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Raypak HD101 - page 1
INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.52B Effective: 1 1-19-09 Replaces: 09-25-09 P/N 241356 Rev . 3 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property damage, personal injury or death . FOR Y OUR SAFETY : Do not store or use gasoline or other flammable vapors and liq ...
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Raypak HD101 - page 2
2 Rev . 3 reflects the following: Changes to: Updated T able E on page 14, T able G on page 18, T roubleshooting flowchart on page 35, T able O on page 38. Additions: Commonwealth of Massachusetts information on page 45 Deletions: None ...
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Raypak HD101 - page 3
WARNINGS 4 Pay Attention to These T erms 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 T ime/T emperature Relationships in Scalds 8 INST ALLA TION 9 Installation Codes 9 Equipment Base 9 Clearances 9 Combustion ...
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Raypak HD101 - page 4
D ANGER: 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. CA UTION: Indicates the presence of hazards or unsa ...
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Raypak HD101 - page 5
BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your Hi Delta heater . Please review the General Safety information before installing the heater . Factory warranty does not a pply to heaters that have been improperly installed or operated (refer to the warranty at the back of this man- ua ...
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Raypak HD101 - page 6
Fig. 1: Component Locations — Angle View Fig. 2: Component Locations — Left Side Fig. 3: Component Locations — Front (Panels removed for clarity) 6 Component Locations ...
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Raypak HD101 - page 7
General Infor ma tion T able A: Basic Data Model No. Q uantity of Burners V ent Size (in.) Flue Intake HD101 2 4 4 HD151 3 4 HD201 4 5 HD251 5 5 HD301 6 5 HD401 8 6 7 Fig. 5: Gas V alves Fig. 4: Air Shutter Adjustment ...
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Raypak HD101 - page 8
GENERAL SAFETY T o meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 210°F . However , water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water , the rec- ommended initial ...
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Raypak HD101 - page 9
INST ALLA TION 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 edi- tion (NFGC). · National Electrical Code, ANSI/NFP A 70 - latest edition (NEC). · Standard for Controls and Safety Devices for ...
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Raypak HD101 - page 10
Fig. 7: Minimum Installed Service Clearances — Indoor/Closet Installations The heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater . Outdoor Installations These heaters are design-certified for outdoor installa- tion. Heaters must not be installed under an overhang unles ...
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Raypak HD101 - page 11
area per 20,000 BTUH (1 1 1 mm 2 per kW) of total input rating of all equipment in the room when the opening is communicating directly with the out- do or s o r t hr ou gh ve rt ic al d uc t( s) . Th e t ot al cross-sectional area shall be at least 1 in. 2 of free area per 10,000 BTUH (222 mm 2 per kW) of total input rating of all equipment in the ...
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Raypak HD101 - page 12
WARNING: Do not use one permanent opening method if the equipment room is under negative pressure conditions or the equipment is common vented with other gas-fired appliances. 1. V entilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors. The tot ...
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Raypak HD101 - page 13
13 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. R ev er sing W ater Connections Follow these instructions to change the water connec- ti on s fr om t he l ef t- ha nd si de ( st ...
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Raypak HD101 - page 14
14 Low T emper a tur e System Heater requires minimum inlet temperature of 105°F . Consult the following sections for piping details. T emperature & Pr essure Gauge The temperature and pressure gauge is shipped loose for field installation. Hydronic Hea ting Pump Selection In order to ensure proper performance of your boiler system, you must i ...
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Raypak HD101 - page 15
15 Fig. 10: Single Boiler — Low T emperature Application (Heat Pump) Primary/Secondary Piping Fig. 1 1: Dual Boiler—Primary/Secondary Piping *Maximum 4 times the pipe diameter or 12”, whichever is less. *Maximum 4 times the pipe diameter or 12”, whichever is less. ...
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Raypak HD101 - page 16
16 T able F: Domestic W ater Heater Flow Rate Requirements ∆ T = T emperature rise, °F . ∆ P = Pressure drop through heat exchanger , ft. SHL = System head loss, ft. (System head loss is based on the heater and tank placed no more than 5 feet apart and 50 feet equivalent length of tubing and fittings.) gpm = Gallons per minute, flow rate. MTS ...
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Raypak HD101 - page 17
17 Gas Supply Connection CA UTION: The heater and its manual shutoff valve must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa). The heater must be isolated from the gas supply piping system by closing the manual shutoff valve during any pressure testing of t ...
