Raypak Swimming Pool Heater 122 322 User Guide

INSTALLATION & OPERATING  
INSTRUCTIONS  
Models 122–322  
Types H, WH & P  
L
W
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 gasoline or other flammable vapors and  
liquids or other combustible materials in the vicinity of this or any other appliance. 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 installer, service agency or  
the gas supplier.  
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for  
future reference.  
CATALOG NO. 1000.53H  
Effective: 09-19-08  
Replaces: 11-16-07  
P/N 241112 Rev. 9  
 
CONTENTS  
WARNINGS  
4
4
Main Burner Adjustment  
37  
37  
38  
38  
38  
38  
39  
39  
Pay Attention to These Terms  
BEFORE INSTALLATION  
Product Receipt  
Safety Inspection  
Follow-Up  
5
5 POST START-UP CHECK  
Model Identification  
5 OPERATION  
Ratings and Certifications  
Installations at Elevation  
Component Locations  
General Information  
5
5
Operating Instructions  
To Turn Off Gas To Appliance  
6 MAINTENANCE  
7
Suggested Minimum Maintenance  
Time/Temperature Relationships in Scalds 8 Schedule  
39  
40  
40  
GENERAL SAFETY  
Clearances  
Equipment Base  
INSTALLATION  
8 APPENDIX  
9
9
9
Inside Combustion Air Contamination  
Installation Codes  
9
Combustion and Ventilation Air  
Conventional Combustion Air Supply  
Water Piping  
11  
11  
12  
13  
15  
17  
17  
19  
21  
32  
33  
33  
33  
33  
34  
34  
Hydronic Heating  
Domestic Hot Water Piping  
Pool Heating  
Gas Supply  
Electrical Power Connections  
Venting  
Outdoor Installation  
High Limit (Manual Reset)  
Flow Switch  
CONTROLS  
Ignition Control Module  
Low Water Cut Off (Optional)  
Operating Control  
WIRING DIAGRAM—MODELS 122  
–322  
35  
36  
36  
36  
36  
36  
36  
36  
36  
36  
37  
PRE-START-UP  
Filling System-Heating Heaters  
Domestic Hot Water Heaters  
Inspect Venting System  
For Your Safety Read Before Lighting  
Pre-Start-Up Check  
INITIAL START-UP  
Tools Needed  
Preparation for Start-Up  
Start-Up  
3
 
WARNINGS - Pay Attention to These Terms  
Indicates the presence of immediate hazards which will cause severe  
DANGER:  
personal injury, death or substantial property damage if ignored.  
Indicates the presence of hazards or unsafe practices which could cause  
WARNING:  
severe personal injury, death or substantial property damage if ignored.  
Indicates the presence of hazards or unsafe practices which could cause  
CAUTION:  
minor personal injury or product or property damage if ignored.  
Indicates special instructions on installation, operation, or maintenance which  
are important but not related to personal injury hazards.  
NOTE:  
DANGER: Make sure the gas on which the heater  
will operate is the same type as that specified on the  
heater rating plate.  
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.  
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.  
Heater should never be covered or have any  
blockage to the flow of fresh air to the heater.  
WARNING: Risk of electrical shock. More than one  
disconnect switch may be required to deenergize the  
equipment before servicing.  
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 - CALIFORNIA PROPOSITION  
65: This product contains chemicals known to the  
State of California to cause cancer, birth defects or  
other reproductive harm.  
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.  
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.  
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.  
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.  
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.  
4
 
the left inside jacket of the heater. The model number  
will have the form H3 0162 or similar depending on the  
heater size and configuration. The first character of the  
model number identifies application (H = Hydronic  
Heating System, WH = Hot Water Supply System, P =  
Pool Application). The second character identifies the  
firing mode (3 - two stage firing, 4 - On/Off firing ). The  
next four places identify the size of the heater.  
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 (refer to the warranty at the back of this man-  
ual). Installation and service must be performed by a  
qualified installer, service agency or the gas supplier.  
If, after reviewing this manual, you still have questions  
which this manual does not answer, please contact  
your local Raypak representative or visit our website at  
Ratings and Certifications  
Standards:  
Gas-Fired Low Pressure Steam and Hot Water  
Heaters, ANSI Z21-13 • CSA 4.9 - latest edition  
Industrial and Commercial Gas-Fired Package  
Heaters, CAN 3.1 - latest edition  
Thank you for purchasing a Raypak product. We hope  
you will be satisfied with the high quality and durability  
of our equipment.  
Gas-Fired Pool Heaters, ANSI Z21.56 • CSA 4.7 -  
latest edition  
Gas Water Heaters, ANSI Z21.10.3 • CSA 4.3 - lat-  
est edition  
Product Receipt  
On receipt of your heater it is suggested that you visu-  
ally check for external damage to the shipping crate. If  
the crate is damaged, make a note to that effect on the  
Bill of Lading when signing for the shipment. Next,  
remove the heater from the shipping packaging.  
Report any damage to the carrier immediately.  
All Raypak heaters are National Board Approved, and  
design-certified and tested by the Canadian Standards  
Association (CSA) for the U.S. and Canada. Each  
heater is constructed in accordance with Section IV of  
the American Society of Mechanical Engineers  
(ASME) Heater Pressure Vessel Code and bears the  
ASME stamp. The heater also complies with the latest  
edition of ASHRAE 90.1 Standard.  
On occasion, items are shipped loose. Be sure that  
you receive the correct number of packages as indi-  
cated on the Bill of Lading.  
WARNING: Altering any Raypak pressure vessel  
by installing replacement heat exchangers, tube  
bundle headers, or any ASME parts not  
manufactured and/or approved by Raypak will  
instantly void the ASME and CSA ratings of the  
vessel and any Raypak warranty on the vessel.  
Altering the ASME or CSA ratings of the vessel also  
violates national, state, and local approval codes.  
Claims for shortages and damages must be filed with  
the carrier by consignee. Permission to return goods  
must be received from the factory prior to shipping.  
Goods returned to the factory without an authorized  
Returned Goods Receipt number will not be accepted.  
All returned goods are subject to a restocking charge.  
When ordering parts, you must specify the model and  
serial number of the heater. When ordering under war-  
ranty conditions, you must also specify the date of  
installation.  
Installations at Elevation  
Rated inputs are suitable for up to 4500 feet elevation  
without de-rate. Consult the Factory for installations at  
any altitude in excess of 4500 feet.  
Purchased parts are subject to replacement only  
under the manufacturer’s warranty. Debits 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  
number are found on the heater data plate located on  
5
 
Component Locations  
COMBUSTION AIR  
INTAKE  
FLUE EXHAUST  
Fig. 1: Component Locations—Back  
PRESSURE RELIEF  
CONNECTION  
WATER OUTLET  
GAS CONNECTION  
WATER INLET  
VIEW PORT  
Fig. 2: Component Locations—Left Side  
HI LIMITS  
Panels removed for clarity  
Fig. 3: Component Locations—Front  
6
 
General Information  
Quantity of  
Vent Size (in.)  
Model  
No.  
Burners Gas Valves Blowers Flue  
Intake  
122  
162  
202  
242  
322  
3
4
5
6
8
2*  
2*  
2*  
2*  
2*  
1
1
1
1
1
4
5
5
5
6
5
5
5
5
5
*Second valve located inside air plenum  
Table A: Basic Data  
Burners per Valve  
Stages  
% Fire at Stage  
Model  
No.  
A
2
3
3
4
5
B
1
1
2
2
3
1
A
A
A
A
A
2
1
2
122  
162  
202  
242  
322  
AB  
AB  
AB  
AB  
AB  
66  
75  
60  
66  
63  
100  
100  
100  
100  
100  
Table B: Manifold Data  
Fig. 5: Air Shutter Adjustment  
Fig. 4: Gas Valve Detail  
7
 
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 purpose hot water, the rec-  
ommended initial setting for the temperature control is  
125°F.  
Safety and energy conservation are factors to be con-  
sidered when setting the water temperature on the  
thermostat. The most energy-efficient operation will  
result when the temperature setting is the lowest that  
satisfies the needs of the application.  
Water temperature over 125°F can  
causeinstantsevereburnsordeath  
from scalds.  
Children, disabled, and elderly are  
at highest risk of being scalded.  
Water temperature over 125°F can cause instant  
severe burns or death from scalds. Children, disabled  
and elderly are at highest risk of being scalded.  
See instruction manual before set-  
ting temperature at water heater.  
Feel water before bathing or showering.  
Temperature limiting valves are available.  
Feel water before bathing or show-  
ering.  
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.  
Temperature limiting valves are  
available, see manual.  
Time/Temperature  
Relationships in Scalds  
The following chart details the relationship of water  
temperature and time with regard to scald injury and  
may be used as a guide in determining the safest  
water temperature for your applications.  
Maximum water temperatures occur just after the  
heater’s burner has shut off. To determine the water  
temperature being delivered, turn on a hot water  
faucet and place a thermometer in the hot water  
stream and read the thermometer.  
Water  
Temp.  
Time to Produce Serious  
Burn  
120°F  
125°F  
130°F  
135°F  
140°F  
145°F  
150°F  
155°F  
More than 5 minutes  
1-1/2 to 2 minutes  
About 30 seconds  
About 10 seconds  
Less than 5 seconds  
Less than 3 seconds  
About 1-1/2 seconds  
About 1 second  
Table courtesy of The Shriners Burn Institute  
Table C: Time to Produce Serious Burn  
8
 
