Raypak 302-902 Installation And Operating Instructions Manual Download Page 8 | Manualshive

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SECTION B: BOILER INSTALLATION

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/NFPA 70 - latest edition.
· Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.
· For Canada only: CAN/CGA B149.1 and .2 Installation Code and C.S.A. C22. 1 C.E.C. Part 1.

EQUIPMENT BASE

The boiler should be mounted on a level, structurally sound surface. The boiler is approved for installation on a combustible
surface but must NEVER be installed on carpeting. Gas fueled equipment installed in enclosed parking garages must be
located at least 18 inches above the floor.

Stacking

Hi Delta units can be stacked two units high with an optional stacking rack. A stacking kit is available from Raypak for this
type of installation.

CAUTION:

The boiler should be located in an area where water leakage will not result in damage to the
area adjacent to the appliance or to the structure. When such locations cannot be avoided, it is
recommended that a suitable catch pan, adequately drained, be installed under the appliance.
The pan must not restrict air flow.

In addition, the boiler shall be installed such that the gas ignition system components are protected from water (dripping,
spraying, rain, etc.) during appliance operation or service (circulator replacement, control replacement, etc.).

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Typical Racked Installation

TOP VIEW

FRONT VIEW

RIGHT SIDE VIEW

Fig# 9239

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Summary of Contents for 302-902

Page 1: ... sinformationmanualprovidedwiththisboiler Installationand servicemustbeperformedbyaqualifiedinstaller serviceagencyorthegassupplier FORYOURSAFETY WHATTODOIFYOUSMELLGAS Donottrytolightanyappliance Donottouchanyelectricalswitch donotuseanyphoneinyourbuilding Immediatelycallyourgassupplierfromaneighbor sphone Followthegassupplier sinstructions Ifyoucannotreachyourgassupplier callthefiredepartment Thi...

Page 2: ...N I ELECTRICAL POWER CONNECTIONS 24 SECTION J VENTING CONNECTIONS 28 J 1 NaturalDraftVerticalVenting 31 J 2 HorizontalThru WallVenting 34 J 3 HorizontalThru WallDirectVenting 36 J 4 VerticalDirectVenting CombustionAir 38 J 5 OutdoorInstallation 43 SECTION K CONTROLS 49 WIRING DIAGRAMS 53 SECTION L GENERALSAFETYPRECAUTIONS 54 SECTION M PRE START UP 55 SECTION N HI DELTAINITIALSTART UP 59 SECTION O ...

Page 3: ...he area around the boiler free of combustible materials gasoline and other flammable liquids and vapors 2 Boiler should never be covered or have any blockage to the flow of fresh air to the boiler WARNING Risk of electrical shock More than one 1 disconnect switch may be required to de energize the equipment before servicing CAUTION Operation of this boiler on low temperature systems requires speci...

Page 4: ...al does not answer please contact the factory or your local Raypak representative ThankyouforpurchasingaRaypakproduct Wehopeyouwillbesatisfiedwiththehighqualityanddurabilityofourequipment PRODUCTRECEIPT On receipt of your product it is suggested that you visually check for external damage to the shipping crate If the crate is damaged make a note to that effect on the Bill of Lading when signing fo...

Page 5: ...oilers are National Board Approved design certified and tested by the International Approval Services IAS a joint venture of American Gas Association Laboratories and the Canadian Gas Association Laboratories for U S A and Canada EachboilerisconstructedinaccordancewithSectionIVoftheAmericanSocietyofMechanicalEngineers ASME BoilerPressureVesselCodeandbearstheASMEstamp Thisboilercomplieswiththelates...

Page 6: ...ection Pressure Relief Connection Water Outlet Electrical Connection Water Inlet Temperature and Pressure Gauge Gas Train Operational Center Control Pressure Relief Valve Heat Exchanger Burner Group Remote Sensor Combustion Air Blower Igniter View Port HIGH DELTA COMPONENT LOCATION Fig 9220 6 BACK LEFT SIDE FRONT ...

Page 7: ...7 General Information ...

