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Raypak 122-322 - page 1
OPERA TING AND INST ALLA TION INSTRUCTIONS Models 122-322 T ype 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. T o do so may result in an explosion or fire. W ARNING: Improper installation, adjustment, alteration, servic ...
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Raypak 122-322 - page 2
T ABLE OF CONTENTS P AGE NO. 4 SECTION A: BEFORE INST ALLING THE HEA TER 8 SECTION B: HEA TER INST ALLA TION 1 1 SECTION C: COMBUSTION AND VENTILA TION AIR 13 SECTION D: W A TER PIPING - GENERAL 14 SECTION E: HYDRONIC HEA TING PIPING 16 SECTION F: DOMESTIC HOT W A TER PIPING 18 SECTION G: POOL HEA TING 19 SECTION H: GAS SUPPL Y CONNECTIONS 21 SECTI ...
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Raypak 122-322 - page 3
DANGER: Make sure the gas on which the heater will operate is the same type as that specified on the heater 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 heater. Instead, shut off the gas supply at a location external to the appliance. WARNI ...
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Raypak 122-322 - page 4
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 p ...
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Raypak 122-322 - page 5
MODEL IDENTIFICATION The model identification number and heater serial number are found on the heater data plate located on the left inside jacket of the heater. The model number will have the form H3 0162 or similar depending on the heater size and configuration. The first character of the model number identifies application (H = Hydronic Heating ...
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Raypak 122-322 - page 6
HI DEL T A COMPONENT LOCA TION 6 BACK LEFT -SIDE FRONT (See detail page 7) (See detail page 7) ...
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Raypak 122-322 - page 7
7 General Information Gas V alve Detail Air Shutter Adjustment ...
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Raypak 122-322 - page 8
SECTION B: HEA TER INST ALLA TION 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/NFP A 70 - latest edition (NEC). · Standard for Controls and Safety Devices f ...
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Raypak 122-322 - page 9
CLEARANCES T ABLE 1 INDOOR INST ALLA TION MINIMUM CLEARANCES FROM COMBUSTIBLE SURF ACES Models Heater Side 122-322 Floor See Note 1 Rear 1" W ater Side 1 2 ” Other Side 1" To p 1 " V ent 2" Note 1 . Do not install on carpeting. When installed according to the listed minimum clearances from combustible construction materials, t ...
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Raypak 122-322 - page 10
OUTDOOR INST ALLA TIONS Raypak Hi Delta Heaters are design certified for outdoor installation. Heaters must not be installed under an overhang that is less than three (3) feet from the top of the heater . Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from heaters installed under overhangs. T ...
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Raypak 122-322 - page 11
SECTION C: COMBUSTION AND VENTILA TION AIR COMBUSTION AND VENTILA TION AIR (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 venting, where combustion air is drawn from the area immedi- ately surroundin ...
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Raypak 122-322 - page 12
COMBUSTION AND VENTILA TION AIR SUPPL Y (FOR CANADA INST ALLA TION) CAUTION: All combustion air has to be drawn from the air outside the building (the mechanical equipment room directly communicates with the outdoors). 1 . V entilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practica ...
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Raypak 122-322 - page 13
SECTION D: W A TER PIPING - GENERAL The heater should be located so that any water leaks will not cause damage to the adjacent area or structures. CAUTION: This heater r equir es forced water cir culation when the burner is operating. See T able D-1 for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the h ...
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Raypak 122-322 - page 14
SECTION E: HYDRONIC HEA TING PIPING PUMP SELECTION In order to ensure proper performance of your boiler system, you must install a properly sized pump. Raypak recommends using a 20°F Delta T as design Delta T . (Delta T is the temperature dif ference between the inlet and outlet water when the heater is firing at full rate). If a Delta T larger th ...
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Raypak 122-322 - page 15
SINGLE BOILER - LOW TEMPERA TURE APPLICA TION (HEA T PUMP) PRIMAR Y/SECONDARY PIPING DUAL BOILER PRIMARY/SECONDARY PIPING 15 ...
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Raypak 122-322 - page 16
SECTION F: DOMESTIC HOT W A TER PIPING When designing the water piping system for domestic water applications, water hardness should be considered. T able F-1 indicates the suggested flow rates for soft, medium and hard water . Hardness is specified as grains per gallon. T ABLE F-1 DOMESTIC W A TER HEA TER FLOW RA TE REQUIREMENTS * Must use optiona ...
