Raypak HI DELTA 122-322 Manual

INSTALLATION & OPERATING
INSTRUCTIONS
CATALOG NO. 1000.53H Effective: 09-19-08 Replaces: 11-16-07 P/N 241112 Rev. 9
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.
Models 122–322
Types H, WH & P
L
W

2
Rev. 9 reflects the following: Changes to: The text in the BEFORE INSTALLATION section on page 5; the text in paragraph
one of the GENERAL SAFETY section on page 8; the text in paragraph one of the Outdoor Installations section on page
10; Table E on page 10; the wiring diagram on page 35.

WARNINGS 4
Pay Attention to These Terms 4
BEFORE INSTALLATION 5
Product Receipt 5
Model Identification 5
Ratings and Certifications 5
Installations at Elevation 5
Component Locations 6
General Information 7
Time/Temperature Relationships in Scalds 8
GENERAL SAFETY 8
Clearances 9
Equipment Base 9
INSTALLATION 9
Installation Codes 9
Combustion and Ventilation Air 11
Conventional Combustion Air Supply 11
Water Piping 12
Hydronic Heating 13
Domestic Hot Water Piping 15
Pool Heating 17
Gas Supply 17
Electrical Power Connections 19
Venting 21
Outdoor Installation 32
High Limit (Manual Reset) 33
Flow Switch 33
CONTROLS 33
Ignition Control Module 33
Low Water Cut Off (Optional) 34
Operating Control 34
WIRING DIAGRAM—MODELS 122
–322 35
PRE-START-UP 36
Filling System-Heating Heaters 36
Domestic Hot Water Heaters 36
Inspect Venting System 36
For Your Safety Read Before Lighting 36
Pre-Start-Up Check 36
INITIAL START-UP 36
Tools Needed 36
Preparation for Start-Up 36
Start-Up 37
Main Burner Adjustment 37
Safety Inspection 37
Follow-Up 38
POST START-UP CHECK 38
OPERATION 38
Operating Instructions 38
To Turn Off Gas To Appliance 39
MAINTENANCE 39
Suggested Minimum Maintenance
Schedule 39
APPENDIX 40
Inside Combustion Air Contamination 40
CONTENTS
3

DANGER: Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
WARNING: Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
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
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: 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.
• 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 deenergize the
equipment before servicing.
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.
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.
WARNINGS - Pay Attention to These Terms
4
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.
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.
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.

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
www.raypak.com.
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. Next,
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. 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
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.
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
• 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
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.
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.
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.
5

Fig# 9399
HI-LIMITS
WATER OUTLET
WATER INLET
GAS CONNECTION
VIEW PORT
PRESSURE RELIEF
CONNECTION
FLUE EXHAUST COMBUSTION AIR
INTAKE
Component Locations
Fig. 1: Component Locations—Back
Fig. 2: Component Locations—Left Side
Panels removed for clarity
Fig. 3: Component Locations—Front
6
HI LIMITS

General Information
Table A: Basic Data
Table B: Manifold Data
Model
No.
Quantity of Vent Size (in.)
Burners Gas Valves Blowers Flue Intake
122 3 2* 1 4 5
162 4 2* 1 5 5
202 5 2* 1 5 5
242 6 2* 1 5 5
322 8 2* 1 6 5
Model
No.
Burners per Valve Stages % Fire at Stage
A B 1 2 1 2
122 2 1 A AB 66 100
162 3 1 A AB 75 100
202 3 2 A AB 60 100
242 4 2 A AB 66 100
322 5 3 A AB 63 100
7
*Second valve located inside air plenum
Fig. 4: Gas Valve Detail
Fig. 5: Air Shutter Adjustment

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 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
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.
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 C: Time to Produce Serious Burn
8

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- latest edi-
tion (NFGC).
· 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).
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.
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: Hotter water increases the risk of scald-
ing! There is a hot water scald potential if the
thermostat is set too high.
Fig. 6: Temperature Control
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.
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.
9
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.
Clearances
Indoor Installations
Heater
Side
Minimum Clearance
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 D: Clearances – Indoor Installations
* DO NOT install on carpeting.

10
  

Fig. 7: 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 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.
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.
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 36”
Vent N/A N/A
Table E: Clearances – Outdoor Installations
TOP VIEW
FRONT VIEW
!$ !$  
Fig. 8: Minimum Clearances from Combustible Surfaces—Outdoor Installations
Outdoor Installations
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.