Page 8: ...ueled equipment installed in enclosed parking garages must be located at least 18 inches above the floor Stacking Hi Delta units can be stacked two units high with an optional stacking rack Astacking kit is available from Raypak for this type of installation CAUTION The boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliance or to the...

Page 9: ...ermanent structural construc tion around the heater However for ease of servicing we recommend a clearance of at least 24 in front and at least 18 on the water connection side This will enable the heater to be serviced in its installed location that is without movement or removal of the heater Clearances less than minimum may require removal of the heater to service either the heat exchanger or th...

Page 10: ...INSTALLATION MINIMUM CLEARANCES Boiler Size Boiler Side 302 902 Rear 12 Right 36 Left 36 Top Unobstructed Vent N A These clearances required where the outdoor vent cap is used If installing the boiler outdoors with a vent stack the indoor clearances may be used The air filter box can be installed on top of the boiler or the rear of the boiler For outdoor installations in snow prone areas it is rec...

Page 11: ... commence within 12 inches 30 cm of the top and one opening shall commence within 12 inches 30 cm of the bottom of the enclosure The minimum dimension of air openings shall be not less than 3 inches 8 cm b All Air from Outdoors The confined space shall communicate with the outdoors in accordance with methods 1 or 2 The minimum dimension of air openings shall not be less than 3 in 8cm Where ducts a...

Page 12: ... more than 18 inches 450 mm nor less than 6 inches 150 mm above the floor level The duct can also Goose Neck through the roof The duct is preferred straight down 18 from floor but do not place near piping This air supply opening requirement shall be in addition to the air opening for ventilation air required in 1 3 For boilers not using a barometric damper in the ventsystem and when air supply is ...

Page 13: ... does recom mend hydrostatically testing the piping connections to the boiler and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based antifreeze Raypak recommends conducting the hydro static test before connecting gas piping or electrical supply Leaks must be repaired at once to prevent damage to the boiler NEVER use petroleum based...

Page 14: ... be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air must be equipped with flow control valves or other automatic means to prevent ...

Page 15: ...12 SINGLEBOILER LOWTEMPERATUREAPPLICATION HEATPUMP PRIMARY SECONDARYPIPING Fig 9223 DUALBOILERPRIMARY SECONDARYPIPING Fig 9232 2 15 ...

Page 16: ...AUTION When this heater is used for both potable water and space heating follow the steps below to insure proper operation A All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water B Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water used for space heating C If the...

Page 17: ...r The pump also serves to circulate water through the heater form the main system piping To complete the installation of the pool heater the pool thermostat needs to be installed in the main return water line This will insure 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 thermostat...

Page 18: ...rranty WINTERIZINGYOURHEATER When heaters installed outdoors in freezing climate areas are to be shut down for the winter please observe the following step by step procedure 1 Turn off manual main gas and main gas shut off Remove the drain plug or open the drain cock located on the bottom header SPAWATER CHEMISTRY NOTE Chemical imbalance can cause severe damage to your heater and associated equipm...

Page 19: ...han 1 2 PSIG Relieve test pressure in the gas supply line before reconnecting the boiler and its manual shut off valve to the gas supplyline FAILURETOFOLLOWTHISPROCEDUREMAYDAMAGETHEGASVALVES Over pressurized gas valves are not covered by warranty The boiler and its gas connections shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use open flame CAU...

Page 20: ...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 W C for Propane gas If an adjustment is needed turn the adjustment screw clockwise to increase pressure or counter clockwise to lower pressure 20 ...

Page 21: ... primary wiring should be 125 of minimum rating It is strongly recommended that all individually powered control modules and the boiler should be supplied from the same power source SURGE PROTECTION Microprocessor based and solid state controls are vulnerable to damage from voltage and amperage fluctuations in the power supply All sensitive control components should be protected by a suitable comm...

Page 22: ...installation are not covered by warranty 4 Provide an external surge suppressor capable of maintaining system integrity 5 Provide overload protection and a disconnect means for equipment serviceability as required by local and state code 6 Install boiler controls thermostats or building management systems in accordance with the applicable manufacturer s instructions 7 Conduit should not be used as...

