HuRay HI-DELTA 302ACE Manual

M E R C H A N D I S I N G , S U P P L Y I N G
A N D M A N U F A C T U R I N G L T D .
H A N D L I N G , I N S T A L L A T I O N A N D
S E R V I C E M A N U A L
HI-DELTA 302ACE-2342ACE
SERIES
h o t w a t e r b o i l e r s f o r c e n t r a l h e a t i n g /
w a t e r h e a t e r s f o r d o m e s t i c h o t w a t e r a n d
t e c h n o l o g i c a l h o t w a t e r s u p p l y
w i t h f a n a s s i s t e d p r e m i x b u r n e r s
t o b e i n s t a l l e d i n d o o r o r o u t d o o r
THE FIRST OPERATION OF THE APPLIANCE MUST BE
CARRIED OUT BY AN AUTHORIZED SERVICE.
CALL A SERVICE LISTED IN THE WARRANTY!
Hungary
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HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
2
LIST OF CONTENTS
4. Version. Closed on 28. 05. 2008
LIST OF CONTENTS
2
1.
GENERAL DESCRIPTION
OF THE GAS APPLIANCE
4
1.1.
PARTS LIST AND PROD
UCT IDENTIFICATION
4
1.1.1.
S rial numb r
4
1.2.
SAFETY INSTRUCTIONS
5
1.3.
TECHNICAL DATA
6
1.4.
GENERAL LAYOUT AND D
ESCRIPTION OF OPERAT
ION
9
1.5.
FIELDS OF APPLICATIO
N
12
1.5.1.
G n ral
points
12
1.5.2.
105
0
C syst ms
12
1.5.3.
Syst ms b low 105
0
C down to 40
0
C
13
1.5.4.
Dir ct h ating of dom stic hot wat r
14
1.5.5.
Syst ms b low 40
0
C
15
1.5.6.
Dir ct h ating of swimming pools
16
2.
TO THE ATTENTION OF
THE USER
17
2.1.
THINGS TO A
RRANGE BEFORE
THE
FIRST
OPERATION OF
THE
APPLIANCE
17
2.2.
HOW TO OPERATE THE A
PPLIANCE
17
2.3.
OPERATION STATUS IND
ICATION
19
2.4.
TEMPERATURE ADJUSTME
NT
20
2.5.
HOW TO TURN OFF THE
APPLIANCE
21
2.6.
UNUSUAL OCCURANCES
21
2.6.1.
Wat r
vapour
p
r cipitation
, cond nsation
21
2.6.2
Smok and sm ll
21
2.6.3.
Strang nois s
21
2.6.4.
Manual high limit
21
2.7.
PERIODIC
MAINTENANCES TO BE C
ARRIED OUT BY THE US
ER
22
3.
TO THE ATTENTION OF THE INSTALLER
23
3.1
VENTING SYST
EMS
24
3.1.1.
Changing th flu outl t on sit of th installation
2
6
3.1.2.
R v rsing th air filt r on sit of th installation
26
3.2
INDOOR INSTALLATION
27
3.3.
OUTDOOR INSTALLATION
28
3.3.1.
Outdoor installation without chimn y
2
8
3.3.2.
Outdoor installation with chimn y
29
3.4.
INSTALLING A GROUP O
F APPLIANCES
30
3.4.1.
Group of applianc s locat d n xt to ach oth r, conn ct d to flu pip s
31
3.4.2.
Two applianc s locat d ov r ach oth r in a boil r room
3
1
3.4.3.
Group of applianc s locat d n xt to ach oth r, conn ct d to th factory
suppli d outdoor v nt kit
32
3.5.
WATER PIPING
33

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
3
3.6.
FLOW RATE DEMANDS FO
R HEATING APPLICATIO
NS
35
3.6.1.
Fr z prot ction for outdoor boil rs
36
3.7.
FLOW RATE DEMANDS FO
R DIRECT HEATING OF
DOMESTIC HOT
WATER
36
3.8.
GAS SUPPLY
37
3.8.1.
Maximum gas supply pr ssur
37
3.8.2.
Gas supply conn ction, r v rsing th sid of th gas conn ction on sit of
th installation
37
3.9.
POWER
SUPPLY
3
8
3.9.1.
Ext rnal th rmostat or stag
-
controll r via
voltag
-
fr contacts
39
3.9.2.
Pump control via 230V 50Hz output
40
3.9.3.
Enabling/disabling of th op ration via
voltag
-
fr contacts
40
3.9.4.
Coll ct d rror signal via
24V 50Hz output
40
3.9.5.
Ext rnal low wat r cut
-
off switch via
voltag
-
fr contacts
40
3.9.6.
Ext rnal flu gas damp r and fan control
40
4.
TO THE ATTENTION OF
THE SERVICE
41
4.1.
TOOLS NEEDED
41
4.2.
ELECTRICAL CONNECTIO
N OF T
HE APPLIANCE
42
4.2.1.
Wiring diagrams
42
4.2.2.
Conn cting th mains pow r supply
47
4.2.3.
Conn cting th pump control
48
4.2.4.
Conn cting an xt rnal th rmostat or burn r stag controll r
48
4.2.5.
