Raypak 1262C Installation & Operating Instructions Manual Download Page 6

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Component Locations

Fig. 1: Component Locations – Back

Fig. 2: Component Locations – Left Side

Panels removed for clarity

Fig. 3: Component Locations – Front

Summary of Contents for 1262C

Page 1: ...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 touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified in...

Page 2: ...2 Revision 2 reflects the following changes Removed California Proposition 65 warning on page 4 ...

Page 3: ...ting 22 Gas Supply 25 Electrical Power Connections 26 Field Wiring Connection 28 Venting 32 Changing the Flue Outlet 34 Venting Installation Tips 34 Venting Configurations 35 Sequence of Operation 40 Controls 44 Wiring Diagrams 992C 1262C 54 Wiring Diagram 1532C 2342C 55 START UP 56 Pre Start up 56 Start up 57 OPERATION 60 Lighting Instructions 60 To Turn Off Gas To Appliance 60 MAINTENANCE 61 Sug...

Page 4: ...eater WARNING Risk of electrical shock More than one disconnect switch may be required to deenergize the equipment before servicing CAUTION Operation of this heater in low temperature systems requires special piping Harmful internal condensation will occur if the inlet water temperature does not exceed 105 F Warranty claims will be denied when condensation occurs CAUTION If this heater is to be in...

Page 5: ...Raypak s standard war ranties Model Identification The model identification number and heater serial number are found on the heater rating plate located on the lower right outside jacket of the heater The model number will have the form H9 1262C or similar depending on the heater size and configuration The letter s in the first group of characters identifies the application H Hydronic Heating WH D...

Page 6: ...Component Locations Fig 1 Component Locations Back Fig 2 Component Locations Left Side Panels removed for clarity Fig 3 Component Locations Front 6 ...

Page 7: ...3 14 10 2072C 23 5 3 14 10 2342C 26 5 3 16 10 Model No Burners per Valve Stages Fire at Stages 1 1A 2 3 4 1 2 3 4 1 2 3 4 992C 6 3 2 1 1 2 1 2 3 54 82 100 1262C 5 3 3 3 1 1 2 1 2 3 1 2 3 4 36 57 79 100 1532C 6 4 4 3 1 1 2 1 2 3 1 2 3 4 35 59 82 100 1802C 6 4 5 5 1 1 2 1 2 3 1 2 3 4 30 50 75 100 2002C 4 5 5 5 4 1 1A 1 1A 2 1 1A 2 3 1 1A 2 3 4 39 61 83 100 2072C 4 5 5 5 4 1 1A 1 1A 2 1 1A 2 3 1 1A 2...

Page 8: ...stream and read the thermometer NOTE When this water heater is supplying general purpose hot water for use by individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further information Water temperature over 125 F can cause instant severe burn...

Page 9: ...al in the Controls section see page 47 For accurate control of water temperature the sensors must be properly installed according with the piping configuration see Applications Modes section for detailed information see page 19 CAUTION Hotter water increases the risk of scald ing There is a hot water scald potential if the thermostat is set too high CAUTION The heaters should be located in an area...

Page 10: ...4 ft 1 2m below or to side of opening 1 ft 30 cm above opening 3 ft 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t M Clearance under veranda porch deck or balcony 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 Natio...

Page 11: ...ent or removal of the heater Service clearances less than the minimums may require removal of the heater to service either the heat exchanger or the burner tray In either case 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 ...

Page 12: ...total cross sectional area should be at least 1 in 2 of free area per 20 000 BTUH 111 mm2 per kW of total input rating of all equipment in the room when the opening is com municating directly with the outdoors or through vertical duct s The total cross sectional area should be at least 1 in 2 of free area per 10 000 BTUH 222 mm2 per kW of total input rating of all equipment in the room when the op...

Page 13: ...n 100 in 2 645 cm2 One opening shall commence within 12 in 305 mm of the top and one opening shall commence within 12 in 305 mm of the bottom of the enclosure The mini mum dimension of air openings shall be not less than 3 in 76 mm in any direction All Air from Outdoors The confined space shall communicate with the out doors in accordance with one of the methods below The minimum dimension of air ...

Page 14: ...rea CAUTION All combustion air must be drawn from the air outside of the building the mechanical equip ment room must communicate directly with the outdoors of not less than 1 in 2 for each 30 000 BTUH mm2 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 ventilation air referred to in 1 This opening s c...