Page 23: ...n the boiler Stage 1 of the boiler to stage 1 of the control Stage 2 of the boiler to stage 2 of the control and so on Set the operating control at the setpoint in which you want the boiler to maintain Ensure that the sensing bulb of the control is at the point in the system that will best maintain the temperature you want For example when you are heating a tank of water you want the operating con...

Page 24: ... that avoids excessive condensate production in the vent Category IV A boiler which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent See Table J 1 for appliance category requirements for the Hi Delta Note For additional information on appliance categorization see appropriate ANSI Z21 Standard and the latest edition St...

Page 25: ...tegory Determination for Venting Purpose and Venting Arrangement 25 TABLEJ 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 ...

Page 26: ...s a problem with Category I and III appliances this provision shall also apply f Locate and guard vent termination to prevent accidental contact by people or pets g DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area unless previously approved by local authority h DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice forma...

Page 27: ...l Fuel Gas Code or in Canada the latest edition of CAN CGA B149 1 and 2 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of local building codes 27 Canada Installations Refer to latest edition of CAN CGA B149 1 and 2 A vent shall not terminate a Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwelli...

Page 28: ... NATURALDRAFTVERTICALVENT NOTE Vent 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 FILTER ...

Page 29: ...s and to prevent physical damage or separation of joints Natural Draft Vertical Vent Termination The vent terminal should be vertical and should terminate outside the building at least two 2 feet above the highest point of the roof that is within 10 feet The vent cap should have a minimum clearance of four 4 feet horizontally from and in no case above or below unless a four 4 foot horizontal dista...

Page 30: ...djust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe toilet paper trick For the Hi Delta check the pressure at a pressure tap located 12 inches above the bottom joint of the first vertical vent pipe Pressure should be anywhere b...

Page 31: ...air is taken from inside the room and the vent is installed horizontally through the wall to the outdoors Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or in Canada the latest edition of CAN CGA B149 1 and 2 Installation Code for Gas BurningAppliances and Equipment 31 OPTIONAL FLUE EXHAUST VENTING 9 MIN FLUE EXHAUST VENT C...

Page 32: ... of condensate in the vent pipes It is recommended that a The vent be installed with a slight downward slope of not more than 1 4 per foot of horizontal run to the vent terminal b The vent be insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that a The vent be installed with a slight upward slope of not more than 1 4 per foot of h...

Page 33: ...t cap must be utilized WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The Stainless Steel direct vent cap must be furnished by the boiler manufacturer in accordance with its listing Use only the special gas vent pipes listed for use with category III gas burning heaters such as the stainless steel Saf ...

Page 34: ...DIRECT VENT Horizontal Thru wall Venting Category III Fig 9230 1 HORIZONTALTHRU WALLVENTINGTABLE 34 SECTION J 3 AIR FILTER BOILER UNIT 6 MIN 36 MIN 12 MIN 9 MIN CONDENSATE TRAP EXHAUST VENT INTAKE VENT ...

Page 35: ... horizontal run to the vent terminal In this case an approved condensate trap must be installed per applicable codes b The intake vent be insulated through the length of the horizontal run Horizontal Thru wall Direct Vent Termination 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 ...

Page 36: ...DIRECT VENT Vertical Venting Category I Fig 9231 1 VERTICALVENTINGTABLE 36 SECTION J 4 AIR FILTER INTAKE VENT BOILER UNIT EXHAUST VENT 3 MIN VENT CAP 3 MIN 1 MIN ...

Page 37: ...ign and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints It is recommended that in colder climates the intake vent be insulated Vertical Direct Vent Termination The exhaust vent terminal should be vertical and should terminate outside the building at least two 2 feet above the highest point of the roof within 10 feet The vent cap should ...

Page 38: ...al snow levels e Vent terminal must be at least 3 feet above any forced air inlet located within 10 feet f Adjacent brick or masonry surfaces must be protected with a rust resistant sheet metal plate g Multiple Outdoor Vent installations require a four 4 feet clearance between vent caps NOTICE Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue cond...

