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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  presence  of  hazards  or  unsafe  practices  which  could  cause

minor personal injury or product or property damage if ignored.

NOTE: 

Indicates special instructions on installation, operation, or maintenance which

are important but not related to personal injury hazards.

DANGER:

Make sure the gas on which the heater

will operate is the same type as that specified on the

heater 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 heater. Instead, shut off

the gas supply at a location external to the heater.

WARNING:

Do not use this heater if any part has

been  under  water.  Immediately  call  a  qualified

service  technician  to  inspect  the  heater  and  to

replace any part of the control system and any gas

control which has been under water.

WARNING:

To minimize the possibility of improper

operation, serious personal injury, fire, or damage to

the heater:

•   Always keep the area around the heater free of

combustible  materials,  gasoline,  and  other

flammable liquids and vapors.

Heater  should  never  be  covered  or  have  any

blockage to the flow of fresh air to the heater.

WARNING  -  CALIFORNIA  PROPOSITION

65: 

This product contains chemicals known to the

State of California to cause cancer, birth 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.

CAUTION: 

If  this  heater  is  to  be  installed  above

radiation level, it must be provided with a low water

cut-off device at the time of heater installation.

CAUTION: 

If  this  heater  is  to  be  installed  in  a

negative or positive pressure equipment room, there

are special installation requirements. Consult factory

for details.

WARNINGS — 

Pay Attention to These Terms

4

CAUTION: 

This  heater  requires  forced  water

circulation  when  the  burner  is  operating.  See

minimum and maximum flow rates. Severe damage

will  occur  if  the  heater  is  operated  without  proper

water flow circulation.

WARNING:

This  unit  contains  refractory  ceramic

fiber  (RCF)  insulation  in  the  combustion  chamber.

RCF, as manufactured, does not contain respirable

crystalline  silica.    However,  following  sustained

exposure  to  very  high  temperatures  (>2192F),  the

RCF  can  transform  into  crystalline  silica

(cristabolite). The International Agency for Research

on  Cancer  (IARC)  has  classified  the  inhalation  of

crystalline  silica  (cristabolite)  as  carcinogenic  to

humans.

When  removing  the  burners  or  heat  exchangers,

take precautions to avoid creating airborne dust and

avoid inhaling airborne fibers. When cleaning spills,

use wet sweeping or High Efficiency Particulate Air

(HEPA)  filtered  vacuum  to  minimize  airborne  dust.

Use  feasible  engineering  controls  such  as  local

exhaust  ventilation  or  dust  collecting  systems  to

minimize airborne dust. Wear appropriate personal

protective  equipment  including  gloves,  safety

glasses  with  side  shields,  and  appropriate  NIOSH

certified respiratory protection, to avoid inhalation of

airborne dust and airborne fiber particles.

Summary of Contents for HI DELTA HD401

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 you...

Page 2: ...13 Figs 10 12 on page 15 Piping Heating Boilers on page 16 Table G on page 18 Table I on page 22 Table K on page 25 Table L on page 27 Table M on page 29 Table N on page 30 Fig 27 on page 34 Table P...

Page 3: ...l Reset 34 High Limit Auto Reset Optional 34 Flow Switch 35 High and Low Gas Pressure Switches Optional 35 Low Water Cut Off Optional 35 WIRING DIAGRAM MODELS HD101 HD151 TYPE WH 36 WIRING DIAGRAM MOD...

Page 4: ...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 t...

Page 5: ...for defec tive replacement parts will not be accepted Parts will be replaced in kind only per Raypak s standard war ranties Model Identification The model identification number and heater serial numb...

Page 6: ...Fig 1 Component Locations Angle View Fig 2 Component Locations Left Side Fig 3 Component Locations Front Panels removed for clarity 6 BEHIND CONTROLLER CONTROLLER OPTIONAL ON HD401 Component Locations...

