Raypak Hi Delta 992B-1262B Page 60 Installation & Operating Instructions Manual Download | Manualshive

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60

APPENDIX

Inside Air Contamination

All heaters experience some condensation during
start-up. The condensate from flue gas is acidic.
Combustion air can be contaminated by certain vapors
in the air which raise the acidity of the condensate.
Higher acidity levels attack many materials including
stainless steel, which is commonly used in high effi-
ciency systems. The heater can be supplied with
corrosion-resistant, non-metallic intake air vent materi-
al. You may, however, choose to use outside
combustion air for one or more of these reasons:

1.

Installation is in an area containing contaminants
listed below which will induce acidic condensation.

2.

You want to reduce infiltration into your building
through openings around windows and doors.

3.

You are using AL29-4C stainless steel vent pipe,
which is more corrosion-resistant than standard
metallic vent pipe. In extremely contaminated ar-
eas, 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 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

•

similar products

Areas where contaminated combustion air commonly
exists:

•

dry cleaning/laundry areas

•

metal fabrication plants

•

beauty shops

•

refrigeration repair shops

•

photo processing plants

•

auto body shops

•

plastic manufacturing plants

•

furniture refinishing areas and establishments

•

new building construction

•

remodeling areas

•

open pit skimmers

Check for areas and products listed above before in-
stalling heater. If found:

•

remove products permanently, OR

•

install TruSeal direct vent

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Summary of Contents for Hi Delta 992B-1262B

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 Rev 5 reflects the following Changes to Fig 11 and Fig 12 on page 17 and Fig 14 on page 19 the addition of a warn ing about RCF refractory on page 4 and a wiring note on page 23 ...

Page 3: ...g 16 Gas Supply 20 Electrical Power Connections 22 Field Wiring Connection 23 Venting 25 Changing the Flue Outlet 27 Venting Installation Tips 28 Venting Configurations 28 Outdoor Installation 33 Controls 33 Heater Sequence of Operation 34 87 Efficiency Boilers Special Instructions 45 Wiring Diagrams 50 START UP 52 Pre Start up 52 Start Up 53 OPERATION 56 Lighting Instructions 56 To Turn Off Gas T...

Page 4: ... defects or other reproductive harm 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 CAUT...

Page 5: ...d only per 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 1262B or similar depending on the heater size and configuration The letter s in the first group of characters identifies the application H Hydronic H...

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

Page 7: ...No 1 1A 2 3 4 1 2 3 4 1 2 3 4 992B 6 3 2 1 1 2 1 2 3 54 82 100 1262B 5 3 3 3 1 1 2 1 2 3 1 2 3 4 36 57 79 100 1532B 6 4 4 3 1 1 2 1 2 3 1 2 3 4 35 59 82 100 1802B 6 4 5 5 1 1 2 1 2 3 1 2 3 4 30 50 75 100 2002B 4 5 5 5 4 1 1A 1 1A 2 1 1A 2 3 1 1A 2 3 4 39 61 83 100 2072B 4 5 5 5 4 1 1A 1 1A 2 1 1A 2 3 1 1A 2 3 4 39 61 83 100 2342B 5 6 5 5 5 1 1A 1 1A 2 1 1A 2 3 1 1A 2 3 4 42 62 81 100 Table A Basic...

Page 8: ...r 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 bu...

Page 9: ...d turn the wheel to the desired setting See Fig 4 CAUTION Hotter water increases the risk of scald ing There is a hot water scald potential if the thermostat is set too high Fig 4 Temperature Controller Equipment Base The heater should be mounted on a level structurally sound surface The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting Gas fuele...

Page 10: ...ce 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 Na...

Page 11: ...d location without movement 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 outdoo...

Page 12: ...point com municating with the outdoors The total cross sectional area shall 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 communicating directly with the out doors or through vertical duct s The total cross sectional area shall be at least 1 in 2 of free area per 10 000 BTUH 222 mm2 per kW of total input rating...

Page 13: ...than 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 a...

Page 14: ... 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 can be ducted to a point not mo...

Page 15: ...nnections 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 perform hydrostatic test 1 Con...

Page 16: ...lve Cold Water Run Cold water run differs from cold water start in that the system water entering the heater remains below 105ºF 41ºC continuously Typically this is the case in swim ming pool heating and water source heat pump applications as well as some others If the system water is kept in a narrow temperature range a perma nent manual bypass can be employed and manually adjusted to achieve an ...