Conn cting th nab
ling/disabling of op ration
50
4.2.6.
Conn cting coll ct d alarm
50
4.2.7.
Conn cting xt rnal low wat r cut
-
off switch
51
4.2.8.
Conn cting xt rnal flu gas damp r and fan control
51
4.2.9.
Op ration of th hot surfac ignitio
n syst m
52
4.2.10.
Op ration of th inn r control pan l, m aning of th control lights
54
4.2.11.
Op ration of th tim d lay r lays, m aning of th control lights
56
4.2.12.
Op ration of th pump control r lay, m aning of th control
lights
56
4.3.
FIRST STARTING OF TH
E APPLIANCE
57
4.3.1.
Ch cking th gas supply pr ssur
57
4.3.2.
Blow r adjustm nt
58
4.3.3.
Burn r gas pr ssur adjustm nt
59
4.3.4.
Saf ty insp ctions
60
4.3.5.
Flam cut
-
out t st
61
4.3.6.
Final ch ck of th op rating applianc
62
4.4.
CONVERTION TO ANOTHE
R TYPE OF GAS
63
4.5.
ASSEMBLY AND CLEANIN
G
OF THE HEAT EXCHANGE
R
64
4.6.
PERIODIC MAINTENANCE
TO BE CARRIED OUT BY
THE SERVICE
66

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
4
1.
GENERAL DESCRIPTION
OF THE
GAS APPLIANCE
1.1. PARTS LIST AND PRODUCT IDENTIFICATION
The gas a
ppliance contains the following parts:
- gas train
- burner s stem
- blower(s)
- water pressure relief valve
- temperature and pressure measuring gauge
- complete burner sequence and safet control
The following accessories are shipped separatel :
- air intake and flue exhaust s stem pipes and parts
- air intake cover for outdoor use
Further accessories:
- Warrant documents, Installation Handling and Service
Manual
- Two pieces of NPT thread pipe adapters.
- External stage controllers, thermostats (optional)
!
Upon th r c ipt of th applianc pl as ch ck
th data on th data plat , particularly th cod s
of th factory numb r, and mak sur that you
r c iv d th product you had ord r d,
undamag d and with v ry acc ssory includ d.
1.1.1.
Factory
numb r
HDXXXX XXXXXXXXXXXXXXXX H B 4 E8 A1 A3 A6
Model Size Manufacturing code number
Application Venting s stem
Opening pressure of the
water relief valve
Efficienc option Material of the
water headers
Material of the heat exchanger tubes Side of the water connections
Application
-H: hot water boiler for central heating s stems,
-W: direct water heating for domestic hot water
and technological s stems
-P: direct water heating for swimming pools.
Venting s stem
-O: outdoor unit with factor supplied outdoor
vent cap.
-B: outdoor or indoor unit with open burner
chamber connected to a flue pipe s stem.
-C: indoor unit with closed burner chamber
connected to a sealed vent s stem.
Opening pressure of water relief valve
-4 bar,
-6 bar,
-8 bar,
-10 bars.
Efficienc option
--: standard efficienc model,
-E8: increased efficienc model.
Material of the water headers
--: standard, glass lined cast iron
-A1: bronze.
Side of the water connections when facing the front of
the unit
--: standard, left sided
-A6: right sided.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
5
1.2.
SAFETY INSTRUCTIONS
!
Natural gas and PB gas contain an odorant to
mak th d t ction of an v ntual gas l akag
asi r. Som p opl ar unabl to id ntify this
sm ll. Ask for a qualifi d s rvic p rson if you
w r unsur about th origin of th sm ll.
If you susp ct gas l akag :
-Do not touch an electrical switch; do not use an
phone in the gas leakage area!
-Do not cause an open flame or spark!
-Close the gas suppl and leave the gas leakage area!
-Immediatel contact a qualified service and inform
the gas supplier in case of need!
-Contact the fire department if ou neither reach the
service nor the gas supplier!
-Follow their instructions!
For our own safet never us
e or store diesel oil, gasoline,
solvents or other flammable liquid or gas next to the gas
appliance because it carries the risk of fire and explosion.
Detecting the presence of LPG gas is more difficult
because it is heavier than air and tends to accumulate at
low areas instead of head height. Pa more attention when
the gas appliance is operated on LPG gas.
The t pe of the operating gas is indicated b the
manufacturer on the data plate of the gas appliance.
!
Gas applianc s that run on LPG or natural gas
ar diff r nt. PB gas typ mod ls cannot b
op rat d on natural gas without th
r adjustm nt of th applianc ! N v r att mpt to
do so oth rwis it is lif -thr at ning!
R adjustm nt of th applianc for a diff r nt gas
typ must b p rform d by a qualifi d s rvic
unit, list d in th warranty.
!
Th gas applianc must not b locat d in air
str ams containing th following ch micals:
Fr on, calcium-chlorid , potassium-chlorid ,
carbon-t tra-chlorid , chlorin , halog ns
r frig rants, p r chlorin - thyl n , trichlorin -
thyl n , hydrochloric-acid, thyl n -
dichlorid , and photo ch micals. Such air is
br athabl but th ch micals in it cr at
corrosiv substanc s, which short n th
lif tim of any gas applianc .

