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  4. 122
  5. Installation & Operating Instructions Manual

Raypak 122 Installation & Operating Instructions Manual

Manual is about: Types H, WH & P Hi Delta

Summary of 122

  • Page 1

    Installation & operating instructions catalog no. 1000.53h effective: 09-19-08 replaces: 11-16-07 p/n 241112 rev. 9 warning: if these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death . For your safety: do not store or use gasolin...

  • Page 2

    2 rev. 9 reflects the following: changes to: the text in the before installation section on page 5; the text in paragraph one of the general safety section on page 8; the text in paragraph one of the outdoor installations section on page 10; table e on page 10; the wiring diagram on page 35..

  • Page 3

    Warnings 4 pay attention to these terms 4 before installation 5 product receipt 5 model identification 5 ratings and certifications 5 installations at elevation 5 component locations 6 general information 7 time/temperature relationships in scalds 8 general safety 8 clearances 9 equipment base 9 ins...

  • Page 4

    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. Caut...

  • Page 5

    Before installation raypak strongly recommends that this manual be re- viewed thoroughly before installing your hi delta heater. Please review the general safety information before installing the heater. Factory warranty does not apply to heaters that have been improperly installed or operated (refe...

  • Page 6

    Fig# 9399 hi-limits water outlet water inlet gas connection view port pressure relief connection flue exhaust combustion air intake component locations fig. 1: component locations—back fig. 2: component locations—left side panels removed for clarity fig. 3: component locations—front 6 hi limits.

  • Page 7

    General information table a: basic data table b: manifold data model no. Quantity of vent size (in.) burners gas valves blowers flue intake 122 3 2* 1 4 5 162 4 2* 1 5 5 202 5 2* 1 5 5 242 6 2* 1 5 5 322 8 2* 1 6 5 model no. Burners per valve stages % fire at stage a b 1 2 1 2 122 2 1 a ab 66 100 16...

  • Page 8

    General safety to meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 210°f. However, water temperatures over 125°f can cause instant severe burns or death from scalds. When supplying general p...

  • Page 9

    Installation installation installation codes installations must follow these codes: · local, state, provincial, and national codes, laws, regulations and ordinances. · national fuel gas code, ansi z223.1- latest edi- tion (nfgc). · national electrical code, ansi/nfpa 70 - latest edition (nec). · sta...

  • Page 10

    10 fig. 7: minimum clearances from combustible surfaces—indoor installations when installed according to the listed minimum clear- ances from combustible construction, these heaters can still be serviced without removing permanent structural construction around the heater. However, for ease of servi...

  • Page 11

    11 a motorized sealed damper to prevent the circula- tion of cold air through the heater during the non-operating hours. Conventional combustion air supply u.S. Installations all air from inside the building the confined space shall be provided with two perma- nent openings communicating directly wi...

  • Page 12

    12 warning: do not use one permanent opening method if the equipment room is under negative pressure conditions or the equipment is common vented with other gas-fired appliances. 1. Ventilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest ...

  • Page 13

    13 low temperature system heater requires minimum inlet temperature of 105°f. Consult the following sections for piping details. Temperature & pressure gauge the temperature and pressure gauge is factory- mounted in the in/out header. Hydronic heating pump selection in order to ensure proper perform...

  • Page 14

    14 fig. 9: single boiler—low temperature application (heat pump) primary/secondary piping fig. 10: dual boiler—primary/secondary piping.

  • Page 15

    15 table g: domestic water heater flow rate requirements Δt = temperature rise, °f. Δp = pressure drop through heat exchanger, ft. Shl = system head loss, ft. (system head loss is based on the heater and tank placed no more than 5 feet apart and 25 feet equivalent length of pipe and fittings.) gpm =...

  • Page 16

    16 fig. 11: single heater—domestic hot water with one storage tank.

  • Page 17

    17 gas supply gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve locat- ed outside the heater jacket. A pounds to inches regulator must be installed to reduce to gas supply pressure to under 10.5 in. Wc. The regulator should be placed a minimum distanc...

  • Page 18

    18 fig. 12: sediment trap orientation supplied by others extents of unit enclosure gas flow to burners sediment trap manual shut off valve supplied by others extents of unit enclosure gas flow to burners union sediment trap manual shut off valve gas supply connection gas supply pressure a minimum of...

  • Page 19

    19 electrical power connections installations 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 n.E.C. Class 1 · heater must be electrically grounded as required by n.E.C. · in can...

  • Page 20

    20 fig. 14: single stage and 2-stage tankstat electrical connections—domestic hot water installer action is required to electrically enable your hi delta heater to operate after making the power con- nections. You must make a connection on terminal block #3 for temperature control connections. This ...