Page 17: ...ulation of the heater water during the cooling cycle It is highly recommend ed that the piping be insulated Air Separation Expansion Tank All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig 10 Three Way Valves Valves designed to blend water temperatures or reduce water circulation through the heater should not be used Raypak heaters are hig...

Page 18: ...6 132 19 0 2 26 9 2072B 30 116 14 8 2 21 0 27 132 19 0 2 26 9 27 132 19 0 2 26 9 2342B 30 132 21 4 2 29 3 30 132 21 4 2 29 3 30 132 21 4 2 29 3 Table H Domestic Water Heater Flow Rate Requirements Pool Heating The Hi Delta pool heater is equipped with an external pump and bypass arrangement as standard equip ment This arrangement blends outlet water with the inlet water to increase the inlet water...

Page 19: ...pening 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 Fig 14 Single Pool Heater Application Automatic Chlorinators and Chemical Feeders All chemicals must be introduced and completely di luted into the pool or spa water before being circulated through t...

Page 20: ...e severe damage to your heater and associated equipment Total Dissolved Solids Total dissolved solids TDS is the measure of all min erals and solids that are dissolved in the water The concentration of total dissolved solids is usually ex pressed in parts per million ppm as measured in a water sample Water with a high TDS concentration will greatly accelerate lime and scale formation in the hot wa...

Page 21: ...e sure the gas piping is protected from physical damage and freezing where required Reversing Gas Supply Connection Reversing the standard fuel connection from the left hand to the right hand side is a simple field operation 1 Disconnect all electrical power from the heater if applicable 2 Disconnect the main gas pipe from the heater if applicable 3 Remove the left and right front panels from the ...

Page 22: ...ions 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 NEC Class 1 Heater must be electrically grounded as required by the NEC In Canada CSA C22 1 C E C Part 1 The heater is wired for 120 VAC 12 amps The volt age is indicated on the tie in leads Consult the wiring diagram shipped with th...

Page 23: ...mponents 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 heater controls thermostats or building management systems in accordance with the applicable manufacturers instructions 6 Conduit should not be used as the earth ground Field Wiring Connectio...

Page 24: ...4 4 Stage Wiring Connection Installer action is required to electrically enable your heater to operate after making the power connections You must make a closed contact connection on Stage 1 connector of the Central Point Wiring CPW board for temperature control connections This will be done based on the controller option selected with your heater order 1 For Pool and Closed Loop Water Source Heat...

Page 25: ...RAM Fig 25 2 Stage Tankstat SINGLE STAGE TANKSTAT STAGE 1 CONNECTION ATTACH STAGE 1 CONNECTIONS ON HEATER TO THE SINGLE STAGE TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE Fig 26 Single Stage Tankstat Venting General Flue Exhaust Tee An optional Flue Exhaust Tee is available to facilitate horizontal venting Any reference to horizontal venting that exits the back of the heater requires this tee Refer to T...

Page 26: ...age or personal injury 3 Gases may form a white vapor plume in winter The plume could obstruct a window view if the ter mination is installed near windows 4 Prevailing winds in combination with below freez ing temperatures can cause freezing of condensate and water ice build up on buildings plants or roofs 5 The bottom of the vent terminal and the air intake shall be located at least 12 in above g...

Page 27: ... require a 4 ft clearance between the ends of vent caps located on the same horizontal 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 publi...

Page 28: ...ency CAUTION The silicone vent gaskets must be prop erly reinstalled to prevent flue gas leakage Replace any torn or worn vent gaskets WARNING Examine the venting system at least once a year Check all joints and vent pipe connections for tightness corrosion or deterioration The maximum and minimum venting length for Cate gory I appliances shall be determined per the NFGC U S or B149 Canada The dia...

Page 29: ...1 Seal any unused opening in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and verify there is no block age restriction leakage corrosion or other unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the com mon venting system are located ...

Page 30: ...t ft in length If horizontal run exceeds 70 equivalent ft an appropri ately sized extractor must be used Each elbow used is equal to 10 ft of straight pipe This will allow installa tion in one of the four following arrangements 70 of straight flue pipe 60 of straight flue pipe and one elbow 50 of straight flue pipe and two elbows 40 of straight pipe and three elbows The vent cap is not considered ...

