Raypak 302-902 manual

INST ALLA TION AND OPERA TING INSTRUCTIONS Models 302-902 T ype H, WH, & P 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. T o do so may result in an explosion or fire. W ARNING: Improper installation, adjustment, alteration, servic[...]

T ABLE OF CONTENTS P AGE NO. 4 SECTION A: BEFORE INST ALLING THE BOILER 8 SECTION B: BOI LER INST ALLA TION 1 1 SECTION C: COMBUSTION AND VENTILA TION AIR 13 SECTION D: W A TER PIPING - GENERAL 14 SECTION E: HYDRONIC HEA TING PIPING 16 SECTION F: DOMESTIC HOT W A TER PIPING 17 SECTION G: POOL HEA TING 19 SECTION H: GAS SUPPL Y CONNECTIONS 21 SECTIO[...]

DANGER: Make sure the gas on which the boiler will operate is the same type as that specified on the boiler model and rating plate. WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the boiler. Instead, shut off the gas supply at a location external to the appliance. WARNI[...]

Pay attention to these terms: DANGER: 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. CAUTION: indicates the p[...]

MODEL IDENTIFICATION The model identification number and boiler serial number are found on the boiler data plate located on the left inside jacket of the boiler. The model number will have the form H3 0752 or similar depending on the boiler size and configuration. The first character of the model number identifies application (H = Hydronic Heating [...]

Combustion Air Filter (Inlet) Flue Exhaust Optional Combustion Air (Inlet) Alternate Flue Connection Gas Supply Connection Pressure Relief Connection W ater Outlet Electrical Connection W ater Inlet T emperature and Pressure Gauge Gas T rain Operational Center Control Pressure Relief V alve Heat Exchanger Burner Group Remote Sensor Combustion Air B[...]

7 General Information[...]

36.0 36.0 12.0 36.0 12.0 SECTION B: BOILER INST ALLA TION INSTALLATION CODES Installations must follow these codes: · Local, state, provincial, and national codes, laws, regulations and ordinances. · National Fuel Gas Code (NFGC), ANSI Z223.1- latest edition. · National Electrical Code (NEC), ANSI/NFP A 70 - latest edition. · Standard for Contr[...]

1 " 12" 1" 1" CLEARANCES T ABLE 1 INDOOR INST ALLA TION MINIMUM CLEARANCES FROM COMBUSTIBLE SURF ACES Boiler Size Boiler Side 302-902 Floor See Note 1 Rear 1" W ater Side 1 2 ” Other Side 1" To p 1 " Front 1" V ent 2" Note 1 . Do not install on carpeting. When installed according to the listed minimum [...]

OUTDOOR INST ALLA TIONS Raypak Hi Delta Boilers are design certified for outdoor installation. Boilers must not be installed under an overhang that is less than three (3) feet from the top of the boiler . Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from boilers installed under overhangs. T [...]

SECTION C: COMBUSTION AND VENTILA TION AIR COMBUSTION AND VENTILA TION AIR (Indoor Units) The boiler must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation. Combustion air can be supplied via conventional venting, where combustion air is drawn from the area immedi- ately surroundin[...]

COMBUSTION AND VENTILA TION AIR SUPPL Y (FOR CANADA INST ALLA TION) CAUTION: All combustion air has to be drawn from the air outside the building (the mechanical equipment room directly communicates with the outdoors). 1 . V entilation of the space occupied by the boiler shall be provided by an opening(s) for ventilation air at the highest practica[...]

SECTION D: W A TER PIPING - GENERAL The boiler should be located so that any water leaks will not cause damage to the adjacent area or structures. CAUTION: This boiler r equires for ced water cir culation when the burner is operating. See T able D-1 for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the b[...]

SECTION E: HYDRONIC HEA TING PIPING PUMP SELECTION In order to insure proper performance of your boiler system, you must install a properly sized pump. Raypak recommends using a 20°F Delta T as design Delta T . (Delta T is the temperature difference between the inlet and outlet water when the boiler is firing at full rate). If a Delta T larger tha[...]

12 SINGLE BOILER - LOW TEMPERA TURE APPLICA TION (HEA T PUMP) PRIMAR Y/SECONDARY PIPING Fig. #9223 DUAL BOILER PRIMARY/SECONDARY PIPING Fig. #9232.2 15[...]

SECTION F: DOMESTIC HOT W A TER PIPING When designing the water piping system for domestic water applications, water hardness should be considered. T able F-1 indicates the suggested flow rates for soft, medium and hard water . Hardness is specified as grains per gallon. T ABLE F-1 DOMESTIC W A TER HEA TER FLOW RA TE REQUIREMENTS D T = T emperature[...]

