Instruction/ maintenance manual of the product WH & P L W Raypak
Go to page of 64
INST ALLA TION AND OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.51 1A Effective: 09-08-06 Replaces: 03-15-05 P/N 241259 Rev . 1 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property dam- age, personal injury or death.
2.
WARNINGS 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 T ime/T emperature Relationships i.
4 D ANGER: Indicates the presence of immediate hazards which will cause severe person- al 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.
5 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 . Factory warranty does not apply to heaters that have been improperly installed or operated.
6.
7 General Infor mation Quant ity of Vent Siz e (in. ) Mode l No. Bur ne rs Gas Va lves Blo wers Fl u e Intake 992A 11 2 + 1* 2 10 10 1262A 14 3 + 1* 2 12 10 1532A 17 4 2 12 10 1802A 20 4 2 14 10 2002A 23 5 3 14 10 2072A 23 5 3 14 10 2342A 26 5 3 16 10 * Hi dden solen oid l ocat ed in side o f air pl enum.
8 GENERAL SAFETY T o meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F . However , water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water , the rec- ommended initial setting for the temperature control is 125°F .
9 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.
10 U.S. Installations 1 Cana d i a n I nst a lla tions 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 b e opened 4 f t ( 1.
11 In addition, the heater 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.
12.
13 three or four sheet metal screws (not supplied) equal- ly distributed around the circumference of the duct. All ducting should be self-supported. The filter housing is not designed to support the air duct.
14 b. Not less than the sum of the areas of all vent connectors in the confined space. 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.
15 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 bulbs and/or thermocou- ples. 7. Remove the eight flange nuts and the in/out head- er from the left-hand side.
16 Failure to exceed 105ºF (41ºC) within 7 minutes may result in the premature failure of the hot surface ignit- er , remote flame sensor , burners and heat exchanger . It can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the vent system.
17 Pressur e Drop in Feet of Head F eedwater R e gula tor Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the high- est point of the system. Install a check valve or back flow device upstream of the regulator , with a manual shut-off valve as required by local codes.
18 P ota ble W ater and Space Heating 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water . 2. T oxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating.
19 circulate water through the heater from the main sys- tem piping. T o complete the installation of the pool heater , the pool thermostat needs to be installed in the main return wa- ter line, upstream of the heater . This will ensure that the heater will be energized at the right time.
20 shut-off. Close isolation valves and remove water pip- ing from the in/out header on the heater . Drain the heater and any piping of all water that may experience below-freezing temperatures. P ool/Spa Water Chemistr y Wa ter Har dness W ater hardness is mainly due to the presence of cal- cium and magnesium salts dissolved in the water .
21 Gas Supply Connection The heater must be isolated from the gas supply pip- ing system by closing the manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.
22 8. Remove the rubber grommet from the left-hand- side panel and reinstall into the standard main gas opening, located on the right-hand side of the heater .
23 CIRCUIT BREAKER WHITE GROUND BLACK GREEN AB C Fig. 18: Wiring Connections Check the power source: AC = 108 V AC Minimum, 132 V AC MAX AB = 108 V AC Minimum, 132 V AC MAX BC = <1 V AC Maximum If the heater does not have a factory-wired stage con- troller , it is factory-wired in an on-off configuration with other stage terminals jumpered.
24 D ANGER: SHOCK HAZARD Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components..
25 Installer action is required to electrically enable your heater to operate after making the power connections. Y ou must make a closed contact connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connections.
26 Combustion Air Su p pl y Exh aus t Configuration Heater Venting Category Certified Mate rial s Combustion Air Inlet M ater ial Ver tic al N atur al Draft Ventin g I “B” Ven t From Ins ide Build.
27 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. 10. DO NOT terminate above any door , window , or gravity air intake.
28 5. Remove the screws, retaining ring and rain gasket from top of heater . 6. Remove the screws, flue collar and gasket from the run side of the tee located in the flue box on top of the heater . 7. Reverse the components and reattach in the new location.
29 T er mination The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the high- est point of the roof that is within 10 ft.
30 speed. Do not operate summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliances being inspected. Follow the manufacturer ’s instructions for lighting each appliance. Adjust thermostat so appliance will operate continuously .
31 Air Inle t Max . Lengt h* Mode l No. Certified Vent in g Mate rial Vent Siz e Max imu m Eq uiv ale nt Vent Lengt h* Combustion Air Intake Pipe Mate rial 10” 12” 992A 10” 1262A 1532A 12” 75.
32 For installations in extremely cold climate, it is re- quired that: 1. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of hori- zontal run to the vent terminal. In this case, an ap- proved condensate trap must be installed per ap- plicable codes.
33 Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that might ob- struct combustion air flow .
34 Fig. 31: External LED Indicator Decal Heater Sequence of Operation Models 992A-1262A 1. The black (hot) wire lead goes directly to the main power switch.
35 Ext er nal L igh ts Li ght Co lor I ndi cati on Power Bl ue Main power is on Call For H eat Yellow Thermostat is closed Sa fety Red One or more sa feties is inopera- tiv e Ign iti on Re d Ign iti o.
