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INSTALLATION & OPERATING
INSTRUCTIONS
®
Models
HD101–HD401
Types H & WH
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. 1000.52 Effective: 06-11-09 Replaces: NEW P/N 241356 Rev. 1
2
CONTENTS
WARNINGS
Pay Attention to These Terms
BEFORE INSTALLATION
Product Receipt
Model Identification
Ratings and Certifications
Installations at Elevation
Component Locations
General Information
GENERAL SAFETY 8
Time/Temperature Relationships in Scalds 8
INSTALLATION
6
7
9
Installation Codes
Equipment Base
Clearances
Combustion and Ventilation Air
Conventional Combustion
9
11
9
9
5
5
5
4
4
5
5
Air Supply
Water Piping
Hydronic Heating
Domestic Hot Water Piping
Gas Supply
Electrical Power Connections
Venting
Outdoor Installation
CONTROLS
Ignition Control Module
Modulating Temperature Control
(Optional)
High Limit (Manual Reset)
High Limit — Auto Reset (Optional)
19
21
31
32
32
11
12
14
16
17
32
32
32
Flow Switch
High and Low Gas Pressure Switches
(Optional)
Low Water Cut Off (Optional)
WIRING DIAGRAM—MODELS
HD101–HD401
HD TROUBLESHOOTING
PRE-START-UP
Filling System-Heating Heaters
Domestic Hot Water Heaters
Inspect Venting System
Pre-Start-Up Check
INITIAL START-UP
Tools Needed
33
33
33
Preparation for Start-Up
Start-Up
Main Burner Adjustment
Gas Valve Adjustment
Gas Type Conversion on Valve
Safety Inspection
Follow-Up
POST START-UP CHECK
Air Filter Inspection/Removal
Heat Exchanger Removal
MAINTENANCE
Suggested Minimum Maintenance
40
41
42
Schedule 42
APPENDIX 43
Inside Combustion Air Contamination 43
36
38
38
38
39
39
39
40
36
36
36
36
36
34
35
36
36
3
WARNINGS — Pay Attention to These Terms
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: 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: 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: Risk of electrical shock. More than one disconnect switch may be required to deenergize the equipment before servicing.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
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.
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.
CAUTION: Operation of this heater in lowtemperature 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.
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
BEFORE INSTALLATION Model Identification
Raypak strongly recommends that this manual be reviewed 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 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.
The model identification number and heater serial number are found on the heater data plate located on the right side jacket of the heater. The model number will have the form H3-HD101 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).
The second character identifies the firing mode (3 two stage firing, 4 - On/Off firing ). The next three places identify the size of the heater.
Ratings and Certifications
Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.
Standards:
Product Receipt
WARNING: Pump motors should NOT be supported by any type of stand or support from above due to possible misalignment of pump and motor which may occur.
On receipt of your heater it is suggested that you visually 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.
• 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 Water Heaters, ANSI Z21.10.3 • CSA 4.3 - latest 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.
On occasion, items are shipped loose. Be sure that you receive the correct number of packages as indicated 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.
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.
Installations at Elevation
When ordering parts, you must specify the model and serial number of the heater. When ordering under warranty conditions, you must also specify the date of installation.
Rated inputs are suitable for up to 2000 feet elevation without de-rate. Consult the Factory for installations at any altitude in excess of 2000 feet.
Purchased parts are subject to replacement only under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted. Parts will be replaced in kind only per Raypak’s standard warranties.
5
Component Locations
Fig. 1: Component Locations — Angle View
Fig. 2: Component Locations — Left Side
Fig. 3: Component Locations — Front (Panels removed for clarity)
6
General Information
Model
No.
HD101
HD151
HD201
HD251
HD301
HD401
Quantity of Burners
2
3
4
5
6
8
Table A: Basic Data
Vent Size (in.)
Flue Intake
4
4
5
5
5
6
4
Fig. 4: Air Shutter Adjustment
Fig. 5: Gas Valves
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 recommended initial setting for the temperature control is
125°F.
Safety and energy conservation are factors to be considered 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.
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 setting temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are available, see manual.
Time/Temperature
Relationships in Scalds
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.
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.
120°F
125°F
130°F
135°F
140°F
145°F
150°F
155°F
Time to Produce Serious
Burn
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 B: Time to Produce Serious Burn
8
The temperature of the water in the heater can be regulated by using the optional temperature control. To comply with safety regulations, the optional temperature control will be 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).
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.
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.).
Fig. 6: Temperature Control
WARNING: This product must be installed by a licensed plumber or gas fitter when installed within the Commonweatlh of Massachusetts.
INSTALLATION
ing! There is a hot water scald potential if the thermostat is set too high.
Clearances
Indoor/Closet Installations
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 edition (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).
Heater Side
Minimum Installed
Service Clearance
Front
Rear
Floor*
Top
Left**
Right**
Water Side
24”
2”
0”
24”
12”
6”
24”
*DO NOT install on carpeting.
**When water connections are on other side.
Table C: Clearances — Indoor/Closet Installations
9
2
FRONT VIEW
TOP VIEW
Fig. 7: Minimum Installed Service Clearances — Indoor/Closet Installations
CAUTION: Service clearances less than the minimums may require removal of the heater to service either the heat exchanger or the burners.
hang. Roof water drainage must be diverted away from heaters installed under overhangs.
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 installation. Heaters must not be installed under an overhang unless clearances are in accordance with local installation codes and the requirements of the gas supplier.
Three sides must be open in the area under the over-
Heater Side
Minimum Installed
Service Clearance
Front
Rear
Top
Other Side
Water Side
24”
12”
Unobstructed
36”
36”
Table D: Clearances — Outdoor Installations
Fig. 8: Minimum Installed Service Clearance — Outdoor Installations
10
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 job site.
area per 20,000 BTUH (111 mm 2 per kW) of total input rating of all equipment in the room when the opening is communicating directly with the outdoors 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 mm 2 per kW) of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct(s).