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Raypak HD101 - page 18
18 Fig. 13: Sediment T rap Orientation Gas Supply Pr essure A minimum of 4 in. WC and a maximum of 10.5 in. WC upstream gas pressure is required under load and no load conditions for natural gas. A minimum of 1 1 in. WC and a maximum of 13 in. WC is required for propane gas. The gas pressure regulator supplied on the heater is for low pressure serv ...
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Raypak HD101 - page 19
19 Install a separate disconnect means for each load. Use appropriate-sized wire as defined by NEC, CSA and/or local code. All primary wiring should be 125% of minimum rating. It is strongly recommended that all individually-pow- ere d contr ol mod ules an d the hea ter sh ould be supplied from the same power source. Sur ge Protection Microprocesso ...
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Raypak HD101 - page 20
20 SINGLE ST AGE T ANKST A T ST AGE 1 CONNECTION A TT ACH ST AGE 1 CONNECTIONS ON HEA TER T O THE SINGLE ST AGE T ANKST A T AS SHOWN IN THE DIAGRAM ABOVE. Fig. 16: Single Stage T ankstat Electrical Connections — Domestic Hot Wa ter Installer action is required to electrically enable your Hi Delta heater to operate after making the power con- nect ...
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Raypak HD101 - page 21
Category II . A heater which operates with a non-posi- ti ve v en t st at ic p re ss ur e an d w it h a ve nt g as temperature that may cause excessive condensate production in the vent. Category III . A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent. Categ ...
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Raypak HD101 - page 22
22 T able I: V enting Category Requirements Combustion Air S upply Exhaust C onfiguration V enting Category Certified A ppliance Material Combustion Air I nlet Material From Inside Building (Non-Direct V enting) V ertical Natural Draft V enting I T ype B or any C ategory I V enting System* Horizontal Thru-wall V enting III Stainless Steel (Gas T ig ...
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Raypak HD101 - page 23
23 U. S. Ins tallations 1 Canad ian Insta llati ons 2 A Clear ance above gr ade , v eranda, p orch , deck, or balcony 1 ft (30 c m) 1 ft (30 c m) B Clear ance to window or do or that may be o pened 4 ft (1.2 m) below or to side of openin g; 1 foot (30 cm) a bove op ening 3 ft (91 cm) C Clearanc e t o per ma nently closed wind ow ** D V ertical clea ...
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Raypak HD101 - page 24
24 ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimen- tal to the operation of regulators, relief valves, or other equipment. Where local experience indi- cates that condensate is a problem with Category I and III appliances, this provision shall also apply ...
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Raypak HD101 - page 25
25 V enting Installation Tips 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 hack- saw . · Do not use nonmetallic intake pipe or fittings that are cracked ...
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Raypak HD101 - page 26
26 Natural Draft V er tical V enting System Installation Natural draft venting uses the natural buoyancy of the h eated flue products to create a thermal driving head that expels the exhaust gases from the flue. The neg- ative draft must be within the range of –0.01 in. to –0.08 in. WC as measured 12 in. from the appliance flue outlet to ensure ...
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Raypak HD101 - page 27
27 each appliance. Adjust thermostat so appliance will operate continuously . e) Check the pressure at a pressure tap located 12 in. above the bottom joint of the first vertical vent pipe. Pressure should be anywhere between -.01 to -.08 in. WC. f) After it has been determined that each appliance remaining connected to the common venting sys- tem p ...
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Raypak HD101 - page 28
28 Horizontal Thr u-wall V enting System (Categor y III) Installation T hese installations utilize the heater-mounted blower to vent the combustion products to the outdoors. Combustion air is taken from the space and the vent is installed horizontally through the wall to the outdoors. A dequate combustion and ventilation air must be sup- plied in a ...
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Raypak HD101 - page 29
29 Fig. 21: Direct V ent Horizontal Thru-Wall V enting (Category III) Model No. Appliance Category Certified V enting Material V ent Size (inches) Max. V enting Length (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) HD101 HD151 III Stainless Steel (Gas T ight) 4 100, 4 Elbows Max. Galvanized Steel PV ...
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Raypak HD101 - page 30
30 Model No. Appliance Category Certified V enting Material V ent Size (inches) Min./Max. V ertical V enting Height (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) Min. Max. HD101 HD151 I T ype B Equivalent 4 6 25* Galvanized Steel PVC ABS CPVC 4 100 HD201 HD251 HD301 5 (HD201) 6 (HD251) 6 (HD301) 1 ...
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Raypak HD101 - page 31
31 V er tical Direct V ent System Installation T hese 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 f rom the flue. The negative draft must be within the range of -0.01 to -0.08 in. WC as me ...
