Manuals / Raypak / Household Appliance / Boiler

Raypak 302-902 manual Table Of Contents Page No

Models: 302-902

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TABLE OF CONTENTS

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4SECTION A: BEFORE INSTALLING THE BOILER

8SECTION B: BOILER INSTALLATION

11	SECTION C: COMBUSTION AND VENTILATION AIR

13SECTION D: WATER PIPING - GENERAL

14SECTION E: HYDRONIC HEATING PIPING

16SECTION F: DOMESTIC HOT WATER PIPING

17SECTION G: POOL HEATING

19	SECTION H:	GAS SUPPLY CONNECTIONS
21	SECTION I:	ELECTRICAL POWER CONNECTIONS
24	SECTION J:	VENTING CONNECTIONS
28	J-1:	Natural Draft Vertical Venting
31	J-2:	HorizontalThru-WallVenting
34	J-3:	Horizontal Thru-Wall Direct Venting
36	J-4:	Vertical Direct Venting/CombustionAir
38	J-5:	Outdoor Installation
43	SECTION K:	CONTROLS
49		WIRING DIAGRAMS

53SECTION L: GENERAL SAFETY PRECAUTIONS

54SECTION M: PRE-START-UP

55SECTION N: HI-DELTA INITIAL START-UP

59SECTION O: POST START-UP CHECK

60SECTION P: OPERATION

61SECTION Q: MAINTENANCE

63APPENDIXA: COMBUSTION AIR CONTAMINATION

64WARRANTY

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Raypak 302-902 manual Table Of Contents Page No