36 33. Power is applied to the optional equipment inter- lock connection (normally jumpered). 34. The 24 V AC signal is then sent to the 24 V AC safe- ty connector . 35. 24 V AC is now sent to the pressure switch (P .S.) terminal on the ignition module.
37 9. 24 V AC is sent to the low water cut-off (optional) and the red power light is energized. 10. 24 V AC is applied to the blue power light located on the diagnostic display board. 1 1. 24 V AC is also applied to the red LED safety shut- down light on the front diagnostic board.
38 37. 24 V AC is now sent to the pressure switch (P .S.) terminal on ignition modules 1 and 2. 38. Once the pressure switch signal is received at ignition module 1, hot surface igniter 1 is ener- gized by a 120 V AC signal from S-1 on ignition module 1.
39 6. T erminals L1 and F1 of the ignition module 2 are powered with 120V AC. 7. 120 V AC power is waiting at relay contacts K-4 to energize the heater blowers. 8. The 120/24 V AC transformer outputs 24 V AC. 9. 24 V AC is sent to the low water cut-off (optional) and the red power light is energized.
40 35. Power is applied to the optional equipment inter- lock connection (normally jumpered). 36. The 24 V AC signal is then sent to the 24 V AC safe- ty connector . 37. 24 V AC is now sent to the pressure switch (P .S.) terminal on the ignition modules.
41 Ignition Module When additional heat is needed, the combustion air blower starts to purge air from the combustion cham- ber for about 15 seconds. On proof-of-air flow , the air- proving switch closes and the igniter is energized. T o ensure safe operation, the gas valve cannot open until the igniter is verified.
42 Fig. 35: Operating Control Low W ater 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 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets.
43 87%-Ef ficienc y Boiler s – Special Instr uctions Wa ter Piping An 87%-efficiency boiler requires a minimum inlet water temperature of 120ºF (49ºC) to prevent exces- sive condensation in the combustion chamber .
44 WARNING: Contact the vent material manufactur- er if there are any questions about the appliance cat- egory or suitability of a vent material for Category II, III or IV applications. Using improper venting materi- als can result in personal injury , death or property damage.
45 Horizontal Thr ough-the-Wall V enting (Categor y IV) WARNING: V ent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure.
46 The stainless steel direct vent cap must be furnished by the boiler manufacturer in accordance with its list- ing (sales order option D-15). Use only double-wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burn- ing boilers, such as the stainless steel Saf-T vent by Heat Fab Inc.
47 Direct V ent - V er tical Vert ica l Ve nt in g Height* Air I nlet Max . Length** Mode l Certified Vent in g Mate rial Vent Siz e Min. Max . Combustion Air Intake Pipe Mate rial 10” 12” 992AE 1.
48 W iring Dia gr ams.
49.
50 ST ART -UP Pre Star t-up Filling System (Heating Boilers) Fill system with water . Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent.
51 Prepar ation Check P ower Supply With multi-meter at incoming power , check voltage between: Hot - Common (≈120 V AC) Hot - Ground (≈120 V AC) Common - Ground (< 1 V AC) Attach Manometers to Measure Pr essures 1. Turn of f main gas valve. 2.
52 Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record. 3. If other gas-fired appliances in the room are on the same gas main, check all pressures on the Hi Delta with all other equipment running.
53 1. Manually close the downstream leak test valve. 2. Open test point A and connect a manometer to it. V erify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in. WC). 3. Open test point B and connect a rubber tube to it.
54 10. T o restart system, follow lighting instructions in the Operation section. 1 1. Check to see that the high limit control is set above the design temperature requirements of the system. For multiple zones: Check to make sure the flow is adjusted as required in each zone.
55 TR OUBLESHOO TING Ste p 7 Ste p 6 Ste p 5 Step 1 Step 2 Step 3 Step 4 Is there a Call For Heat? Is Disable j um p er intact? ( J1 ) Is there 120VAC at J8 Connecto r on the CPW board? Do the combust.
56 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency .
57 W eekl y For low-pressure heaters, test low-water cut-off device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance should shut-off and ignition fault light should come on. Depress reset button to reset).
58 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.
59 LIMITED PARTS WARRANTY HI DELTA – TYPES H AND WH MODELS 992A–2342A SCOP E Ray pak, Inc. (“ Ray pak” ) w arr ants to the o rig inal ow ner that al l par ts of th is hea ter w hic h a re ac t.
60 LIMITED PARTS WARRANTY HI DELTA – TYPE P MODELS 992A–2342A SCOP E Ray pak, Inc. (“ Ray pak ”) w arr ants to th e orig inal ow ner th at al l par ts o f this hea ter w hic h a re actu al ly .
61.
62.
63.
ww w .raypak.c om Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.
An important point after buying a device Raypak WH & P L W (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 WH & P L W 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 WH & P L W - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Raypak WH & P L W you will learn all the available features of the product, as well as information on its operation. The information that you get Raypak WH & P L W will certainly help you make a decision on the purchase.
If you already are a holder of Raypak WH & P L W, 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 WH & P L W.
However, one of the most important roles played by the user manual is to help in solving problems with Raypak WH & P L W. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Raypak WH & P L W 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