SECTION G: POOL HEA TING CAUTIO CAUTION: Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation. Improper flow control can damage the heater . Uncontrolled flow (too high) or restricted flow (too low) can seriously damage the heater . Follow these instructi[...]

A UTOMA TIC CHLORINA TORS AND CHEMICAL FEEDERS All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater . Do not place chlorine tablets or bromine sticks in the skimmer . High chemical concentrations will result when the pump is not running (i.e. overnight). Chlorinators must feed[...]

SECTION H: GAS SUPPL Y CONNECTIONS DANGER: Make sure the gas on which the boiler will operate is the same type as specified on the boiler model and rating plate. Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve located outside the heater jacket. A pounds to inches regulator must be installed to redu[...]

GAS PRESSURE REGULA T O R The gas valve pressure regulator(s) on the boiler are nominally preset at 3.5" W .C. for Natural gas, and 10.5" W .C. for Propane gas manifold pressure. The pressure at the gas valve outlet tap, measured with a manometer ,while in operation should be 3.5 ± 0.1" W .C. for Natural gas and 10.5" ± 0.1&qu[...]

CIRCUIT BREAKER WHITE GROUND BLACK GREEN AB C VOL T-OHM METER SECTION I: ELECTRICAL POWER CONNECTIONS Installations must follow these codes: · National Electrical Code and any other national, state, provincial or local codes or regulations having jurisdiction. · Safety wiring must be N.E.C. Class 1. · Boiler must be electrically grounded as requ[...]

MAKING THE ELECTRICAL CONNECTIONS Refer to Fig. #9227 W iring Connection, and Fig. #9233 or Fig. #9234 W iring Diagram. 1 . V erify circuit breaker is properly sized by referring to boiler rating plate. A dedicated circuit breaker should be provided. 2 . T urn off all power to the boiler . V erify that power has been turned of f by testing with a v[...]

ELECTRICAL CONNECTIONS - DOMESTIC HOT W A TER CAUTION: Label all wir es prior to disconnection when servicing controls. W iring errors can cause impr oper and danger ous operation. V erify proper operation after servicing. DANGER - SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to c[...]

SECTION J: VENTING CONNECTIONS GENERAL CAUTION: Proper installation of flue exhaust venting is critical for the safe and efficient operation of the boiler . Definition of Appliance Categories Boilers are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Category I. A [...]

Category Determination for Venting Purpose and Venting Arrangement 25 TABLE J-1 * As defined in the latest edition of the National Fuel Gas Code, or in Canada, the latest edition of the CAN/CGA B149.1 and B149.2.[...]

Support of V ent S tack The weight of the vent stack or chimney must not rest on the boiler vent connection. Support must be provided in compliance with applicable codes. The vent should also be supported to maintain proper clearances from combustible materials. Use insulated vent pipe spacers where the vent passes through combustible roofs and wal[...]

V enting Installation T ips 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 hacksaw (34 teeth per inch). · Do not use nonmetallic intake pipe or fittings th[...]

28 SECTION J-1 Natural Draft V ertical V enting (Category I) NA TURAL DRAFT VER TICAL VENT NOTE: **V ent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the National Fuel Gas Code for further details. (ANSI Z223.1) Fig. #9228 10' OR LESS 2' MIN VENT CAP 2' MIN VENT PIPE BOILER UNIT COMBUSTION AIR FIL T[...]

• Natural Draft V ertical V enting System Installation Natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The negative draft must be within the range of -.01” to -.10” negative W .C. as measured 12 inches from the appliance flue outlet to in[...]

Common venting systems may be too large when an existing unit is removed. At the time of removal of an existing appliance, the following steps must be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. a [...]

SECTION J-2 Horizontal Thru-W all V enting (Category III) Fig. #9229.1 HORIZONT AL THRU-W ALL VENTING (CA TEGOR Y III) T ABLE • Horizontal Thru-wall V enting System (Category III) Installation These installations utilize the boiler-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from inside the room and the[...]

The total length of the horizontal thru-wall exhaust vent system should not exceed seventy (70) feet in length. If horizontal run exceeds 70 feet, an appropriately sized extractor must be used. T o maintain proper operation pressure reading must be between -.01 to -.1 W .C. as measured 12 inches from the appliance flue outlet. Each elbow used is eq[...]

• Horizontal Thru-wall Direct V ent T ermination The flue exhaust direct vent cap MUST be mounted on the exterior of the building. The direct vent cap cannot be installed in a well or below grade. The direct vent cap must be installed at least one (1) foot above ground level and above normal snow levels. The Raypak supplied flue exhaust direct ve[...]