Combustion and Ventilation Air
Combustion Air Filter
3.
In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of a motorized sealed damper to prevent the circulation of cold air through the heater during non-operating hours.
This heater is supplied with an integral combustion air filter. This filter will reduce the amount of particulates passed through the combustion system and heat exchanger but will not protect against chemical inside air contamination (See Appendix). The filter must be checked periodically to verify that adequate combustion air is being supplied to the heater. See the
Maintenance section of this manual for information on checking the filter and establishing service intervals.
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 supplied 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 comply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
Conventional Combustion Air
Supply
U.S. Installations
All Air from Inside the Building
The confined space shall be provided with TWO permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined 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 opening shall have a minimum free area of 1 in.
2 per 1,000
BTUH (22 cm² per kW) of the total input rating of all gas utilization equipment in the confined space, but not less than 100 in.² (645 cm²). One opening shall commence within 6-3/4 in. of the top, and one opening shall commence within 6-3/4 in. of the bottom, of the enclosure. The minimum dimension of air openings shall be not less than 3 in. (8 cm) in any direction.
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
Direct Combustion Air
If outside air is drawn through the intake pipe directly to the unit for combustion:
The confined space shall communicate with the outdoors in accordance with methods 1 or 2 below. 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.
1. Install combustion air direct vent in accordance with the venting section of this manual.
2.
Provide adequate ventilation of the space occupied by the heater(s) by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area shall be at least 1 in.
2 of free
11
1. Two permanent openings, one commencing within 12 in. (30 cm) of the top, and one commencing within 12 in. (30 cm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
a. Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.
4000 BTUH (5.5 cm 2 per kW) of total input rating of all equipment in the enclosure.
2 per b. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in.
BTUH (11 cm 2
2 per 2000 per kW) of total input rating of all equipment in the enclosure.
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 in.
2 per 7000 BTUH (310 mm 2 per kW) up to and including 1 million BTUH, plus
1 in.
2 per 14000 BTUH (155 mm 2 per kW) in excess of 1 million BTUH. This opening(s) shall be either located at or ducted to a point not 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 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 outdoors 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:..
a. 1 2 per 3000 BTUH (7 cm 2 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.
3. For heaters not using a barometric damper in the 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 supply opening(s) having a total cross-sectional area of not less than 1 in.
2 for each 30,000 BTUH (70 mm 2 per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere with the intended purpose of the opening(s) for ventilation air referred to (1). This opening(s) can be ducted to a point not 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.
Installations in Canada
4. Refer to the latest version of the B149 for additional information.
CAUTION: All combustion air must be drawn from the air outside of the building; the mechanical equipment room must communicate directly with the outdoors.
Water Piping
General
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 in.
mm 2 .).
2 (6500
2. For heaters using a barometric damper in the vent system, and when air supply is provided by natu-
12
The heater should be located so that any water leaks will not cause damage to the adjacent area or structures.
CAUTION: This heater requires forced water circulation when the burner is operating. See Table E and Table F 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.
Reversing Water Connections
Follow these instructions to change the water connections from the left-hand side (standard) to the right-hand side.
1.
Disconnect all electrical power from the heater (if applicable).
2.
Label all electrical connections and conduit lines.
This may include the flow switch, low water cut-off probe and/or pump.
3.
Disconnect or isolate the main gas pipe from the heater (if applicable).
Fig. 9: Torque Sequence
4.
Remove both in/out and return header access panels by removing all sheet metal screws.
5.
Remove all plumbing fittings to the header. This will include both inlet and outlet water pipe unions and the pressure relief valve and drain piping.
Relief Valve Piping
6.
Remove limits, control bulbs and/or sensors.
7.
Remove the six flange nuts and the in/out header from the left-hand side.
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.
8.
Remove the six flange nuts and the return header from the right-hand side.
9.
Remove the header stud bolts from each tube sheet.
10. Reverse the headers and stud bolts to the new location.
11. Install NEW red beveled O-rings flush against both tube sheets with the bevel facing outward.
12. Push the header firmly against the O-rings. Install and tighten the flange nuts onto the stud bolts until finger tight.
13. Slowly tighten the flange nuts, starting from the center nut (number 1) in Fig. 9 and working sequentially around the header as indicated.
Torque all nuts to 25 ft/lb. DO NOT OVER-TIGHT-
EN.
14. Re-route the capillary(s), wiring, etc., to the new location, adding thermal paste and shim to the capillary well.
13
Hydrostatic Test Low Temperature System
Unlike many other types of heaters, Raypak heaters do not require hydrostatic testing prior to being placed in operation. The heat exchanger has already been factory-tested and is rated for 160 PSI maximum operating 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 recommends conducting the hydrostatic test before connecting gas piping or electrical supply.
Heater requires minimum inlet temperature of 105°F.
Consult the following sections for piping details.
Temperature & Pressure Gauge
The temperature and pressure gauge is shipped loose for field installation.
Hydronic Heating
Pump Selection
Leaks must be repaired at once to prevent damage to the heater. NEVER use petroleum-based stop-leak compounds.
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.
In order to ensure proper performance of your boiler system, you must install a properly sized pump.
Raypak recommends using a 20°F ΔT as design ΔT.
(ΔT is the temperature difference between the inlet and outlet water when the heater is firing at full rate).
If a ΔT other than 20°F is necessary, see Table E for flow rate requirements.
Pressure Drop in Feet of Head
Feedwater Regulator
2. Make sure constant gauge pressure has been maintained throughout test.
3. Check for leaks. Repair if found.
Raypak recommends that a feedwater regulator be installed and set at 12 psi 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.
Model
No.
Input
MBTUH
HD101 100
HD151 150
HD201 199
HD251 250
HD301 299
HD401 399
Output
MBTUH
10°F ΔT 20°F ΔT 30°F ΔT Min. Flow Max. Flow gpm ΔP (ft) gpm ΔP (ft) gpm ΔP (ft) gpm ΔP (ft) ΔT gpm ΔP (ft) ΔT
84
126
167
210
251
335
17
25
33
44
1.2
2.9
5.2
9.2
13
17
21
25
34
0.7
1.3
2.1
3.0
5.6
14
17
22
0.9
1.3
2.5
*Flow switch will not activate at less than 12 gpm.