Page 39: ...m 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 Take four of the self tapping screws from the kit and screw into the holes as shown in Fig 2 Fig 2 5 Slide tinnerman clips over the small bracket as shown in Fig 3 Fig 3 ...

Page 40: ...the holes as shown in Fig 4 8 Slide the vent cap down into the vent collar as shown in Fig 5 Fig 5 9 Drill a 3 16 pilot hole into the vent cap through each of the upper holes in the vent collar See Fig 6 Also see finished assembly below Fig 6 10 Take four of the self tapping screws from the kit and screw into the holes as shown in Fig 6 Also see finished assembly below 11 Turn the power on and tur...

Page 41: ...is to be installed outdoors the air intake collar and filter box must be relocated to the back of the unit to prevent recirculation of flue products 1 Turn off the gas and power to the unit Air intake Vent collar collar 2 Remove the four screws holding the air intake collar on the top of the unit 3 Remove the four screws holding the cover plate See Fig 1 Cover plate 4 Remove the white gasket paper...

Page 42: ... the unit using four screws provided in the kit 14 Install filter under filter box on top of air intake See Fig 3 NOTE The filter media fits loosely in the filter box When the fans energize the filter is drawn onto the top of the collar and is held in place by the suction The checked side of filter sits on air intake collar Side view 15 Install two screws in the holes behind cover plate See Fig 4 ...

Page 43: ...ore installation adjustment or service of the Central Point Wiring board or any boiler controls Failure to do so may result in board damage boiler malfunction property damage personal injury or death CAUTION This appliance has provisions to be connected to more than one 1 supply source To reduce the risk of electric shock disconnect all such connections before servicing CAUTION Risk of electric sh...

Page 44: ...nergized and the pump will turn on If the pump generates enough flow to activate the flow switch the flow light would turn on then power will be applied to the thermostat terminal of the Ignition Module and the Blower will activate TheAir Pressure Switch would then close and the pressure switch terminal on the Ignition Module will be energized the blower light will turn on The Unit will now underg...

Page 45: ...zed and the pump will turn on If the pump generates enough flow to activate the flow switch the flow light will turn on then power will be applied to the thermostat terminal of the Ignition Module and the Blower will activate TheAir Pressure Switch will close and the pressure switch terminal on the Ignition Module will be energized the blower light will turn on The Unit will now undergo a 15 secon...

Page 46: ...ump generates enough flow to activate the flow switch the flow light will turn on power will be applied to the thermostat terminal of the Ignition Module and the Blower will activate The Air Pressure Switch will close and the pressure switch terminal on the Ignition Module will be energized the blower light will turn on The Unit will now undergo a 15 second pre purge After the pre purge cycle Hot ...

Page 47: ...ve only after the igniter is proven to be capable of ignition HIGHLIMIT MANUALRESET The boiler is equipped with a manual reset high limit temperature device Push the reset button and adjust the setting to 30 F or 40 F above desired operating temperature FLOW SWITCH Dual purpose control shuts off boiler in case of pump failure or low water flow Mounted and wired in series with the main gas valve Ch...

Page 48: ...ow gas pressure switch optional mounts upstream of the gas valve to ensure that sufficient gas pressure is present for proper regulator performance The low gas pressure switch automatically shuts down the boiler if gas supply drops below the factory setting of 5 W C for Natural gas and 10 W C for Propane gas The high gas pressure switch optional mounts down stream of the gas valve If the gas press...

Page 49: ...49 WIRE DIAGRAM MODEL 302 402 Reference Drawing Number M152462 Rev M H4 W1 ...

Page 50: ...WIRE DIAGRAM MODEL 302 402 Reference Drawing Number M152470 Rev J H3 W3 50 ...

Page 51: ...51 WIRE DIAGRAM MODEL 502 752 Reference Drawing Number M152464 Rev R H3 HW3 ...

