Instruction/ maintenance manual of the product HD101 Raypak
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INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.52 Effective: 06-1 1-09 Replaces: NEW P/N 241356 Rev . 1 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property damage, personal injury or death .
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WARNINGS 4 Pay Attention to These T erms 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Info.
D ANGER: 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.
BEFORE INST ALLA TION 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 .
Fig. 1: Component Locations — Angle View Fig. 2: Component Locations — Left Side Fig. 3: Component Locations — Front (Panels removed for clarity) 6 Component Locations.
General Infor mation T able A: Basic Data Model No. Quantity of Burners V ent 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.
GENERAL SAFETY T o 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.
INST ALLA TION INST ALLA TION 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/NFP A 70 - latest edition (NEC).
TOP VIEW FRONT VIEW 2 Fig. 7: Minimum Installed Service Clearances — Indoor/Closet Installations 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.
area per 20,000 BTUH (1 1 1 mm 2 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).
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. V entilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors.
13 WARNING: Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur .
14 Low T emper ature System Heater requires minimum inlet temperature of 105°F . Consult the following sections for piping details. T emperature & Pr essur e Gauge The temperature and pressure gauge is shipped loose for field installation.
15 Fig. 10: Single Boiler — Low T emperature Application (Heat Pump) Primary/Secondary Piping Fig. 1 1: Dual Boiler—Primary/Secondary Piping *Maximum 4 times the pipe diameter or 12”, whichever is less. *Maximum 4 times the pipe diameter or 12”, whichever is less.
16 T able F: Domestic W ater Heater Flow Rate Requirements Δ T = T emperature rise, °F . Δ P = 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 50 feet equivalent length of tubing and fittings.
17 Gas Supply Connection CA UTION: The heater and its manual shutoff valve must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.
18 Fig. 13: Sediment T rap Orientation Gas Supply Pr essur e A minimum of 4 in. WC and a maximum of 10.5 in. WC upstream gas pressure is required under load and no load conditions for natural gas. A minimum of 1 1 in. WC and a maximum of 13 in. WC is required for propane gas.
19 Electrical P ow er 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.
20 SINGLE ST AGE T ANKST A T ST AGE 1 CONNECTION A TT ACH ST AGE 1 CONNECTIONS ON HEA TER TO THE SINGLE ST AGE T ANKST A T AS SHOWN IN THE DIAGRAM ABOVE. 2-ST AGE T ANKST A T ST AGE 1 CONNECTION ST AGE 2 CONNECTION OR ST AGE 1 CONNECTION OF HEA TER 2 A TT ACH ST AGE 1 CONNECTIONS ON HEA TER TO ST AGE 1 CONNECTION ON T ANKST A T .
See T able H for appliance category requirements for the Hi Delta. Deter mination of Appliance Categor y for V enting Pur poses and V enting Ar r angements 21 Heater must be electrically grounded in accordance with NEC and C22.1(in Canada). NOTES: 1. Field installed ground to inside of junction box.
22 T able H: V enting Category Requirements Combustion Air Supply Exhaust Configuration V enting Category Certified Appliance Material Combustion Air Inlet Material From Inside Building (Non-Direct V .
23 U.S. Installations 1 Can adian I nstalla tions 2 A Clearance abov e grade , veran da, porch , deck, or balcony 1 ft ( 30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 f t ( 1 .
24 ances shall not terminate over public walkways or 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.
25 V enting 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 .
26 Natural Draft V er tical V enting 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 –0.
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.
28 Horizontal Thr u-wall V enting System (Categor y III) Installation These installations utilize the heater-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from the space and the vent is installed horizontally through the wall to the outdoors.
29 Fig. 20: Direct V ent Horizontal Thru-Wall V enting (Category III) Model No. Appliance Category Certified V enting Material V ent Size (inches) Max. V enting Length (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) HD101 HD151 III Stainless Steel (Gas T ight) 4 100, 4 Elbows Max.
30 Model No. Appliance Category Certified V enting Material V ent Size (inches) Min./Max. V ertical V enting Height (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max.
31 V er tical Dir ect V ent 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.
Modulating T emper ature Control (Optional) This heater can be equipped with a Raypak modulat- ing temperature control. For operation with this control, refer to the T emp-T racker Installation and Operating Instructions, Raypak Catalog number 5000.66 (P/N 241 177).
33 Lo w Wa ter Cut Of f (Optional) The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets.
34 WIRING DIA GRAM—MODELS HD101–HD401.
35 Ste p 8 HD Troubleshooting Ste p 8 Ste p 9 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Is there a Call For Heat? Is Disable connection intact? Does the Pump come on? Is 24VAC at the NC side of.
36 PRE-ST ART -UP Filling System-Heating Hea ter s 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.
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38 Check the Gas Supply Pressur e 1. Slowly turn on main gas shut-off valve. 2. Read the gas supply pressure from the manome- ter; minimum supply pressure is 4 in. WC, recommended supply is 7 in. WC for natural gas (minimum 1 1.0 in. WC for LP gas). 3.
39 3. Carefully remove 2-stage solenoid. 4. Skip to Step 9 for LO-fire adjustment only . 5. Locate and remove Lo-fire adjustment cap. 6. Carefully remove the spring & weight. 7. Using an allen wrench, turn clockwise to increase and counterclockwise to decrease the HI-fire man- ifold pressure.
40 • Insert ignition control lockout tests as safety check. F ollo w-Up • Safety checks must be recorded as performed. • T urn unit on. After main burner ignition: • Check Manometer(s) for proper reading(s). • Cycle unit several times and recheck readings.
41 3. Remove the (4) screws holding the panel in place. 4. Pull the air filter out for inspection. Replace if nec- essary . 5. When replacing, note the direction of the air flow defined on the side of the filter . The arrow should be pointing downward.
heater operating efficiency . Maintenance as outlined below may be performed by the owner . Y ear ly (Be ginning of each hea ting season): 1. Annual service call by qualified service agency .
43 2. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal. 3. Visually inspect venting system for proper func- tion, deterioration or leakage. 4. Check that heater area is free from combustible materials, gasoline, and other flammable vapors and liquids.
44 • 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 • .
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ww w .raypa k .com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A..
An important point after buying a device Raypak HD101 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Raypak HD101 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Raypak HD101 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Raypak HD101 you will learn all the available features of the product, as well as information on its operation. The information that you get Raypak HD101 will certainly help you make a decision on the purchase.
If you already are a holder of Raypak HD101, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Raypak HD101.
However, one of the most important roles played by the user manual is to help in solving problems with Raypak HD101. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Raypak HD101 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
