Raypak 302-902 Manuel utilisateur

INSTALLATION

AND OPERATING

INSTRUCTIONS

Models 302-902

Type H, WH, & P

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.

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage,

personal injury or loss of life. Refer to the user’s information manual provided with this boiler. Installation and

service must be performed by a qualified installer, service agency or the gas supplier.

FOR YOUR SAFETY

WHAT TO DO IF YOU SMELLGAS:

· 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.

This manual should be maintained in legible condition

and kept adjacent to the boiler or kept in a safe place

for future reference.

P/N 240757

CATALOG NO. 1000.50K

Effective: 08-01-03

Replaces: 01-15-03

TABLE OF CONTENTS

PAGE

NO.

4 SECTION A: BEFORE INSTALLING THE BOILER

8 SECTION B: BOILER INSTALLATION

11 SECTION C: COMBUSTION AND VENTILATION AIR

13 SECTION D: WATER PIPING - GENERAL

14 SECTION E: HYDRONIC HEATING PIPING

16 SECTION F: DOMESTIC HOT WATER PIPING

17 SECTION 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: Horizontal Thru-Wall Venting

34 J-3: Horizontal Thru-Wall Direct Venting

36 J-4: Vertical Direct Venting/Combustion Air

38 J-5: Outdoor Installation

43 SECTION K: CONTROLS

49 WIRING DIAGRAMS

53 SECTION L: GENERAL SAFETY PRECAUTIONS

54 SECTION M: PRE-START-UP

55 SECTION N: HI-DELTA INITIAL START-UP

59 SECTION O: POST START-UP CHECK

60 SECTION P: OPERATION

61 SECTION Q: MAINTENANCE

63 APPENDIX A: COMBUSTION AIR CONTAMINATION

64 WARRANTY

DANGER: Make sure the gas on which the boiler will operate is the same type as that specified

on the boiler model and rating plate.

WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or

disconnect the electrical supply to the boiler. Instead, shut off the gas supply at a

location external to the appliance.

WARNING: Do not use this boiler if any part has been under water. Immediately call a qualified

service technician to inspect the boiler and to replace any part of the control system

and any gas control which has been under water.

WARNING: To minimize the possibility of improper operation, serious personal injury, fire, or

damage to the boiler, never violate the following safety rules:

1. Always keep the area around the boiler free of combustible materials,

gasoline, and other flammable liquids and vapors.

2. Boiler should never be covered or have any blockage to the flow of fresh air

to the boiler.

WARNING: Risk of electrical shock. More than one (1) disconnect switch may be required to de-

energize the equipment before servicing.

CAUTION: Operation of this boiler on low temperature systems requires special piping to insure

correct operation.

CAUTION: If this boiler is to be installed above radiation level, it must be provided with a low

water cutoff device at the time of boiler installation.

CAUTION: This boiler requires forced water circulation when the burner is operating. See

minimum and maximum flow rates. Severe damage will occur if the boiler is

operated without proper water flow circulation.

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

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.

NOTICE: indicates special instructions on installation, operation, or maintenance which are important

but not related to personal injury hazards.

SECTION A: BEFORE INSTALLING THE BOILER

Raypak strongly recommends that this manual be reviewed thoroughly before installing your Raypak boiler. Please review

the General Safety Precautions on Section L before installing the boiler. Factory warranty does not apply to boilers that have

been improperly installed or operated. Installation and service must be performed by a qualified installer, service agency or

gas supplier. If, after reviewing this manual, you still have questions which this manual does not answer, please contact the

factory or your local Raypak representative.

Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.

PRODUCT RECEIPT

On receipt of your product 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. Remove the boiler from the shipping

packaging. Report any damage to the carrier immediately.

On occasion, some items will be 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.

When ordering parts, you must specify the Model and Serial Number of the boiler. When ordering under warranty conditions,

you must also specify the date of installation.

Purchased parts are subject to replacement only under the manufacturer's warranty. Debits for defective replacement part will

not be accepted and will be replaced in kind only per Raypak's standard warranties.

MODEL IDENTIFICATION

The model identification number and boiler serial number are found on the boiler data plate located on the left inside jacket

of the boiler. The model number will have the form H3 0752 or similar depending on the boiler size and configuration. The first

character of the model number identifies application (H = Hydronic Heating System, W = Hot Water Supply System, P = Pool

Application). The second character identifies the firing mode (3-two stage firing). The next four places identify the size of

the boiler.