The temperature of the water in the heater can be reg-  
ulated by using the temperature control. To comply  
with safety regulations, the temperature control is set  
at the lowest setting when shipped from the factory.  
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-fueled equipment installed  
in enclosed parking garages must be located at least  
18 in. above the floor.  
To adjust the water temperature, insert a small straight  
screwdriver into the adjustment screw on the front of  
temperature control and turn the wheel to the desired  
setting (See Fig. 6).  
CAUTION: The heater should be located in an area  
where water leakage will not result in damage to the  
area adjacent to the appliance or to the structure.  
When such locations cannot be avoided, it is  
recommended that a suitable catch pan, adequately  
drained, be installed under the appliance. The pan  
must not restrict air flow.  
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.).  
WARNING: This product must be installed by a  
licensed plumber or gas fitter when installed within  
the Commonweatlh of Massachusetts.  
Fig. 6: Temperature Control  
CAUTION: Hotter water increases the risk of scald-  
ing! There is a hot water scald potential if the  
thermostat is set too high.  
Clearances  
Indoor Installations  
INSTALLATION  
Minimum Clearance Recommended  
Heater  
from Combustible  
Surfaces  
Service  
Side  
Clearance  
Installation Codes  
Floor*  
Rear  
0”  
1”  
0”  
24”  
24”  
24”  
1”  
Installations must follow these codes:  
Water Side  
Other Side  
Top  
12”  
1”  
·
·
·
·
Local, state, provincial, and national codes, laws,  
regulations and ordinances.  
National Fuel Gas Code, ANSI Z223.1- latest edi-  
tion (NFGC).  
1”  
Front  
Open  
2”  
24”  
2”  
National Electrical Code, ANSI/NFPA 70 - latest  
edition (NEC).  
Standard for Controls and Safety Devices for  
Automatically Fired Heaters, ANSI/ASME CSD-1,  
when required (CSD-1).  
For Canada only: CAN/CGA B149 Installation  
Code (B149) and C.S.A. C22. 1 C.E.C. Part 1  
(C22. 1).  
Vent  
* DO NOT install on carpeting.  
Table D: Clearances – Indoor Installations  
·
9
 
FRONT VIEW  
TOP VIEW  
Fig. 7: Minimum Clearances from Combustible Surfaces—Indoor Installations  
Outdoor 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 servicing, we recommend a clearance of at  
least 24 in. in front, and at least 36 in. on the water  
connection side. This will allow the heater to be serv-  
iced in its installed location without movement or  
removal of the heater.  
These heaters are design-certified for outdoor installa-  
tion. Heaters must not be installed under an overhang  
unless clearances are in accordance with local instal-  
lation codes and the requirements of the gas supplier.  
Three sides must be open in the area under the over-  
hang. Roof water drainage must be diverted away  
from heaters installed under overhangs.  
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.  
Recommended  
Service  
Min. Clearance  
from Combustible  
Surfaces  
Heater  
Side  
Clearance  
Front  
Rear  
Open  
24”  
24”  
36”  
36”  
36”  
N/A  
12”  
36”  
Water Side  
Other Side  
Top  
36”  
Unobstructed  
N/A  
Vent  
Table E: Clearances – Outdoor Installations  
Fig. 8: Minimum Clearances from Combustible Surfaces—Outdoor Installations  
10  
 
a motorized sealed damper to prevent the circula-  
tion of cold air through the heater during the  
non-operating hours.  
These clearances are required when the outdoor  
vent cap is used. If installing the heater outdoors  
with a vent stack, the indoor clearances may be  
utilized.  
Conventional Combustion Air  
Supply  
The combustion air intake hood MUST be used for  
outdoor installations. The hood is shipped loose and  
installed on the side of the heater over the filter box at  
the job site.  
U.S. Installations  
All Air from Inside the Building  
Combustion and Ventilation Air  
The confined space shall be provided with two perma-  
nent openings communicating directly with an  
additional room(s) of sufficient volume so that the com-  
bined volume of all spaces meets the criteria for an  
unconfined space. The total input of all gas utilization  
equipment installed in the combined space shall be  
considered in making this determination. Each open-  
ing shall have a minimum free area of 1 square inch  
per 1,000 Btu per hour (22 cm² per kW) of the total  
input rating of all gas utilization equipment in the con-  
fined space, but not less than 100 in.² (645 cm²). One  
opening shall commence within 12 in. (30 cm) of the  
top, and one opening shall commence within 12 in. (30  
cm) of the bottom, of the enclosure. The minimum  
dimension of air openings shall be not less than 3 in.  
(8 cm) in any direction.  
Indoor Units  
The heater must be supplied with sufficient quantities  
of non-contaminated air to support proper combustion  
and equipment ventilation. Combustion air can be sup-  
plied via conventional means where combustion air is  
drawn from the area immediately surrounding the  
heater, or via direct vent, where combustion air is  
drawn directly from outside. All installations must com-  
ply with the requirements of the NFGC (U.S.) and  
B149 (Canada), and all local codes.  
CAUTION: Combustion air must not be  
contaminated by corrosive chemical fumes which  
can damage the heater and void the warranty. (See  
the Appendix.)  
All Air from Outdoors  
The confined space shall communicate with the out-  
doors in accordance with methods 1 or 2. The  
minimum dimension of air openings shall not be less  
than 3 in. (8 cm) in any direction. Where ducts are  
used, they shall be of the same cross-sectional area  
as the free area of the openings to which they connect.  
Direct Combustion Air  
If outside air is drawn through the intake pipe directly  
to the unit for combustion:  
1. Install combustion air direct vent in accordance  
with the venting section of this manual.  
1. Two permanent openings, one commencing with-  
in 12 in. (30 cm) of the top, and one commencing  
within 12 in. (30 cm) of the bottom, of the enclo-  
sure 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.  
2. Provide adequate ventilation of the space occu-  
pied by the heater(s) by an opening(s) for  
ventilation air at the highest practical 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 of all equipment in the room when the  
opening is communicating with the outdoors  
through horizontal duct(s).  
a. Where directly communicating with the out-  
doors or where communicating to the  
outdoors through vertical ducts, each opening  
shall have a minimum free area of 1 sq in. per  
4000 Btu per hr (5.5 cm2 per kW) of total input  
rating of all equipment in the enclosure.  
b. Where communicating with the outdoors  
through horizontal ducts, each opening shall  
have a minimum free area of 1 sq in. per 2000  
3. In cold climates, and to mitigate potential freeze-  
up, Raypak highly recommends the installation of  
11  
 
Btu per hr (11 cm2 per kW) of total input rating  
of all equipment in the enclosure.  
than 18 in. (450 mm) nor less than 6 in. (150 mm)  
above the floor level. The duct can also "Goose  
Neck" through the roof. The duct is preferred  
straight down 18” from floor, but do not place near  
piping. This air supply opening requirement shall  
be in addition to the air opening for ventilation air  
required in (1).  
2. One permanent opening, commencing within 12  
in. (30 cm) of the top of the enclosure, shall be  
permitted where the equipment has clearances of  
at least 1 in. (2.5 cm) from the sides and back and  
6 in. (16 cm) from the front of the appliance. The  
opening shall directly communicate with the out- 3. For heaters not using a barometric damper in the  
doors or shall communicate through a vertical or  
horizontal duct to the outdoors or spaces (crawl or  
attic) that freely communicate with the outdoors,  
and shall have a minimum free area of:  
vent system, and when air supply is provided by  
natural air flow from outdoors for a power burner  
and there is no draft regulator, drafthood or similar  
flue gas dilution device installed in the 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 sq. in. for each 30,000 BTUH (70  
sq. mm per kW) of total rated input of the burn-  
er(s), and the location of the opening(s) shall not  
interfere with the intended purpose of the open-  
ing(s) for ventilation air referred to (1). This  
opening(s) can be ducted to a point neither more  
than 18 in. (450 mm) nor less than 6 in. (150 mm)  
above the floor level. The duct can also "Goose  
Neck" through the roof. The duct is preferred to be  
straight down 18” from floor, but do not place near  
piping.  
a. 1 sq in. per 3000 Btu per hr (7 cm2 per kW) of  
the total input rating of all equipment located in  
the enclosure, and  
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.  
Canadian Installations  
4. Refer to the latest version of the B149 for addition-  
al information.  
CAUTION: All combustion air must be drawn from  
the air outside of the building; the mechanical equip-  
ment room must communicate directly with the  
outdoors.  
Water Piping  
General  
The heater should be located so that any water leaks  
will not cause damage to the adjacent area or struc-  
tures.  
1. Ventilation 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. The total cross-sectional area of  
such an opening(s) shall be at least 10% of the  
area required in (2) and (3), but in no case shall  
the cross-sectional area be less than 10 sq. in.  
(6500 sq. mm.).  
CAUTION: This heater requires forced water  
circulation when the burner is operating. See Table F  
and Table G for minimum and maximum flow rates  
and water pump selection. The pump must be  
interlocked with the heater to prevent heater  
operation without water circulation.  
2. For heaters using a barometric damper in the vent  
system, and when air supply is provided by natu-  
ral air flow from the outdoors for natural draft,  
partial fan assisted, fan-assisted or power draft-  
assisted burners, there shall be a permanent air  
supply opening(s) having a cross section area of  
not less than 1 sq. in. per 7000 BTUH (310 sq. mm  
per kW) up to and including 1 million BTUH, plus  
1 sq. in. per 14000 BTUH (155 sq. mm per kW) in  
excess of 1 million BTUH. This opening(s) shall be  
either located at or ducted to a point neither more  
Relief Valve Piping  
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. Refer to  
local codes.  
12  
 
