Raypak Boiler 302A 902A User Guide
INSTALLATION AND OPERATING  
INSTRUCTIONS  
Models  
302A-902A Types H, WH & P  
L
W
WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property dam-  
age, personal injury or death.  
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other com-  
bustable materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.  
WHAT TO DO IF YOU SMELL GAS:  
• 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.  
Installation and service must be performed by a qualified installer, service agency or the  
gas supplier.  
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for  
future reference.  
CATALOG NO. 1000.501B  
Effective: 09-08-06  
Replaces: 01-01-05  
P/N 240757 Rev. 1  
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CONTENTS  
WARNINGS  
BEFORE INSTALLATION  
Product Receipt  
4 APPENDIX  
53  
53  
54  
54  
55  
5
Inside Air Contamination  
5 WARRANTIES  
Model Identification  
Ratings and Certifications  
Component Locations  
General Information  
GENERAL SAFETY  
Time/Temperature Relationships in  
Scalds  
INSTALLATION  
Installation Codes  
Equipment Base  
5
5
6
7
8
Type H and WH  
Type P  
8
9
9
9
Stacking  
9
Clearances  
Combustion and Ventilation Air  
10  
12  
Conventional Combustion Air Supply 13  
Water Piping  
Hydronic Heating  
Gas Supply  
14  
16  
20  
22  
23  
25  
27  
28  
28  
33  
33  
34  
Electrical Power Connections  
Field Wiring Connection  
Venting  
Changing the Flue Outlet  
Venting Installation Tips  
Venting Configurations  
Controls  
Outdoor Installation  
Heater Sequence of Operations  
87%-Efficiency Boilers –  
Special Instructions  
Water Piping  
39  
39  
44  
45  
45  
46  
49  
49  
49  
50  
51  
Wiring Diagram  
START-UP  
Pre Start-up  
Start-Up  
OPERATION  
Lighting Instructions  
To Turn Of Gas To Appliance  
TROUBLESHOOTING  
MAINTENANCE  
Suggested Minimum  
Maintenance Schedule  
51  
Preventative Maintenance Schedule 51  
3
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WARNINGS  
Pay Attention to These Terms  
Indicates the presence of immediate hazards which will cause severe person-  
al injury, death or substantial property damage if ignored.  
DANGER:  
WARNING:  
CAUTION:  
NOTE:  
Indicates the presence of hazards or unsafe practices which could cause  
severe personal injury, death or substantial property damage if ignored.  
Indicates the presence of hazards or unsafe practices which could cause  
minor personal injury or product or property damage if ignored.  
Indicates special instructions on installation, operation, or maintenance which  
are important but not related to personal injury hazards.  
DANGER: Make sure the gas on which the heater  
will operate is the same type as that specified on the  
heater rating plate.  
WARNING - CALIFORNIA PROPOSITION  
65: This product contains chemicals known to the  
State of California to cause cancer, birth defects or  
other reproductive harm.  
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 heater.  
CAUTION: Operation of this heater in low-temper-  
ature systems requires special piping. Harmful inter-  
nal condensation will occur if the inlet water temper-  
ature does not exceed 105°F. Warranty claims will  
be denied when condensation occurs.  
WARNING: Do not use this heater if any part has  
been under water. Immediately call a qualified serv-  
ice technician to inspect the heater and to replace  
any part of the control system and any gas control  
which has been under water.  
CAUTION: If this heater is to be installed above  
radiation level, it must be provided with a low water  
cut-off device at the time of heater installation.  
WARNING: To minimize the possibility of improper  
operation, serious personal injury, fire, or damage to  
the heater:  
CAUTION: If this heater is to be installed in a neg-  
ative or positive pressure equipment room, there are  
special installation requirements. Consult factory for  
details.  
•
Always keep the area around the heater free of  
combustible materials, gasoline, and other flam-  
mable liquids and vapors.  
•
Heater should never be covered or have any  
blockage to the flow of fresh air to the heater.  
WARNING: Risk of electrical shock. More than one  
disconnect switch may be required to de-energize  
the equipment before servicing.  
4
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number will have the form H9 1262A or similar  
depending on the heater size and configuration. The  
letter(s) in the first group of characters identifies the  
application (H = Hydronic Heating, WH = Domestic  
Hot Water (DHW), P = Pool). The number which fol-  
lows identifies the firing mode (1 or 4 = on-off, 3 =  
2-stage, 8 = 3-stage and 9 = 4-stage). The second  
group of characters identifies the size of the heater  
(four numbers representing the approximate MBTUH  
input), and, where applicable, a letter, indicating the  
manufacturing series. An “E” suffix indicates 87% effi-  
ciency (Category II or IV venting) (“H” stamped boilers  
only).  
BEFORE INSTALLATION  
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  
apply to heaters that have been improperly installed or  
operated. (Refer to the warranty at the back of this  
manual.) 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  
manufacturer or your local Raypak representative.  
