Raypak Hi Delta 302A-902A User manual

INSTALLATION AND OPERATING
INSTRUCTIONS
CATALOG NO. 1000.501B Effective: 09-08-06 Replaces: 01-01-05 P/N 240757 Rev. 1
WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property dam-
age, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other com-
bustable 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.
Models
302A-902A Types H, WH & P
L
W

2

WARNINGS 4
BEFORE INSTALLATION 5
Product Receipt 5
Model Identification 5
Ratings and Certifications 5
Component Locations 6
General Information 7
GENERAL SAFETY 8
Time/Temperature Relationships in
Scalds 8
INSTALLATION 9
Installation Codes 9
Equipment Base 9
Stacking 9
Clearances 10
Combustion and Ventilation Air 12
Conventional Combustion Air Supply 13
Water Piping 14
Hydronic Heating 16
Gas Supply 20
Electrical Power Connections 22
Field Wiring Connection 23
Venting 25
Changing the Flue Outlet 27
Venting Installation Tips 28
Venting Configurations 28
Controls 33
Outdoor Installation 33
Heater Sequence of Operations 34
87%-Efficiency Boilers –
Special Instructions 39
Water Piping 39
Wiring Diagram 44
START-UP 45
Pre Start-up 45
Start-Up 46
OPERATION 49
Lighting Instructions 49
To Turn Of Gas To Appliance 49
TROUBLESHOOTING 50
MAINTENANCE 51
Suggested Minimum
Maintenance Schedule 51
Preventative Maintenance Schedule 51
APPENDIX 53
Inside Air Contamination 53
WARRANTIES 54
Type H and WH 54
Type P 55
CONTENTS
3

4
DANGER: Indicates the presence of immediate hazards which will cause severe person-
al injury, death or substantial property damage if ignored.
WARNING: Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
CAUTION: Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
NOTE: Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
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.
WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified serv-
ice technician to inspect the heater and to replace
any part of the control system and any gas control
which has been under water.
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 flam-
mable liquids and vapors.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
CAUTION: Operation of this heater in low-temper-
ature systems requires special piping. Harmful inter-
nal condensation will occur if the inlet water temper-
ature does not exceed 105°F. Warranty claims will
be denied when condensation occurs.
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 neg-
ative or positive pressure equipment room, there are
special installation requirements. Consult factory for
details.
WARNINGS
Pay Attention to These Terms

5
BEFORE INSTALLATION
Raypak strongly recommends that this manual be re-
viewed thoroughly before installing your Hi Delta
heater. Please review the General Safety information
before installing the heater. Factory warranty does not
apply to heaters that have been improperly installed or
operated. (Refer to the warranty at the back of this
manual.) Installation and service must be performed
by a qualified installer, service agency or gas supplier.
If, after reviewing this manual, you still have questions
which this manual does not answer, please contact the
manufacturer or your local Raypak representative.
Thank you for purchasing a Raypak product. We hope
you will be satisfied with the high quality and durability
of our equipment.
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. Remove
the heater from the shipping packaging. Report any
damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that
you receive the correct number of packages as indi-
cated on the Bill of Lading.
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.
Purchased parts are subject to replacement only
under the manufacturer’s warranty. Debits for defec-
tive replacement parts will not be accepted and 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 rating plate located on
the lower right outside jacket of the heater. The model
number will have the form H9 1262A or similar
depending on the heater size and configuration. The
letter(s) in the first group of characters identifies the
application (H = Hydronic Heating, WH = Domestic
Hot Water (DHW), P = Pool). The number which fol-
lows identifies the firing mode (1 or 4 = on-off, 3 =
2-stage, 8 = 3-stage and 9 = 4-stage). The second
group of characters identifies the size of the heater
(four numbers representing the approximate MBTUH
input), and, where applicable, a letter, indicating the
manufacturing series. An “E” suffix indicates 87% effi-
ciency (Category II or IV venting) (“H” stamped boilers
only).
Ratings and Certifications
Standards:
• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired
Hot Water Boilers
• CAN 3.1 - latest edition, Industrial and
Commercial Gas-Fired Package Boilers
• ANSI Z21.56 · CSA 4.7 - latest edition Gas-Fired
Pool Heaters
• ANSI Z21.10.3 · CSA 4.3 - latest edition Gas
Water Heaters
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.
Rated inputs are suitable for up to 5,000 ft elevation
without de-rating. Consult the factory for installations
at altitudes over 5,000 ft above sea level.
WARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube
bundle headers, or any ASME parts not manufac-
tured 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.