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
6
1.3.
TECHNICAL DATA
Mod l
Numb r
of stag s
Nominal n t input
(kW)
Gas consumption
Flu gas
volum
(m3/h)
W ight
(kg)
Natural gas LPG gas
Natural gas
(Nm3/h)
LPG gas
(kg/h)
302ACE 1 80 80 8,016 6,2 160 171
402ACE
1
110
110
11,022
8,5
220
200
502ACE
2
140
140
14,028
10,9
280
245
652ACE 2 180 180 18,036 14,0 360 266
752ACE 2 200 200 20,040 15,5 400 304
902ACE 2 250 250 25,050 19,4 500 333
Mod l
HD 302A
CE
HD 402A
CE
HD 502
ACE
HD 652A
CE
HD 752A
CE
HD 902A
CE
A
Width (mm)
914
1092
1270
1537
171
5
1981
B
Operational centre control panel on the front of the boiler
C
Water pressure relief valve
D Mounting cover for ignition parts
E
Electrical connections
F
Water outlet
(reversible), female thread 2
”(NPT)
G
Gas suppl connecti
on, (reversible) m
ale thread
(GAS)
3/4
3/4
5/4
5/4
5/4
5/4
H
Outdoor cap (optional)
I
Temperature and pressure gauge
J
Viewing window to burners
K
Flue exhaust (reversible option) (mm)
130
150
150
200
200
200
L
Flow switch
M Combustion air inlet filter (with protective cover for outdoor boilers)
R
Water inlet
(reversible) female thread 2
”(NPT)
T
Combustion air connection for sealed chamber (mm)
150
150
150
150
150
150
W
Distance between the supports (mm)
457
470
559
692
781
914
X
1 degree sloop on jacket t
op toward the back of the unit

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
7
Mod l
Numb r
of stag s
Nominal n t input
(kW)
Gas consumption
Flu gas
volum
(m3/h)
W ight
(kg)
Natural gas LPG gas Natural gas
(Nm3/h)
LPG gas
(kg/h)
992ACE 2 270 270 27,054 20,9 540 405
1262ACE 3 340 340 34,068 26,3 680 455
1532ACE 4 420 420 42,084 32,5 840 551
1802ACE 4 490 490 49,098 38,0 980 608
2002ACE
4
550
550
55,110
42,6
1100
653
2072ACE
4
570
570
57,114
44,2
1140
653
2342ACE 4 640 640 64,128 49,6 1280 684
Mod l
HD 992 ACE
HD 1262 A
CE
HD 1532 ACE
HD 1802 ACE
HD 2002 ACE
HD 2072 ACE
HD 2342 ACE
A Width (mm)
1451
1740
2029
2315
2604
2604
2893
B
Operational
centre
control panel on the front of the boiler
C
Water pressure relief valve
D
Mounting cover for ignition parts
E
Electric
al connections
F
Water outlet (reversible), female thread 2 ½”(NPT)
G
Gas suppl connection, (reversible) male thread 2" (
GAS
)
H
Outdoor cap (optional)
I
Temperature and pressure gauge
J
Viewing window to burners
K
Flue exhaust (reversible option) (m
m)
250
300
300
350
350
350
400
L
Flow switch
M
Combustion air inlet filter (with protective cover for outdoor boilers)
R Water inlet (reversible) female thread 2 ½”(NPT)
T
Combustion air connection for sealed chamber (mm)
250
250
250
250
250
250
2
50
W
Distance between the supports (mm)
427
522
619
714
811
811
907
X
1 degree sloop on jacket top toward the back of the unit

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
8
Combustion efficienc (without E8 option) 93,2 %
→
Minimal allowed inlet water temperature: 40 oC
Combustion efficienc (with E8 option) 96,6 %
→
Minimal allowed inlet temperature: 49 oC
Nominal gas suppl pressure (natural gas):
20/25 mbar
Flue gas temperature:
121
-
138
o
C
Nominal gas suppl pressure(
L
PG
gas):
50 mbar
Maximal allowed outlet water temperature:
105
o
C
Maximal allowed gas pressure upstream of valve:
200 mbar
Water pressure relief valve opening:
Max. 10 bar
Flue gas NO
x
emission (natural gas):
26 mg/m
3
Flue gas CO emission (natural gas):
43 mg/m
3
Electric suppl
230V / 50Hz
Flue gas NO
x
emissi
on (
LPG
gas):
44 mg/m
3
Total electric input demand:
VA + P
pump
Flue gas CO emission (
LPG
gas):
80 mg/m
3
Protection
:
IP X4
Flue gas CO
2
emission (natural gas):
7,8
–
8,2 %
Categor
:
II
2H3B/P
Burner pressure (natural gas)
8,9
+
0,2
mbar
Burner pressure (LPG gas)
24
,
5
+
0,5
mbar
Model Quantit of burner
tubes
Quantit of gas valves
Quantit of blowers
Maximal electric input under continuous
load
Without pump
Pieces
.
Pieces
.
Pieces
.