  • Page 21

    21 single stage tankstat stage 1 connection attach stage 1 connections on heater to the single stage tankstat as shown in the diagram above. 2-stage tankstat stage 1 connection stage 2 connection or stage 1 connection of heater 2 attach stage 1 connections on heater to stage 1 connection on tankstat...

  • Page 22

    22 table h: venting category requirements combustion air supply exhaust configuration venting category certified appliance material combustion air inlet material from inside building (non-direct venting) vertical natural draft venting i type b or and category i venting system* horizontal thru-wall v...

  • Page 23

    23 u.S. Installations 1 canadian installations 2 a clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) b clearance to window or door that may be opened 4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) c clearance to permanently closed w...

  • Page 24

    24 over an area where condensate or vapor could create a nuisance or hazard or could be detrimen- tal to the operation of regulators, relief valves, or other equipment. Where local experience indi- cates that condensate is a problem with category i and iii appliances, this provision shall also apply...

  • Page 25

    25 venting installation tips support piping: · horizontal runs- at least every five (5) feet. · vertical runs - use braces: · under or near elbows follow items listed below to avoid personal injury or property damage. · cut nonmetallic intake pipe with fine-toothed hack- saw. · do not use nonmetalli...

  • Page 26

    26 natural draft vertical venting system installation natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The neg- ative draft must be within the range of -.01 in. To -.08 in. Wc as measured 12 in. ...

  • Page 27

    27 each appliance. Adjust thermostat so appliance will operate continuously. E) check the pressure at a pressure tap located 12 in. Above the bottom joint of the first vertical vent pipe. Pressure should be anywhere between -.01 to -.08 in. Wc. F) after it has been determined that each appliance rem...

  • Page 28

    28 horizontal thru-wall venting system (category iii) installation these installations utilize the heater-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the out- doors. Adequate c...

  • Page 29

    29 fig. 20: direct vent horizontal thru-wall venting (category iii) 12" 36" min. 12" min. 6" vent cap vent pipe combustion air filter boiler unit intake vent intake vent model no. Appliance category certified venting material vent size (inches) max. Venting length (feet) combustion air intake pipe m...

  • Page 30

    30 horizontal thru-wall direct vent system (category iii) installation these installations utilize the heater mounted blower to draw combustion air from outdoors and vent com- bustion products to the outdoors. The total length of the thru-wall exhaust vent cannot exceed forty (40) feet in length for...

  • Page 31

    31 36" 12" min. 36" min. Vent cap vent pipe combustion air filter boiler unit intake vent model no. Appliance category certified venting material vent size (inches) min./max. Vertical venting height (feet) combustion air intake pipe material air inlet size (inches) max. Air intake length (feet) 122 ...

  • Page 32

    32 vertical direct vent system installation these installations utilize the heater mounted blower to draw combustion air from outdoors and uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The negative draft must be wi...

  • Page 33

    33 controls ignition control module the interrupted proved ignition device conserves ener- gy. When additional heat is needed, the combustion air blower starts to purge all air from the combustion chamber for about 15 seconds. On proof of air flow, the air proving switch closes and the igniter is en...

  • Page 34

    34 low water cut off (optional) the low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 3-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig. 24: flow switch fig....

  • Page 35

    35 wiring diagram—models 122–322.

  • Page 36

    36 pre-start-up filling system-heating heaters fill system with water. Purge all air from the system using purge valve sequence. After system is purged of air, lower system pressure. Open valves for normal system operation, fill system through feed pressure. Manually open air vent on the compression...

  • Page 37

    37 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 manifold gas pressure tapping. (see gas valve detail on page 7.) • attach one 12" scale manometer to — pull rubber tube from air press...

  • Page 38

    38 follow-up • safety checks must be recorded as performed. • turn unit on. After main burner ignition: • check manometer for proper reading. • cycle unit several times and recheck readings • re-analyze with unit running record or print results. • remove all manometers and replace hose, remove jumpe...

  • Page 39

    39 8. Turn on all electric power to the appliance. 9. Set thermostat to desired setting. The appliance will operate. 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) tim...

  • Page 40

    40 monthly: 1. Check for piping leaks around circulators, mixing valves, relief valves, and other fittings. If found, repair at once. Do not use petroleum-based stop leak compounds. 2. Visually inspect burner flame. 3. Visually inspect venting system for proper func- tion, deterioration or leakage. ...

  • Page 41

    41 limited parts warranty commercial boilers type hi-delta sizes 122 to 322 models h and wh scope: raypak, inc. (“raypak”) warrants to the original owner that all parts of this boiler which are actually manufactured by raypak will be free from failure under normal use and service for the specified w...

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  • Page 44: Www.Raypak.Com

    Www.Raypak.Com raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (805) 278-5468 litho in u.S.A..