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INSTALLATION & OPERATING
INSTRUCTIONS
Models 122–322
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 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 n
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Rev. 9 reflects the following: Changes to: The text in the BEFORE INSTALLATION section on page 5; the text in paragraph one of the GENERAL SAFETY section on page 8; the text in paragraph one of the Outdoor Installations section on page 10; Table E on page 10; the wiring diagram on page 35. 2
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CONTENTS WARNINGS 4 Main Burner Adjustment 37 Pay Attention to These Terms 4 Safety Inspection 37 BEFORE INSTALLATION 5 Follow-Up 38 Product Receipt 5 POST START-UP CHECK 38 Model Identification 5 OPERATION 38 Ratings and Certifications 5 Operating Instructions 38 Installations at Elevation 5 To Turn Off Gas To Appliance 39 Component Locations 6 MAINTENANCE 39 General Information 7 Suggested Minimum Maintenance Time/Temperature Relationships in Scalds 8 Schedule 39 GENERAL SAFETY 8APPENDIX 40 C
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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
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the left inside jacket of the heater. The model number BEFORE INSTALLATION will have the form H3 0162 or similar depending on the heater size and configuration. The first character of the Raypak strongly recommends that this manual be re- model number identifies application (H = Hydronic viewed thoroughly before installing your Hi Delta Heating System, WH = Hot Water Supply System, P = heater. Please review the General Safety information Pool Application). The second character identifies the bef
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Component Locations COMBUSTION AIR FLUE EXHAUST INTAKE Fig. 1: Component Locations—Back PRESSURE RELIEF CONNECTION WATER OUTLET GAS CONNECTION WATER INLET VIEW PORT Fig. 2: Component Locations—Left Side HI LIMITS HI-LIMITS Fig# 9399 Panels removed for clarity Fig. 3: Component Locations—Front 6
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General Information Quantity of Vent Size (in.) Model No. Burners Gas Valves Blowers Flue Intake 122 3 2* 1 4 5 162 4 2* 1 5 5 202 5 2* 1 5 5 242 6 2* 1 5 5 322 8 2* 1 6 5 *Second valve located inside air plenum Table A: Basic Data Burners per Valve Stages % Fire at Stage Model No. A B 1 2 1 2 122 2 1 A AB 66 100 162 3 1 A AB 75 100 202 3 2 A AB 60 100 242 4 2 A AB 66 100 322 5 3 A AB 63 100 Table B: Manifold Data Fig. 5: Air Shutter Adjustment Fig. 4: Gas Valve Detail 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 temperature control. To comply with safety regulations, the temperature control is set The heater should be mounted on a level, structurally at the lowest setting when shipped from the factory. sound surface. The heater is approved for installation on a combustible surface but must NEVER be To adjust the water temperature, insert a small straight installed on carpeting. Gas-fueled equipment installed screwd
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FRONT VIEW TOP VIEW Fig. 7: Minimum Clearances from Combustible Surfaces—Indoor Installations When installed according to the listed minimum clear- Outdoor Installations ances from combustible construction, these heaters can still be serviced without removing permanent These heaters are design-certified for outdoor installa- structural construction around the heater. However, for tion. Heaters must not be installed under an overhang ease of servicing, we recommend a clearance of at
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a motorized sealed damper to prevent the circula- These clearances are required when the outdoor tion of cold air through the heater during the vent cap is used. If installing the heater outdoors non-operating hours. with a vent stack, the indoor clearances may be utilized. Conventional Combustion Air The combustion air intake hood MUST be used for Supply outdoor installations. The hood is shipped loose and installed on the side of the heater over the filter box at U.S. Installations the job sit
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2 Btu per hr (11 cm per kW) of total input rating than 18 in. (450 mm) nor less than 6 in. (150 mm) of all equipment in the enclosure. above the floor level. The duct can also "Goose Neck" through the roof. The duct is preferred 2. One permanent opening, commencing within 12 straight down 18” from floor, but do not place near in. (30 cm) of the top of the enclosure, shall be piping. This air supply opening requirement shall permitted where the equipment has clearances of be in addition to the ai
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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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Fig. 9: Single Boiler—Low Temperature Application (Heat Pump) Primary/Secondary Piping Fig. 10: Dual Boiler—Primary/Secondary Piping 14
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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. 11: Single Heater—Domestic Hot Water with One Storage Tank 16
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Winterizing Your Heater Pool Heating When heaters installed outdoors in freezing climate CAUTION: Power to the heater should be areas are to be shut down for the winter, please interlocked with the main system pump to make sure observe the following procedure: the heater does not fire without the main system pump in operation. Improper flow control can Heaters installed outdoors in freezing climate areas damage the heater. Uncontrolled flow (too high) or should be shut down for the winter. To sh
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MANUAL SHUT OFF VALVE GAS FLOW SUPPLIED SUPPLIED GAS MANUAL BY OTHERS BY OTHERS FLOW SHUT OFF VALVE EXTENTS OF SEDIMENT TRAP UNIT ENCLOSURE EXTENTS OF UNIT ENCLOSURE SEDIMENT TRAP TO BURNERS UNION TO BURNERS Fig. 12: Sediment Trap Orientation Gas Supply Connection Gas Supply Pressure A minimum of 7 in. WC and a maximum of 10.5 in. WC CAUTION: The heater and its manual shutoff valve upstream gas pressure is required under load and no must be disconnected from the gas supply during load cond
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Electrical Power Connections Installations must follow these codes: · National Electrical Code and any other national, state, provincial or local codes or regulations hav- ing 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, 12 AMPS. The volt- AC = 108 Volts AC Minimum, 132 Volts AC MAX age is indicated on the tie-in leads. Consult the wiring AB = 108 Volts AC Minimum, 132 Volts AC
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Fig. 14: Single Stage and 2-Stage Tankstat 1. For Pool and Closed Loop Water Source Heat Electrical Connections—Domestic Pump applications, your heater should be config- Hot Water ured to operate in an ON/OFF firing mode. This means that you will connect a single-pole control DANGER—SHOCK HAZARD: Make sure to stage one of stage selector (Terminals 4 & 5). electrical power to the heater is disconnected to Then jumper the remaining firing stages. For avoid potential serious injury or damage to exa