NOTE: Basis for minimum flow — 13 gpm or 40°F ΔT maximum flow — gpm, except for header.
13
13
13
13
13
17
0.7
13 44
0.7
20 44
3.3
27 44
0.7
34 44
0.8
40 44
1.4
40 44
8.8
8.8
4
6
8.9
8
9.2
10
9.4
11
9.8
15
Table E: Heater Rates of Flow and Pressure Drops
14
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 10: Single Boiler — Low Temperature Application (Heat Pump) Primary/Secondary Piping
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 11: Dual Boiler—Primary/Secondary Piping
15
Piping—Heating Boilers
All high points should be vented. Purge valves and a bypass valve should be installed. A boiler installed above radiation level must be provided with a low water cut-off device. The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler.
Valves designed to blend water temperatures or reduce water circulation through the boiler should not be used. Raypak boilers are high recovery low mass boilers not subject to thermal shock. Raypak offers a full line of electric sequencers that produce direct reset of boiler water temperature. Refer to the Controls
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 recommended that the piping be insulated.
When designing the water piping system for domestic water applications, water hardness should be considered. Table E indicates the suggested flow rates for soft, medium and hard water. Hardness is specified as grains per gallon.
Air-Separation/Expansion Tank
Three-Way Valves
All boilers should be equipped with a properly sized expansion tank and air separator fitting as shown in the piping diagrams (Fig. 10–12).
Model
No.
HD101
HD151
HD201
HD251
HD301
HD401
Input
MBTUH
Output
MBTUH
Soft (0–4 grains per gallon) Medium (5–15 grains per gallon)
ΔT gpm ΔP MTS SHL ΔT gpm ΔP MTS SHL
Hard* (16–25** grains per gallon)
ΔT gpm ΔP MTS SHL
100
150
199
250
299
399
85
128
169
213
254
339
9 20 1.8
1-1/2 3.8
7 26 3.0
1-1/2
13 20 1.8
1-1/2 3.8
10 26 3.1
1-1/2
17 20 1.9
1-1/2 3.9
13 26 3.2
1-1/2
21 20 1.9
1-1/2 3.9
16 26 3.2
1-1/2
25 20 1.9
1-1/2 3.9
20 26 3.2
1-1/2
34 20 2.0
1-1/2 4.0
26 26 3.3
1-1/2
6.3
6.3
6.4
6.5
6.5
6.6
8
9
4
6
45
45
45
45
9.2
9.2
9.4
9.6
1-1/2
1-1/2
1-1/2
1-1/2
11 45 9.8
1-1/2
15 45 10.3
1-1/2
18.0
18.1
18.2
18.5
18.7
19.1
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 50 feet equivalent length of tubing 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 130°F for scale free operation. For operating temperatures above 130°F, a water softener must be utilized.
Table F: Domestic Water Heater Flow Rate Requirements
16
Fig. 12: Single Heater — Domestic Hot Water with One Storage Tank
Gas Supply
Gas Supply Connection
DANGER: Make sure the gas on which the heater will operate is the same type as specified on the heater’s rating plate.
Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. A pounds to inches regulator must be installed to reduce the natural gas supply pressure to under 10.5 in. WC (13.0 in. WC for propane gas). 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.
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 psi (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 psi. 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.
17
Fig. 13: Sediment Trap Orientation
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.
pressure exceeds 14 in. WC, an intermediate gas pressure regulator, of the lockup type, must be installed.
When connecting additional gas utilization equipment to the gas piping system, the existing piping must be checked to determine if it has adequate capacity.
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.
Gas Pressure Regulator
Gas Supply Pressure
A minimum of 4 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
The gas valve pressure regulator(s) on the heater are nominally preset at 3 in. WC for natural gas, and 10.0
in. WC for propane gas manifold pressure. The pressure at the gas valve outlet tap, measured with a manometer, while in operation should be 3.0 in. ± 0.3
in. WC (HI), and 1.0 in. ± 0.1 WC (LO) for natural gas and 10.0 in. ± 0.1 in. WC (HI), and 3.5 in. ± 0.1 in. WC
(LO) for propane gas. If an adjustment is needed, turn the adjustment screw clockwise to increase pressure or counter-clockwise to decrease pressure.
Model
No.
Input
(KBTUH) N
100
3/4”
P N
105 385 340
1”
P
1-1/4”
N P
1-1/2”
N P
HD101
HD151
HD201
HD251
150
199
250
50 180 160 530 600
30 95 95 355 360
20 50 60 230 240
HD301
HD401
299
399
15
5
35
20
45
25
170
80
170
100
550
365
360
210
Natural gas – 1,000 BTUH per ft 3 , .60 specific gravity at 0.5 in. WC pressure drop
Propane gas – 2,500 BTUH per ft 3 , 1.50 specific gravity at 0.5 in. WC pressure drop
Table G: Maximum Equivalent Pipe Length
18
Electrical Power Connections
Installations must follow these codes:
· National Electrical Code and any other national, state, provincial or local codes or regulations having 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, less than 12 AMPS.
The voltage 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 connected 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.
Surge Protection
Check the Power Source
AC = 108 Volts AC Minimum, 132 Volts AC MAX
AB = 108 Volts AC Minimum, 132 Volts AC MAX
BC = < 1 Volt AC
Fig. 14: Check Power Source
Making the Electrical Connections
Refer to Fig. 14 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.
It is strongly recommended that all individually-powered control modules and the heater should be supplied from the same power source.
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.
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 connections or components.
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 vulnerable to damage from voltage and amperage fluctuations in the power supply. All sensitive control components should be protected by a suitable commercial-grade surge protection device.
4. Provide an external surge suppressor capable of maintaining system integrity.
5. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code.
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
Electrical Connections — Domestic
Hot Water
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.