RATINGS AND CERTIFICATIONS

STANDARDS

ANSI Z21.13b-1994, Gas Fired Hot Water Boilers

CAN 3.1 M77; Industrial and Commercial Gas-Fired Package Boilers

ANSIZ21.56-1998<>CSA4.7-M98Gas-FiredPoolHeaters

ANSI Z21.10.3-1998<>CSA 4.3-M98 Gas Water Heaters

All Raypak boilers are National Board Approved, design certified and tested by the International Approval Services (IAS)

(a joint venture of American Gas Association Laboratories and the Canadian Gas Association Laboratories) for U.S.A. and

Canada. Each boiler is constructed in accordance with Section IV of the American Society of Mechanical Engineers (ASME)

Boiler Pressure Vessel Code and bears the ASME stamp. This boiler complies with the latest edition of ASHRAE 90.1 Standard.

Altering any RAYPAK pressure vessel by installing replacement heat-exchangers, tube bundle headers, or any other ASME

part not manufactured and/or approved by RAYPAK will instantly void the ASME, AGA, and CGA ratings of the vessel and

any RAYPAK warranty on the vessel. Altering the ASME, AGA and CGA ratings of the vessel also violates national, state,

and local approval codes.

Rated inputs are suitable for up to 4500 feet elevation without derate . Consult the Factory for installations at altitudes in excess

of 4500 feet.

Combustion Air

Filter (Inlet) Flue Exhaust

Optional

Combustion Air (Inlet)

Alternate Flue Connection

Gas Supply Connection

Pressure Relief Connection

Water Outlet

Electrical Connection

Water Inlet

Temperature and Pressure Gauge

Gas Train Operational Center Control

Pressure Relief Valve

Heat Exchanger

Burner Group Remote Sensor

Combustion Air

Blower

Igniter

View Port

HIGH DELTA COMPONENT LOCATION

Fig. #9220

BACK

LEFT-SIDE

FRONT

General Information

36.0

12.0

36.0

12.0

SECTION B: BOILER INSTALLATION

INSTALLATIONCODES

Installations must follow these codes:

· Local, state, provincial, and national codes, laws, regulations and ordinances.

· National Fuel Gas Code (NFGC), ANSI Z223.1- latest edition.

· National Electrical Code (NEC), ANSI/NFPA 70 - latest edition.

· Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

· For Canada only: CAN/CGA B149.1 and .2 Installation Code and C.S.A. C22. 1 C.E.C. Part 1.

EQUIPMENT BASE

The boiler should be mounted on a level, structurally sound surface. The boiler 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 inches above the floor.

Stacking

Hi Delta units can be stacked two units high with an optional stacking rack. Astacking kit is available from Raypak for this

type of installation.

CAUTION: The boiler 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 boiler 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.).

Typical Racked Installation

TOP VIEW

FRONT VIEW RIGHT SIDE VIEW

Fig# 9239

12" 1" 1"

CLEARANCES

TABLE 1

INDOOR INSTALLATION

MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES

Boiler Size

Boiler Side 302-902

Floor See Note 1

Rear 1"

Water Side 12”

Other Side 1"

Top 1"

Front 1"

Vent 2"

Note 1. Do not install on carpeting.

When installed according to the listed minimum clearances from combustible construction mate-

rials, the Raypak heaters can still be serviced without removing permanent structural construc-

tion around the heater.

However, for ease of servicing, we recommend a clearance of at least 24” in front, and at least

18” on the water connection side. This will enable the heater to be serviced in its installed

location, that is, without movement or removal of the heater.

Clearances less than minimum, may require removal of the heater to service either the heat

exchanger or the burner tray. In either case, the heater must be installed in a manner that will

enable the heater to be serviced without removing any structure around the heater.

TOP VIEW FRONT VIEW

Fig. #9221.1

OUTDOOR INSTALLATIONS

Raypak Hi Delta Boilers are design certified for outdoor installation. Boilers must not be installed under an

overhang that is less than three (3) feet from the top of the boiler. Three (3) sides must be open in the area

under the overhang. Roof water drainage must be diverted away from boilers installed under overhangs.

TABLE 2

OUTDOOR INSTALLATION MINIMUM CLEARANCES

Boiler Size

Boiler Side 302-902

Rear 12"

Right 36”

Left 36"

Top Unobstructed

Vent N/A

These clearances required where the outdoor vent cap is used. If installing the boiler outdoors with a vent stack, the

indoor clearances may be used.

The air filter box can be installed on top of the boiler or the rear of the boiler.

For outdoor installations in snow prone areas, it is recommended that the filter kit be installed on to the rear of the boiler,

to prevent recirculation and blockage.

SIDE VIEW FRONT VIEW

Fig # 9297

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