Page 15: ...atic test ing of the piping connections to the heater and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based anti freeze Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply Leaks must be repaired at once to prevent damage to the heater NEVER use petroleum based stop leak compounds To ...

Page 16: ...es automatic functionality to con trol a proportional 3 way valve to provide Cold Water Protection for Single or Cascade configurations See Fig 9 H models MIX TYPE PUMP H models include a second option for individual Cold Water Protection method PUMP MIX TYPE PUMP uses a Variable Speed Pump as a CWP mech anism recommended for those systems that require low lead non ferrous plumbing Applications th...

Page 17: ...ary Secondary piping arrangement is the method recommended and the only method supported by Raypak for installation of Hi Delta equipment Proper system design should always include system flow in excess of the connected boiler flow for proper operation Boiler Flow 15 Min System Flow When appropriate a Buffer De coupler Tank can be used where system flow may be reduced below the connected boiler fl...

Page 18: ...ly sized expansion tank and air separator fitting as shown in Fig 14 System Sensor Installation The System Sensor S3 is required for all selectable mode unless the unit s firing rate will be controlled by Fig 14 Air Separation Expansion Tank an external source such as the Temp Tracker MOD Hybrid sequencer sales option B 36 Proper place ment and method of installation are critical for proper operat...

Page 19: ...de range of applications The installer design engineer should refer to the following Modes to determine which best fits the intended application and functionality for the unit being installed Type H models of Hi Delta have three modes available to them to address the various applications the units can be applied to Type WH and P units will only have one configuration available to them For detailed...

Page 20: ...m and hard water Water hardness is ex pressed in grains per gallon NOTE A Tank Aquastat can be used in lieu of the Indirect DHW Sensor S5 See the Versa IC manual for additional details Fig 21 Dual Heaters Reverse Return with Primary Secondary Piping Maximum 4 times the pipe diameter or 12 whichever is less Fig 19 MODE 2 Single Boiler with Indirect on System Loop Mode 2 Type H Units Only This mode ...

Page 21: ...order to reduce scald hazard potential Automatic Chemical Feeders All chemicals must be introduced and completely dilut ed into the water before being circulated through the heater High chemical concentrations will result when the pump is not running e g overnight CAUTION When this heater is used for both potable water and space heating observe the following to ensure proper operation Fig 23 WH Un...

Page 22: ...T GPM P MTS SHL T GPM P MTS SHL T GPM P MTS SHL 992C 29 60 2 7 2 5 2 17 98 7 3 2 13 3 13 132 13 1 2 23 6 1262C 29 72 4 4 2 7 9 19 115 11 3 2 19 4 16 132 14 8 2 25 3 1532C 29 86 7 1 2 11 9 22 120 13 7 2 22 5 20 132 16 5 2 27 0 1802C 29 102 10 9 2 17 4 26 120 15 1 2 23 9 23 132 18 3 2 28 7 2002C 29 112 13 9 2 21 6 26 132 19 0 2 29 5 26 132 19 0 2 29 5 2072C 31 117 15 1 2 23 4 27 132 19 0 2 29 5 27 1...

Page 23: ...s to full fire 4 Adjust Valve A until the inlet water temperature is 105 F NOTE Opening the valve will increase the temperature and closing the valve will decrease the temperature 5 If this process does not raise the inlet water tem perature to 105 F and Valve A is fully open then slowly throttle Valve B closed to increase the inlet water temperature to 105 F Automatic Cold Water Protection Option...

Page 24: ... 4 7 3 7 4 7 6 7 8 Total Alkalinity ppm 120 150 120 150 80 120 Calcium Hardness ppm 200 300 150 200 200 400 Salt ppm 3000 Maximum 3000 Maximum 3000 Maximum Free Chlorine ppm 2 3 2 3 2 3 Total Dissolved Solids ppm 1500 Maximum 1500 Maximum 1500 Maximum Free Chlorine MUST NOT EXCEED 5 ppm In salt water chlorinated pools the total TDS can be as high as 4500 ppm Table I Water Chemistry generate a scal...

Page 25: ...the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1 2 psi 3 45 kPa CAUTION Do not use Teflon tape on gas line pipe thread A pipe compound rated for use with natural and propane gases is recommended Apply sparingly only on male pipe ends leaving the two end threads bare CAUTION Support gas supply piping with hangers not by the heater or its accessori...

Page 26: ...mum gas supply pressure set point of 13 0 in WC are required for propane gas The gas pressure regu lator s supplied on the heater is for low pressure service If upstream pressure exceeds 14 0 in WC 1 2 psi at any time an intermediate gas pressure regulator of the lockup type must be installed When connecting additional gas utilization equipment to the gas piping system the existing piping must be ...