DIRECT VENT Horizontal Thru-wall V enting (Category III) Fig. #9230.1 HORIZONT AL THRU-W ALL VENTING T ABLE 34 SECTION J-3 AIR FIL TER BOILER UNIT 6" MIN. 36" MIN. 12" MIN. 9" MIN. CONDENSA TE TRAP EXHA UST VENT INT AKE VENT[...]

• Horizontal Thru-wall Dir ect V ent System (Category III) Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors. The total length of the thru-wall exhaust vent cannot exceed forty (40) feet in length for the flue outlet. Each elbow used is equal to ten[...]

DIRECT VENT V ertical V enting (Category I) Fig. #9231.1 VER TICAL VENTING T ABLE 36 SECTION J-4 AIR FIL TER INT AKE VENT BOILER UNIT EXHA UST VENT 3' MIN. VENT CAP 3' MIN. 1' MIN.[...]

• V ertical Direct V ent System Installation These installations utilize the boiler 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 from the flue. The negative draft must be within the range of- 0.01 to- 0.10” negative W [...]

SECTION J-5 Outdoor Installation Outdoor models are self -venting when installed with the factory-supplied restricted direct vent cap and require no additional vent piping. This special vent cap is provided with the boiler in accordance with AGA/CGA requirements. It must be installed directly on the boiler . See Section B for correct clearances. Ca[...]

39 HI DEL T A OUTDOOR VENT INSTRUCTIONS 1. T urn off the power and shut of f the gas to heater . Heater as shipped 2. Slide the vent collar from kit over the collar on heater as shown in Fig. 1 . 3. Drill a 3/16” pilot hole into the heater collar through each of the holes on the lower vent collar . See Fig. 1 . Fig. 1 4. T ake four of the self-ta[...]

40 HI DEL T A OUTDOOR VENT INSTRUCTIONS CONTINUED 6. Slide the collector over vent collar , aligning the holes over the openings in the tinnerman clips as shown i n Fig. 4 . Fig. 4 7. T ake four of the screws from the kit and screw into the holes as shown in Fig. 4 . 8. Slide the vent cap down into the vent collar as shown i n Fig. 5 . Fig. 5 9. Dr[...]

41 HI DEL T A FIL TER BOX KIT NOTICE: These instructions are intended for use by qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel are required to be licensed in some states. Persons not qualified shall not attempt repairs [...]

42 HI DEL T A FIL TER BOX INSTRUCTIONS CONTINUED 11. Mark the four holes through filter box for screw locations. Air intake collar 12. Using a 1/16 drill bit, drill a pilot hole in each of the holes previously marked. 13. Mount the filter box to the unit using four screws provided in the kit. 14. Install filter under filter box on top of air intake[...]

SECTION K: CONTROLS W ARNING: Installation, adjustment and service of boiler controls including timing of various operating functions must be performed by a qualified installer , service agency or the gas supplier . Failur e to do so may r esult in control damage, boiler malfunction, pr operty damage, personal injury , or death. W ARNING: T urn off[...]

44 HI-DEL T A Model 302-402 The black (hot) wire leads you directly to the Main Power Switch. This switch is located at the bottom right-front corner of the control compartment. When the main power switch is placed in the “ON” position, both the 120 v and 24 v terminal blocks on the Main Circuit Board will be powered and the power light will tu[...]

HI-DEL T A Model 502-752 The black (hot) wire leads you directly to the Main Power Switch. This switch is located at the bottom right-front corner of the control compartment. When the main power switch is placed in the “ON” position, both the 120 v and 24 v terminal blocks on the Main Circuit Board will be powered and the power light will turn [...]

46 HI-DEL T A Model 902 The black (hot) wire leads you directly to the Main Power Switch. This switch is located at the bottom right-front corner of the control compartment. When the main power switch is placed in the “ON” position, both the 120 v and 24 v terminal blocks on the Main Circuit Board will be powered and the power light will turn o[...]

IGNITION CONTROL MODULE The interrupted proved ignition device conserves energy . When additional heat is needed, the combustion air blower starts to purge all air from the combustion chamber for about 15 seconds. On proof of air flow , the air proving switch closes and the igniter is energized, eliminating the fuel costs of maintaining a constant [...]

LOW W A TER CUT OFF (OPTIONAL) The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 3 second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig.# J-5 LOW W A TER CUTOFF HIGH AND LOW GAS PRESSURE SWITCHES The low gas [...]