Hydrostatic Test  
Low Temperature System  
Unlike many other types of heaters, Raypak heaters Heater requires minimum inlet temperature of 105°F.  
do not require hydrostatic testing prior to being placed Consult the following sections for piping details.  
in operation. The heat exchanger has already been  
factory-tested and is rated for 160 PSI maximum oper-  
ating pressure. However, Raypak does recommend  
hydrostatically testing the piping connections to the  
heater and the rest of the system prior to operation.  
This is particularly true for hydronic systems using  
expensive glycol-based antifreeze. Raypak recom-  
mends conducting the hydrostatic test before  
connecting gas piping or electrical supply.  
Temperature & Pressure Gauge  
The temperature and pressure gauge is factory-  
mounted in the in/out header.  
Hydronic Heating  
Pump Selection  
Leaks must be repaired at once to prevent damage to  
the heater. NEVER use petroleum-based stop-leak  
compounds.  
In order to ensure proper performance of your boiler  
system, you must install a properly sized pump.  
Raypak recommends using a 20°F Delta T as design  
Delta T. (Delta T is the temperature difference between  
the inlet and outlet water when the heater is firing at  
full rate). If a Delta T larger than 20°F is necessary,  
see Table F for minimum flow rate requirements.  
1. Connect fill water supply. Fill heater with water (be  
sure bleed valve is open). When water flows from  
bleed valve, shut off water. Close bleed valve.  
Carefully fill the rest of the system, being sure to  
eliminate any entrapped air by using high point  
vents. Close feed valve. Test at standard operating  
pressure for at least 24 hours.  
Pressure Drop in Feet of Head  
Feedwater Regulator  
2. Make sure constant gauge pressure has been  
maintained throughout test.  
Raypak recommends that a feedwater regulator be  
installed and set at 12 PSIG minimum pressure at the  
highest point of system. Install a check valve or back  
flow device upstream of the regulator, with a manual  
shut off valve as required by local codes.  
3. Check for leaks. Repair if found.  
10°F ΔT  
20°F ΔT  
30°F ΔT  
Min. Flow  
Max. Flow  
Model  
No.  
gpm ΔP (ft) gpm ΔP (ft) gpm ΔP (ft) gpm ΔP (ft)  
ΔT  
20  
27  
34  
40  
40  
gpm ΔP (ft) ΔT  
122  
162  
202  
242  
322  
20  
27  
34  
40  
2.5  
4.5  
10  
13  
17  
20  
27  
<1.0  
1.10  
1.85  
2.65  
4.70  
10*  
10  
10  
10  
14  
<1.0  
<1.0  
<1.0  
<1.0  
1.4  
30  
30  
30  
44  
44  
5.3  
5.4  
7
9
7.2  
11  
14  
18  
<1.0  
1.3  
5.5  
11  
9
10.0  
11.8  
12.2  
2.2  
12  
* Flow switch (when used) will not activate at less than 12 gpm.  
NOTE: Basis for minimum flow - 10 gpm or 40° Delta T  
maximum flow - 44 gpm, except for 1.25” header.  
Table F: Heater Rates of Flow and Pressure Drops  
13  
 
Fig. 9: Single Boiler—Low Temperature Application (Heat Pump) Primary/Secondary Piping  
Fig. 10: Dual Boiler—Primary/Secondary Piping  
14  
 
Piping—Heating Boilers  
Three-Way Valves  
All high points should be vented. Purge valves and a Valves designed to blend water temperatures or  
bypass valve should be installed. A boiler installed reduce water circulation through the boiler should not  
above radiation level must be provided with a low be used. Raypak boilers are high recovery low mass  
water cut-off device. The boiler, when used in connec- boilers not subject to thermal shock. Raypak offers a  
tion with a refrigeration system, must be installed so full line of electric sequencers that produce direct reset  
the chilled medium is piped in parallel with the boiler of boiler water temperature. Refer to the Controls  
with appropriate valves to prevent the chilled medium  
from entering the boiler.  
Section in our Complete Catalog.  
Domestic Hot Water Piping  
The boiler piping system of a hot water heating boiler  
connected to heating coils located in air handling units  
where they may be exposed to circulating refrigerated  
air, must be equipped with flow control valves or other  
automatic means to prevent gravity circulation of the  
boiler water during the cooling cycle. It is highly recom-  
mended that the piping be insulated.  
When designing the water piping system for domestic  
water applications, water hardness should be consid-  
ered. Table G indicates the suggested flow rates for  
soft, medium and hard water. Hardness is specified as  
grains per gallon.  
Air-Separation/Expansion Tank  
All boilers should be equipped with a properly sized  
expansion tank and air separator fitting as shown in  
the diagrams.  
Soft (0–4 grains per gallon) Medium (5–15 grains per gallon) Hard* (16–25** grains per gallon)  
Model  
No.  
ΔT gpm ΔP MTS SHL ΔT gpm  
ΔP  
MTS  
SHL  
7.8  
7.9  
8.0  
5.9  
6.6  
ΔT gpm  
ΔP  
MTS  
SHL  
10.3  
10.4  
10.5  
16.1  
16.5  
122  
162  
202  
242  
322  
10  
14  
17  
21  
27  
20  
20  
20  
20  
20  
2.5 1-1/4 4.9  
2.5 1-1/4 4.9  
2.6 1-1/4 5.0  
2.6 1-1/2 3.5  
2.7 1-1/2 3.6  
8
26  
26  
26  
26  
27  
4.0 1-1/4  
4.1 1-1/4  
4.2 1-1/4  
4.3 1-1/2  
4.8 1-1/2  
7
9
30  
30  
30  
44  
44  
5.3 1-1/4  
5.4 1-1/4  
5.5 1-1/4  
11.8 1-1/2  
12.2 1-1/2  
11  
13  
16  
20  
11  
9
12  
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 = Gallons per minute, flow rate.)  
MTS = Minimum tubing size.  
*Must utilize optional cupro-nickel tubes.  
**With Hard Water (16-25 grains per gallon), the operating control must be set no higher than 130F for scale free operation. For operating temper-  
atures above 130F, a water softener must be utilized.  
Table G: Domestic Water Heater Flow Rate Requirements  
15  
 
Fig. 11: Single Heater—Domestic Hot Water with One Storage Tank  
16  
 
Winterizing Your Heater  
Pool Heating  
When heaters installed outdoors in freezing climate  
areas are to be shut down for the winter, please  
observe the following procedure:  
CAUTION: Power to the heater should be  
interlocked with the main system pump to make sure  
the heater does not fire without the main system  
pump in operation. Improper flow control can  
damage the heater. Uncontrolled flow (too high) or  
restricted flow (too low) can seriously damage the  
heater. Follow these instructions to make sure your  
heater is properly installed.  
Heaters installed outdoors in freezing climate areas  
should be shut down for the winter. To shut down  
heater, turn off manual main gas valve and main gas  
shut-off. Close isolation valves and remove water pip-  
ing from the in/out header of the heater. Drain the  
heater and any piping of all water that may experience  
below freezing temperatures.  
The Hi Delta pool heater is equipped with an external  
pump and bypass arrangement that blends outlet  
water with the inlet to increase the inlet water temper-  
ature, thereby reducing the likelihood of condensation  
forming on the heat exchanger. The pump also serves  
to circulate water through the heater from the main  
system piping.  
Pool and Spa Water Chemistry  
NOTE: Chemical imbalance can cause severe  
damage to your heater and associated equipment.  
Maintain your water pH between 7.4 and 7.8 and  
total alkalinity between 100 and 150 ppm. If the  
mineral content and dissolved solids in the water  
become too high, scale forms inside the heat  
exchanger tubes, reducing heater efficiency and also  
damaging the heater. If the pH drops below 7.2, the  
heater will be severely damaged.  
To complete the installation of the pool heater, the pool  
thermostat needs to be installed in the main return  
water line. This will ensure that the heater will be ener-  
gized at the right time. If the main water line is too far  
away from the heater and the capillary bulb will not  
reach it, locate the pool thermostat adjacent to the  
main line and run wires back to the heater.  
NOTE: Heat exchanger damage resulting from  
chemical imbalance and/or scaling is not covered  
under the warranty.  
Adjustment of the bypass valve is critical to proper  
operation of the heater. The bypass valve should be  
adjusted to achieve a minimum inlet water tempera-  
ture of 105°F and an outlet water temperature  
between 120°F and 140°F. When starting with a cold  
pool, make initial adjustments. Make final adjustments  
when pool water approaches desired temperature.  
Gas Supply  
DANGER: Make sure the gas on which the heater  
will operate is the same type as specified on the  
heater’s rating plate.  
Automatic Chlorinators and  
Chemical Feeders  
All chemicals must be introduced and completely dilut-  
ed into the pool or spa water before being circulated  
through the heater. Do not place chlorine tablets or  
bromine sticks in the skimmer. High chemical concen-  
trations will result when the pump is not running (i.e.  
overnight).  
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 distance of 10 times the pipe  
diameter upstream of the heater gas controls. All gas  
piping must be tested after installation in accordance  
with local codes. The heater and its gas connection  
must be leak-tested before placing it in operation.  
Chlorinators must feed downstream of the heater and  
have an anti-siphoning device to prevent chemical  
backup into the heater when the pump is shut off.  
NOTE: High chemical concentrates from feeders  
and chlorinators that are out of adjustment will cause  
very rapid corrosion to the heat exchanger in the  
heater. Such damage is not covered under the  
warranty.  
17  
 
MANUAL  
SHUT OFF  
VALVE  
GAS  
FLOW  
SUPPLIED  
SUPPLIED  
GAS  
MANUAL  
SHUT OFF  
VALVE  
BY OTHERS  
BY OTHERS  
FLOW  
EXTENTS OF  
SEDIMENT TRAP  
UNIT ENCLOSURE  
EXTENTS OF  
UNIT ENCLOSURE  
SEDIMENT  
TRAP  
TO BURNERS  
UNION  
TO BURNERS  
Fig. 12: Sediment Trap Orientation  
Gas Supply Connection  
Gas Supply Pressure  
A minimum of 7 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 11 in.  
WC and a maximum of 13 in. WC is required for  
propane gas. The gas pressure regulator supplied on  
the heater is for low pressure service. If upstream  
pressure exceeds 14 in. WC, an intermediate gas  
pressure regulator, of the lockup type, must be  
installed.  
CAUTION: 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 PSIG (3.45 kPa). The  
heater must be isolated from the gas supply piping  
system by closing the manual shutoff valve during  
any pressure testing of the gas supply piping system  
at test pressures equal to or less than 1/2 PSIG.  
Relieve test pressure in the gas supply line before  
reconnecting the heater and its manual shut off valve  
to the gas supply line. FAILURE TO FOLLOW THIS  
PROCEDURE MAY DAMAGE THE GAS VALVES.  
Over pressurized gas valves are not covered by  
warranty. The heater and its gas connections shall  
be leak tested before placing the appliance in  
operation. Use soapy water for leak test: DO NOT  
use open flame.  
When connecting additional gas utilization equipment  
to the gas piping system, the existing piping must be  
checked to determine if it has adequate capacity.  
Gas Pressure Regulator  
The gas valve pressure regulator(s) on the heater are  
nominally preset at 3.5 in. WC for natural gas, and  
10.5 in. WC for propane gas manifold pressure. The  
pressure at the gas valve outlet tap, measured with a  
manometer,while in operation should be 3.5 0.1 in.  
CAUTION: Do not use Teflon tape on gas line pipe  
thread. A pipe compound rated for use with gas  
systems is recommended. Apply sparingly only on  
male pipe ends.  
WC for natural gas and 10.5 in.  
0.1 in. WC for  
propane gas. If an adjustment is needed, turn the  
adjustment screw clockwise to increase pressure or  
counter-clockwise to decrease pressure.  
CAUTION: Support gas supply piping with  
hangers, not by the heater or its accessories. Ensure  
the gas piping is protected from physical damage  
and freezing where required.  
18  
 