Ratings and Certifications  
Thank you for purchasing a Raypak product. We hope  
you will be satisfied with the high quality and durability  
of our equipment.  
Standards:  
•
•
•
•
ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired  
Hot Water Boilers  
Product Receipt  
CAN 3.1  
-
latest edition, Industrial and  
On receipt of your heater it is suggested that you visu-  
ally 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 heater from the shipping packaging. Report any  
damage to the carrier immediately.  
Commercial Gas-Fired Package Boilers  
ANSI Z21.56 · CSA 4.7 - latest edition Gas-Fired  
Pool Heaters  
ANSI Z21.10.3 · CSA 4.3 - latest edition Gas  
Water Heaters  
All Raypak heaters are National Board Approved, and  
design-certified and tested by the Canadian Standards  
Association (CSA) for the U.S. and Canada. Each  
heater is constructed in accordance with Section IV of  
the American Society of Mechanical Engineers  
(ASME) Heater Pressure Vessel Code and bears the  
ASME stamp. The heater also complies with the latest  
edition of ASHRAE 90.1 Standard.  
On occasion, items are shipped loose. Be sure that  
you receive the correct number of packages as indi-  
cated 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.  
WARNING: Altering any Raypak pressure vessel  
by installing replacement heat exchangers, tube  
bundle headers, or any ASME parts not manufac-  
tured and/or approved by Raypak will instantly void  
the ASME and CSA ratings of the vessel and any  
Raypak warranty on the vessel. Altering the ASME or  
CSA ratings of the vessel also violates national,  
state, and local approval codes.  
When ordering parts, you must specify the model and  
serial number of the heater. When ordering under war-  
ranty conditions, you must also specify the date of  
installation.  
Purchased parts are subject to replacement only  
under the manufacturer’s warranty. Debits for defec-  
tive replacement parts will not be accepted and will be  
replaced in kind only per Raypak’s standard war-  
ranties.  
Rated inputs are suitable for up to 5,000 ft elevation  
without de-rating. Consult the factory for installations  
at altitudes over 5,000 ft above sea level.  
Model Identification  
The model identification number and heater serial  
number are found on the heater rating plate located on  
the lower right outside jacket of the heater. The model  
5
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Component Locations  
Fig. 1: Component Locations – Back  
Fig. 2: Component Locations – Left Side  
Panels removed for clarity  
Fig. 3: Component Locations – Front  
6
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General Information  
Vent Size  
(in.)  
Quantity of  
Model  
No.  
Gas  
Valves  
Burners  
Blowers Flue Intake  
302A  
402A  
502A  
652A  
752A  
902A  
6
1
1
2
2
2
3
1
1
1
1
1
1
5
6
6
8
8
8
6
6
6
6
6
6
8
10  
13  
15  
18  
Table A: Basic Data  
# Burners per  
Valve  
% Fire at  
Stage  
Stages  
Model  
No.  
1
6
8
5
7
8
6
2
3
1
1
1
1
1
1
2
1
2
302A  
402A  
502A  
652A  
752A  
902A  
100  
100  
5
6
7
6
1, 2  
1,2  
1,2  
50 100  
54 100  
53 100  
6
1, 1A 1, 1A, 2 66 100  
Table B: Manifold Data  
# Burners  
per Valve  
Valve  
Staging  
% Firing  
at Stage  
Model  
No.  
1
4
5
2*  
2
1
1
1
2
1
2
302A  
402A  
1, 2  
1, 2  
66  
63  
100  
100  
3
* Valve 2 is inside the air plenum on H3/WH3 302A-402A  
Table C: 2-Stage Design Option  
7
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GENERAL SAFETY  
To meet commercial hot water use needs, the high  
limit safety control on this water heater is adjustable up  
to 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 setting for the temperature control is  
125°F.  
Safety and energy conservation are factors to be con-  
sidered when setting the water temperature on the  
thermostat. The most energy-efficient operation will  
result when the temperature setting is the lowest that  
satisfies the needs of the application.  
Water temperature over 125°F can  
causeinstantsevereburnsordeath  
from scalds.  
Water temperature over 125°F can cause instant  
severe burns or death from scalds. Children, disabled  
and elderly are at highest risk of being scalded.  
Children, disabled, and elderly are  
at highest risk of being scalded.  
See instruction manual before set-  
ting temperature at water heater.  
•
•
Feel water before bathing or showering.  
Temperature limiting valves are available.  
Feel water before bathing or show-  
ering.  
NOTE: When this water heater is supplying general  
purpose hot water for use by individuals, a thermo-  
statically controlled mixing valve for reducing point of  
use water temperature is recommended to reduce  
the risk of scald injury. Contact a licensed plumber or  
the local plumbing authority for further information.  
Temperature limiting valves are  
available, see manual.  
Time/Temperature  
Relationships in Scalds  
Maximum water temperatures occur just after the  
heater’s burner has shut off. To determine the water  
temperature being delivered, turn on a hot water  
faucet and place a thermometer in the hot water  
stream and read the thermometer.  