STAGE 1
CONNECTION
SINGLE
STAGE
TANKSTAT
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.
ATTACH STAGE 1 CONNECTIONS
ON HEATER TO THE SINGLE STAGE
TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.
Fig. 15: Single Stage Tankstat
2-STAGE
TANKSTAT
Installer action is required to electrically enable your Hi
Delta heater to operate after making the power connections. 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.
For operation with a Temp-Tracker controller, refer to the Temp-Tracker Installation and Operating
Instructions, Raypak Catalog number 5000.66 (P/N
241177).
STAGE 1
CONNECTION
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.
STAGE 2 CONNECTION OR
STAGE 1 CONNECTION
OF HEATER 2
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.
Fig. 16: 2-Stage Tankstat
20
Heater must be electrically grounded in accordance with NEC and C22.1(in Canada).
See Table H for appliance category requirements for the Hi Delta.
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.
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.
Venting
Determination of Appliance
Category for Venting Purposes and
Venting Arrangements
General
CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the heater.
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.
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.
Category I. A heater which operates with a non-positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent.
Category II. A heater which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent.
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.
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.
21
Combustion Air
Supply
Exhaust
Configuration
Vertical Natural
Draft Venting
Venting Category
Certified
Appliance Material
I
Type B or any
Category I Venting
System*
Combustion Air
Inlet Material
From Inside
Building (Non-Direct
Venting) Horizontal
Thru-wall
Venting
Vertical Venting
III
I
Stainless Steel
(Gas Tight)
Type B or any
Category I Venting
System*
From Outside
Building (Direct
Venting)
Horizontal
Thru-wall
Venting
III
Stainless Steel
(Gas Tight)
Galvanized Steel
PVC
ABS
CPVC
*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 required.
NOTE: During winter months check the vent cap and make sure no blockage occurs from build up of snow.
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 installed in horizontal or vertical runs of vent pipe as necessary. Installation in a bull-head tee is acceptable as shown in the NFGC.
1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.
2. Give special attention to the location of the vent termination 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 operation, to maintain –0.01 to –0.08 in. WC, 12 in. from the heater outlet, at all firing conditions.
3. Gases may form a white vapor plume in winter.
The plume could obstruct a window view if the termination is installed in close proximity to windows.
Support of Vent Stack
The weight of the vent stack or chimney must not rest on the heater vent connection. Support must be provided in compliance with applicable codes. The vent should also be supported to maintain proper clearances from combustible materials.
4.
Prevailing winds, in combination with below freezing temperatures, can cause freezing of condensate and water/ice build-up on buildings, plants or roofs.
5.
The bottom of the vent terminal and the air intake shall be located at least 12 in. above grade, including normal snow line.
Use insulated vent pipe spacers where the vent passes through combustible roofs and walls.
6. Un-insulated single-wall metal vent pipe shall not be used outdoors on cold climates for venting gas utilization equipment.
22
7. Through-the-wall vents for Category II and IV appliances and non-categorized condensing appli-
Fig. 17: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
A
B
C
D
U.S. Installations
1
Clearance above grade, veranda, porch, deck, or balcony
1 ft (30 cm)
Clearance to window or door that may be opened
Clearance to permanently closed window
Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the terminal
4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening
*
5 ft (1.5m)
Clearance to unventilated soffit
Clearance to outside corner
*
*
Canadian Installations
1 ft (30 cm)
3 ft (91 cm)
*
*
2
E
F
*
*
G
H
I
J
K
Clearance to inside corner
Clearance to each side of center line extended above meter/regulator assembly
Clearance to service regulator vent outlet
Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance
Clearance to mechanical air supply inlet
6 ft (1.83m)
*
*
4 ft (1.2m) below or to side of opening; 1 ft (30 cm) above opening
3 ft (91 cm) above if within
10 ft (3m) horizontally
*
3 ft (91 cm) within a height
15 ft above the meter/regulator assembly
6 ft (1.83m)
3 ft (91 cm)
6 ft (1.83m)
L
M
Clearance above paved sidewalk or paved driveway located on public property
Clearance under veranda, porch, deck or balcony
7 ft (2.13m)
*
7 ft (2.13m) t
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
ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. Where local experience indicates that condensate is a problem with Category
I and III appliances, this provision shall also apply.
g) The vent terminal of a direct vent appliance with an input over 50,000 BTUH per hour shall require a 12-inch vent terminal clearance.
h) Terminate vent at least one (1) foot above grade, including normal snow line.
8. Locate and guard vent termination to prevent accidental contact by people or pets.
i) Multiple direct vent installations require a four (4) foot clearance between vent caps.
Installations in Canada
9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area.
Refer to latest edition of CAN/CGA-B149.
10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations.
A vent shall not terminate:
11. Locate or guard vent to prevent condensate from damaging exterior finishes. Use a rust resistant sheet metal backing plate against brick or masonry surfaces.
a) Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings.
b) Less than 7 ft. (2.1m) above a paved sidewalk or paved driveway located on public property.
12. 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.
US Installations d) Above a meter/regulator assembly within 3 ft.
(914mm) horizontally of the vertical center-line of the regulator.
Refer to latest edition of the National Fuel Gas Code.
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, four (4) feet horizontally, or one (1) foot above any door, window or gravity air inlet to the building.
f) Less than 1 ft. (305mm) above grade level.
b) The vent must not be less than seven (7) feet above grade when located adjacent to public walkways.
g) Within the 3 ft. (914mm) 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.
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 horizontally, and in no case above or below unless four (4) feet horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment.
(ii) the distance between the top of the vent termination 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 adjacent walls.
f) DO NOT terminate vent closer than five (5) feet below roof overhang.
24
Venting Installation Tips
Support piping:
· horizontal runs- at least every five (5) feet.
· vertical runs - use braces:
· under or near elbows
Follow items listed below to avoid personal injury or property damage.
on, Venting of Equipment, of the latest edition of
NFGC, or in Canada, B149 Installation Code for Gas
Burning Appliances and Equipment, or applicable provisions of local building codes.
