Raypak 302A-902A manual Relief Valve Piping Hydrostatic Test, Cold Water Operation

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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.

6.Remove limits, control bulbs and/or thermocou- ples.

7.Remove the eight flange nuts and the in/out head- er from the left-hand side.

8.Remove the eight flange nuts and the return head- er from the right-hand side.

9.Reverse the headers to the new location.

10.Install NEW red beveled O-rings flush against both tube sheets with the bevel facing outward.

11.Push the header firmly against the O-rings. Install and tighten the flange nuts onto the stud bolts until finger tight.

12.Slowly tighten the flange nuts, starting from the center nut (number 1) in Fig. 9 and working se- quentially around the header as indicated. Torque all nuts to 25 ft/lb. DO NOT OVER-TIGHTEN.

13.Re-route the capillary(s), wiring etc. to the new location, adding thermal paste and shim to the capillary well.

Fig. 9: Torque Sequence

Relief Valve Piping

WARNING: Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur. Refer to local codes.

Hydrostatic Test

Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in opera- tion. The heat exchanger has already been factory- tested and is rated for 160 psi operating pressure. However, Raypak does recommend hydrostatic test- ing of 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 anti-freeze. Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply.

Leaks must be repaired at once to prevent damage to the heater. NEVER use petroleum-based stop-leak compounds.

To perform hydrostatic test:

1.Connect fill water supply. With bleed valve open, fill heater with water. When water flows from bleed valve, shut off water. Close bleed valve. Carefully fill the rest of the system, making sure to eliminate any entrapped air by using high-point vents. Close feed valve. Test at standard operating pressure for at least 24 hours.

2.Make sure constant gauge pressure has been maintained throughout test.

3.Check for leaks. Repair if found.

Cold Water Operation

CAUTION: Damaging internal condensation may occur if the heater inlet water temperature does not exceed 105ºF (41ºC) within 7 minutes of start-up.

A heater operated with an inlet temperature of less than 105ºF (41ºC) must have a manual bypass or an approved low-temperature operation system to pre- vent problems with condensation. A manual bypass, shown in Fig. 15, must be piped into the system at the time of installation. This piping is like a primary/sec- ondary boiler installation with a bypass acting as the secondary boiler piping. Raypak strongly recommends that thermometer(s) be placed into the heater piping next to the in/out header to facilitate temperature adjustment. Inlet water temperatures below 105ºF (41ºC) can excessively cool the products of combus- tion, resulting in condensation on the heat exchanger and in the flue.