Page 52: ...WIRE DIAGRAM MODEL 902 Reference Drawing Number M152465 Rev P H3 W3 52 ...

Page 53: ...d injury and may be used as a guide in determining the safest water temperature for your applications Temperature Time to Produce Serious Burn Temperature Time to Produce Serious Burn 120 F More than 5 minutes 140 F Less than 5 seconds 125 F 1 1 2 to 2 minutes 145 F Less than 3 seconds 130 F About 30 seconds 150 F About 1 1 2 seconds 135 F About 10 seconds 155 F About 1 second Table courtesy of Th...

Page 54: ...TING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor 3 WHATTO DO IFYOU SMELLGAS Do not try to light any appliance Do not touch any electrical switch do not use any telephone in your building Immediately call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions If you can...

Page 55: ...l damage or failure 2 2 Attach Manometers to Measure Pressures Attach 24 scale manometer to the first main gas shut off valve pressure tapping Attach one 12 scale manometer to the outlet side of the second main gas shut off valve pressure tapping Attach one 12 scale manometer to Pull rubber tube from air pressure switch off the aluminum tubing and connect the manometer using a tee TurnOffMainGasVa...

Page 56: ... necessary Your Hi Delta is tuned in 3 4 Safety Inspection Replace main gas manifold adjustment cap Check all thermostats and high limit settings During the following safety checks leave manometers hooked up check and record If other gas fired equipment are in the room and on same gas main check all pressures on the Hi Delta with all other equipment running Remember incoming gas pressure could be ...

Page 57: ...on by closing manual gas valve Watch for shut down due to loss of supervised flame signal as pressure is being reduced Flame signal should be lost before manifold pressure goes below 2 inches water column LEAK TEST PROCEDURE DUAL SEAT GAS VALVES Proper leak testing requires three pressure test points in the gas train Test point A is upstream of the automatic gas valve On the first automatic valve ...

Page 58: ... for a build up of pressure Increasing pressure indicates a leaking gas valve 6 Remove rubber test tube and manometers Close each test point valve as the tubes are removed 7 Connect a manometer to each test point one at a time and look for a build up of pressure If a build up of pressure is detected check each test point valve to see if it is tightly closed If leak persists replace test point valv...

Page 59: ...it control above boiler water temperature and burner should reignite after pre purge time delay 9 Test ignition system safety device Turn on manual gas valve Turn power on Set thermostat to call for heat When the unit is in operation Disconnect combustion air blower pressure switch burner should go off immediately Wait 5 minutes Reconnect combustion air pressure switch burner should reignite after...

Page 60: ...The igniter will glow after the pre purge time delay 15 seconds After igniter reaches temperature 45 seconds the main valve will open System will try for ignition three 3 times If ignition is not sensed lockout will commence 10 If the appliance will not operate follow the instruction To Turn Off Gas To Appliance and call your service technician or gas supplier 11 Replace access panel TOTURNOFFGAST...

Page 61: ...ctions 9 Follow oil lubricating instructions on circulator Over oiling will damage circulator Water lubricated circulators do not need oiling 10 To avoid potential of severe burn DO NOT REST HANDS ON OR GRASPPIPES Use a light touch return piping will heat up quickly 11 Check blower and blower motor Clean and oil as necessary 12 Check for piping leaks around circulators relief valves and other fitt...

Page 62: ...ng and Installation Instructions Manual 4 Check piping and wiring of all interlocks and shutoff valves 5 Inspect burner components Annually 1 Flame failure detection system pilot turndown test 2 Test high limit and operating temperature See page 48 of the Operating and Installation Instructions Manual 3 Check flame sensors Flame signal should be greater than 1 microamp 4 Conduct a combustion test ...

Page 63: ...d metallic vent pipe In extremely contaminated area 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 hydrochlori...

Page 64: ...aid 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 manufactured by it but Raypak will apply any such warranty as may be provided to it by the parts manufacturer TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and s...

Page 65: ... Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 FAX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada L4T 1G2 905 677 7999 FAX 905 677 8036 6 99 Litho in U S A www raypak com ...

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