Contents

INSTALLATION AND OPERATING INSTRUCTIONS FORYOURSAFETYModels Type H, WH, & P FORYOURSAFETYTABLE OF CONTENTS PAGE NO DANGER PRODUCTRECEIPT SECTION A BEFORE INSTALLING THE BOILERDANGER MODEL IDENTIFICATION RATINGS AND CERTIFICATIONSFRONT BACKLEFT-SIDE HIGH DELTA COMPONENT LOCATIONGeneral Information INSTALLATIONCODES SECTION B BOILER INSTALLATIONTypical Racked Installation EQUIPMENT BASECLEARANCES Boiler Size OUTDOORINSTALLATIONSOUTDOOR INSTALLATION MINIMUM CLEARANCES Boiler SideCOMBUSTION AND VENTILATION AIR Indoor Units SECTION C COMBUSTION AND VENTILATION AIRDIRECT VENT-INSTALLATON Page TEMPERATURE & PRESSURE GAUGE SECTION D: WATER PIPING - GENERALLOW TEMPERATURE SYSTEM RELIEFVALVE PIPINGPRESSURE DROP IN FEET OF HEAD FEEDWATER REGULATOR SECTION E HYDRONIC HEATING PIPINGPUMP SELECTION PIPING - HEATING BOILERSFig. #9232.2 DUALBOILERPRIMARY/SECONDARYPIPINGFig. #9223 SECTION F DOMESTIC HOT WATER PIPING POTABLE WATER AND SPACE HEATINGAPPLICATIONSECTION G POOL HEATING H BYPASSSPAWATER CHEMISTRY AUTOMATIC CHLORINATORS AND CHEMICALFEEDERSWINTERIZINGYOUR HEATER SINGLEPOOLHEATERAPPLICATIONGAS SUPPLY CONNECTION SECTION H GAS SUPPLY CONNECTIONSDANGER GAS SUPPLY PRESSUREGAS PRESSURE REGULATOR FIGURE CHECK POWER SOURCE SECTION I ELECTRICAL POWER CONNECTIONSCHECK THE POWER SOURCE FIELD-CONNECTEDCONTROLLERSAT OTHER END ALTERNATE POWER IN LOCATIONS FIELD WIRING CONNECTIONMAIN POWER AND PUMP POWER IN ALTERNATE LOCATION MAKING THE ELECTRICAL CONNECTIONSBREAK THE WIRE NUTAT THE ELECTRICAL CONNECTIONS - DOMESTIC HOT WATERBREAK THE WIRE NUTAT THE DANGERDefinition ofAppliance Categories SECTION J VENTING CONNECTIONSGENERAL TABLE J-1 General Support of Vent StackVent Terminal Location Venting Installation Tips VENTING CONFIGURATIONSCOMBUSTION AIR FILTER BOILER UNIT NATURAL DRAFT VERTICALVENT10 OR LESS VENT CAP 2 MIN 2 MIN VENT PIPE Fig. #9228Natural Draft Vertical Vent Termination 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 HORIZONTALTHRU-WALLVENTINGCATEGORY III TABLE SECTION J-2Horizontal Thru-WallVenting Category HI DELTA SLEEVE FLUE CONVERSION Horizontal Thru-wallDirect Vent Termination Horizontal Thru-wallVenting SECTION J-3DIRECT VENT CategoryHorizontal Thru-wallDirect Vent Termination DIRECT VENT SECTION J-4Vertical Venting Category VENTVertical Direct Vent System Installation Vertical Direct Vent TerminationNOTICE NOTICE Outdoor InstallationSECTION J-5 HIDELTAOUTDOORVENTKITANDINSTRUCTIONSHI DELTA OUTDOOR VENT INSTRUCTIONS Heater as shipped Fig. Fig. FigFig. Fig. Fig. Finished assembly HI DELTA OUTDOOR VENT INSTRUCTIONS CONTINUEDMODEL HI DELTA FILTER BOX KITTHISKITINCLUDES PARTNUMBERHI DELTA FILTER BOX INSTRUCTIONS CONTINUED FilterTABLE L-1LED INDICATORS SECTION K CONTROLSBoiler Sequence of Operations HI-DELTAModelThe black hot wire leads you directly to the Main Power Switch. This switch is located at the bottom right-frontcorner of the control compartment. When the main power switch is placed in the “ON” position, both the 120 v and 24 v terminal blocks on the Main Circuit Board will be powered and the power light will turn on. When the Auto On- Off switch is turned ON, the following 24 v safety components are immediately energized Low Water Cut-off,Blocked Vent Switch, Manual Reset Limit Control, Low Gas Pressure Switch optional and the High Gas Pressure Switch optional. At this point if all the preceding safety switches are closed, then Relay K 1 n.c. will be energized and the safety light will turn off. The boiler is now ready for a call for heat HI-DELTAModelHI-DELTAModel902 FLOW SWITCH HIGH LIMIT MANUAL RESETMANUALRESETHIGHLIMIT FLOWSWITCHLOW WATER CUT OFF OPTIONAL HIGH AND LOW GAS PRESSURE SWITCHESGAS PRESSURE SWITCH LOW WATER CUTOFFWIRE DIAGRAM MODEL Reference Drawing Number M152462-Rev.M H4/W1WIRE DIAGRAM MODEL Reference Drawing Number M152470-Rev.J H3/W3WIRE DIAGRAM MODEL Reference Drawing Number M152464-RevR H3/HW3WIRE DIAGRAM MODEL Reference Drawing Number M152465 Rev-P H3/W3SECTION L GENERAL SAFETY PRECAUTIONS Feel water before bathing or showeringFILLING SYSTEM-HEATINGBOILERS SECTION M PRE-START-UPFOR YOUR SAFETY READ BEFORE LIGHTING DOMESTIC HOTWATER BOILERS2.0PREPARATION FOR START-UP SECTION N HI-DELTAINITIAL START-UP1.0TOOLS NEEDED WARNING DO NOT TURN ON GAS AT THIS TIME3.0START-UP Your Hi-Deltais tuned inLEAK TEST PROCEDURE DUAL-SEATGAS VALVES PILOT TURN DOWN TEST FOR RAYPAK HI DELTA BOILERSPage SECTION O POST START-UPCHECK SECTION P OPERATION TOTURN OFFGASTOAPPLIANCEYearly Beginning of each heating season SECTION Q MAINTENANCESUGGESTED MINIMUM MAINTENANCE SCHEDULE DailyWeekly PREVENTIVE MAINTENANCE SCHEDULEDaily MonthlyAPPENDIX A INSIDECOMBUSTIONAIRCONTAMINATIONADDITIONAL WARRANTY EXCLUSIONS LIMITED PARTS WARRANTY COMMERCIAL BOILERSHEATEXCHANGERWARRANTY PARTS REPLACEMENT