Watts
302 ACE
6
1
1
525
402 ACE
8
1
1
525
502 ACE
10
2
1
595
65
2 ACE
13
2
1
595
752 ACE
15
2
1
595
902 ACE
18
3
1
620
992 ACE
11
2
2
955
1262 ACE
14
3
2
985
1532 ACE
17
4
2
1055
1802 ACE
20
4
2
1055
2002 ACE
23
5
3
1510
2072 ACE
23
5
3
1510
2342 ACE
26
5
3
1510
Model
Number of burner tubes per
each gas valve Number of burner stages % of nominal input at stage
1
1A
2
3
4
1
2
3
4
1
2
3
4
302 ACE 6 - - - - 1 - - - 100 - - -
402 ACE
8
-
-
-
-
1
-
-
-
100
-
-
-
502 ACE 5 - 5 - - 1 1,2 - - 50 100 - -
652 ACE
7
-
6
-
-
1
1,2
-
-
54
100
-
-
752 ACE 8 - 7 - - 1 1,2 - - 53 100 - -
902 ACE
6
-
6
6
-
1,2
1,2,3
-
-
66
100
-
-
992 ACE 6 5 1 1, 2 - - 55 100 - -
1262 ACE
5
3
6
1
1,2
1, 2, 3
-
36
57
100
-
1532 ACE 6 4 4 3 1 1,2 1, 2, 3 1, 2, 3, 4 35 59 82 100
1802 ACE
6
4
5
5
1
1,2
1, 2, 3
1,
2, 3, 4
30
50
75
100
2002 ACE 5 4 5 4 5 1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 39 61 78 100
2072 ACE
5
4
5
4
5
1, 1A
1, 1A, 2
1, 1A, 2, 3
1, 1A, 2, 3, 4
39
61
78
100
2342 ACE
5
5
5
5
6
1, 1A
1, 1A, 2
1, 1A, 2, 3
1, 1A, 2, 3, 4
39
58
77
100

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
9
1.4.
GENERAL LAYOUT AND D
ESCRIPTION OF OPERAT
ION
The Hi
-
Delta 30
2ACE
-
2342ACE series gas appliances can
be used as heating boilers of central heating s stems
circulating liquid medium.
The can be installed
-indoors (in a conventional boiler room),
-outdoors (without an structure around them),
or instead the can be used as a water heater for the direct
heating of:
-domestic hot water,
-hot water for technological purposes,
-swimming pools.
As a water heater the can be installed
-indoors (in a conventional boiler room),
-outdoors (without an structure around them), if
there is no risk of freezing.
The combustion air is being drawn b two or three
blowers direct from the adjacent area of the gas appliance
or through air intake pipes. The burnt gas can be
discharged through small diameter horizontal or vertical
vent s stems which are t pical for gas appliances operating
under positive pressure. Outdoor installations are self-
venting when installed with the optional factor supplied
outdoor vent kit and do not require additional vent piping.
The gas is burnt in 100% primer air premix stainless steel
burner tubes enclosed with the heavil heat insulated
combustion chamber, minimizing the emission of harmful
materials. The heat generated in the low mass and low
volume die-rolled copper fin tubes which are resistible to
12 bars can be removed b the intensive flow of the
heating substance.
This is wh
whenever the burners are on a properl sized
circulation pump must alwa s be operated as well. The
appliance with the help of a built in rela switches on and
off the pump on time. (The pump is not included in the
kit). The burners are divided into groups on the basis of
burner stages. Each burner group receives the gas
through one or more parallel built gas valves. Onl the
burner groups needed for the given heat demand are
switched on in order to minimize the number of switches.
In stand b mode no gas is consumed, due to the
intermittent, direct burner ignition s stem. Although the
appliance has its own built in thermostat it is advised to
connect the appliance to external thermostat(s) or other
stage controllers. The appliances are capable to suppl
collected alarm signal and operation signal to building
surveillance s stems. The are able to receive low water
level signal. The can control external flue gas extractors
or fresh air suppl blowers.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
10

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
11
All Hi
-
Deltas
from 30
2ACE up to 2342ACE
are wired
similarl , up to safe limits, but the quantit of gas valves,
blowers and igniters differ from model to model.
Information can be obtained about the actual status of the
operation and faults through the control lights of the outer
and inner panels and time rela s.
Whenever the “SAFETY” light of the outer diagnostic
panel is on 24V AC signal is generated on the “ALARM”
output terminal of the inner panel, which can be carried as
a collected error signal.
The two-wa main power switch can be found on the C
rail located on the front right upper part in the electric
box. The 230V main circuit and the inlet terminal of the
24V control circuit are energized and the “POWER” light
of the outer diagnostic panel is on when the main switch is
switched on. The safet components are instantl supplied
b energ :
At this stage, on condition the preventive safet switches
are closed, the “SAFETY ERROR” light goes out and the
appliance is read for operation.
In case of an error “SAFETY ERROR” light would sta
on and the appliance will not start its operation.
In case of demand for heat of an outer source the
“HEAT DEMAND” light goes on. The pump control
rela starts the pump connected to the gas appliance.