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 Canada, C22.1  
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 the heater in the instruction  
packet. The remote tank control stat, thermostat, or  
electronic heater control as applicable, may be con-  
nected to stage selector terminal (See wiring diagram).  
24 Volts are supplied to this connection through the  
heater transformer. DO NOT attach line voltage to the  
“TH” leads. Before starting the heater check to ensure  
proper voltage to the heater and pump.  
AC = 108 Volts AC Minimum, 132 Volts AC MAX  
AB = 108 Volts AC Minimum, 132 Volts AC MAX  
BC = < 1 Volt AC  
Fig. 13: Check Power Source  
Making the Electrical Connections  
Refer to Fig. 14 Wiring Connection, and the Wiring  
Diagram.  
Install a separate disconnect means for each load.  
Use appropriate-sized wire as defined by NEC, CSA  
and/or local code. All primary wiring should be 125% of  
minimum rating.  
1. Verify circuit breaker is properly sized by referring  
to heater rating plate. A dedicated circuit breaker  
should be provided.  
2. Turn off all power to 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.  
It is strongly recommended that all individually-pow-  
ered control modules and the heater should be  
supplied from the same power source.  
Surge Protection  
3. Observe proper wire colors while making electrical  
connections. Many electronic controls are polarity  
sensitive. Components damaged by improper  
electrical installation are not covered by warranty.  
Microprocessor-based and solid state controls are vul-  
nerable to damage from voltage and amperage  
fluctuations in the power supply. All sensitive control  
components should be protected by a suitable com-  
mercial-grade surge protection device.  
4. Provide an external surge suppressor capable of  
maintaining system integrity.  
If any of the original wire as supplied with the heater  
must be replaced, it must be replaced with 105°C wire  
or its equivalent.  
5. Provide overload protection and a disconnect  
means for equipment serviceability as required by  
local and state code.  
Check the Power Source  
6. Install heater controls, thermostats, or building  
management systems in accordance with the  
applicable manufacturer’s instructions.  
WARNING: Using a volt-ohm meter (VOM), check  
the following voltages at the terminal block inside the  
unit. Make sure proper polarity is followed and house  
ground is proven.  
7. Conduit should not be used as the ground. There  
must be a solidly wired ground.  
NOTE: A grounding electrode conductor shall be  
used to connect the equipment grounding  
conductors, the equipment enclosures, and the  
grounded service conductor to the grounding  
electrode.  
19  
 
Fig. 14: Single Stage and 2-Stage Tankstat  
1. For Pool and Closed Loop Water Source Heat  
Electrical Connections—Domestic  
Hot Water  
Pump applications, your heater should be config-  
ured to operate in an ON/OFF firing mode. This  
means that you will connect a single-pole control  
to stage one of stage selector (Terminals 4 & 5).  
Then jumper the remaining firing stages. For  
example, if your heater is a 162, you will jumper  
stage two. Then your heater will either be on at full  
fire, or it will be off.  
DANGER—SHOCK HAZARD: Make sure  
electrical power to the heater is disconnected to  
avoid potential serious injury or damage to  
components.  
CAUTION: Label all wires prior to disconnection  
when servicing controls. Wiring errors can cause  
improper and dangerous operation. Verify proper  
operation after servicing.  
2. For multi-stage controller connections, connect  
each stage of the control to the corresponding  
stage selector terminal block in the heater. Stage  
1 of the heater to stage 1 of the control. Stage 2 of  
the heater to stage 2 of the control, and so on. Set  
the operating control at the setpoint in which you  
want the heater to maintain. Ensure that the sens-  
ing bulb of the control is at the point in the system  
that will best maintain the temperature you want.  
For example, when you are heating a tank of  
water, you want the operating control sensor bulb  
in the tank.  
NOTE: Minimum 18 AWG, 105°C, stranded wire  
must be used for all low voltage (less than 30 volts)  
external connections to the unit. Solid conductors  
should not be used because they 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.  
Consult the wiring diagram shipped with the heater in  
the instruction packet. The Stage 1 connections are for  
the remote tank control through the heaters 24 volt  
transformer. DO NOT attach line voltage to the Stage  
1 connection. Before starting heater, check to ensure  
proper voltage to heater and pump.  
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 will  
be done based on the controller option selected with  
your heater order.  
20  
 
SINGLE  
STAGE  
TANKSTAT  
Venting  
General  
CAUTION: Proper installation of flue venting is criti-  
cal for the safe and efficient operation of the heater.  
Definition of Appliance Categories  
Heaters are divided into four categories based on the  
pressure produced in the exhaust and the likelihood of  
condensate production in the vent.  
STAGE 1  
CONNECTION  
Category I. A heater which operates with a non-posi-  
tive vent static pressure and with a vent gas  
temperature that avoids excessive condensate pro-  
duction in the vent.  
ATTACH STAGE 1 CONNECTIONS  
ON HEATER TO THE SINGLE STAGE  
Category II. A heater which operates with a non-posi-  
tive vent static pressure and with a vent gas  
temperature that may cause excessive condensate  
production in the vent.  
TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.  
Fig. 15: Single Stage Tankstat  
Category III. A heater which operates with a positive  
vent pressure and with a vent gas temperature that  
avoids excessive condensate production in the vent.  
2-STAGE  
TANKSTAT  
Category IV. A heater which operates with a positive  
vent pressure and with a vent gas temperature that  
may cause excessive condensate production in the  
vent.  
See Table H for appliance category requirements for  
the Hi Delta.  
STAGE 2 CONNECTION OR  
STAGE 1  
STAGE 1 CONNECTION  
CONNECTION  
OF HEATER 2  
NOTE: For additional information on appliance  
categorization, see appropriate ANSI Z21 Standard  
and the NFGC (U.S.), or B149 (Canada), or  
applicable provisions of local building codes.  
ATTACH STAGE 1 CONNECTIONS ON HEATER  
TO STAGE 1 CONNECTION ON TANKSTAT.  
ATTACH STAGE 2 CONNECTIONS OR  
STAGE 1 CONNECTION OF HEATER 2  
TO STAGE 2 CONNECTIONON TANKSTAT  
AS SHOWN IN THE DIAGRAM.  
Determination of Appliance  
Category for Venting Purposes and  
Venting Arrangements  
Fig. 16: 2-Stage Tankstat  
Heater must be electrically grounded in accordance  
with NEC and C22.1(in Canada).  
WARNING: Contact the manufacturer of the vent  
material if there is any question about the appliance  
categorization and suitability of a vent material for  
application on a Category III or IV vent system.  
Using improper venting materials can result in  
personal injury, death or property damage.  
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 with  
105°C wire or its equivalent.  
21  
 
Combustion Air  
Supply  
Exhaust  
Configuration  
Certified  
Appliance Material  
Combustion Air  
Inlet Material  
Venting Category  
Type B or and  
Category I Venting  
System*  
Vertical Natural  
I
Draft Venting  
From Inside  
Building (Non-Direct  
Venting)  
Horizontal  
Thru-wall  
Venting  
Stainless Steel  
(Gas Tight)  
III  
I
Type B or and  
Category I Venting  
System*  
Vertical Venting  
Galvanized Steel  
PVC  
From Outside  
Building (Direct  
Venting)  
ABS  
CPVC  
Horizontal  
Thru-wall  
Venting  
Stainless Steel  
(Gas Tight)  
III  
*As defined in the latest edition of the NFGC, or in Canada, the B149.  
Table H: Venting Category Requirements  
Barometric Damper  
Vent Terminal Location  
A barometric damper may be required when vent  
heights exceed 25 feet or when the draft is greater  
than -0.08 in. WC. In these installations, a barometric  
damper (single acting) is recommended.  
NOTE: During winter months check the vent cap  
and make sure no blockage occurs from build up of  
snow. Condensate can freeze on the vent cap.  
Frozen condensate on the vent cap can result in a  
blocked flue condition.  
The damper should be installed NO CLOSER than 18  
in. from the discharge of the unit and no closer than 18  
in. from a combustible ceiling. The damper can be General  
installed in horizontal or vertical runs of vent pipe as  
necessary. Installation in a bull-head tee is acceptable Give special attention to the location of the vent termi-  
as shown in the NFGC.  
nation to avoid possibility of property damage or  
personal injury.  
The weights on the damper should be adjusted per the  
damper manufacturer’s instructions for proper opera- a) Gases may form a white vapor plume in winter.  
tion.  
The plume could obstruct a window view if the ter-  
mination is installed in close proximity to windows.  
Support of Vent Stack  
b) Prevailing winds could cause freezing of conden-  
sate and water/ice build-up on building, plants or  
roof.  
The weight of the vent stack or chimney must not rest  
on the heater vent connection. Support must be pro-  
vided in compliance with applicable codes. The vent  
should also be supported to maintain proper clear-  
ances from combustible materials.  
c) The bottom of the vent terminal and the air intake  
shall be located at least 12 in. above grade.  
d) Un-insulated single-wall metal vent pipe shall not  
be used outdoors on cold climates for venting gas  
utilization equipment.  
Use insulated vent pipe spacers where the vent pass-  
es through combustible roofs and walls.  
e) Through-the-wall vents for Category II and IV  
appliances and non-categorized condensing appli-  
ances shall not terminate over public walkways or  
22  
 