Page 27: ...i meter prior to working with any electrical connections or components 3 Observe proper wire colors while making electri cal connections Many electronic controls are polarity sensitive Components damaged by improper electrical installation are not covered by warranty 4 Provide overload protection and a disconnect means for equipment serviceability as required by local and state code 5 Install heat...

Page 28: ...nimum 18 AWG wire for runs of up to 150 feet 4 Mount the outdoor sensor on an exterior surface of the building preferably on the north side in an area that will not be affected by direct sunlight and that will be exposed to varying weather conditions Field Wiring Connection CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause im proper and dangerous operat...

Page 29: ...elta boiler NOTE Alternately a thermostat contact closure can be used in lieu of the sensor for indirect operation Connect the thermostat to the terminals marked INDIRECT DHW OVERIDE CAUTION Sensor and control wiring must NOT be run in conduit or chases with line voltage 2 To enable this remote control function set dip switch 5 to the UP position on the PIM DIP switch 5 Toggles between an EMS UP s...

Page 30: ...nly 5A maxi mum 2 Connect the boiler pump enable wires to the termi nal block at the rear of their unit The connections are dry contacts rated for pilot duty only 5A maxi mum 3 Connect the system supply sensor to terminals 6 and 7 on the field wiring strip located on the Master PIM See Fig 33 4 Connect the Outdoor sensor if used to terminals 8 and 9 on the field wiring strip located on the Master ...

Page 31: ...cade configurations System pump all models and DHW pump H models Follower out puts must be connected in parallel order to support operation durning Limp Along mode For detailed wiring instructions see VERSA IC manu al catalog 5000 72 Modbus BMS Communication The VERSA IC control is equipped as standard with a communications port for connectivity to building automation via Modbus protocol Refer to ...

Page 32: ...ence to horizontal venting that exits the back of the heater requires this tee Refer to Table K for the appropriate kit for your model Appliance Categories Heaters 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 heater which operates with a non pos itive vent static pressure and with a vent gas temp...

Page 33: ...9 DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area 10 DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations 11 Locate or guard vent to prevent condensate from damaging exterior finishes Use a rust resistant sheet metal backing plate against brick or mason ry surfaces 12 DO NOT extend exposed vent pipe outside...

Page 34: ...rizontal plane Canadian Installations Refer to latest edition of B149 Installation code A vent shall not terminate 1 Directly above a paved sidewalk or driveway which is located between two single family dwell ings and serves both dwellings 2 Less than 7 ft 2 13 m above a paved sidewalk or paved driveway located on public property 3 Within 6 ft 1 8 m of a mechanical air supply inlet to any buildin...

Page 35: ...he vent shall also be supported for the design and weight of the material employed to maintain clear ances and to prevent physical damage or separation of joints See table M for Category I venting guidelines Termination The vent terminal should be vertical and should termi nate outside the building at least 2 ft above the highest point of the roof that is within 8 ft for Model 992C and 10 ft for a...

Page 36: ... 10 ft per elbow Max 3 elbows Vertical direct vent applications require the use of positive pressure vent systems Maximum combustion air duct length terminated at 100 equivalent ft hoods and bathroom exhausts at maximum speed Do not operate summer exhaust fan Close fireplace dampers 4 Place in operation the appliances being inspected Follow the manufacturer s instructions for lighting each applian...

Page 37: ...alled to prevent the potential accumulation of condensate in the vent pipes It is required that CAT III CERTIFIED INSULATED EXHAUST VENTING Fig 40 Horizontal Through the Wall Venting Category III 1 The vent must be installed with a slight downward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal 2 The vent must be insulated through the length of the horizontal run F...

Page 38: ...ble N Each elbow used is equal to 10 ft of straight pipe This will allow installation in any arrangement that does not exceed the lengths shown in Table N The flue direct vent cap is not considered in the overall length of the venting system Care must be taken during assembly that all joints are sealed properly and are airtight The vent must be installed to prevent the potential ac cumulation of c...

Page 39: ...bustion air from outdoors and force the heated flue products through the vent pipe under posi tive pressure The vent material must be in accordance with the above instructions for vent mate rials Vent material must be listed by a nationally recognized test agency Note When vertical height exceeds 25 ft consult factory prior to installation Fig 43 Ducted Air Vertical Fig 42 Vent Cap Configurations ...