The contacts of the flow switch close if the pump is able
to suppl at least the minimal demanded flow through the
heat exchanger. The “FLOW” light goes on and all
blowers start to operate. The contacts of the air pressure
switches close and the appropriate ordinal number of
“BLOWER” lights up. The thermostat input of the
ignition controller is supplied and a 15 second long pre-
purge period is followed b the glowing up of the hot
surface igniter. The heating up period lasts for about 30
seconds then an attempt for the igniting begins.
The appropriate gas valve is supplied during the four
second long ignition attempt. “STAGE 1” control light
goes on. The gas valve onl sta s open if the remote
sensor is able to sense flame during these four seconds.
Stage 1 begins to operate and its control light sta s on.
Gas valve 2 will be supplied and “STAGE 2” light goes on
in case of further heat demand, following the necessar
time dela .
At the 1
262ACE model gas valve #3
will be supplied and
“STAGE 2” light goes on in case of further heat demand,
following the necessar time dela .
The ignition s stems of models 1532ACE through-
2342ACE are duplicated. At these models upon heat
demand for stage 3 the ignition controller #2 is supplied
and the 15 seconds pre-purge period followed b the
glowing up of the hot surface igniter #2 is started. The
heating up period lasts for about 30 seconds than an
ignition attempt begins.
Gas valve #3 is supplied during the successful igniting
attempt for four seconds. “STAGE 3” control light goes
on. The gas valve onl sta s open if the remote sensor #2
is able to sense flame within these four seconds. Stage 3
begins to operate and its control light sta s on.
Gas valve #4 will be supplied and “STAGE 4” light goes
on in case of further heat demand, following the
necessar time dela .
In case of a failure of one ignition s stem the other will
take over the load automaticall , this wa the appliance is
able to operate at about 50% performance.
The contacts of the flow switch sta open if the pump is
unable to suppl at least the minimal demanded flow
through the heat exchanger. The “FLOW” light does not
go on. The appliance does not start even in case of heat
demand, or it stops operation. Onl “POWER” and
“HEAT DEMAND” lights sta on.
The ignition controller attempts ignition 5 times in
sequence before locking out in case of an ignition failure.
“SAFETY” light goes on.
The appliance purges for 15 seconds before locking out
whenever the “BLOCKED VENT” light is on.
“SAFETY” light goes on.
The appropriate ordinal number “BLOWER” light goes
out if an of the blowers is unable to create the minimal
pressure difference that is needed for the operation. The
appliance purges for 15 seconds before locking out.
“SAFETY” light goes on.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
12
1.5.
FIELDS OF APPLICATIO
N
- Heating s stems for buildings
- Direct heating of domestic hot water
- Direct heating of the water of swimming pools
- Direct water heating for technological processes
1.5.1.
G n ral points
Please consider thoroughl during the design and
installation of the complete s stem that even the tiniest
built-in part is able to withstand the overpressures,
temperatures, and chemical actions which could appl
during operation!
Appropriate heating substance flow must be assured
through the heat exchanger of the Hi-Delta during the
operation of the burners. The appliance is able to start/
stop the operation of a single phase pump or control the
magnetic switch of a three phase pump b its built in rela .
The output voltage is 230VAC/50 Hz. (Pump is not
included in the appliance)
The built
-
in flow switch prevents the operation for the
burners of the Hi-Delta effectivel if there is too little
flow through the heat exchanger.
!
Hot liquid can gr ss th wat r pr ssur r li f
valv . Discharg piping must b pip d n ar th
floor and clos to a drain to avoid th possibility
of any p rsonal injury or prop rty damag . Th
piping must b rout d so that no discharg d
liquid could fr z in it.
1.5.2.
105
0
C syst ms
The great mechanical strength and thermal-shock
resistance of the die-rolled copper finned tubes heat
exchanger and temperature range of the operating built
thermostat makes Hi-Deltas able to operate with 105 0C
outlet-temperature continuousl . Proper overpressure
must be secured in such s stems to prevent the boiling of
the heating substance. The rubber membrane of the
closed expansion tank, which is often used in such
s stems, is usuall unable to endure such high
temperatures therefore proper volume connector must be
inserted to avoid direct contact with the hot heating
substance liquid.
The residual heat must be removed from the heat
exchanger after the burners stop. Either should the pump
run continuousl or intermittentl so that it onl starts
when there is a heat demand and stops after all burner
stages, overrunning for a time that can be adjusted on the
pump rela between 1-10 minutes.
The built in flow switch prevents the operation for the
burners of the Hi-Delta effectivel if there is too little
flow through the heat exchanger. It might happen during
the operation that a valve is left closed or half-closed in
the s stem b accident. A formation of steam and a
reduction of flow might result. The operation of the built
in flow switch and the thermal shock resistance of the
heat exchanger together ensure that no breakdown could
occur even in such situation.
The manual high limit must be adjusted to its highest
setting.
The adjusted value on the auto high limit must not exceed
105 0C to avoid in locked position lockout of the
appliance.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
13
1.5.3.
Syst ms b low 105
0
C down to 40
0
C
The great mechanical strength and thermal-shock
resistance of the die-rolled copper finned tubes heat
exchanger makes Hi-Deltas ideal to operate in high
temperature s stems.