Page 31: ...Horizontal Through the Wall The total length of the through the wall flue cannot exceed 40 equivalent ft in length for the flue outlet Each elbow used is equal to 10 ft of straight pipe This will allow installation in one of the three following arrangements 40 of straight flue pipe 30 of straight flue pipe and one elbow 20 of straight flue pipe and two elbows The total length of air supply pipe ca...

Page 32: ...sted for use with Category III gas burning heaters such as the AL29 4C stainless steel vents offered by Heat Fab Inc 800 772 0739 Protech System Inc 800 766 3473 Z Flex 800 654 5600 or American Metal Products 800 423 4270 Pipe joints must be positively sealed Follow carefully the vent manufacturer s installation instructions WARNING No substitutions of flue pipe or vent cap material are allowed Su...

Page 33: ... Do not locate adjacent to any window door walk way or gravity air intake The vent must be located a minimum of 4 ft horizontally from such areas 4 Install above grade level and above normal snow levels 5 Vent terminal must be at least 3 ft above any forced air inlet located within 10 ft 6 Adjacent brick or masonry surfaces must be pro tected with a rust resistant sheet metal plate Freeze Protecti...

Page 34: ... are verified to ensure that it is safe to operate the heater The safety compo nents wired into the diagnostic board are low water cut off optional blocked vent switch man ual vent temp switch optional manual reset high limit low gas pressure switch high gas pressure switch optional and auto reset high limit option al 13 If any of the safeties do not close a signal is sent to the Universal Diagnos...

Page 35: ...ront status panel 31 A 24 VAC signal is also sent to the TH terminal located on the ignition module 32 Once the 24 VAC TH signal is received at the ignition module the internal contacts between F1 and F2 close sending a 120 VAC signal to the 120 VAC pilot duty terminals located at J14 on the cir cuit board 33 The 120 VAC signal continues to the coil of the blower relay K 3 N O 34 The 120 VAC signa...

Page 36: ...t pin 3 of the stage 2 connections on the CPW board 51 After closure of the stage 2 contacts Gas valve 2 is energized 52 The stage 2 LED on the status display board is now illuminated 53 Power is applied to pin 5 of the stage 3 connec tions on the CPW board 54 After closure of the stage 3 contacts power is applied to TD 2 55 After a 5 second countdown TD 2 contacts close 56 Gas valve 3 then receiv...

Page 37: ...he control compartment is now powered If the switch is ON and there is no call for heat CFH the heater is in standby mode 20 After the standby switch is placed into the ON position a 24 VAC signal is sent to the enable disable connection normally jumpered 21 24 VAC switched power is applied to the S24V ter minal on ignition modules 1 and 2 22 When the enable disable contacts are closed the 24 VAC ...

Page 38: ...m up before opening gas valve 1 again The standard ignition module will attempt ignition a maximum of three times prior to ignition lockout 48 If ignition module one locks out a signal will be sent to the Universal Diagnostics Board and to the status display board to indicate an ignition fault 49 When power is sent to gas valve 1 it is also sent to time delay relay 1 TD 1 which starts a 5 second c...

Page 39: ... ond time delay relay will not allow the alarm to sound unless a safety or limit circuit stays ener gized for more than 5 seconds 12 Power is applied to terminal P1 1 of the Universal Diagnostics Board 24 VAC power is then applied in series to all typically closed safeties wired into the heater All safeties are verified to ensure that it is safe to operate the heater The safety components wired in...

Page 40: ...ndicate the fault 38 A 24 VAC signal is now sent to the blower LED s on the status board 39 Power is applied to the optional equipment inter lock connection normally jumpered 40 The 24 VAC signal is then sent to the 24 VAC safe ty connector 41 24 VAC is now sent to the pressure switch P S terminal on the ignition modules 42 Once the pressure switch signal is received at ignition module one the hea...

Page 41: ...ed by a 120 VAC signal from S 1 on ignition module 2 for approximately 30 seconds The hot surface ignit er must draw greater than 3 1 amps while being energized or ignition lockout will occur after three tries 59 If ignition module two locks out a signal will be sent to the Universal Diagnostics Board and to the status display board to indicate an ignition fault 60 Once the ignition module determi...

Page 42: ... call for heat 3 Flashes Ignition lockout 4 Flashes Low igniter current 5 Flashes Low 24 VAC check control supply voltage 6 Flashes Internal fault Replace module Fig 32 Ignition Module Table N Ignition Module Diagnostic LED Codes The optional single try ignition module will lock out after failing to light one time To reset it press and release the small recessed black push button located inside of...