· Cut nonmetallic intake pipe with fine-toothed hacksaw.
· 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 nonmetallic intake pipe or fittings.
To make metallic vent joints:
· Do not install seams of vent pipe on bottom of runs.
· 100% Seal all joints and seams with high temperature silicone sealant.
WARNING: Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness, corrosion or deterioration.
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)
Model
No.
Appliance
Category
Certified
Venting
Material
Minimum
Recommended
Vent Size (inches)
Min./Max. Venting Length without
Barometric Damper (feet)**
Min.
Max.
Air Inlet Max.
Length (feet)
HD101
HD151
HD201
HD251
HD301
I
Type B or
Equivalent
4
5
6
(HD201) 6
(HD251) 6
(HD301) 11
8
25
HD401 6
**Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the NFGC for further details. (ANSI Z223.1)
Table J: Natural Draft Vertical Venting
100
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 negative draft must be within the range of –0.01 in. to
–0.08 in. WC as measured 12 in. from the appliance flue outlet to ensure proper operation. Vent material must be listed by a nationally recognized test agency.
The maximum and minimum venting length for
Category I appliance shall be determined per the latest edition of the NFGC (U.S.) or B149 Installation
Code (Canada).
Natural Draft Vertical Venting with
Common Venting System, Category I
Appliance Only
Manifolds that connect more than one heater to a common 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 diameter of vent flue pipe should be sized according 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 HD101 and HD151, 5” for HD201,
HD251 and HD301, and 6” for HD401.
NOTE: Vent Adapter will have to be used to connect
B vent to the unit.
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.
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 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 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.
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 followed 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.
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 terminate 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 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 consistent 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 common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common vent system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate 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
Fig. 19: Horizontal Thru-Wall Venting (Category III) each appliance. Adjust thermostat so appliance will operate continuously.
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 system 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.
g) Any improper operation of the common venting 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 system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in Appendix G in the NFGC (US) and Appendix B of the B149
Installation Code (Canada).
Model
No.
Appliance
Category
Certified
Venting
Material
HD101
HD151
HD201
HD251
HD301
HD401
III
Stainless
Steel
(Gas Tight)
Vent Size
(inches)
4
5
6
Table K: Horizontal Thru-Wall Venting (Category III)
Max. Venting
Length (feet)
100
27
Horizontal Thru-wall Venting
System (Category III) Installation b) The vent be insulated through the length of the horizontal run.
These installations utilize the heater-mounted blower to vent the combustion products to the outdoors.
Combustion air is taken from the space and the vent is installed horizontally through the wall to the outdoors.
Adequate combustion and ventilation air must be supplied in accordance with the NFGC or, in Canada, the
B149 Installation Code.
Horizontal Thru-wall Direct Vent
Termination
The flue exhaust direct vent cap MUST be mounted on the exterior of the building. The direct vent cap cannot be installed in a well or below grade. The direct vent cap must be installed at least one (1) foot above ground level and above normal snow levels.
The total length of the horizontal thru-wall exhaust vent system should not exceed one hundred (100) feet in length. If horizontal run exceeds 100 feet, an appropriately sized extractor must be used. Each elbow used is equal to ten (10) feet of straight pipe. This will allow installation in one of the four following combinations.
· 100’ of straight flue pipe.
· 90' of straight flue pipe and one elbow.
· 80' of straight flue pipe and two elbows.
· 70' of straight pipe and three elbows.
· 60' of straight pipe and four elbows.
Multiple direct vent caps MUST NOT be installed with one combustion air inlet directly above a direct vent cap. This vertical spacing would allow the flue products 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 should be installed in the same horizontal plane with a three (3) foot clearance from the side of one vent cap to the side of the adjacent vent cap(s).
The vent cap is not considered in the overall length of the venting system. The vent must be installed to prevent the flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight.
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.
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.
WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.
The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is recommended 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.
The flue exhaust direct vent cap must be furnished by the heater manufacturer in accordance with its
listing. 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 the vent manufacturers installation instructions carefully.
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 condensate trap must be installed per applicable codes.
28
Fig. 20: Direct Vent Horizontal Thru-Wall Venting (Category III)
Model
No.
HD101
HD151
HD201
HD251
HD301
HD401
Appliance
Category
III
Certified
Venting
Material
Vent Size
(inches)
Max.
Venting
Length
(feet)
Combustion
Air Intake
Pipe
Material
Stainless
Steel
(Gas Tight)
4
5
100,
4 Elbows
Max.
Galvanized
Steel
PVC
ABS
CPVC
6
Table L: Horizontal Thru-Wall Venting
Air Inlet
Size
(inches)
4
Max. Air
Intake
Length
(feet)
100
29
Fig. 21: Direct Vent—Vertical Venting (Category I)
Model
No.
Appliance
Category
Certified
Venting
Material
Vent
Size
(inches)
Min./Max. Vertical
Venting Height (feet)
Min.
Max.
Combustion
Air Intake
Pipe
Material
Air Inlet
Size
(inches)
HD101
HD151
HD201
HD251
HD301
HD401
I
Type B
Equivalent
4
5
6
6
(HD201) 6
(HD251) 6
(HD301) 11
8
25*
Galvanized
Steel
PVC
ABS
CPVC
4
*Over 25 feet, use single acting barometric damper. Consult the factory for additional information.
Table M: Vertical Venting
Max. Air
Intake
Length
(feet)
100
30
Vertical Direct Vent System
Installation blockage from snow. The vent cap must have a minimum 3 foot clearance from the air inlet opening.
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 a thermal driving head that expels the exhaust gases from the flue. The negative draft must be within the range of -0.01 to -0.08 in. WC as measured 12 in. from the appliance outlet to ensure proper operation. The vent material must be in accordance with the above instructions for vent materials. Vent material must be listed by a nationally recognized test agency.