Please consider thoroughl during the design and
installation of the complete s stem that even the tiniest
built-in part is able to withstand the overpressures,
temperatures, and chemical actions which could appl
during operation!
The residual heat must be removed from the heat
exchanger after the burners stop. Either could the pump
run continuousl or intermittentl so that it onl starts
when there is a heat demand and stops after all burner
stages, overrunning for a time that can be adjusted on the
pump rela between 1-10 minutes.
The built in flow switch prevents the operation for the
burners of the Hi-Delta effectivel if there is too little
flow through the heat exchanger.
The return temperature of the Hi-Delta ACE appliances
is not allowed to sta below 40 C during continuous
operation.
The return temperature of the Hi-Delta ACE appliances
with E8 option is not allowed to sta below 49 C during
continuous operation.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
14
1.5.4.
Dir ct h ating of
dom stic hot wat r
Ever Hi-Delta is ideal for heating domestic hot water due
to its glass lined cast iron headers, small volume copper or
cupro–nickel heat exchanger tubes, eas access for
cleaning the waterwa s, up to 10 bar opening pressure
relief valve. It can be operated even at 80 °C suppl
temperatures continuousl .
The suppl water that comes from the drinking water
s stem is heated directl in the ver own heat exchanger of
the Hi-Delta.
The water heater is to be connected to a proper sized
domestic hot water storage tank (without inside heat
exchanger). The water to be heated is circulated
between the tank and the water heater b a pump built
into the return water line upstream of the heater.
The thermostat of the storage tank starts the water heater
when the temperature drops in the tank.
The operation of the pump is controlled b the Hi-Delta
itself with the built-in 230/24 V rela .
The tank thermostat stops the water heater when the
desired water temperature is reached.
The residual heat must be removed from the heat
exchanger after the burners stop. The pump stops after
overrunning for a time that can be adjusted on the pump
rela between 1-10 minutes.
S mbols
Safet valve
Pump
P
ipe connection
Discharge
valve
Check
valve
Ball
valve
Thermometer
Return from
circulation
Cold Water
from drinking
water suppl
s stem
Domestic
hot water
out

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
15
1.5.5.
Syst ms b low 40
0
C
Little temperature rise on the heat e
xchanger during operation,
high insensitivit to condensation and wide operation range of
the built in thermostats make Hi-Deltas suitable for operating in
low temperature s stems. Outlet temperatures below 40 0C are
needed for swimming pool heating and some technological
processes.
A main s stem pump must be built in. The operation of this
pump must be a precondition for the operation of the appliance.
A thermostat or a sensor must be built into the outgoing or
return line of the main s stem to control the temperature of the
heating substance. It secures that the appliance begins to operate
on the right time.
The greatest allowed flow must be assured through the heat
exchanger of the appliance during the operation of the burners
to ensure that the temperature rise through the heat exchanger
would be as little as possible. (See chapter 3.6.) The appliance
must operate a primer pump b itself with its built in rela .
Either could the pump run continuousl or intermittentl so that
it onl starts when there is a heat demand and stops after all
burner stages, overrunning for a time that can be adjusted on the
pump rela between 1-10 minutes.
The residual heat will be utilized in the s stem not causing
temporar temperature rise during the next restart.
The primer pump serves to take out a part of the colder heating
substance from the main s stem to circulate it through the heat
exchanger of the appliance then pouring it back into the main
s stem mixed up with its flow to reach the desired outlet
temperature that is less than 40 0C.
!
Th r turn t mp ratur of th Hi-D ltas is allow d
to b d cr as d to 40 0C only. Low r r turn
t mp ratur than this must b avoid d b caus th
wat r cont nt of th flu gas b gins to cond nsat
on th h at xchang r. Soot b gins to form on th
h at xchang r that blocks th fins which is
flammabl . Op rating th applianc in flu gas
cond nsing mod continuously is not a normal
op rating condition th r for any fault that r sults
from it is xclud d from th warranty.
The simplest wa to overcome this technical problem is to build
a b pass line into the primer loop which mixes some portion of
the heated liquid coming from the appliance to the colder flow
arriving from the main s stem. The temperature of the heating
substance will be increased this wa . Proper adjustment of the
valve in the b pass is important for the correct operation of the
appliance. The valve must be opened until the inlet temperature
of the appliance reaches minimum 40 0C. The adjustment can
be done manuall or b some automatic equipment. The built
in flow switch prevents the operation for the burners of the Hi-
Delta effectivel if there is too little flow through the heat
exchanger. Further flow switch can be used for proving the
operation of the main s stem pump.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
16
1.5.6.
Dir ct h ating of swimming pools
Direct heating of the water for swimming pools is a t pical
example of low temperature applications. Below 40 0C
Proper adjustment of the b pass valve is ver important
for the correct operation of the heater. The return water
temperature entering the Hi-Delta must be minimum 40
0C.
The valve must be adjusted while
-the water in the swimming pool is cold,
-The water reaches its desired temperature.
The sensor must measure the inlet temperature of the
heater when an automatic b pass valve is used.
