Raypak HD401 manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.52B Effective: 1 1-19-09 Replaces: 09-25-09 P/N 241356 Rev . 3 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property damage, personal injury or death . FOR Y OUR SAFETY : Do not store or use gasoline or other flammable vapors and liq[...]

2 Rev . 3 reflects the following: Changes to: Updated T able E on page 14, T able G on page 18, T roubleshooting flowchart on page 35, T able O on page 38. Additions: Commonwealth of Massachusetts information on page 45 Deletions: None[...]

WARNINGS 4 Pay Attention to These T erms 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 T ime/T emperature Relationships in Scalds 8 INST ALLA TION 9 Installation Codes 9 Equipment Base 9 Clearances 9 Combustion[...]

D ANGER: Indicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored. CA UTION: Indicates the presence of hazards or unsa[...]

BEFORE INST ALLA TION 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 a pply to heaters that have been improperly installed or operated (refer to the warranty at the back of this man- ua[...]

Fig. 1: Component Locations — Angle View Fig. 2: Component Locations — Left Side Fig. 3: Component Locations — Front (Panels removed for clarity) 6 Component Locations[...]

General Infor ma tion T able A: Basic Data Model No. Q uantity of Burners V ent Size (in.) Flue Intake HD101 2 4 4 HD151 3 4 HD201 4 5 HD251 5 5 HD301 6 5 HD401 8 6 7 Fig. 5: Gas V alves Fig. 4: Air Shutter Adjustment[...]

GENERAL SAFETY T o 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 [...]

INST ALLA TION INST ALLA TION Installation Codes Installations must follow these codes: · Local, state, provincial, and national codes, laws, regulations and ordinances. · National Fuel Gas Code, ANSI Z223.1- latest edi- tion (NFGC). · National Electrical Code, ANSI/NFP A 70 - latest edition (NEC). · Standard for Controls and Safety Devices for[...]

Fig. 7: Minimum Installed Service Clearances — Indoor/Closet Installations The heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater . Outdoor Installations These heaters are design-certified for outdoor installa- tion. Heaters must not be installed under an overhang unles[...]

area per 20,000 BTUH (1 1 1 mm 2 per kW) of total input rating of all equipment in the room when the opening is communicating directly with the out- do or s o r t hr ou gh ve rt ic al d uc t( s) . Th e t ot al cross-sectional area shall be at least 1 in. 2 of free area per 10,000 BTUH (222 mm 2 per kW) of total input rating of all equipment in the [...]

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 appliances. 1. V entilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors. The tot[...]

13 WARNING: Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur . Refer to local codes. R ev er sing W ater Connections Follow these instructions to change the water connec- ti on s fr om t he l ef t- ha nd si de ( st [...]

14 Low T emper a tur e System Heater requires minimum inlet temperature of 105°F . Consult the following sections for piping details. T emperature & Pr essure Gauge The temperature and pressure gauge is shipped loose for field installation. Hydronic Hea ting Pump Selection In order to ensure proper performance of your boiler system, you must i[...]

15 Fig. 10: Single Boiler — Low T emperature Application (Heat Pump) Primary/Secondary Piping Fig. 1 1: Dual Boiler—Primary/Secondary Piping *Maximum 4 times the pipe diameter or 12”, whichever is less. *Maximum 4 times the pipe diameter or 12”, whichever is less.[...]

16 T able F: Domestic W ater Heater Flow Rate Requirements ∆ T = T emperature rise, °F . ∆ P = Pressure drop through heat exchanger , ft. SHL = System head loss, ft. (System head loss is based on the heater and tank placed no more than 5 feet apart and 50 feet equivalent length of tubing and fittings.) gpm = Gallons per minute, flow rate. MTS [...]

17 Gas Supply Connection CA UTION: 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). The heater must be isolated from the gas supply piping system by closing the manual shutoff valve during any pressure testing of t[...]

18 Fig. 13: Sediment T rap Orientation Gas Supply Pr essure A minimum of 4 in. WC and a maximum of 10.5 in. WC upstream gas pressure is required under load and no load conditions for natural gas. A minimum of 1 1 in. WC and a maximum of 13 in. WC is required for propane gas. The gas pressure regulator supplied on the heater is for low pressure serv[...]

19 Install a separate disconnect means for each load. Use appropriate-sized wire as defined by NEC, CSA and/or local code. All primary wiring should be 125% of minimum rating. It is strongly recommended that all individually-pow- ere d contr ol mod ules an d the hea ter sh ould be supplied from the same power source. Sur ge Protection Microprocesso[...]

20 SINGLE ST AGE T ANKST A T ST AGE 1 CONNECTION A TT ACH ST AGE 1 CONNECTIONS ON HEA TER T O THE SINGLE ST AGE T ANKST A T AS SHOWN IN THE DIAGRAM ABOVE. Fig. 16: Single Stage T ankstat Electrical Connections — Domestic Hot Wa ter Installer action is required to electrically enable your Hi Delta heater to operate after making the power con- nect[...]

Category II . A heater which operates with a non-posi- ti ve v en t st at ic p re ss ur e an d w it h a ve nt g as 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. Categ[...]

22 T able I: V enting Category Requirements Combustion Air S upply Exhaust C onfiguration V enting Category Certified A ppliance Material Combustion Air I nlet Material From Inside Building (Non-Direct V enting) V ertical Natural Draft V enting I T ype B or any C ategory I V enting System* Horizontal Thru-wall V enting III Stainless Steel (Gas T ig[...]