49 WIRE DIAGRAM MODEL 302-402 Reference Drawing Number M152462-Rev. M H4/W1[...]

WIRE DIAGRAM MODEL 302-402 Reference Drawing Number M152470-Rev. J H3/W3 50[...]

51 WIRE DIAGRAM MODEL 502-752 Reference Drawing Number M152464-Rev R H3/HW3[...]

WIRE DIAGRAM MODEL 902 Reference Drawing Number M152465 Rev-P H3/W3 52[...]

SECTION L: GENERAL SAFETY PRECAUTIONS T o meet commercial water use needs, the temperature Hi-Limt on this hot water boiler is adjustable up to 210°F . However , water temperatures over 125°F can cause severe burns instantly or death from scalds. The preferred starting point for setting the control for supplying general purpose hot water is 125°[...]

SECTION M: PRE-ST AR T -UP FILLING SYSTEM-HEA TING BOILERS Fill system with water . Pur ge all air from the system using purge valve sequence. After system is pur ged 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 cl[...]

SECTION N: HI-DEL T A INITIAL ST AR T -UP 1 . 0 TOOLS NEEDED • One 12-0-12, 24” scale manometer • 6-0-6, 12” scale manometers • 7/16” open end wrench • 1/2” open end wrench • Screwdriver • V olt meter • 3/16” Allen wrench • Jumper cable 2 . 0 PREP ARA TION FOR ST AR T -UP W ARNING: DO NOT TURN ON GAS A T THIS TIME 2 . 1 Ch[...]

3.0 S T A R T - U P 3 . 1 Blower Adjustment 1 . Disconnect all fan pressure switch tubings at plenum and connect manometer using a tee. 2 . Close all manual firing valves. 3 . Turn power on; 4 . Check manometers attached to fan pressure switches. The readings should be 1.4 + .2"W .C. for propane and natural gas. If not, adjust the air shutter [...]

57 PILOT TURN DOWN TEST FOR RA YP AK HI DEL T A BOILERS The Hi Delta boilers, depending on their size, have from two to five burner sections. Each burner section is supplied gas by dual gas valves incorporated in single valve body . A maximum of three burner sections may be controlled by a single hot surface ignition system. The middle of the three[...]

4 ) Next, close the upstream manual gas valve and remove the manometers from test point A and from test point B. Connect a rubber tube from test point A to test point B and open the upstream manual gas valve. Make sure that test points A & B have been opened so as to allow gas to flow . This will bring pressure to the second valve seat. 5 ) Ope[...]

SECTION O: POST ST AR T -UP CHECK Check off steps as completed: 1 . Boiler and heat distribution units or storage tank filled with water? 2 . Automatic air vent, if used, open two full turns during venting procedure? 3 . Air purged from system? 4 . Air purged from gas piping? Piping checked for leaks? 5 . Followed start-up procedure for proper star[...]

SECTION P: OPERA TION OPERA TING INSTRUCTIONS Lighting Instructions 1. STOP! Read the safety information first. 2 . Set the thermostat to the lowest setting. 3 . Turn off all electric power to the appliance. 4 . This appliance is equipped with an ignition device which automatically lights the burner . Do Not try to light the burner by hand. 5 . Rem[...]

SECTION Q: MAINTENANCE SUGGESTED MINIMUM MAINTENANCE SCHEDULE: Regular service by a qualified service agency and maintenance must be performed to assure maximum boiler operating ef ficiency . Maintenance as outlined below may be performed by the owner . Y early (Beginning of each heating season): 1 . Annual service call by qualified service agency [...]

PREVENTIVE MAINTENANCE SCHEDULE Required procedure in CSD-1 States and good practice for all Hi-Delta installations. Daily 1 . Check gages, monitors and indicators. (See page 6 of the Operating and Installation Instructions Manual). 2 . Check instrument and equipment settings. (See page 49-50 of the Operating and Installation Instructions Manual). [...]

APPENDIX A INSIDE COMBUSTION AIR CONT AMINA TION: All boilers experience some condensation during start-up. The condensate from flue gas is slightly acidic. In most cases the pH level is not harmful to vents or drains. When combustion air is contaminated by vapors from products in areas listed below , the acidic levels in the condensate increase. H[...]

64 LIMITED PARTS WARRANTY COMMERCIAL BOILERS TYPE HI-DELTA SIZES 302 TO 902 MODELS H AND W SCOPE: Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the condit[...]

Raypak, Inc. , 2151 Eastman A venue, Oxnard, CA 93030 (805) 278-5300 F AX: (800) 872-9725 Raypak Canada L TD , 2805 Slough S treet, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 F AX: (905) 677-8036 6-99 Litho in U. S. A. www .raypak.com[...]