Page 7: ...eneral Information Table A Basic Data Model No Quantity of Burners Vent Size in Flue Intake HD101 2 4 4 HD151 3 4 HD201 4 5 HD251 5 5 HD301 6 5 HD401 8 6 7 Fig 5 Gas Valves Fig 4 Air Shutter Adjustmen...

Page 8: ...mometer in the hot water 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 reduci...

Page 9: ...the thermostat is set too high ADJUSTMENT WHEEL Fig 6 Temperature Controller Equipment Base The heater should be mounted on a level structurally sound surface The heater is approved for installation...

Page 10: ...with local instal lation codes and the requirements of the gas supplier Three sides must be open in the area under the over Table D Service Clearances Outdoor Installations Fig 8 Minimum Installed Ser...

Page 11: ...12 in 30 cm of the bottom of the enclosure shall be provided The openings shall communicate directly or by ducts with the out doors or spaces crawl or attic that freely communicate with the outdoors C...

Page 12: ...he same space in addition to the opening for ventilation air required in 1 there shall be a permanent air sup ply opening s having a total cross sectional area of not less than 1 in 2 for each 30 000...

Page 13: ...ng all sheet metal screws 5 Remove all plumbing fittings to the header This will include both inlet and outlet water pipe unions and the pressure relief valve and drain piping 6 Remove limits control...

Page 14: ...85 17 1 3 13 0 7 14 44 8 8 4 HD151 150 128 26 3 0 13 0 7 13 0 7 20 44 8 8 6 HD201 199 169 34 5 3 17 1 3 13 3 4 27 44 8 9 8 HD251 250 213 44 9 2 21 2 1 14 1 0 13 0 7 34 44 9 2 10 HD301 299 254 25 3 1...

Page 15: ...erature Application Heat Pump Primary Secondary Piping Fig 12 Dual Boiler Primary Secondary Piping Maximum 4 times the pipe diameter or 12 Max Maximum 4 times the pipe diameter or 12 Max Fig 10 Single...

Page 16: ...ng Boilers All high points should be vented Purge valves and a bypass valve should be installed A boiler installed above radiation level must be provided with a low water cut off device The boiler whe...

Page 17: ...ns shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use open flame Gas Supply Gas piping must have a sediment trap ahead of the heater gas controls a...

Page 18: ...er while in operation should be as indicated in Table G If an adjustment is needed turn the adjust ment screw clockwise to increase pressure or counter clockwise to decrease pressure Electrical Power...

Page 19: ...the heater Verify that power has been turned off by testing with a volt ohm meter prior to working with any electrical connec tions or components 3 Observe proper wire colors while making electrical...

Page 20: ...y can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones on the unit or larger JUMPERED WHEN NOT USED...

Page 21: ...unded in accordance with NEC and C22 1 in Canada NOTES 1 Field installed ground to inside of junction box 2 If any of the original wire as supplied with the heater must be replaced it must be replaced...

Page 22: ...to 0 08 in WC 12 in from the heater outlet at all firing conditions Support of Vent Stack The weight of the vent stack or chimney must not rest on the heater vent connection Support must be pro vided...

Page 23: ...e 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 pav...

Page 24: ...no case above or below unless four 4 feet horizontal distance is maintained from elec tric meters gas meters regulators and relief equipment e Terminate vent at least six 6 feet away from adja cent wa...

Page 25: ...ce with the section on Venting of Equipment of the latest edition of NFGC or in Canada B149 Installation Code for Gas Burning Appliances and Equipment or applicable pro visions of local building codes...

Page 26: ...in Canada the B149 Installation Code for Gas Burning Appliances and Equipment Gas vents supported only by flashing and extended above the roof more than five feet should be securely guyed or braced t...

Page 27: ...tal Thru wall Venting Category III g Any improper operation of the common venting system should be corrected so that the installation conforms with the latest edition of the NFGC US and the B149 Insta...