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Raypak 122-322 - page 17
17 SINGLE HEA TER DOMESTIC HOT W A TER WITH ONE ST ORAGE T ANK ...
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Raypak 122-322 - page 18
SECTION G: POOL HEA TING CAUTIO CAUTION: Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation. Improper flow control can damage the heater . Uncontrolled flow (too high) or restricted flow (too low) can seriously damage the heater . Follow these instructi ...
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Raypak 122-322 - page 19
SECTION H: GAS SUPPL Y CONNECTIONS DANGER: Make sure the gas on which the heater will operate is the same type as specified on the heater model and 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 redu ...
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Raypak 122-322 - page 20
GAS PRESSURE REGULA TOR The gas valve pressure regulator(s) on the heater are nominally preset at 3.5" W .C. for Natural gas, and 10.5" W .C. for Propane gas manifold pressure. The pressure at the gas valve outlet tap, measured with a manometer ,while in operation should be 3.5 ± 0.1" W .C. for Natural gas and 10.5" ± 0.1" ...
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Raypak 122-322 - page 21
CIRCUIT BREAKER WHITE GROUND BLACK GREEN AB C VOL T-OHM METER SECTION I: 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 requir ...
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Raypak 122-322 - page 22
MAKING THE ELECTRICAL CONNECTIONS Refer to Fig. #9403 W iring Connection, and W iring Diagram #152564. 1 . V erify circuit breaker is properly sized by referring to heater rating plate. A dedicated circuit breaker should be provided. 2 . T urn off all power to the heater . V erify that power has been turned off by testing with a volt-ohm meter prio ...
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Raypak 122-322 - page 23
ELECTRICAL CONNECTIONS - DOMESTIC HOT W A TER CAUTION: Label all wir es prior to disconnection when servicing contr ols. W iring errors can cause impr oper and danger ous operation. V erify proper operation after servicing. DANGER - SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to ...
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Raypak 122-322 - page 24
SECTION J: VENTING CONNECTIONS GENERAL CAUTION: Proper installation of flue exhaust venting is critical for the safe and efficient operation of the heater . 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 ...
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Raypak 122-322 - page 25
Category Determination for Venting Purpose and Venting Arrangement 25 TABLE J-1 * As defined in the latest edition of the NFGC, or in Canada, the B149.1 and .2 ...
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Raypak 122-322 - page 26
Support of V ent 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. Use insulated vent pipe spacers where the vent passes through combustible roofs and wall ...
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Raypak 122-322 - page 27
V enting Installation T ips 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. · Cut nonmetallic intake pipe with fine-toothed hacksaw . · Do not use nonmetallic intake pipe or fittings that are cracked or d ...
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Raypak 122-322 - page 28
28 SECTION J-1 Natural Draft V ertical V enting (Category I) NA TURAL DRAFT VERTICAL VENT NOTE: **V ent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the NFGC for further details. (ANSI Z223.1) ...
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Raypak 122-322 - page 29
• Natural Draft V ertical V enting System Installation 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 -.01” to -.08” W .C. as measured 12 in. from the appliance flue outlet to ensure proper ...
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Raypak 122-322 - page 30
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 ...
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Raypak 122-322 - page 31
SECTION J-2 Horizontal Thru-W all V enting (Category III) HORIZONT AL THRU-W ALL VENTING (CA TEGOR Y III) T ABLE • Horizontal Thru-wall V enting System (Category III) Installation These installations utilize the heater-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from inside the room and the vent is inst ...
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Raypak 122-322 - page 32
The total length of the horizontal thru-wall exhaust vent system should not exceed seventy (70) feet in length. If horizontal run exceeds 70 feet, an appropriately sized extractor must be used. T o maintain proper operation pressure reading must be between -.01” to -.08” W .C. as measured 12 in. from the appliance flue outlet. Each elbow used i ...
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Raypak 122-322 - page 33
DIRECT VENT Horizontal Thru-wall V enting (Category III) HORIZONT AL THRU-W ALL VENTING T ABLE 33 SECTION J-3 ...
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Raypak 122-322 - page 34
• Horizontal Thru-wall Dir ect V ent System (Category III) Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors. The total length of the thru-wall exhaust vent cannot exceed forty (40) feet in length for the flue outlet. Each elbow used is equal to ten ...
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Raypak 122-322 - page 35
DIRECT VENT V ertical V enting (Category I) VER TICAL VENTING T ABLE 35 SECTION J-4 ...
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Raypak 122-322 - page 36
• V ertical Direct V ent System Installation 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” W .C. as ...