Continuous monitoring is not needed in this case. The
water temperature of the swimming pool must be
controlled b a thermostat built into the main s stem
return line upstream of the heater. It secures that the
heater begins operation at the right time. Chemical
imbalance can cause serious damage to the heater and
connecting equipment. The pH value of the water to be
kept between 7,2 and 7,8 , the total alkalinit to be kept
between 100 and 150 ppm.
Lime and scale will form on the inner surface of the heat
exchanger and the efficienc of the appliance decreases if
the mineral content of the water and the quantit of the
dissolved solids becomes too high. All chemicals must be
introduced and completel diluted into the pool water
before being circulated through the heater. The use of
automatic chlorinators and chemical feeders significantl
increases the safet of operation. Chlorinators must feed
downstream of the heater and have an anti-siphoning
device to prevent chemical back-up into the heater when
the pump is shut off. This problem of course does not
occur if there is a separate line built for the heater onl .
!
Hi
-
D ltas us
d for dir ct h ating of swimming
pools must b fitt d with bronz h ad rs flow-
turning chamb rs and wat r conn ctions to
liminat l ctrolytic corrosion.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
17
2.
TO THE ATTENTION OF
THE USER
2.1. THINGS TO ARRANGE BEFORE THE FIRST OPERATION OF THE APPLIANCE
The installation of the Hi-Deltas must be executed b a
qualified person onl . The procedure must be permitted b
the local gas supplier prior to the installation. The appl ing
standards and local regulation must be respected. The
installer has to notif the local gas supplier of the finish of
the work. The gas supplier tests the pressure tightness of
new gas pipes then connects them to the existing gas
network. One of the authorized services must be called for
the first operation of the appliance. The service person will
check out the proficienc of the installation, connects
electricit , starts up and tunes the appliance.
!
First op ration of th applianc is allow d to b
x cut d by an authoriz d s rvic only. Th
warranty p riod starts as of th dat of th first
op ration. Th s rvic will charg you for first
starting th applianc .
2.2. HOW TO OPERATE THE APPLIANCE
Before starting up the Hi-Delta:
-Make sure that the appliance and the whole h draulic
s stem is filled up with the proper heating substance!
-Check out and stop drippings on the h draulic s stem!
-Purge out air from the h draulic s stem! Air being
strapped in the s stem ma impede circulation.
-Purge out air from gas pipes!
-Check in the warrant leaflet if the first start up of the
appliance was carried out b an authorized service.
Check out that the appliance is adjusted to the same
gas t pe being supplied!
-Have ou looked over the operation instructions in
this handling manual, which was supplied together
with the appliance? Have ou read the ”SAFETY
INSTRUCTIONS 1.2.”? In case of an abnormit
please call that service, which did the first start up of
the appliance!
For turning on the appliance:
-Switch off ever electric suppl that leads to the
appliance! Watch out for several electric suppl
sources might be! Take off the side panel of the
electric control box!
-First turn the auto high limit to its lowest temperature
setting! Push in the red button on the manual high
limit to check out if it is not in locked position
lockout! Turn the auto high limit to its desired
operating temperature setting than turn the manual
high limit to a temperature setting at least 5 0C higher
to the auto high limit!
-Check out and the pump overrun time on the TD
ECONO time dela rela ! The value can be adjusted
between 1-10 minutes.
-Switch on ever electric suppl leading to the
appliance and power it b switching on the two poles
rocker switch on the C rail! The “UNDER
POWER” light goes on. Watch out for 230 V AC
equipments operating in the control box from now!
-Turn the rocker switch located on the side of the
appliance to “ON” position!
-Pushing the reset button of the ignition controller(s)
located on the C rail can be released an ignition
failure that could rise earlier. (It is also indicated b
the “SAFETY” light.)
-Open the gas cock leading to the appliance!
-Wait five minutes allowing an eventual gas residue
escaping! Check for smell of gas especiall around the
floor! Follow the procedures given at the "SAFETY
INSTRUCTIONS 1.2." if ou smell gas!
-Continue turning on the appliance if there is no smell
of gas!
-Achieve heat demand b the proper setting of
thermostats and stage controllers! The „HEAT
DEMAND” light goes on.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
18
!
Do not att mpt to ignit th burn rs with a
match! Th burn rs will b ignit d automatically
by th applianc wh n n d d. Th r d colour
“SAFETY” light on th sid pan l go s on in
cas of an ignition failur .
-If necessar the ignition sequence is repeated five
times, then the appliance locks out in locked position
if remote sensing is not established. The “SAFETY”
light goes on. The ignition error can be reset b
pushing the reset button located on the C rail. The
appliance tries to start again in case of a heat demand.
-The manual high limit locks out the appliance in
locked position if the temperature setting of it is
lower than the setting of the auto high limit. (It is
also indicted b red the “SAFETY” light.) Wait until
the heating substance cools back then adjust the
manual high limit to a temperature at least 5 0C higher
than the value on the automatic high limit. Restart the
appliance b pushing the red button on the manual
high limit!