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Contents Installation and Operating Instructions Page Contents Pay Attention to These Terms Ratings and Certifications Before InstallationProduct Receipt Model IdentificationComponent Locations Back Component LocationsGeneral Information Model # Burners per Stages Fire at ValveModel # Burners Valve Firing Per Valve Staging General Safety Time/Temperature Relationships in ScaldsWater Time to Produce Serious Temp Burn Stacking InstallationInstallation Codes Equipment BaseIndoor Installations Outdoor InstallationsClearances Installations1 Canadian Installations2 Direct Vent Combustion and Ventilation AirIndoor Units Reversing Air FilterAll Air from Inside the Building InstallationsConventional Combustion Air Supply TruSeal Combustion AirReversing Water Connections Canadian InstallationsWater Piping GeneralCold Water Operation Relief Valve Piping Hydrostatic TestMin. Flow Max Flow Gpm Temperature & Pressure GaugeHydronic Heating Pump SelectionThree-Way Valves Pressure Drop in Feet of Head Feedwater RegulatorPiping Air-Separation/Expansion TankPool Heating Potable Water and Space HeatingWinterizing Your Heater Automatic Chlorinators and Chemical FeedersTotal Dissolved Solids Gas SupplyPool/Spa Water Chemistry Water Hardness PH of WaterGas Supply Connection Reversing Gas Supply ConnectionTable J Maximum Equivalent Pipe Length Field-Connected Controllers Electrical Power ConnectionsCheck the Power Source Gas Supply PressureMaking the Electrical Connections Field Wiring ConnectionWiring Connections Appliance Categories VentingStainless Steel Support of Vent StackVent Terminal Location Direct Venting Horizontal ThroughInstallations Canadian InstallationsChanging the Flue Outlet Natural Draft Vertical Venting Category Venting Installation TipsVenting Configurations InstallationMin Max TerminationCommon Venting System Model Venting Vent Size Height Intake Pipe Max. LengthHorizontal Through-the-Wall Venting Category Horizontal Through-the-Wall Venting CategoryDirect Vent Horizontal Through- the-Wall Max. Length Venting Vent Size Equivalent Intake PipeMaterial Direct Vent Vertical Outdoor Installation ControlsFreeze Protection Models 302A, 402A, 502A, 652A, 752A and 902A Heater Sequence of OperationAuto Reset High Limit Red Auto reset option External Lights Color IndicationInternal Lights Color Indication Code Condition Ignition ModuleOperating Control High Limit Manual ResetFlow Switch High and Low Gas Pressure SwitchesHigh/Low Gas Pressure Switch Direct Venting Horizontal Through AL29-4C 87%-Efficiency Boilers Special Instructions Water PipingVenting Appliance Categories Model 10F 20F 30F Min. Flow Max Flow GpmVertical Venting Category Vent Terminal LocationCondensate Management 40’ 752AE Combustion Air 902AE 30’ 80’ Certified Maximum Combustion Air Air Inlet Model VentingMaterial Vent Length 100’ DuctedDirect Vent Horizontal Through- the-Wall 100’ 40’ 752A 902A Direct Vent VerticalCertified Vertical Venting Combustion Air Air Inlet 302A 100’ 402A Galvanized Steel 502A 75’ Category 25’Wiring Diagram Pre Start-up START-UPBlower Adjustment Main Burner AdjustmentStart-Up Pilot Turn-Down Test Safety InspectionLeak Test Procedure Dual-Seat Gas Valves Follow-UpLeak Test Post Start-Up CheckOperation Lighting InstructionsTo Turn Off Gas To Appliance Step TroubleshootingMaintenance Suggested Minimum Maintenance SchedulePreventive Maintenance Schedule As Required WeeklySemi-Annually AnnuallyInside Air Contamination AppendixLimited Parts Warranty HI Delta Types H and WH Limited Parts Warranty HI Delta Type P

302A-902A specifications

The Raypak 302A-902A is a highly regarded pool and spa heater, known for its efficiency and reliability in delivering warmth to residential and commercial aquatic applications. This heater stands out due to its robust design, advanced technology, and user-friendly features.

One of the key characteristics of the Raypak 302A-902A is its dual fuel capability, which means it can run on either natural gas or propane. This flexibility allows users to choose their preferred fuel type, contributing to operational efficiency and cost-effectiveness. With a BTU output ranging from 302,000 to 902,000, the Raypak heater is capable of quickly heating large volumes of water, making it ideal for pools, spas, and hot tubs.

The heater incorporates advanced technology such as a stainless steel heat exchanger, which not only ensures excellent thermal conductivity but also promotes durability against corrosion. This is especially advantageous in harsh environments, where exposure to chemicals can significantly impact the lifespan of traditional copper heat exchangers. The Raypak 302A-902A's heat exchanger is designed to withstand the rigors of constant use while maintaining high performance levels.

Another prominent feature of the Raypak 302A-902A is its digital display control system, which simplifies the operation and monitoring of the heater. Users can easily set and adjust temperatures, as well as access diagnostic information, all through an intuitive interface. This digital control not only enhances user experience but also aids in the timely maintenance of the unit.

Energy efficiency is another major selling point of the Raypak 302A-902A. The heater is designed with environmentally friendly practices in mind, utilizing a low NOx burner that minimizes harmful emissions. This not only meets environmental regulations but also makes it a greener alternative for heating needs.

In terms of installation, the compact design of the Raypak 302A-902A allows for versatile placement options, whether in a residential backyard or a commercial environment. Its user-friendly installation process ensures that homeowners and businesses alike can enjoy the benefits of heated water with minimal hassle.

Overall, the Raypak 302A-902A is an exemplary choice for anyone seeking a high-quality, efficient, and flexible pool and spa heating solution. Its combination of robust engineering, advanced technology, and user-focused features solidifies its position as a leader in the market, promising effective heating for years to come. Whether for personal enjoyment or commercial use, this heater delivers exceptional performance that meets diverse heating needs.
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