Outdoor Installation
Outdoor models are self-venting when installed with the factory-supplied vent assembly and air intake cover and require no additional vent piping. This special vent assembly is provided with the heater in accordance with CSA requirements. It must be installed directly on the heater. See the Venting section for correct clearances.
The maximum and minimum venting length for
Category I appliance shall be determined per the latest edition of the NFGC (U.S.) and B149 Installation
Code (Canada).
Care must be taken when locating the outdoor unit because the flue gases discharged from the vent assembly can condense as they leave the assembly.
Improper location can result in damage to adjacent structures or building finish. For maximum efficiency and safety, the following precautions must be observed: The connection from the appliance exhaust vent to the 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 and, where necessary, have means provided for 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 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) Outdoor models must be installed outdoors and must use the outdoor vent assembly and air intake cover supplied by the manufacturer.
b) Periodically check venting system. The heater’s 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.
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 consistent with the NFGC, or in Canada, the B149
Installation Code. 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) Do not locate adjacent to any window, door walkway, 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.
d) Install above grade level and above normal snow levels.
e) Vent must be at least 3 feet above any forced air inlet located within 10 feet.
f) Adjacent brick or masonry surfaces must be protected with a rust-resistant sheet metal plate.
g) Multiple Outdoor Vent installations require a four
(4) feet clearance between vent assemblies.
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
NOTE: Condensate can freeze on the vent assembly. Frozen condensate on the vent assembly can result in a blocked flue condition.
The vent assembly must be furnished by the heater manufacturer in accordance with its listing.
31
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.
Modulating Temperature
Control (Optional)
This heater can be equipped with a Raypak modulating temperature control. For operation with this control, refer to the Temp-Tracker Installation and Operating
Instructions, Raypak Catalog number 5000.66 (P/N
241177).
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.
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 deenergize the equipment before servicing.
Fig. 23: Modulating Temperature Control
High Limit (Manual Reset)
Ignition Control Module
The interrupted proved ignition device conserves energy. 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 energized, eliminating the fuel costs of maintaining a constant pilot.
The heater is equipped with a manual reset high limit temperature device. If the optional adjustable limit is used, push the reset button and adjust the setting to
30°F or 40°F above desired operating temperature.
To ensure safe operation, the gas valve cannot open until the igniter is verified as capable of igniting the gas. The ignition module is an electronic device which closes the main gas valve within 8/10 of a second whenever the flame is interrupted. The main burner is automatically lit when the device is powered and prepurged. The unit performs its own safety check.
Fig. 22: Ignition Module
32
Fig. 24: Manual Reset High Limit
High Limit — Auto Reset
(Optional)
This heater may be equipped with an optional adjustable auto reset high limit temperature device.
The optional adjustable auto reset high limit is located behind the front panel (see Fig. 3). Adjust the setting to approx. 20°F (10°C) above desired outlet temperature.
cient gas pressure is present for proper regulator performance. The low gas pressure switch automatically shuts down the heater if gas supply drops below the recommended setting of 4.0 in. WC for natural gas, and 9.0 in. WC for propane gas.
The high gas pressure switch (optional) connection mounts down-stream of the gas valve. If the gas pressure regulator fails, the high gas pressure switch automatically shuts down the burner. The high gas pressure switch automatically shuts down the heater if gas manifold pressure rises above the recommended setting of 4.0 in. WC for natural gas, and 10.5 in. WC for propane gas.
Fig. 25: High Limit — Auto Reset (Optional)
Flow Switch
Dual-purpose control shuts off heater in case of pump failure or low water flow. Mounted and wired in series with the main gas valve.
NOTE: Flow switch will not operate if flow is less than 12 gpm.
Fig. 27: Gas Pressure Switch
Low Water Cut Off (Optional)
The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets.
Fig. 26: Flow Switch
High and Low Gas Pressure
Switches (Optional)
The low gas pressure switch (optional) connection mounts upstream of the gas valve to ensure that suffi-
33
Fig. 28: Low Water Cut Off
WIRING DIAGRAM—MODELS HD101–HD401
34
HD Troubleshooting
Does the main power switch provide power to the green power LED?
NO
Check the switch, transformer and/or line voltage
Step 1
Step 2
YES
YES
Is Disable connection intact?
Is there a Call For Heat?
YES
NO
NO
Is temperature controller installed?
NO
Is there 120VAC at the pump or pump relay contacts? Step 3
Does the Pump come on?
YES
Reattach.
NO
NO
Install.
Check and correct power connections at main terminal block, circuit breaker panel or pump relay.
Step 4
Does the combustion air blower come on?
YES
NO
Is there 120VAC at the blower or blower relay contacts 1 and 5?
NO
Check and correct power connections at main terminal block, ignition module, circuit breaker panel or blower relay.
Step 5 Is 24VAC at the NC side of the air pressure switch?
YES
NO
Is blower pressure setting correct?
YES
NO
Correct the blower shutter setting.
Replace air pressure switch.
Step 6
Is 24VAC at PS on ignition module?
Is connecting plug secure?
YES
Step 7 Does igniter prove? NO
NO Correct wiring.
Is Amp draw during heatup for HSI greater than
3.1 Amps?
NO Replace HSI
YES
YES Is air switch bouncing?
NO
YES
Step 8
Is the flame sensor signal to the ignition module greater than 1 uA DC? NO
Is inlet gas supply pressure correct?
YES
YES
Step 8 Is the unit running?
YES NO
Step 9 The unit is okay
Is manifold gas pressure correct?
YES
Call our Technical Service Department
1-800-947-2975 Outside California
1-800-627-2975 Inside California
NO
NO
Correct inlet gas supply pressure
Replace gas valve
Adjust manifold gas pressure.
35
PRE-START-UP
NOTE: Digital manometers are not recommended.
Filling System-Heating Heaters
Preparation for Start-Up
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.
WARNING: Do not turn on gas at this time.
Check Power Supply
Domestic Hot Water Heaters
Purge all air from system before lighting heater. This can be normally be accomplished by opening a downstream valve.