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Raypak 122-322 - page 37
SECTION J-5 Outdoor Installation Outdoor models are self-venting when installed with the factory-supplied restricted direct vent cap and require no additional vent piping. This special vent cap is provided with the heater in accordance with CSA requirements. It must be installed directly on the heater . See Section B for correct clearances. Care mu ...
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Raypak 122-322 - page 38
SECTION K: CONTROLS W ARNING: 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 . Failur e to do so may result in contr ol damage, heater malfunction, pr operty damage, personal injury , or death. W ARNING: T urn off ...
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Raypak 122-322 - page 39
IGNITION MODULE Fig. J-3 MANUAL RESET HIGH LIMIT Fig. J-4 FLOW SWITCH THERMOSTAT CONTROL 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 c ...
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Raypak 122-322 - page 40
LOW W A TER 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 3-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig.# J-5 LOW W A TER CUT -OFF 40 Drw . #8996.1 ...
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Raypak 122-322 - page 41
41 WIRE DIAGRAM MODELS 122-322 Reference Drawing Number M152564C ...
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Raypak 122-322 - page 42
SECTION L: GENERAL SAFETY PRECAUTIONS T o meet commercial water use needs, the temperature Hi-Limt on this hot water heater is adjustable up to 210°F . However, water temperatures over 125°F can cause severe burns instantly or death from scalds. The preferred starting point for setting the control for supplying general purpose hot water is 125°F ...
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Raypak 122-322 - page 43
SECTION M: PRE-ST AR T -UP FILLING SYSTEM-HEA TING HEA TERS Fill system with water . Purge all air from the system using pur ge 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 cl ...
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Raypak 122-322 - page 44
SECTION N: INITIAL ST ART -UP 1 . 0 TOOLS NEEDED • One 12-0-12, 24” scale manometer • T wo 6-0-6, 12” scale manometers • 7/16” open end wrench • 1/2” open end wrench • Screwdriver • V olt meter • 3/16” Allen wrench 2 . 0 PREP ARA TION FOR ST ART -UP W ARNING: DO NOT TURN ON GAS A T THIS TIME 2.1 Check Power Supply W ith volt ...
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Raypak 122-322 - page 45
3.0 S T A R T - U P 3.1 Blower Adjustment 1 . Disconnect fan pressure switch tubing at plenum and connect manometer using a tee. 2 . Close all manual firing valves. 3 . Turn power on; 4 . Check manometers attached to fan pressure switch. The readings should be : .5 + .1” W .C. for models 102 and 122 .7 + .1” W .C. for models 202, 242, 322 If no ...
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Raypak 122-322 - page 46
SECTION O: POST ST AR T -UP CHECK Check off steps as completed: 1 . Heater and heat distribution units or storage tank filled with water? 2 . Automatic air vent, if used, open two full turns during venting procedure? 3 . Air purged from system? 4 . Air purged from gas piping? Piping checked for leaks? 5 . Followed start-up procedure for proper star ...
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Raypak 122-322 - page 47
SECTION P: OPERA TION OPERA TING INSTRUCTIONS Lighting Instructions 1. STOP! Read the safety information first. 2 . Set the thermostat to the lowest setting. 3 . Turn off all electric power to the appliance. 4 . This appliance is equipped with an ignition device which automatically lights the burner . Do Not try to light the burner by hand. 5 . Rem ...
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Raypak 122-322 - page 48
SECTION Q: MAINTENANCE SUGGESTED MINIMUM MAINTENANCE SCHEDULE: Regular service by a qualified service agency and maintenance must be performed to ensure maximum heater operating ef ficiency . Maintenance as outlined below may be performed by the owner . Y early (Beginning of each heating season): 1 . Annual service call by qualified service agency ...
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Raypak 122-322 - page 49
APPENDIX A INSIDE COMBUSTION AIR CONT AMINA TION: 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. H ...
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Raypak 122-322 - page 50
Fig # 241093 50 ...
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Raypak 122-322 - page 51
51 HEA T EXCHANGER DET AIL ...
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Raypak 122-322 - page 52
52 ...
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Raypak 122-322 - page 53
53 ...
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Raypak 122-322 - page 54
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Raypak 122-322 - page 55
LIMITED P ARTS W ARRANTY COMMERCIAL HEA TERS TYPE HI DEL T A MODELS 122 T O 322 MODELS H AND WH SCOPE: Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditi ...
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Raypak 122-322 - page 56
Raypak, Inc. , 2151 Eastman A venue, Oxnard, CA 93030 • (805) 278-5300 • Fax (800) 872-9725 Raypak Canada L TD , 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 • (905) 677-7999 • Fax (905) 677-8036 Litho in U. S. A. www .raypak.com ...
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