Page 40: ...y leave the cap Improper location can result in damage to adjacent structures or building finish For maximum efficiency and safety the following precautions must be observed 1 Outdoor models must be installed outdoors and must use the outdoor vent cap flow switch cover and air intake hood available from the manufac turer sales order option D 11 2 Periodically check venting system The heater s vent...

Page 41: ...sent to the MIX MIN value 11 The VERSA Control Board and PIM check the safety circuit and will stop from going into a trial for ignition if any of the safety devices is in an error fault condition 12 If no fault condition is found the air pressure switch if present is verified to be in the open position before the blower is energized 13 The blower s are energized 14 The air pressure switches are v...

Page 42: ...ected after the final trial for ignition the PIM enters ignition lockout and the LED on the PIM indicates the fault code for ignition lockout The VERSA IC Display should also state Ignition Lockout Models 1532C 2342C 1 Upon initial application of 24VAC power the PIM resets with all outputs in the OFF state 2 The Primary PIM and VERSA IC Control perform a processor and memory self test to ensure pr...

Page 43: ...med that the Primary PIM is leading the rotation sequence 20 The Hi Limit sensor is confirmed to read below the Hi Limit setpoint 21 The gas valve relay contacts are verified open if closed a fault code will be issued and the heater will post purge and go into a hard lockout condi tion 22 The Hi Delta units are equipped with a Hot Surface Igniter a The Primary PIM control turns on the HSI and the ...

Page 44: ...urge delay before additional ignition attempts are started If no flame is detected after the final trial for ignition the PIM enters ignition lockout and the LED on the PIM indicates the fault code for ignition lockout The VERSA IC Display should also state Ignition Lockout Freeze Protection To enable freeze protection DIP switch position 7 on the PIM must be turned on UP position This is the defa...

Page 45: ... have an additional optional adjustable manual reset high temperature device Standard The fixed setting manual reset high limit is built into the PIM it utilizes a dual element sensor located on the outlet see Fig 40 To reset a high limit lock out press and release the RESET button located on the user interface High Limit Auto Reset Optional This heater may be equipped with an optional adjust able...

Page 46: ...gas valve If the gas pressure regulator fails the high gas pres sure switch automatically shuts down the burner The high gas pressure switch automatically shuts down the heater if gas manifold pressure rises above the setting of 5 0 in WC for natural gas and 11 5 in WC for propane gas These safety devices can emit small amounts of fuel gas and must be vented to a safe discharge location outdoors p...

Page 47: ...ble when its corresponding mode is active User Interface The user interface consists of several Menu options Press the MENU button to scroll through the different menus in the interface Press the ITEM button to scroll through available items within a selected menu And the UP and DOWN buttons allow for setting changes to items in the ADJUST menu Refer to Fig 47 for dis play and key locations For de...

Page 48: ... the number field displays if the indirect DHW sensor fails Boil OUTLET 22 to 266ºF Always Current boiler outlet temperature as communicated from the PIM the number field displays Boil INLET 22 to 266ºF Always Current boiler outlet temperature as communicated from the PIM the number field displays if the outlet sensor fails Boil T 0 to 252ºF Always Current boiler inlet temperature as communicated ...

Page 49: ...o 10 F Differential for the target indirect DHW tank temperature requires IND Sensor ON 6 F IND SUPPLY H MODE 2 3 OFF 50 F to PIM value Target boiler temperature for the DHW heat exchanger during indirect DHW operation requires IND Sensor OFF 180 F DHW PRIORITY H MODE 2 OFF ON Selects whether or not Indirect DHW priority is active during indirect DHW operation OFF PRI OVR H MODE 2 3 Au 0 10hr to 2...

Page 50: ...Limit temperature EMS VDC ALL Current EMS signal in Volts DC FIRE RATE ALL PIM firing rate OUTLET MAX H Mode 1 2 3 Defines Max Outlet temperature offset above Target Setpoint Press and hold up and down arrows for 3 seconds to enable adjustment see VERSA IC manual catalog 5000 72 OPERATOR ALL Operator Potentiometer setting on PIM DIFF ALL Current auto differential Fixed by PIM PUMP POST ALL Sets th...

Page 51: ...c to clear INLET LO All Records the lowest boiler outlet temperature Press UP DOWN for 1 sec to clear DELTA T All Captures the highest Delta T temperature recorded Press UP DOWN buttons for 3 sec to clear this entry OUTDOOR HI H MODE 1 2 3 Records the highest outdoor temperature Press UP DOWN for 1 sec to clear OUTDOOR LO H MODE 1 2 3 Records the lowest outdoor temperature Press UP DOWN for 1 sec ...