Page 43: ...utomati cally shuts down the heater if gas supply drops below the factory setting of 5 0 in WC for natural gas and 10 0 in WC for propane gas The high gas pressure switch optional connection mounts down stream of the stage 1 gas valve If the gas pressure regulator fails the high gas pressure switch automatically shuts down the burner The high sheets supplied with your heater paperwork See the Gene...

Page 44: ...r date stamp associated with these faults 5 Continue to push SW2 to view subsequent faults 44 SW1 SW2 Fig 40 UDB Diagnostic Board NOTE To clear the fault history press and hold both SW1 and SW2 for 5 seconds Once cleared the history cannot be recovered UDB Diagnostic Board This heater is equipped with a diagnostic board which will indicate faults as they occur It has the ability to retain up to 25...

Page 45: ... Hi Delta CAUTION Proper installation of flue venting is criti cal for the safe and efficient operation of the boiler NOTE For additional information on appliance categorization see appropriate code NFGC U S and B149 Canada or applicable local building codes 20 F T 30 F T 40 F T Min Flow Max Flow Model No gpm P ft gpm P ft gpm P ft gpm P ft T gpm P ft T 992BE 86 5 6 57 2 5 43 1 4 43 1 4 40 132 13 ...

Page 46: ...relief valves or other equipment 8 Locate and guard vent termination to prevent acci dental contact by people or pets 9 DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area unless previously approved by local authority 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 con...

Page 47: ... Steel PVC ABS CPVC 40 75 pressure reading must be between 0 01 and 0 1 in WC as measured 12 in from the appliance flue outlet Each elbow used is equal to 10 ft of straight pipe This will allow installation in one of the four following com binations 70 of straight flue pipe 60 of straight flue pipe and one elbow 50 of straight flue pipe and two elbows 40 of straight pipe and three elbows The vent ...

Page 48: ...t 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 condensate in the vent pipes It is recommended that 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...

Page 49: ...n vertical height exceeds 25 ft consult factory prior to installation Fig 44 Direct Vent Vertical Table R Category II or IV Vertical Venting Vent lengths are based on a lateral length of 2 ft Refer to the latest edition of the NFGC for further details When vertical height exceeds 25 ft consult factory prior to installation Subtract 10 ft per elbow Max 3 elbows Maximum combustion air duct length te...

Page 50: ...50 Wiring Diagram Models 992B 1262B ...

Page 51: ...51 Wiring Diagram Models 1532B 2342B ...

Page 52: ... building Immediately call your gas supplier from a neigh bor s telephone Follow the gas supplier s instructions WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas con trol knob Never use tools If th...

Page 53: ...failure Failure 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 ...

Page 54: ...ised pilot to light the burner sections on either side of it The burn er sections on either side of the supervised section pilot are electrically interlocked with the supervised ignition system so as they are not energized unless flame is proven on the center section which is acting as a pilot to light the right and left hand sections The pilot turn down test is conducted as follows 1 Turn off man...

Page 55: ... restore electrical power to heater Fig 45 Leak Test This completes leak testing for a single Hi Delta mani fold riser Repeat steps 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 Verif...

Page 56: ...urn on main manual 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 Set thermostat to desired setting The appliance will operate The igniter will glow after the ...

Page 57: ... 1 800 947 2975 Outside California 1 800 627 2975 Inside California Replace gas valve Are the gas valve settings correct Replace fan relay Replace fan Replace air pressure switch Correct the air settings or you may have to clean burners heat exchanger and or air filter NO Check the switch and or line voltage YES Does the power switch provide power to the control panel Unit is in standby mode Reatt...

Page 58: ...le 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 visually inspect hot surface ig niter and sensor for damage cracking or debris build up 7 Check operation of safety devices Refer to manu facturers instructions 8 Fo...

Page 59: ...ct a combustion test at full fire Carbon di oxide should be 7 5 to 8 5 at full fire for natural gas and between 9 2 to 9 8 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...

Page 60: ...contaminated ar eas 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...

Page 61: ...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 62: ...tal Dissolved Solids TDS must be no greater than 2500 PPM 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 Ra...

Page 63: ...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 64: ...__________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ ___________________________________________________________...

Page 65: ...65 ...

Page 66: ...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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