Page 28: ...a slight upward slope of not more than 1 4 per foot of horizontal run to the vent terminal In this case an approved conden sate trap must be installed per applicable codes Horizontal Thru wall Direct...

Page 29: ...ize inches Max Venting Length feet Combustion Air Intake Pipe Material Air Inlet Size inches Max Air Intake Length feet HD101 HD151 III Stainless Steel Gas Tight 4 100 4 Elbows Max Galvanized Steel PV...

Page 30: ...Air Intake Length feet Min Max HD101 HD151 I Type B Equivalent 4 6 25 Galvanized Steel PVC ABS CPVC 4 100 HD201 HD251 HD301 5 HD201 6 HD251 6 HD301 11 HD401 6 8 Table N Vertical Venting Fig 23 Direct...

Page 31: ...or braced to withstand snow and wind loads The vertical direct vent cap is designed for roof top mounting only The air inlet opening MUST be installed one 1 foot above the roof line or above normal sn...

Page 32: ...ired to de energize the equipment before servicing Fig 24 Ignition Module Outdoor Air Reset Temperature Controller Models HD101 through HD301 Type H are factory equipped with an electronic outdoor air...

Page 33: ...he boiler and is cycled off using a 5 minute fixed purge delay after burner operation has ceased S1 Boiler Outlet Sensor S2 System Supply Sensor S3 Outdoor Air Sensor P1 Boiler Pump The DIP switch set...

Page 34: ...with an optional adjust able auto reset high limit temperature device Fig 29 Manual Reset High Limit Fig 28 Digital Temperature Control Direct Domestic Hot Water In this configuration the controller w...

Page 35: ...ure that suffi Fig 30 High Limit Auto Reset Optional cient gas pressure is present for proper regulator per formance The low gas pressure switch automatically shuts down the heater if gas supply drops...

Page 36: ...36 WIRING DIAGRAM MODELS HD101 HD151 TYPE WH...

Page 37: ...37 WIRING DIAGRAM MODELS HD101 HD151 TYPE H...

Page 38: ...38 WIRING DIAGRAM MODELS HD201 HD401 TYPE WH...

Page 39: ...39 WIRING DIAGRAM MODELS HD201 HD401 TYPE H...

Page 40: ...cro Amp A DC The unit is okay YES Replace HSI NO Adjust manifold gas pressure Correct wiring Is Amp draw during heat up for HSI greater than 3 1 Amps YES Is there 120VAC at the pump or pump relay cont...

Page 41: ...L START UP Tools Needed One 8 0 8 16 scale manometer Two 6 0 6 12 scale manometers 7 16 open end wrench 1 2 open end wrench Screwdriver Standard Phillips 3 8 open end wrench Multi meter 3 16 Allen wre...

Page 42: ...d or adjust the service regulator Start Up Blower Adjustment 1 A nylon tee fitting is connected with hoses in line with the air pressure switches Disconnect the plugged side and connect a manometer 2...

Page 43: ...hile the heater is running locate the HI or LO cap located adjacent to ON OFF switch 2 Remove the appropriate cap 3 Using a flat screwdriver turn clockwise to increase and counterclockwise to decrease...

Page 44: ...ame gas main check all pressures on the Hi Delta SS with all other equipment running Check thermostats for ON OFF operation Check High limits for ON OFF operation While in operation check flow switch...

Page 45: ...st limit control While burner is operating move indicator on high limit control below actual heater water temperature Burner should go off while blower and circulator continue to operate Raise setting...

Page 46: ...e air filter out for inspection Replace if nec essary 5 Replace the panel and screws before operating Fig 39 Inspect the Air Filter Heat Exchanger Removal Refer to Fig 40 for the following procedure 1...

Page 47: ...tial of severe burn DO NOT REST HANDS ON OR GRASP PIPES 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 aroun...

Page 48: ...ard metallic vent pipe In extremely contaminated areas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave sol...

Page 49: ...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...

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Page 52: ...52 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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