-The automatic high limit stopped the appliance
because it is adjusted to a lower temperature than an
external thermostat or stage controller connected. It
is a general rule that the temperature setting of the
automatic high limit must alwa s be higher than the
highest possible temperature allowed b an external
thermostat or stage controller Adjust the Automatic
high limit to a higher temperature value, as
appropriate!
-There is no gas!
-The flow through the heat exchanger is not proper.
The appliance does not start despite “POWER” and
“HEAT DEMAND” lights are on. “FLOW” light is
off. Check if the pump connected to the appliance is
working and the position of the closing fittings in
h draulic s stem!
-Call an authorized service if the appliance is still not
working!
-Follow the instructions at the „HOW TO TURN
OFF THE APPLIANCE 2.5,” part and call an
authorized service if the burners do not sta on after
several attempts!
-The appliance begins the ignition sequence. The
“FLOW” light goes on indicating that the pump is
operating and there is a required amount of heating
substance flow. The proper operation of the blowers
is indicated b the appropriate “BLOWER” light
turning on. All of the blowers in a given model must
operate simultaneousl . The number of the blowers
differs model b model. The ignition glows up after
the pre-purge time (in 15 seconds) the gas valve of the
appropriate stage opens after the igniter reaches the
necessar temperature. (in about 45 seconds) The
green light of the appropriate “STAGE” indicates that
a given stage is in operation. The appliance is read for
operation now and it will operate when there is a heat
demand.
-Mount back the side cover of the electric control box!
Check the following things if the appliance does not start
or stops during the operation!
-Burnt out fuses, cut-outs and switched off circuit
breakers in the electric network leading to the
appliance.
-If an of the blowers is unable to produce the
necessar pressure difference its “BLOWER” light
goes off, the appliance stops in about 15 seconds and
the “SAFETY” light goes on. Check and clean the air
filter when needed! Check if the air s stem is blocked
!
Mount back the side cover of the electric control box
and tr again if the appliance is read to operate!
-The blowers are unable to forward an air when the
flue s stem is blocked in 100%. The occurring error is
the same as it was at the previous point. The
“BLOCKED VENT” light is not lit.
-The “BLOCKED VENT” light goes on when the flue
s stem is blocked partiall .
!
R pair and maint nanc works during th
warranty p riod ar allow d to b carri d out by
an authoriz d s rvic only. Th list of th
authoriz d s rvic s is includ d in th warranty
card.

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
19
2.3.
OPERATION STATUS IND
ICATION
T
he actual operation status of the
Hi
-
Delta 30
2ACE
-
2342ACE appliances is indicated through led panels on site.
The Hi-Delta is an integrated s stem that controls its safe
operation thoroughl . Forwarding the 24V AC collected
error signal that applies on the ALARM output of the inner
panel whenever the “SAFETY” light is on is an expedient
compromise for building management s stems.
Each signal that is indicated on the outer panel can be
forwarded to a building management s stem but it increases
the costs significantl , while not giving an significant
advantage in most cases. Knowing the meaning of the inner
panel lights is unnecessar for the user. Detailed
information about them can be found at 4.2.10.
Out r
P
an
l
L
ights
Light
Colour
M aning
POWER
blue
Main power is on
HEAT DEMAND
ellow
External
thermostat
contacts are closed
BLOCKED VENT
red
Vent s stem is blocked
SAFETY
red
The appliance was stopped b one or more safet
reason(s)
FLOW
green
Heating subst
ance
flow
through the heat exchanger is
present
BLOWER1
green
Blower
1.
i
s on and
pressure difference
is
present
BLOWER2
green
Blower
2.
is on and pressure difference is present
BLOWER3
green
Blower 3. is on and pressure
difference
is present
STAGE1
gr
een
1. stage is on
STAGE2
green
2. stage is on
STAGE3
green
3. stage is on
STAGE4
green
4. stage is on

HANDLING MANUAL SERVICE MANUAL
RAYPAK HI DELTA BOILERS/WATER HEATERS
WITH FAN ASSISTED PREMIX BURNERS
20
2.4.
TEMPERATURE ADJUSTME
NT
The selected outlet temperature is indicated on the circular scales
of the automatic high limit and the manual high limit.
The temperatures can be adjusted b turning the knob.
The highest allowed outlet temperature in technological and
heating s stems is 105 0C, if all necessar technical conditions are
given.
The highest allowed outlet temperature for commercial domestic
hot water applications is 80 0C .
The highest allowed outlet temperature for direct heating of
swimming pools is less than 60 0C .
Turn the knob of the automatic high limit to the desired value to
select the outlet temperature!
The selected temperature of the automatic high limit shall be
higher than the highest required temperature on an external
thermostat or stage controller connected to the appliance
otherwise the desired operating temperature will never be
achieved!
The selected temperature of the manual high limit shall be at
least 5 0C higher than the highest required temperature on the
automatic high limit and an external thermostat or stage
controller connected otherwise the appliance will lock out in
locked position! Restarting the appliance is possible onl b
manual intervention. Wait until the heating substance cools
back then adjust the manual high limit to a temperature at
least 5 0C higher to the value on the automatic high limit.
Restart the appliance b pushing the red button on the
manual high limit!