Fig. 17: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations  
U.S. Installations1  
Canadian Installations2  
Clearance above grade, veranda, porch,  
deck, or balcony  
A
1 ft (30 cm)  
1 ft (30 cm)  
4 ft (1.2m) below or to side  
of opening; 1 foot (30 cm)  
above opening  
Clearance to window or door that may be  
opened  
B
C
3 ft (91 cm)  
Clearance to permanently closed window  
*
*
Vertical clearance to ventilated soffit located  
above the terminal within a horizontal dis-  
tance of 2 ft (61cm) from the centerline of the  
terminal  
D
5 ft (1.5m)  
*
E
F
Clearance to unventilated soffit  
Clearance to outside corner  
Clearance to inside corner  
*
*
*
*
*
G
6 ft (1.83m)  
3 ft (91 cm) within a height  
15 ft above the me-  
ter/regulator assembly  
Clearance to each side of center line ex-  
tended above meter/regulator assembly  
H
I
*
*
Clearance to service regulator vent outlet  
6 ft (1.83m)  
Clearance to non-mechanical air supply inlet 4 ft (1.2m) below or to side  
to building or the combustion air inlet to any  
of opening; 1 ft (30 cm)  
J
3 ft (91 cm)  
other appliance  
above opening  
3 ft (91 cm) above if within  
10 ft (3m) horizontally  
K
L
Clearance to mechanical air supply inlet  
6 ft (1.83m)  
7 ft (2.13m) t  
Clearance above paved sidewalk or paved  
driveway located on public property  
7 ft (2.13m)  
Clearance under veranda, porch, deck or  
balcony  
M
*
12 in. (30 cm) TT  
1
2
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code  
In accordance with the current CAN/CGA-B149 Installation Codes  
t
Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves  
both dwellings  
TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and  
underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)  
*
Clearances in accordance with local installation codes and the requirements of the gas supplier  
Table I: Vent/Air Inlet Termination Clearances  
23  
 
over an area where condensate or vapor could g) The vent terminal of a direct vent appliance with  
create a nuisance or hazard or could be detrimen-  
tal to the operation of regulators, relief valves, or  
other equipment. Where local experience indi-  
an input over 50,000 Btu per hour shall require a  
12-inch vent terminal clearance.  
cates that condensate is a problem with Category h) Terminate vent at least one (1) foot above grade,  
I and III appliances, this provision shall also apply. including normal snow line.  
f) Locate and guard vent termination to prevent acci- i) Multiple direct vent installations require a four (4)  
dental contact by people or pets.  
foot clearance between vent caps.  
g) DO NOT terminate vent in window well, stairwell,  
alcove, courtyard or other recessed area, unless  
previously approved by local authority.  
Canada Installations  
Refer to latest edition of CAN/CGA-B149.  
A vent shall not terminate:  
h) DO NOT terminate above any door, window, or  
gravity air intake. Condensate can freeze, causing  
ice formations.  
a) Directly above a paved sidewalk or driveway  
which is located between two single family  
dwellings and serves both dwellings  
i) Locate or guard vent to prevent condensate from  
damaging exterior finishes. Use a 2’ x 2’ rust  
resistant sheet metal backing plate against brick  
or masonry surfaces.  
b) Less than 7 ft.(2.13m)above a paved sidewalk or  
paved driveway located on public property  
j) DO NOT extend exposed vent pipe outside of  
building. Condensate could freeze and block vent  
pipe.  
c) Within 6 ft(1.8m) of a mechanical air supply inlet to  
any building  
d) Above a meter/regulator assembly within 3  
ft(900mm) horizontally of the vertical centre-line of  
the regulator  
US Installations  
Refer to latest edition of NFGC.  
Vent termination requirements are as follows:  
e) Within 6 ft.(1.8m) of any gas service regulator vent  
outlet  
a) Vent must terminate at least four (4) feet below, f) Less than 1 ft.(300mm) above grade level  
four (4) feet horizontally, or one (1) foot above any  
door, window or gravity air inlet to the building.  
g) Within the 3 ft.(1m) of a window or door which can  
be opened in any building, any non-mechanical air  
supply inlet to any building or the combustion air  
inlet of any other appliance  
b) The vent must not be less than seven (7) feet  
above grade when located adjacent to public walk-  
ways.  
h) Underneath a verandah, porch or deck, unless  
c) Terminate vent at least three (3) feet above any  
forced air inlet located within ten (10) feet.  
(i) the verandah, porch or deck is fully open on a  
minimum of two sides beneath the floor, and  
d) Vent must terminate at least four (4) feet horizon-  
tally, and in no case above or below unless four (4)  
feet horizontal distance is maintained, from elec-  
tric meters, gas meters, regulators, and relief  
equipment.  
(ii) the distance between the top of the vent termi-  
nation and the underside of the verandah,  
porch or deck is greater than 1 ft (30 cm).  
e) Terminate vent at least six (6) feet away from adja-  
cent walls.  
f) DO NOT terminate vent closer than five (5) feet  
below roof overhang.  
24  
 
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.  
Venting Installation Tips  
Support piping:  
·
·
·
horizontal runs- at least every five (5) feet.  
vertical runs - use braces:  
under or near elbows  
10 FEET  
OR LESS  
VENT CAP  
Follow items listed below to avoid personal injury or  
property damage.  
2' MIN.  
2' MIN.  
·
·
·
·
Cut nonmetallic intake pipe with fine-toothed hack-  
saw.  
Do not use nonmetallic intake pipe or fittings that  
are cracked or damaged.  
Do not use nonmetallic intake fittings if they are  
cut or altered.  
Do not drill holes, or use screws or rivets, in non-  
metallic intake pipe or fittings.  
To make metallic vent joints:  
VENT PIPE  
·
·
Do not install seams of vent pipe on bottom of  
runs.  
100% Seal all joints and seams with high temper-  
ature silicone sealant.  
COMBUSTION AIR  
FILTER  
WARNING: Examine the venting system at least  
once a year. Check all joints and vent pipe  
connections for tightness, corrosion or deterioration.  
BOILER  
UNIT  
NOTE: The words "Flue Exhaust", "Flue" and  
"Exhaust Vent" are used interchangeably.  
Venting Configurations  
For heaters connected to gas vents or chimneys, vent  
installations shall be in accordance with the section  
Fig. 18: Natural Draft Vertical Venting (Category I)  
Min./Max. Venting  
Minimum  
Certified  
Model Appliance  
Venting  
Length without  
Recommended  
No.  
Category  
Barometric  
Material  
Vent Size (inches)  
Damper (feet)**  
122  
4
162  
202  
242  
Type B or  
Equivalent  
I
5
5/25  
322  
6
**Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the NFGC for fur-  
ther details. (ANSI Z223.1)  
Table J: Natural Draft Vertical Venting  
25  
 
Natural Draft Vertical Venting  
System Installation  
CAUTION: Listed vent cap terminal must be used  
and sized adequately to evacuate the flue products  
from the heaters.  
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. from the appliance flue out-  
let to ensure proper operation. Vent material must be  
listed by a nationally recognized test agency.  
Natural Draft Vertical Venting with  
Common Venting System, Category I  
Appliance Only  
Manifolds that connect more than one heater to a com-  
mon chimney must be sized to handle the combined  
load. Consult available guides for proper sizing of the  
manifold and the chimney. At no time should the area  
of the vent be less than the area of the largest heater  
exhaust outlet.  
The maximum and minimum venting length for  
Category I appliance shall be determined per the lat-  
est edition of the NFGC (U.S.) or B149 Installation  
Code (Canada).  
The diameter of vent flue pipe should be sized accord-  
ing to Part 11 of the latest edition of the NFGC (U.S.)  
and part 7 and appendix B of the B149 Installation  
Code (Canada). The minimum flue pipe diameter for  
conventional negative draft venting using double-wall  
B type vent is 4” for 122, 5” for 162, 202 and 242, 6”  
for 322.  
WARNING: Vent connectors serving appliances  
vented by natural draft shall not be connected into  
any portion of mechanical draft systems operating  
under a positive pressure.  
CAUTION: Vent connectors for natural draft  
venting systems must be type “B” vent or better.  
NOTE: Vent Adapter will have to be used to connect  
B vent to the unit.  
Common venting systems may be too large when an  
existing unit is removed. At the time of removal of an  
existing appliance, the following steps must be fol-  
lowed with each appliance remaining connected to the  
common venting system placed in operation, while the  
other appliances remaining connected to the common  
venting system are not in operation.  
The connection from the appliance vent to the stack  
must be as direct as possible and shall be the same  
diameter as, or larger than the vent outlet. The hori-  
zontal breaching of a vent must have an upward slope  
of not less than 1/4 inch per linear foot from the heater  
to the vent terminal. The horizontal portions of the vent  
shall also be supported for the design and weight of  
the material employed to maintain clearances and to  
prevent physical damage or separation of joints.  
a) Seal any unused opening in the common venting  
system.  
Natural Draft Vertical Vent  
Termination  
b) Visually inspect the venting system for proper size  
and horizontal pitch and determine there is no  
blockage or restriction, leakage, corrosion or other  
unsafe condition.  
The vent terminal should be vertical and should termi-  
nate outside the building at least two (2) feet above the  
highest point of the roof that is within 10 feet. The vent  
cap should have a minimum clearance of four (4) feet  
horizontally from and in no case above or below  
(unless a four (4) foot horizontal distance is main-  
tained) electric meters, gas meters, regulators and  
relief equipment. The distance of the vent terminal  
from adjacent public walkways, adjacent buildings,  
open windows and building openings must be consis-  
tent with the NFGC, or 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 to withstand snow and wind  
loads.  
c) 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 and other spaces  
of the building. Turn on clothes dryers and any  
appliance not connected to the common vent sys-  
tem. Turn on any exhaust fans, such as range  
hoods and bathroom exhausts, so they will oper-  
ate at maximum speed. Do not operate summer  
exhaust fan. Close fireplace dampers.  
d) Place in operation the appliances being inspected.  
Follow the manufacturers instructions for lighting  
26  
 
