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.
3
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.
4
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.
5
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
6
BACK
LEFT-SIDE
FRONT
7
General Information
36.0
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.).
8
Typical Racked Installation
TOP VIEW
FRONT VIEW RIGHT SIDE VIEW
Fig# 9239
1
"
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.
9
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.
10
SIDE VIEW FRONT VIEW
Fig # 9297
Ce manuel convient aux modèles suivants
6
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