23 U. S. Ins tallations 1 Canad ian Insta llati ons 2 A Clear ance above gr ade , v eranda, p orch , deck, or balcony 1 ft (30 c m) 1 ft (30 c m) B Clear ance to window or do or that may be o pened 4 ft (1.2 m) below or to side of openin g; 1 foot (30 cm) a bove op ening 3 ft (91 cm) C Clearanc e t o per ma nently closed wind ow ** D V ertical clea[...]

24 ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimen- tal to the operation of regulators, relief valves, or other equipment. Where local experience indi- cates that condensate is a problem with Category I and III appliances, this provision shall also apply[...]

25 V enting Installation Tips Support piping: · horizontal runs- at least every five (5) feet. · vertical runs - use braces: · under or near elbows Follow items listed below to avoid personal injury or property damage. · Cut nonmetallic intake pipe with fine-toothed hack- saw . · Do not use nonmetallic intake pipe or fittings that are cracked [...]

26 Natural Draft V er tical V enting System Installation Natural draft venting uses the natural buoyancy of the h eated flue products to create a thermal driving head that expels the exhaust gases from the flue. The neg- ative 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[...]

27 each appliance. Adjust thermostat so appliance will operate continuously . e) Check the pressure at a pressure tap located 12 in. above the bottom joint of the first vertical vent pipe. Pressure should be anywhere between -.01 to -.08 in. WC. f) After it has been determined that each appliance remaining connected to the common venting sys- tem p[...]

28 Horizontal Thr u-wall V enting System (Categor y III) Installation T hese 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. A dequate combustion and ventilation air must be sup- plied in a[...]

29 Fig. 21: Direct V ent Horizontal Thru-Wall V enting (Category III) Model No. Appliance Category Certified V enting Material V ent Size (inches) Max. V enting Length (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) HD101 HD151 III Stainless Steel (Gas T ight) 4 100, 4 Elbows Max. Galvanized Steel PV[...]

30 Model No. Appliance Category Certified V enting Material V ent Size (inches) Min./Max. V ertical V enting Height (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) Min. Max. HD101 HD151 I T ype B Equivalent 4 6 25* Galvanized Steel PVC ABS CPVC 4 100 HD201 HD251 HD301 5 (HD201) 6 (HD251) 6 (HD301) 1 [...]

31 V er tical Direct V ent System Installation T hese 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 f rom the flue. The negative draft must be within the range of -0.01 to -0.08 in. WC as me[...]

Modulating T emper a tur e Control (Optional) T his heater can be equipped with a Raypak modulat- ing temperature control. For operation with this control, refer to the T emp-T racker Installation and Operating Instructions, Raypak Catalog number 5000.66 (P/N 241 177). High Limit (Manual R eset) The heater is equipped with a manual reset high limit[...]

33 Lo w Wa ter Cut Of f (Optional) The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig. 27: Flow Switch Fig. 29: Low W ater Cut Off Flow Switc h Dual-purpo[...]

34 WIRING DIA GRAM—MODELS HD101–HD401[...]

35 YES Ste p 9 HD101-HD401 Troubleshooting YES YES NO NO YES YES NO YES YES NO YES YES NO NO YES NO Ste p 10 YES NO YES YES NO NO YES NO Yes NO YES YES NO S tep 1 S tep 2 S tep 3 Step 4 Step 5 Step 6 Step 7 Step 8 Is there a Call For Heat? Is Disable c onnec tion intact? Does the Pump come on? Is 24VAC at the NO side of the air pressure switch? Is [...]

36 PRE-ST ART -UP Filling System-Heating Hea ter s F ill 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.[...]

37[...]

38 Check the Gas Supply Pressur e 1. Slowly turn on main gas shut-off valve. 2. Read the gas supply pressure from the manome- te r; m in im um s up pl y pr es su re i s 4 in . WC , recommended supply is 7 in. WC for natural gas ( minimum 1 1.0 in. WC for LP gas). 3. If pressure is > 14 in. WC, turn off the valve. 4. Check if the service regulato[...]

39 3. Carefully remove 2-stage solenoid. 4. Skip to Step 9 for LO-fire adjustment only . 5. Locate and remove Lo-fire adjustment cap. 6. Carefully remove the spring & weight. 7. Using an allen wrench, turn clockwise to increase and counterclockwise to decrease the HI-fire man- ifold pressure. Heater will not run while adjusting HI-fire pressure[...]

40 F ollo w-Up • Safety checks must be recorded as performed. • T urn unit on. After main burner ignition: • 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[...]

41 3. Remove the (4) screws holding the panel in place. 4. Pull the air filter out for inspection. Replace if nec- essary . 5. When replacing, note the direction of the air flow defined on the side of the filter . The arrow should be pointing downward. 6. Replace the panel and screws before operating. Fig. 34: Remove the Screws and Panel Fig. 35: I[...]

heater operating efficiency . Maintenance as outlined below may be performed by the owner . Y ear l y (Beginning of eac h heating season): 1. Annual service call by qualified service agency . 42 MAINTENANCE Suggested Minimum Maintenance Schedule: Regular service by a qualified service agency and maintenance must be performed to ensure maximum J ACK[...]

43 2. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal. 3. Visually inspect venting system for proper func- tion, deterioration or leakage. 4. Check that heater area is free from combustible materials, gasoline, and other flammable vapors and liquids. 5. Check for and remove any obstructio[...]

44 • 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. Areas causing contaminated combustion air: • dry clean[...]

45 (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required T o Be V ented" in the most current edition of NFP A 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or s[...]

46 NOTES: ______________ ____________ __________________ _____________ ____________ __________________ ______ ______________ ____________ __________________ _____________ ____________ __________________ ______ ______________ ____________ __________________ _____________ ____________ __________________ ______ ______________ ____________ ____________[...]

47[...]

w w w .r ay pak .co m Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.[...]