12"  
MIN  
INSULATED  
EXHAUST  
VENTING  
FLUE EXHAUST  
VENT CAP  
COMBUSTION  
AIR FILTER  
12" MIN  
BOILER  
UNIT  
Fig. 19: Horizontal Thru-Wall Venting (Category III)  
each appliance. Adjust thermostat so appliance g) Any improper operation of the common venting  
will operate continuously.  
system should be corrected so that the installation  
conforms with the latest edition of the NFGC (US)  
and the B149 Installation Code (Canada). When  
re-sizing any portion of the common venting sys-  
tem, the common venting system should be  
re-sized to approach the minimum size as deter-  
mined using the appropriate tables in Appendix G  
in the NFGC (US) and Appendix B of the B149  
Installation Code (Canada).  
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  
remaining connected to the common venting sys-  
tem properly vents when tested as outlined above,  
return doors, windows, exhaust fans, fireplace  
dampers and other gas burning appliances to their  
previous conditions of use.  
Certified  
Model Appliance  
Venting  
Vent Size  
(inches)  
Max. Venting  
Length (feet)  
No.  
Category  
Material  
122  
4
5
6
70  
162  
202  
242  
Stainless  
Steel  
(Gas Tight)  
Subtract 10 ft per  
elbow, maximum  
three elbows  
III  
322  
Table K: Horizontal Thru-Wall Venting (Category III)  
27  
 
Horizontal Thru-wall Venting  
System (Category III) Installation  
Horizontal Thru-wall Direct Vent  
Termination  
These installations utilize the heater-mounted blower The flue exhaust direct vent cap MUST be mounted on  
to vent the combustion products to the outdoors. the exterior of the building. The direct vent cap cannot  
Combustion air is taken from inside the room and the be installed in a well or below grade. The direct vent  
vent is installed horizontally through the wall to the out- cap must be installed at least one (1) foot above  
doors. Adequate combustion and ventilation air must ground level and above normal snow levels. The  
be supplied to the mechanical room in accordance Raypak supplied flue exhaust direct vent cap must be  
with the NFGC or, in Canada, the B149 Installation utilized.  
Code.  
WARNING: No substitutions of flue pipe or vent  
The total length of the horizontal thru-wall exhaust  
cap material are allowed. Such substitutions would  
jeopardize the safety and health of inhabitants.  
vent system should not exceed seventy (70) feet in  
length. If horizontal run exceeds 70 feet, an appropri-  
ately sized extractor must be used. To maintain proper  
operation pressure reading must be between -.01 to - The Stainless Steel direct vent cap must be fur-  
.08 in. WC as measured 12 in. from the appliance flue nished by the heater manufacturer in accordance  
outlet. Each elbow used is equal to ten (10) feet of with its listing.  
straight pipe. This will allow installation in one of the  
four following combinations.  
Use only the special gas vent pipes listed for use with  
category III gas burning heaters, such as the stainless  
steel vent by Heat Fab Inc (800-772-0739), Protech  
Systems, Inc. (800-766-3473) or Z-Flex (800-654-  
5600). Pipe joints must be positively sealed. Follow  
carefully the vent manufacturers installation instruc-  
tions.  
· 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 in the overall length of  
the venting system.  
The vent must be installed to prevent the flue gas leak-  
age. Care must be taken during assembly to ensure  
that all joints are sealed properly and are airtight.  
The vent must be installed to prevent the potential  
accumulation of condensate in the vent pipes. It is rec-  
ommended that:  
a) The vent be installed with a slight downward slope  
of not more than 1/4" per foot of horizontal run to  
the vent terminal.  
b) The vent be insulated through the length of the  
horizontal run.  
For appliances installed in extreme cold climate, it is  
recommended that:  
a) The vent be installed with 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.  
b) The vent be insulated through the length of the  
horizontal run.  
28  
 
12"  
VENT PIPE  
VENT CAP  
INTAKE  
VENT  
36" MIN.  
INTAKE  
VENT  
COMBUSTION AIR  
FILTER  
6"  
12" MIN.  
BOILER  
UNIT  
Fig. 20: Direct Vent Horizontal Thru-Wall Venting (Category III)  
Max.  
Venting  
Length  
(feet)  
Combustion  
Air Intake  
Pipe  
Max. Air  
Intake  
Length  
(feet)  
Certified  
Venting  
Material  
Air Inlet  
Model  
No.  
Appliance  
Category  
Vent Size  
(inches)  
Size  
(inches)  
Material  
122  
4
5
6
40  
Subtract 10  
ft per  
40  
Subtract 10  
ft per  
Galvanized  
Steel  
162  
202  
242  
Stainless  
Steel  
(Gas Tight)  
III  
PVC  
5
elbow,  
elbow,  
ABS  
CPVC  
Max. two  
elbows  
Max. two  
elbows  
322  
Table L: Horizontal Thru-Wall Venting  
29  
 
Horizontal Thru-wall Direct Vent  
System (Category III) Installation  
Horizontal Thru-wall Direct Vent  
Termination  
These installations utilize the heater mounted blower The flue exhaust direct vent cap MUST be mounted on  
to draw combustion air from outdoors and vent com- the exterior of the building. The direct vent cap cannot  
bustion products to the outdoors.  
be installed in a well or below grade. The direct vent  
cap must be installed at least one (1) foot above  
The total length of the thru-wall exhaust vent cannot ground level and above normal snow levels.  
exceed forty (40) feet in length for the flue outlet. Each  
elbow used is equal to ten (10) feet of straight pipe. Multiple direct vent caps MUST NOT be installed with  
This will allow installation in one of the three following one combustion air inlet directly above a direct vent  
combinations.  
cap. This vertical spacing would allow the flue prod-  
ucts from the direct vent cap to be pulled into the  
combustion air intake installed above. This type of  
installation can cause non warrantable problems with  
components and poor operation of the unit due to the  
recirculation of flue products. Multiple direct vent caps  
· 40’ of straight flue pipe.  
· 30' of straight flue pipe and one elbow.  
· 20' of straight flue pipe and two elbows.  
The total length air supply pipe cannot exceed forty should be installed in the same horizontal plane with a  
(40) feet in length for the combustion air inlet. Each three (3) foot clearance from the side of one vent cap  
elbow used is equal to ten (10) feet of straight pipe. to the side of the adjacent vent cap(s).  
This will allow installation in one of the three following  
combinations.  
Combustion air supplied from outdoors must be free of  
particulate and chemical contaminants. To avoid a  
blocked flue condition, keep the vent cap clear of  
snow, ice, leaves, debris, etc.  
· 40’ of straight combustion air pipe  
· 30' of straight combustion air pipe and one elbow.  
· 20' of straight combustion air pipe and two elbows.  
WARNING: No substitutions of flue pipe or vent  
cap material are allowed. Such substitutions would  
jeopardize the safety and health of inhabitants.  
The flue exhaust direct vent cap is not 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 Stainless Steel flue exhaust direct vent cap  
The vent must be installed to prevent the potential must be furnished by the heater manufacturer in  
accumulation of condensate in the vent pipes. It is rec- accordance with its listing. Use only the special gas  
ommended that:  
vent pipes listed for use with category III gas burning  
heaters, such as the stainless steel vent by Heat Fab  
a) The vent be installed with a slight downward slope Inc (800-772-0739), Protech Systems, Inc. (800-766-  
of not more than 1/4" per foot of horizontal run to 3473) or Z-Flex (800-654-5600). Pipe joints must be  
the vent terminal.  
positively sealed. Follow carefully the vent manufac-  
turers installation instructions.  
b) The vent be insulated through the length of the  
horizontal run.  
For appliances installed in extreme cold climate, it is  
recommended that:  
a) The vent be installed with 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.  
b) The vent be insulated through the length of the  
horizontal run.  
30  
 
36"  
VENT CAP  
36" MIN.  
12" MIN.  
VENT PIPE  
INTAKE  
VENT  
COMBUSTION  
AIR FILTER  
BOILER  
UNIT  
Fig. 21: Direct Vent—Vertical Venting (Category I)  
Min./Max.  
Combustion  
Max. Air  
Intake  
Length  
(feet)  
Certified  
Venting  
Material  
Vertical  
Venting  
Height  
(feet)  
Air Inlet  
Size  
(inches)  
Model  
No.  
Appliance  
Category  
Vent Size  
(inches)  
Air Intake  
Pipe  
Material  
122  
4
5
6
40  
Subtract 10  
ft per  
Galvanized  
Steel  
162  
202  
242  
Type B  
Equivalent  
I
5/25  
PVC  
5
elbow,  
ABS  
CPVC  
Max. two  
elbows  
322  
Table M: Vertical Venting  
31  
 