6
Component Locations
Fig. 1: Component Locations – Back
Fig. 2: Component Locations – Left Side
Panels removed for clarity
Fig. 3: Component Locations – Front

7
General Information
Quantity of Vent Size
(in.)
Model
No. Burners Gas
Valves Blowers Flue Intake
302A 6 1 1 5 6
402A 8 1 1 6 6
502A 10 2 1 6 6
652A 13 2 1 8 6
752A 15 2 1 8 6
902A 18 3 1 8 6
# Burners per
Valve Stages % Fire at
Stage
Model
No. 123 1 2 12
302A 6 1100
402A 8 1100
502A 5 5 11,250100
652A 7 6 11,254100
752A 8 7 11,253100
902A 6 6 6 1, 1A 1, 1A, 2 66 100
Table A: Basic Data
Table B: Manifold Data
# Burners
per Valve
Valve
Staging
% Firing
at Stage
Model
No. 12*1 2 1 2
302A 4 2 1 1, 2 66 100
402A 5 3 1 1, 2 63 100
Table C: 2-Stage Design Option
* Valve 2 is inside the air plenum on H3/WH3 302A-402A

8
GENERAL SAFETY
To meet commercial hot water use needs, the high
limit safety control on this water heater is adjustable up
to 210°F. However, water temperatures over 125°F
can cause instant severe burns or death from scalds.
When supplying general purpose hot water, the rec-
ommended initial setting for the temperature control is
125°F.
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 cause instant
severe burns or death from scalds. Children, disabled
and elderly are at highest risk of being scalded.
• Feel water before bathing or showering.
• Temperature limiting valves are available.
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.
NOTE: When this water heater is supplying general
purpose hot water for use by individuals, a thermo-
statically 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.
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 show-
ering.
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.
Water
Temp.
Time to Produce Serious
Burn
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About 1 second
Table courtesy of The Shriners Burn Institute
Table D: Time to Produce Serious Burn

9
INSTALLATION
INSTALLATION
Installation Codes
Installations must follow these codes:
• Local, state, provincial, and national codes, laws,
regulations and ordinances
• National Fuel Gas Code, ANSI Z223.1/NFPA 54 –
latest edition (NFGC)
• National Electrical Code, ANSI/NFPA 70 - latest
edition (NEC)
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1,
when required (CSD-1)
• For Canada only: CAN/CGA B149.1 installation
Code (B149.1) and CSA C22.1 C.E.C. Part 1
(C22.1)
The temperature of the water in the heater can be reg-
ulated by using the temperature controller. To comply
with safety regulations, the temperature controller is
set at the lowest setting when shipped from the facto-
ry.
To adjust the water temperature, insert a small straight
screwdriver into the adjustment screw on the front of
temperature controller and turn the wheel to the
desired setting (See Fig. 4.).
CAUTION: Hotter water increases the risk of scald-
ing! There is a hot water scald potential if the thermo-
stat is set too high.
Fig. 4: Temperature Controller
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.
Stacking
Hi Delta units can be stacked two units high with an
optional stacking rack. A seismic-certified stacking kit
is available from Raypak for this type of installation.
CAUTION: The heaters should be located in an
area where water leakage will not result in damage
to the area adjacent to the appliances or to the struc-
ture.
When such locations cannot be avoided, it is recom-
mended that a suitable catch pan, adequately drained,
be installed under the appliance. The pan must not
restrict air flow.
Fig. 5: Typical Stacked Installation

10
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.).
Clearances
Indoor Installations
Heater
Side
Minimum Clear-
ance
from Combustible
Surfaces
Recommended
Service
Clearance
Floor* 0” 0”
Rear 1” 24”
Water Side 12” 24”
Other Side 1” 24”
Top 1” 1”
Front Open 24”
Vent 2” 2”
Table E: Clearances – Indoor Installations
TOP VIEW
FRONT VIEW
Venting not shown for clarity. Heater must be vented
per instructions in this manual
Fig. 6: Minimum Clearances from Combustible
Surfaces – Indoor Installations
When installed according to the listed minimum clear-
ances from combustible construction, these heaters
can still be serviced without removing permanent
structural construction around the heater. However, for
ease of servicing, we recommend a clearance of at
least 24 in. in front, and at least 12 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.
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.
Outdoor Installations
These heaters are design-certified for outdoor installa-
tion. Heaters must not be installed under an overhang
that is less than 3 ft from the top of the heater. Three
sides must be open in the area under the overhang.
Roof water drainage must be diverted away from
heaters installed under overhangs.
Heater
Side
Min. Clearance
from Combustible
Surfaces
Recommended
Service
Clearance
Front Open 24”
Rear 12” 24”
Water Side 36” 36”
Other Side 36” 36”
Top Unobstructed Unobstructed
Vent N/A N/A
Table F: Clearances – Outdoor Installations
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.
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 jobsite.
* DO NOT install on carpeting.