Inspect Venting System:
2. Ensure vent terminations are installed per code and are clear of all debris or blockage.
Pre-Start-Up Check
Fig. 29: Check Power Source
1. Check all vent pipe connections and flue pipe material.
With volt meter at incoming power check voltage between:
Hot - Common (~120 VAC)
Hot - Ground (~120 VAC)
Common - Ground (< 1 VAC)
1. Verify heater is filled with water.
2. Check system piping for leaks. If found, repair immediately.
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.
3. Vent air from system. Air in system can interfere with water circulation.
4. Purge air from gas line up to heater.
Attach Manometers to Measure
Pressures
INITIAL START-UP
Tools Needed
• One 8–0–8, 16” scale manometer
• Two 6–0–6, 12” scale manometers
• 7/16” open end wrench
• 1/2” open end wrench
• Screwdriver (Standard & Phillips)
• 3/8” open end wrench
• Multi-meter
• Attach 16" scale manometer to the main gas shutoff valve supply 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 the tee near the blower housing.
• 3/32” Allen wrench (Honeywell gas valve)
• 5/32” Allen wrench (Invensys gas valve)
• #10 Torx driver w/center hole (Invensys gas valve)
36
37
Check the Gas Supply Pressure 0.3 in. WC (HI) and 1.0 in. ± 0.1 in. WC (LO) for natural gas or 10.0 in. ± 0.1 in. WC (HI), and 3.5
in. ± 0.1 in. WC (LO) for propane gas.
1. Slowly turn on main gas shut-off valve.
2. Read the gas supply pressure from the manometer; minimum supply pressure is 4 in. WC, recommended supply is 7 in. WC for natural gas
(minimum 11.0 in. WC for LP gas).
6. If the pressure reading differs by more than the tolerance given, adjust the gas valve accordingly.
See gas valve adjustment section below for instructions.
3. If pressure is > 14 in. WC, turn off the valve.
Gas Valve Adjustment
4. Check if the service regulator is installed and/or adjust the service regulator.
Firing Stage Natural Gas Propane Gas
Start-Up
HI or ON/OFF 2.9–3.1 in. WC 9.9–10.1 in. WC
Blower Adjustment
LO 0.9–1.1 in. WC 3.4–3.6 in. WC
1. Connect manometer to the plugged side of the tee.
Table N: Manifold Pressures
Honeywell Gas Valve
2. Close manual firing valve.
3. Turn power on.
1.
While the heater is running, remove plastic cap located behind ON/OFF knob.
4. Check manometers attached to fan pressure switch. This (LO) speed pressure reading should be:
–0.2 in. WC for models HD101 and HD151.
–0.3 in. WC for models HD201–HD401.
If not, adjust the air shutter on the blower to attain the correct value. (See air shutter adjustment page 7).
2. Locate the HI or LO screw to adjust.
3. Using a small flat screwdriver, turn clockwise to increase and counterclockwise to decrease manifold pressure. See nominal gas valve manifold settings in Table N above.
4. Replace plastic cap when pressure is set.
5. Turn power off.
White Rodgers Gas Valve
6. Reinstall rubber plug on tee.
Main Burner Adjustment
1. While the heater is running, locate the HI or LO cap located adjacent to ON/OFF switch.
2. Remove the appropriate cap.
1. Turn off unit.
2. Open manual firing valve.
3. Turn on the unit, wait 15 seconds, and the igniter should glow. There’s a sight glass to check igniter at both ends of the heater. Gas valve should be open after 45 seconds.
3. Using a flat screwdriver, turn clockwise to increase and counterclockwise to decrease manifold pressure. See nominal gas valve manifold settings above.
4. Replace cap(s) when pressure is set.
4. If burner does not light on first trial. It will retry, up to 3 times.
Invensys (Model HD401 Natural
Only)
5. Main burner ignition – check manifold gas pressure at gas valve manifold pressure tap. (See gas valve details on page 7) This should read 3.0 in. ±
1. Turn heater off.
38
2. Locate and remove the Torx tamper resistant screw. (Shown in Fig. 30)
3. Carefully remove 2-stage solenoid.
4.
Skip to Step 9 for LO-fire adjustment only.
5. Locate and remove Lo-fire adjustment cap.
6. Carefully remove the spring & weight.
1. Turn off gas supply at the appliance service level.
2. Remove the pressure regulator cover assembly.
3. Remove the existing stem/spring assembly.
4. Insert the replacement stem/spring assembly.
7. Using an allen wrench, turn clockwise to increase and counterclockwise to decrease the HI-fire manifold pressure. Heater will not run while adjusting
HI-fire pressure.
5. Replace the pressure regulator cover assembly and tighten screws.
6. Mount conversion labels on the gas valve.
8. Carefully place the spring & weight back in before replacing LO-fire adjustment cap.
9. For LO-fire adjustment, tighten the cap to increase the pressure, loosen to decrease.
10. When correct settings are set, replace the solenoid and tamper screw in place.
Fig. 31: Gas Type Conversion on Honeywell Valve
Fig. 30: Gas Valve Adjustment (Invensys Valve)
Gas Type Conversion on Valve
WARNING: Burner orifices must be changed when changing gas type.
NOTE: Model HD401 requires replacement of valve.
39
Safety Inspection
• Replace main gas manifold adjustment screw cap.
• Check all thermostats and high limit settings.
• During the following safety checks leave manometers 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
SS with all other equipment running.
• 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 (optional) must be set at 3.5 in. WC for natural gas and 10.5 in. WC for LP gas.
• High gas pressure switch (optional) at 1 in. WC above manifold pressure.
• Insert ignition control lockout tests as safety check.
Follow-Up
• Safety checks must be recorded as performed.
• Turn unit on.
· Turn on manual gas valve. Turn power on.
· Set thermostat to call for heat.
· When the unit is in operation. Disconnect combustion air blower pressure switch, burner should go off immediately.
· Wait 5 minutes.
· Reconnect combustion air pressure switch, burner should reignite after pre-purge time delay.