blockage from snow. The vent cap must have a mini-  
mum 3 foot clearance from the air inlet opening.  
Vertical Direct Vent System  
Installation  
Outdoor 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 Outdoor models are self-venting when installed with  
a thermal driving head that expels the exhaust gases the factory-supplied restricted direct vent cap and  
from the flue. The negative draft must be within the require no additional vent piping. This special vent cap  
range of -0.01 to -0.08 in. WC as measured 12 in. from is provided with the heater in accordance with CSA  
the appliance outlet to ensure proper operation. The requirements. It must be installed directly on the  
vent material must be in accordance with the above heater. See Section B for correct clearances.  
instructions for vent materials. Vent material must be  
listed by a nationally recognized test agency.  
Care must be taken when locating the outdoor unit  
because the flue gases discharged from the vent hood  
The maximum and minimum venting length for can condense as they leave the hood. Improper loca-  
Category I appliance shall be determined per the lat- tion can result in damage to adjacent structures or  
est edition of the NFGC (U.S.) and B149 Installation building finish. For maximum efficiency and safety, the  
Code (Canada).  
following precautions must be observed:  
The connection from the appliance exhaust vent to the a) Outdoor models must be installed outdoors and  
stack must be as direct as possible and should be the  
same as or larger than the vent outlet. The vent must  
be installed to prevent accumulation of condensate  
must use the outdoor vent hood supplied by the  
manufacturer.  
and, where necessary, have means provided for b) Periodically check venting system. The heater’s  
drainage of condensate. The horizontal breaching of a  
vent must have an upward slope of not less than 1/4  
inch per linear foot from the heater to the vent termi-  
nal. The horizontal portions of the vent shall also be  
supported for the design and weight of the material  
employed to maintain clearances and to prevent phys-  
ical damage or separation of joints.  
venting areas must never be obstructed in any  
way and minimum clearances must be observed  
to prevent restriction of combustion and ventilation  
air. Keep area clear and free of combustible and  
flammable materials.  
c) Do not locate adjacent to any window, door walk-  
way, or gravity air intake. The vent must be located  
a minimum of four (4) feet horizontally, or four (4)  
feet below, or one (1) foot above such areas.  
Vertical Direct Vent Termination  
The exhaust vent terminal should be vertical and  
should terminate outside the building at least two (2)  
feet above the highest point of the roof within 10 feet.  
The vent cap should have a minimum clearance of  
four (4) feet horizontally from and in no case above or  
below (unless a four (4) foot horizontal distance is  
maintained) electric meters, gas meters, regulators  
and relief equipment. The distance of the vent terminal  
from adjacent public walkways, adjacent buildings,  
open windows and building openings must be consis-  
tent with the NFGC, or in Canada, the B149.  
Installation Code. Gas vents supported only by flash-  
ing and extended above the roof more than five feet  
should be securely guyed or braced to withstand snow  
and wind loads.  
d) Install above grade level and above normal snow  
levels.  
e) Vent terminal must be at least 3 feet above any  
forced air inlet located within 10 feet.  
f) Adjacent brick or masonry surfaces must be pro-  
tected with a rust-resistant sheet metal plate.  
g) Multiple Outdoor Vent installations require a four  
(4) feet clearance between vent caps.  
NOTE: Condensate can freeze on the vent cap.  
Frozen condensate on the vent cap can result in a  
blocked flue condition.  
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 snow  
levels that might obstruct combustion air flow. This  
dimension is critical to the correct operation of the  
heater and venting system and reduces the chance of  
The restricted vent cap must be furnished by the  
heater manufacturer in accordance with its listing.  
An outdoor air filter, supplied by the manufacturer is  
mounted on the heater.  
32  
 
CONTROLS  
WARNING: Installation, adjustment and service of  
heater controls including timing of various operating  
functions must be performed by a qualified installer,  
service agency or the gas supplier. Failure to do so  
may result in control damage, heater malfunction,  
property damage, personal injury, or death.  
WARNING: Turn off the power to the heater before  
installation, adjustment or service of the heater  
controls. Failure to do so may result in heater  
malfunction, property damage, personal injury, or  
death.  
Fig. 22: Ignition Module  
High Limit (Manual Reset)  
The heater is equipped with a manual reset high limit  
temperature device. Push the reset button and adjust  
the setting to 30° F or 40° F above desired operating  
temperature.  
CAUTION: This appliance has provisions to be  
connected to more than one (1) supply source. To  
reduce the risk of electric shock, disconnect all such  
connections before servicing.  
CAUTION: Risk of electric shock. More than one  
(1) disconnect switch may be required to de-  
energize the equipment before servicing.  
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 ener-  
gized, eliminating the fuel costs of maintaining a  
constant pilot.  
Fig. 23: Manual Reset High Limit  
To ensure safe operation, the gas valve cannot open  
until the pilot igniter is verified. The 100% igniter safe-  
ty is an electronic device which closes the main gas  
valve within 8/10 of a second whenever the flame is  
interrupted. Main burner is automatically lit when the  
device is powered and pre-purged. Unit performs its  
own safety check and opens the main valve only after  
the igniter is proven to be capable of ignition.  
33  
 
Flow Switch  
Low Water Cut Off (Optional)  
Dual-purpose control shuts off heater in case of pump The low water cut off automatically shuts down the  
failure or low water flow. Mounted and wired in series burner whenever water level drops below the level of  
with the main gas valve. Check with Manufacturer for  
the sensing probe. A 3-second time delay prevents  
proper paddle size. Utilize correct paddle size for prop- premature lockout due to temporary conditions such  
er operation.  
as power fluctuations or air pockets.  
NOTE: Flow switch will not operate if flow is less  
than 20 gpm.  
Fig. 25: Low Water Cut Off  
Fig. 24: Flow Switch  
34  
 
WIRING DIAGRAM—MODELS 122–322  
35  
 
4. Use only your hand to push in or turn the gas con-  
trol knob. Never use tools. If the knob will not turn  
by hand, do not try to repair it, call a qualified serv-  
ice technician. Forced or attempted repair may  
result in a fire or explosion.  
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 tank until  
water appears, then close vent.  
5. Do not use this appliance if any part has been  
under water, immediately call a qualified service  
technician to inspect the appliance and to replace  
any part of the control system and any gas control  
which has been under water.  
6. Check around unit for debris and remove com-  
bustible products, i.e. gasoline, etc.  
Domestic Hotwater Heaters  
Purge all air from system before lighting heater. This  
can be normally be accomplished by opening a down-  
stream valve.  
Pre-Start-Up Check  
1. Verify heater is filled with water.  
Inspect Venting System:  
2. Check system piping for leaks. If found, repair  
immediately.  
1. Check all vent pipe connections and flue pipe  
material.  
3. Vent air from system. Air in system can interfere  
with water circulation.  
2. Ensure vent terminations are installed per code  
and are clear of all debris or blockage.  
4. Purge air from gas line up to heater.  
INITIAL START-UP  
Tools Needed  
For Your Safety Read Before  
Lighting  
WARNING: If you do not follow these instructions  
exactly, a fire or explosion may result causing  
property damage, personal injury or loss of life.  
One 12-0-12, 24” scale manometer  
Two 6-0-6, 12” scale manometers  
7/16” open end wrench  
1/2” open end wrench  
Screwdriver  
1. This appliance does have an intermittent pilot. It is  
equipped with an ignition device which automati-  
cally lights the pilot. DO NOT try to light the pilot or  
burner by hand.  
Volt meter  
3/16” Allen wrench  
2. BEFORE OPERATING, smell all around the appli-  
ance area for gas. Be sure to smell next to the  
floor because some gas is heavier than air and will  
settle on the floor.  
Preparation for Start-Up  
WARNING: Do not turn on gas at this time.  
Check Power Supply  
3. WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any  
telephone in your building.  
Immediately call your gas supplier from a neigh-  
bor's telephone. Follow the gas supplier's  
instructions.  
If you cannot reach your gas supplier, call the fire  
department.  
With volt meter at incoming power check voltage  
between:  
Hot - Common (~120 VAC)  
Hot - Ground (~120 VAC)  
Common - Ground (< 1 VAC)  
36  
 
6. Reconnect fan pressure switch tubing to original  
position.  
WARNING: If Common - Ground is > 1 VAC,  
STOP: Contact electrician to correct ground failure.  
Failure to do this may burn out 120V-24V  
transformer, or may cause other safety control  
damage or failure.  
Main Burner Adjustment  
1. Turn off unit.  
Attach Manometers to Measure  
Pressures  
2. Open manual firing valve.  
3. Turn on the unit, wait 15 seconds, and the igniter  
should glow. Sight glass to check igniter at both  
ends of the heater. Gas valve should be open after  
45 seconds.  
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 pressure switch off the aluminum  
tubing and connect the manometer using a tee.  
4. If burner does not light on first trial. It will retry, up  
to 3 times.  
5. Main burner ignition – check manifold gas pres-  
sure at gas valve manifold pressure tap. (See gas  
valve detail page 7) This should read 3.5 0.1 in.  
WC for natural gas or 10.5 0.1 in. WC for LP gas.  
Turn Off Main Gas Valve;  
Check the Gas Supply Pressure  
1. Slowly turn on main gas shut-off valve.  
6. If the pressure reading differs by more than 0.1  
in. WC. Remove manifold adjustment screw cover  
off the pressure regulator on the gas valve, adjust  
main burner manifold pressure. Replace the man-  
ifold adjustment screw cap on the gas valve.  
2. Read the gas supply pressure from the manome-  
ter; minimum supply pressure is 5” W.C.,  
recommended supply is 7” W.C. for natural gas  
(minimum 11” W.C. for LP gas).  
Your Hi Delta is tuned in!  
3. If pressure is > 14" W.C., turn off the valve.  
Safety Inspection  
4. Check if the service regulator is installed and/or  
adjust the service regulator.  
Replace main gas manifold adjustment screw cap.  
Check all thermostats and high limit settings.  
During the following safety checks leave manome-  
ters hooked up, check and record.  
If other gas fired equipment are in the room and on  
same gas main check all pressures on the Hi Delta  
with all other equipment running.  
Start-Up  
Blower Adjustment  
Check thermostats for ON/OFF operation.  
Check High limits for ON/OFF operation.  
While in operation, check flow switch operation  
Check the low gas pressure switches (For proper  
adjustment, if available, use the attached  
manometers to set pressure. The scales on the  
switch are approximate only); Low gas pressure  
switch must be set at 5 in. WC for natural gas and  
10 in. WC for LP gas.  
1. Disconnect fan pressure switch tubing at plenum  
and connect manometer using a tee.  
2. Close all manual firing valves.  
3. Turn power on.  
4. Check manometers attached to fan pressure  
switch. The readings should be :  
High gas pressure switch (optional) at 1 in. WC  
above manifold pressure.  
0.5 0.1 in. WC for models 102 and 122.  
0.7 0.1 in. WC for models 202, 242, 322.  
If not, adjust the air shutter on the blower to attain  
the correct value. (See air shutter adjustment  
page 7).  
Insert ignition control lockout tests as safety  
check.  
5. Turn power off.  
37  
 