Page 52: ...ery degree the outdoor temperature drops the tempera ture of the heating water will increase one degree With the VERSA both ends of the slope are adjustable It is factory set at 70 F water temperature Boil START at 70 F outdoor air OUT START and 180 F water temperature Boil DESIGN at 10 F out door air OUT DESIGN Each building has different heat loss characteristics A very well insulated building w...

Page 53: ...est annual temperature where the building is located This temperature is used when completing heat loss calculations for the building Boiler Design Boil DESIGN The Boil DESIGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the OUT DESIGN temperature Warm Weather Shut Down WWSD When the outdoor air temperature rises above the WWSD setting t...

Page 54: ...54 Wiring Diagram Models 992C 1262C ...

Page 55: ...55 Wiring Diagram Models 1532C 2342C ...

Page 56: ...s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life Use only your hand to push in or turn the gas con trol knob Never use tools If the knob will not turn by hand do not try to repair it call a qu...

Page 57: ...ure to do this may burn out 120V 24V transformer or may cause other safety control damage or failure Start Up Blower Adjustment 1 Turn off power 2 Unplug cap at pressure switches and connect ma nometer s to the tee 3 Close all manual firing valves 4 Turn power on 5 Check manometers attached to fan pressure switch The reading should be 1 4 1 in WC for propane gas and natural gas If not adjust the a...

Page 58: ...rs Local Heat DHW EMS demands must be present for burner operation On the first press of the Up button the test step is held and HOLD is flashed at 1Hz On the second press of the Up button the test step is incremented If boiler outlet temperature reaches the PIM Hi Limit the boiler will be ramped down to keep the temperature in a safe range Press of the Up button from Boiler Max will End the User ...

Page 59: ... 1 8 for each riser Post Start Up Check Check off steps as completed 1 Verify that the heater and heat distribution units or storage tank are filled with water 2 Confirm that the automatic air vent if used was opened two full turns during the venting proce dure 3 Verify that air has been purged from the system 4 Verify that air has been purged from the gas pip ing and that the piping has been chec...

Page 60: ...nual gas valve 7 Wait 5 minutes to clear out any gas Then smell for gas especially near the floor If you then smell gas STOP Follow the steps in the safety informa tion on the front cover of this manual If you do not smell gas go to next step 8 Turn on all electrical power to the appliance 9 Provide contact closure across the Enable Disable terminals at the field wiring block 10 Set thermostat to ...

Page 61: ...stem for proper func tion deterioration or leakage 3 Check that area is free from combustible materi als gasoline and other flammable vapors and liquids 4 Check for and remove any obstruction to the flow of combustion or ventilation air to heater 5 Follow pre start up check in the Start up section 6 Visually inspect burner flame It should be light blue Remove and replace hot surface ig niter and s...

Page 62: ...ors 4 Conduct a combustion test at full fire Carbon di oxide should be 8 2 0 5 at full fire for natural gas and 9 4 0 5 for propane gas Carbon monoxide should be 150 ppm 5 Check coils for 60 cycle hum or buzz Check for leaks at all valve fittings using a soapy water solu tion Test other operating parts of all safety shut off and control valves and increase or decrease set tings depending on the ty...

Page 63: ...taminated areas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners chlorine based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varnish removers hydrochloric acid muriatic acid cements and glu...

Page 64: ...to water PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts not ma...

Page 65: ...over any shipping costs to and from the service provider or to or from the installation site All of the foregoing costs and expenses are your responsibility WARRANTY EXCLUSIONS This Limited Warranty does NOT apply 1 if the Heater has been moved from its original place of installation or if the original owner no longer owns the property where the original installation was made 2 if the Heater is no...

Page 66: ...PLIED WARRANTIES INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIOD SPECIFIED ABOVE RAYPAK S SOLE LIABILITY WITH RESPECT TO ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS LIMITED WARRANTY OR IN CONTRACT TORT OR NEGLIGENCE OR OTHERWISE FOR CLAIMS FOR SPECI...

Page 67: ...ight _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size _______________ Vent Termination Type __________________ Pump Size _________ boiler Pump HP ______ Combustion Air Openings Low __________ in2 Impeller trim____________ Pump Model___________ Ventilation air Hi...

Page 68: ... wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements sh...

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Page 72: ...72 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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