After main burner ignition:
• Check Manometer(s) for proper reading(s).
• Cycle unit several times and recheck readings.
• Re-analyze with unit running record or print results.
• Remove all Manometers and replace hose, replace all gas pressure caps.
• Check for gas leaks one more time.
POST START-UP CHECK
4. Air purged from gas piping? Piping checked for leaks?
10. To restart system, follow lighting instructions in the
Operation section.
11. High limit control set to design temperature requirements of system? For multiple zones: flow adjusted as required in each zone?
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.
Check off steps as completed:
1. Heater and heat distribution units or storage tank filled with water?
13. Observed several operating cycles for proper operation?
2. Automatic air vent, if used, open two full turns during venting procedure?
14. Set room thermostat or tankstat to desired temperature?
3. Air purged from system?
15. Reviewed all instructions shipped with this heater with owner or maintenance person, returned to envelope and given to owner?
Air Filter Inspection/Removal
5. Followed start-up procedure for proper start-up?
1. Turn power off.
6. Is burner flame visible?
7. Test safety controls: If heater is equipped with a low water cut-off or additional safety controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when controls are tested. When safety devices are restored, burners should reignite after pre-purge time delay.
2. Locate the Air Filter panel below the air intake duct.
8. Test limit control: While burner is operating, move indicator on high limit control below actual heater water temperature. Burner should go off while blower and circulator continue to operate. Raise setting on limit control above heater water temperature and burner should reignite after pre-purge time delay. NOTE: This test doesn’t apply to fixed setting high limits.
9. Test ignition system safety device:
Fig. 32: Locate the Air Filter Panel
40
3. Remove the (4) screws holding the panel in place.
Heat Exchanger Removal
Refer to Fig. 35 for the following procedure.
1. Before beginning, make sure the heater is cool to the touch. Shut water, gas and electricity off, close valves and relieve pressure, then remove the relief valve. Remove side inspection panels.
2. Remove screw behind inspection panels holding the jacket top down.
3. Remove the front panel. Remove two additional screws holding the jacket top to the top support.
4. Disconnect vent pipe from the flue exhaust and set aside.
5. Remove jacket top, then disconnect vent switch hose.
Fig. 33: Remove the Screws and Panel
4. Pull the air filter out for inspection. Replace if necessary.
6. Remove two rows of screws holding the flue collector to the combustion chamber. Remove two additional screws located on the front combustion panel. Cut any silicone holding the flue collector and heat exchanger in place.
7. Carefully lift and remove the flue collector.
8. Lift heat exchanger straight up being careful not to damage the refractory.
9. Reverse the above procedure to re-install. Make sure sufficient high temperature silicone sealant
(RTV) is placed along the vertical sides of the tube sheet and flue collector.
Fig. 34: Inspect the Air Filter
5. When replacing, note the direction of the air flow defined on the side of the filter. The arrow should be pointing downward.
6. Replace the panel and screws before operating.
41
JACKET TOP
REMOVAL
FLUE COLLECTOR
REMOVAL
ACCESS
PANEL
REMOVAL
ACCESS
PANEL
REMOVAL
Fig. 35: Heat Exchanger Removal
MAINTENANCE
heater operating efficiency. Maintenance as outlined below may be performed by the owner.
Suggested Minimum
Maintenance Schedule:
Yearly (Beginning of each heating season):
Regular service by a qualified service agency and maintenance must be performed to ensure maximum
1. Annual service call by qualified service agency.
42
2. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal.
2. Visually inspect burner flame.
3. Visually inspect venting system for proper function, deterioration or leakage.
3. Visually inspect venting system for proper function, deterioration or leakage.
4. Check air vents for leakage.
4. Check that heater area is free from combustible materials, gasoline, and other flammable vapors and liquids.
Quarterly:
1. Check relief valve. Refer to manufacturer’s instructions on valve.
5. Check for and remove any obstruction to the flow of combustion or ventilation air to heater.
2. Test low water cut-off, if used. Refer to manufacturer’s instructions.
6. Follow pre-start-up check in the Initial Start-up section.
3. Check the air filter; replace if necessary.
7. Visually inspect burner flame. Should see light blue flame. Visually inspect hot surface igniter for damage, cracking or debris build-up.
APPENDIX
8. Check operation of safety devices. Refer to manufacturer’s instructions.
Inside Combustion Air
Contamination:
9. Follow oil-lubricating instructions on circulator (if required). Over-oiling will damage circulator.
Water-lubricated circulators do not need oiling.
10. To avoid potential of severe burn, DO NOT REST
HANDS ON OR GRASP PIPES. Use a light touch
- return piping will heat up quickly.
All heaters experience some condensation during start-up. The condensate from flue gas is slightly 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.
11. Check blower and blower motor. Clean and oil as necessary.
12. Check for piping leaks around circulators, relief valves and other fittings. Repair, if found. DO NOT use petroleum based stop leak.
The heater can use special corrosion-resistant nonmetallic intake vent material. You may, however, choose to use outside combustion air for one or more of these reasons:
13. Check air filter and replace if necessary.
Daily:
1. Check that heater area is free from combustible materials, gasoline, and other flammable vapors and liquids.
• 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.
2. Check for and remove any obstruction to the flow of combustion or ventilation air to heater.
Products causing contaminated combustion air:
• spray cans containing chloro/fluorocarbons
• permanent wave solutions
Monthly:
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.
• chlorine-based swimming pool chemicals
•
• calcium chloride used for thawing sodium chloride used for water softening
43
• paint or varnish removers
• 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.
Areas causing contaminated combustion air:
• dry cleaning/laundry areas and establishments
• metal fabrication plants
• refrigeration repair shops
• photo processing plants
• auto body shops
• plastic manufacturing plants
• furniture refinishing areas and establishments
• new building construction
Check for areas and products as listed above before installing heater. If found:
• remove products permanently, OR
• provide outdoor combustion air.
44
45
46
47
www.raypak.com
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468
Litho in U.S.A.
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