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Raypak HD101 - page 32
Modulating T emper a tur e Control (Optional) T his heater can be equipped with a Raypak modulat- ing temperature control. For operation with this control, refer to the T emp-T racker Installation and Operating Instructions, Raypak Catalog number 5000.66 (P/N 241 177). High Limit (Manual R eset) The heater is equipped with a manual reset high limit ...
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Raypak HD101 - page 33
33 Lo w Wa ter Cut Of f (Optional) The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig. 27: Flow Switch Fig. 29: Low W ater Cut Off Flow Switc h Dual-purpo ...
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Raypak HD101 - page 34
34 WIRING DIA GRAM—MODELS HD101–HD401 ...
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Raypak HD101 - page 35
35 YES Ste p 9 HD101-HD401 Troubleshooting YES YES NO NO YES YES NO YES YES NO YES YES NO NO YES NO Ste p 10 YES NO YES YES NO NO YES NO Yes NO YES YES NO S tep 1 S tep 2 S tep 3 Step 4 Step 5 Step 6 Step 7 Step 8 Is there a Call For Heat? Is Disable c onnec tion intact? Does the Pump come on? Is 24VAC at the NO side of the air pressure switch? Is ...
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Raypak HD101 - page 36
36 PRE-ST ART -UP Filling System-Heating Hea ter s F ill system with water . Purge all air from the system using purge 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 close vent. ...
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Raypak HD101 - page 37
37 ...
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Raypak HD101 - page 38
38 Check the Gas Supply Pressur e 1. Slowly turn on main gas shut-off valve. 2. Read the gas supply pressure from the manome- te r; m in im um s up pl y pr es su re i s 4 in . WC , recommended supply is 7 in. WC for natural gas ( minimum 1 1.0 in. WC for LP gas). 3. If pressure is > 14 in. WC, turn off the valve. 4. Check if the service regulato ...
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Raypak HD101 - page 39
39 3. Carefully remove 2-stage solenoid. 4. Skip to Step 9 for LO-fire adjustment only . 5. Locate and remove Lo-fire adjustment cap. 6. Carefully remove the spring & weight. 7. Using an allen wrench, turn clockwise to increase and counterclockwise to decrease the HI-fire man- ifold pressure. Heater will not run while adjusting HI-fire pressure ...
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Raypak HD101 - page 40
40 F ollo w-Up • Safety checks must be recorded as performed. • T urn unit on. After main burner ignition: • Check Manometer(s) for proper reading(s). • Cycle unit several times and recheck readings. • Re-analyze with unit running record or print results. • Remove all Manometers and replace hose, replace all gas pressure caps. • Check ...
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Raypak HD101 - page 41
41 3. Remove the (4) screws holding the panel in place. 4. Pull the air filter out for inspection. Replace if nec- essary . 5. When replacing, note the direction of the air flow defined on the side of the filter . The arrow should be pointing downward. 6. Replace the panel and screws before operating. Fig. 34: Remove the Screws and Panel Fig. 35: I ...
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Raypak HD101 - page 42
heater operating efficiency . Maintenance as outlined below may be performed by the owner . Y ear l y (Beginning of eac h heating season): 1. Annual service call by qualified service agency . 42 MAINTENANCE Suggested Minimum Maintenance Schedule: Regular service by a qualified service agency and maintenance must be performed to ensure maximum J ACK ...
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Raypak HD101 - page 43
43 2. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal. 3. Visually inspect venting system for proper func- tion, deterioration or leakage. 4. Check that heater area is free from combustible materials, gasoline, and other flammable vapors and liquids. 5. Check for and remove any obstructio ...
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Raypak HD101 - page 44
44 • hydrochloric acid/muriatic acid • cements and glues • antistatic fabric softeners used in clothes dryers • chloride-type bleaches, detergents, and cleaning solvents found in household laundry rooms • adhesives used to fasten building products • ... and other similar products. Areas causing contaminated combustion air: • dry clean ...
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Raypak HD101 - page 45
45 (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required T o Be V ented" in the most current edition of NFP A 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or s ...
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Raypak HD101 - page 46
46 NOTES: ______________ ____________ __________________ _____________ ____________ __________________ ______ ______________ ____________ __________________ _____________ ____________ __________________ ______ ______________ ____________ __________________ _____________ ____________ __________________ ______ ______________ ____________ ____________ ...
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Raypak HD101 - page 47
47 ...
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Raypak HD101 - page 48
w w w .r ay pak .co m Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A. ...
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