off immediately.  
Follow-Up  
·
·
Wait 5 minutes.  
Reconnect combustion air pressure switch, burner  
should reignite after pre-purge time delay.  
Safety checks must be recorded as performed.  
Turn unit on.  
10. To restart system, follow lighting instructions in the  
Operation section.  
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.  
11. High limit control set to design temperature  
requirements of system? For multiple zones: flow  
adjusted as required in each zone?  
Remove all Manometers and replace hose,  
remove jumper, replace all gas pressure caps.  
Check for gas leaks one more time.  
12. Heater cycled with thermostat? Raise to highest  
setting and verify heater goes through normal  
start-up cycle. Reduce to lowest setting and verify  
heater goes off.  
POST START-UP CHECK  
13. Observed several operating cycles for proper  
operation?  
Check off steps as completed:  
14. Set room thermostat or tankstat to desired temper-  
ature?  
1. Heater and heat distribution units or storage tank  
filled with water?  
15. Reviewed all instructions shipped with this heater  
with owner or maintenance person, returned to  
envelope and given to owner or placed in pocket  
inside front panel on heater?  
2. Automatic air vent, if used, open two full turns dur-  
ing venting procedure?  
3. Air purged from system?  
4. Air purged from gas piping? Piping checked for  
leaks?  
OPERATION  
Operating Instructions  
5. Followed start-up procedure for proper start-up?  
6. Is burner flame visible?  
Lighting Instructions  
7. Test safety controls: If heater is equipped with a 1. STOP! Read the safety information first.  
low water cut-off or additional safety controls, test  
for operation as outlined by manufacturer. Burner 2. Set the thermostat to the lowest setting.  
should be operating and should go off when con-  
trols are tested. When safety devices are restored, 3. Turn off all electric power to the appliance.  
burners should reignite after pre-purge time delay.  
4. This appliance is equipped with an ignition device  
8. Test limit control: While burner is operating, move  
indicator on high limit control below actual heater  
water temperature. Burner should go off while  
which automatically lights the burner. Do Not try to  
light the burner by hand.  
blower and circulator continue to operate. Raise 5. Remove upper front panel.  
setting on limit control above heater water temper-  
ature and burner should reignite after pre-purge 6. Turn on main manual gas valve.  
time delay.  
7. Wait five (5) minutes to clear out any gas. Then  
9. Test ignition system safety device:  
smell for gas, especially near the floor. If you then  
smell gas. STOP! Follow the steps in the safety  
information on the front cover. If you do not smell  
gas, go to next step.  
·
·
·
Turn on manual gas valve. Turn power on.  
Set thermostat to call for heat.  
When the unit is in operation. Disconnect combus-  
tion air blower pressure switch, burner should go  
38  
 
8. Turn on all electric power to the appliance.  
Yearly (Beginning of each heating  
season):  
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)  
times. If ignition is not sensed, lockout will com-  
mence.  
1. Annual service call by qualified service agency.  
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.  
10. If the appliance will not operate, follow the instruc-  
tion "To Turn Off Gas To Appliance", and call your  
service technician or gas supplier.  
4. Check that heater area is free from combustible  
materials, gasoline, and other flammable vapors  
and liquids.  
11. Replace access panel.  
To Turn Off Gas To Appliance  
1. Set the thermostat to lowest setting.  
5. Check for and remove any obstruction to the flow  
of combustion or ventilation air to heater.  
6. Follow pre-start-up check in the Initial Start-up  
section.  
2. Turn off all electric power to the appliance if serv-  
ice is to be performed.  
7. Visually inspect burner flame. Should see light  
blue flame. Visually inspect hot surface igniter for  
damage, cracking or debris build-up.  
3. Remove upper front panel.  
4. Turn off main manual gas valve.  
5. Replace access panel.  
8. Check operation of safety devices. Refer to manu-  
facturer’s instructions.  
If heater fails to start, check for:  
9. Follow oil-lubricating instructions on circulator.  
Over-oiling will damage circulator. Water-lubricat-  
ed circulators do not need oiling.  
Loose connections, blown fuse or service switch  
off?  
High temperature limit switch set below heater 10. To avoid potential of severe burn, DO NOT REST  
water temperature?  
Thermostat set below room temperature?  
Gas not turned on at meter or heater?  
HANDS ON OR GRASP PIPES. Use a light touch  
- return piping will heat up quickly.  
Incoming gas pressure less than 6 in. WC for nat- 11. Check blower and blower motor. Clean and oil as  
ural gas, 11 in. WC for LP gas.  
necessary.  
12. Check for piping leaks around circulators, relief  
valves and other fittings. Repair, if found. DO NOT  
use petroleum based stop leak.  
MAINTENANCE  
Suggested Minimum  
Maintenance Schedule:  
Daily:  
1. Check that heater area is free from combustible  
materials, gasoline, and other flammable vapors  
and liquids.  
Regular service by a qualified service agency and  
maintenance must be performed to ensure maximum  
heater operating efficiency. Maintenance as outlined  
below may be performed by the owner.  
2. Check for and remove any obstruction to the flow  
of combustion or ventilation air to heater.  
39  
 
Products causing contaminated combustion air:  
Monthly:  
spray cans containing chloro/fluorocarbons  
permanent wave solutions  
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.  
chlorinated waxes/cleaners  
chlorine-based swimming pool chemicals  
calcium chloride used for thawing  
sodium chloride used for water softening  
refrigerant leaks  
2. Visually inspect burner flame.  
paint or varnish removers  
3. Visually inspect venting system for proper func-  
tion, deterioration or leakage.  
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  
... and other similar products.  
4. Check air vents for leakage.  
Quarterly:  
1. Check relief valve. Refer to manufacturer’s  
instructions on valve.  
Areas causing contaminated combustion air:  
2. Test low water cut-off, if used. Refer to manufac-  
turer’s instructions.  
dry cleaning/laundry areas and establishments  
metal fabrication plants  
beauty shops  
3. Clean screen and air filter in intake.  
refrigeration repair shops  
photo processing plants  
auto body shops  
plastic manufacturing plants  
urniture refinishing areas and establishments  
new building construction  
remodeling areas.  
APPENDIX  
Inside Combustion Air  
Contamination:  
All heaters experience some condensation during Check for areas and products as listed above before  
start-up. The condensate from flue gas is slightly installing heater. If found:  
acidic. In most cases the pH level is not harmful to  
vents or drains. When combustion air is contaminated  
by vapors from products in areas listed below, the  
acidic levels in the condensate increase. Higher acidic  
levels attack many materials, including stainless steel  
commonly used in high efficiency systems.  
remove products permanently, OR  
provide outdoor combustion air.  
The heater can use special corrosion-resistant non-  
metallic intake vent material. You may, however,  
choose to use outside combustion air for one or more  
of these reasons:  
installation is in an area containing contaminants  
listed below which will induce acidic condensation.  
you want to reduce infiltration into your building  
through openings around windows and doors.  
you are using AL29-4C stainless steel vent pipe,  
which is more corrosion-resistant than standard  
metallic vent pipe. In extremely contaminated  
areas, this may also experience deterioration.  
40  
 
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 warranty periods and subject to the conditions set forth in this Warranty. Labor  
charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the  
owner’s responsibility.  
HEAT EXCHANGER WARRANTY:  
Domestic Hot Water  
Five (5) years from date of boiler installation. Includes copper heat exchanger with bronze and cast iron waterways.  
Ten (10) years from date of boiler installation. Includes only cupro nickel heat exchanger with bronze or cast iron waterways.  
Space Heating (Closed Loop System)  
Ten (10) years from date of boiler installation. Includes both cupro nickel and copper heat exchanger with bronze or cast iron waterways.  
Thermal Shock Warranty  
Twenty (20) years from date of boiler installation against “Thermal Shock” (excluded, however, if caused by boiler operation at large  
changes exceeding 150°F between the water temperature at intake and boiler temperature, or operating at boiler temperatures exceeding  
230°F).  
ANY OTHER PART MANUFACTURED BYRAYPAK:  
One (1) Year warranty from date of boiler installation, or eighteen (18) months from date of factory shipment based on Raypak’s records,  
whichever comes first.  
SATISFACTORY PROOF OF INSTALLATION DATE, SUCHAS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTYWILL  
BE VOID IFTHE BOILER RATING PLATE ISALTERED OR REMOVED.  
ADDITIONAL WARRANTY EXCLUSIONS:  
This warranty does not cover failures or malfunctions resulting from:  
1. Failure to properly install, operate or maintain the boiler in accordance with our printed instructions provided;  
2. Abuse, alteration, accident, fire, flood and the like;  
3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;  
4. High velocity flow exceeding boiler design rates;  
5. Failure of connected systems devices, such as pump or controller;  
6. Use of non-factory authorized accessories or other components in conjunction with the boiler system;  
7. Failing to eliminate air from, or replenish water in, the connected water system;  
8. Chemical contamination of combustion air or use of chemical additives 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 manufactured by it, but Raypak  
will apply any such warranty as may be provided to it by the parts manufacturer.  
TO MAKE WARRANTY CLAIM:  
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the problem.  
The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service Manager,  
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be received  
from Raypak before replacement of any part.  
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY:  
This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN  
LIEU OFALLOTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUTNOTLIMITEDTO IMPLIED WARRANTIES OF MERCHANTABIL-  
ITYAND FITNESS FORAPARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITYANDTHE SOLE REMEDYAGAINSTRAYPAK WITH RESPECtTTO  
DEFECTIVE PARTS SHALLBEAS PROVIDED IN THIS WARRANTY. ITISAGREED THAT RAYPAK SHALLHAVE NO LIABILITY, WHETHER  
UNDERTHIS WARRANTY, OR IN CONTRACT,TORT, NEGLIGENCE OR OTHERWISE, FORANYSPECIAL, CONSEQUENTIAL, OR INCIDENTAL  
DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states do not allow limitations on how long an implied warranty lasts, or  
for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not apply to you.  
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that  
you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective  
date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manufacture plus  
thirty (30) days.  
_____________________________________________________ ______________________________________________  
Name of Owner  
_____________________________________________________ ______________________________________________  
Address Address  
Name of Dealer  
_____________________________________________________ ______________________________________________  
_____________________________________________________ ______________________________________________  
Model No.  
Serial No.  
Date of Installation:_____________________________________ Date of Initial Operation: ___________________________  
CORPORATE HEADQUARTERS:  
41  
 
42  
 
43  
 
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468  
Litho in U.S.A.  
 

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