 14 10 2342B 26 5 3 16 10 *Hidden solenoid valve located inside of air plenum. Table A: Basic Data Burners per Valve Stages % Fire at Stage Model No. 1 1A 2 3 4 1 2 3 4 1 2 3 4 992B 6 3 2 1 1, 2 1, 2, 3 54 82 100 1262B 5 3 3 3 1 1,2 1, 2, 3 1, 2, 3, 4 36 57 79 100 1532B 6 4 4 3 1
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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 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 thermostat. The most energy-efficient operation will Wate
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The temperature of the water in the heater can be reg- Equipment Base ulated by using the temperature controller. To comply with safety regulations, the temperature controller is The heater should be mounted on a level, structurally set at the lowest setting when shipped from the facto- sound surface. The heater is approved for installation ry. on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed To adjust the water temperature, insert a small straigh
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Fig. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 2 U.S. Installations Canadian Installations Clearance above grade, veranda, porch, A 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be B of opening; 1 foot (30 cm) 3 ft (91 cm) opened above opening C Clearance to permanently closed window ** Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- D 5
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In addition, the heater shall be installed such that the When installed according to the listed minimum clear- gas ignition system components are protected from ances from combustible construction, these heaters water (dripping, spraying, rain, etc.) during appliance can still be serviced without removing permanent operation or service (circulator replacement, control structural construction around the heater. However, for replacement, etc.). ease of servicing, we recommend a clearance of at lea
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Reversing Air Filter Follow these instructions to change the air duct con- nection from the left-hand side (standard) to the right-hand side: 1. Remove the four screws and the dust cover from the right-hand side of the heater. 2. Remove the four screws and the air filter bracket from the left-hand side of the heater. 3. Reverse the components and reattach in the new location, making sure that the air filter locking bracket is on the bottom. (The air filter locking bracket is reversible.) Direct
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three or four sheet metal screws (not supplied) equal- space shall be considered in making this determina- ly distributed around the circumference of the duct. All tion. Each opening shall have a minimum free area of 2 2 ducting should be self-supported. The filter housing is 1 in. per 1,000 BTUH (2,225 mm per kW) of the total not designed to support the air duct. input rating of all gas utilization equipment in the con- 2 2 fined space, but not less than 100 in. (645 cm ). One opening shall com
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2 2 b. Not less than the sum of the areas of all vent of not less than 1 in. for each 30,000 BTUH mm connectors in the confined space. per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere with the intended purpose of the opening(s) for WARNING: Do not use one permanent opening ventilation air referred to in (1). This opening(s) method if the equipment room is under negative can be ducted to a point not more than 18 in. (450 pressure conditions or
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5. Remove all plumbing fittings to the header. This Hydrostatic Test will include both inlet and outlet water pipe unions and the pressure relief valve and drain piping. Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in 6. Remove limits, control bulbs and/or thermocou- operation. The heat exchanger has already been fac- ples. tory-tested and is rated for 160 psi operating pressure. However, Raypak does recommend hydrostatic test- 7. Remove
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system, such as a three-way proportional valve or a Failure to exceed 105ºF (41ºC) within 7 minutes may modulating two-way valve to control the bypass, result in the premature failure of the hot surface ignit- should be utilized. er, remote flame sensor, burners and heat exchanger. It can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of Cold Water Run the vent system. The bypass allows part of the heater discharge water to be mixed with the cool
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heaters which are not subject to thermal shock. Pressure Drop in Feet of Head Raypak offers a full line of electronic sequencers that Feedwater Regulator produce direct reset of heater water temperature. (Refer to the Controls section of the Raypak Catalog.) Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the highest point of the system. Install a check valve or back flow device upstream of the regulator, with a manual shut-off valve as required
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Potable Water and Space Heating CAUTION: When this heater is used for both potable water and space heating, observe the following to ensure proper operation. 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, Fig. 13: Single Domestic Hot Water Heater and Storage shall not be introduced into the potable water used Tank for space heating. Pool Hea
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circulate water through the heater from the main sys- slowly throttle Valve B closed to increase the inlet tem piping. water temperature to 105°F. 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 will be energized at the right time. If the main water line is too far away from the heater and the capillary bulb will not reach it, locate the pool thermo- stat adjacent
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shut-off. Close isolation valves and remove water pip- Total Dissolved Solids ing from the in/out header on the heater. Drain the heater and any piping of all water that may experience Total dissolved solids (TDS) is the measure of all min- below-freezing temperatures. erals and solids that are dissolved in the water. The concentration of total dissolved solids is usually ex- Pool/Spa Water Chemistry pressed in parts per million (ppm) as measured in a water sample. Water with a high TDS concentr