The following chart details the relationship of water  
temperature and time with regard to scald injury and  
may be used as a guide in determining the safest  
water temperature for your applications.  
Water  
Temp.  
Time to Produce Serious  
Burn  
120°F  
125°F  
130°F  
135°F  
140°F  
145°F  
150°F  
155°F  
More than 5 minutes  
1-1/2 to 2 minutes  
About 30 seconds  
About 10 seconds  
Less than 5 seconds  
Less than 3 seconds  
About 1-1/2 seconds  
About 1 second  
Table courtesy of The Shriners Burn Institute  
Table D: Time to Produce Serious Burn  
8
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The temperature of the water in the heater can be reg-  
ulated by using the temperature controller. To comply  
with safety regulations, the temperature controller is  
set at the lowest setting when shipped from the facto-  
ry.  
Equipment Base  
The heater should be mounted on a level, structurally  
sound surface. The heater 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 in. above the floor.  
To adjust the water temperature, insert a small straight  
screwdriver into the adjustment screw on the front of  
temperature controller and turn the wheel to the  
desired setting (See Fig. 4.).  
Stacking  
Hi Delta units can be stacked two units high with an  
optional stacking rack. A seismic-certified stacking kit  
is available from Raypak for this type of installation.  
CAUTION: The heaters should be located in an  
area where water leakage will not result in damage  
to the area adjacent to the appliances or to the struc-  
ture.  
When such locations cannot be avoided, it is recom-  
mended that a suitable catch pan, adequately drained,  
be installed under the appliance. The pan must not  
restrict air flow.  
Fig. 4: Temperature Controller  
CAUTION: Hotter water increases the risk of scald-  
ing! There is a hot water scald potential if the thermo-  
stat is set too high.  
INSTALLATION  
Installation Codes  
Installations must follow these codes:  
•
•
•
•
Local, state, provincial, and national codes, laws,  
regulations and ordinances  
National Fuel Gas Code, ANSI Z223.1/NFPA 54 –  
latest edition (NFGC)  
National Electrical Code, ANSI/NFPA 70 - latest  
edition (NEC)  
Standard for Controls and Safety Devices for  
Automatically Fired Boilers, ANSI/ASME CSD-1,  
when required (CSD-1)  
•
For Canada only: CAN/CGA B149.1 installation  
Code (B149.1) and CSA C22.1 C.E.C. Part 1  
(C22.1)  
Fig. 5: Typical Stacked Installation  
9
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In addition, the heater shall be installed such that the When installed according to the listed minimum clear-  
gas ignition system components are protected from ances from combustible construction, these heaters  
water (dripping, spraying, rain, etc.) during appliance can still be serviced without removing permanent  
operation or service (circulator replacement, control structural construction around the heater. However, for  
replacement, etc.).  
ease of servicing, we recommend a clearance of at  
least 24 in. in front, and at least 12 in. on the water  
connection side. This will allow the heater to be serv-  
iced in its installed location without movement or  
removal of the heater.  
Clearances  
Indoor Installations  
Service clearances less than the minimums 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.  
Minimum Clear- Recommended  
ance  
from Combustible  
Surfaces  
Service  
Clearance  
Heater  
Side  
Floor*  
Rear  
0”  
1”  
0”  
24”  
24”  
24”  
1”  
Outdoor Installations  
Water Side  
Other Side  
Top  
12”  
1”  
These heaters are design-certified for outdoor installa-  
tion. Heaters must not be installed under an overhang  
that is less than 3 ft from the top of the heater. Three  
sides must be open in the area under the overhang.  
Roof water drainage must be diverted away from  
heaters installed under overhangs.  
1”  
Front  
Open  
2”  
24”  
2”  
Vent  
* DO NOT install on carpeting.  
Recommended  
Service  
Min. Clearance  
from Combustible  
Surfaces  
Heater  
Side  
Table E: Clearances – Indoor Installations  
Clearance  
Front  
Rear  
Open  
24”  
12”  
36”  
24”  
36”  
Water Side  
Other Side  
Top  
36”  
36”  
Unobstructed  
N/A  
Unobstructed  
N/A  
Vent  
Table F: Clearances – Outdoor Installations  
TOP VIEW  
These clearances are required when the outdoor  
vent cap is used. If installing the heater outdoors  
with a vent stack, the indoor clearances may be  
utilized.  
The combustion air intake hood MUST be used for  
outdoor installations. The hood is shipped loose and  
installed on the side of the heater over the filter box at  
the jobsite.  
FRONT VIEW  
Venting not shown for clarity. Heater must be vented  
per instructions in this manual  
Fig. 6: Minimum Clearances from Combustible  
Surfaces – Indoor Installations  
10  
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Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations  
U.S. Installations1  
Canadian Installations2  
Clearance above grade, veranda, porch,  
deck, or balcony  
A
1 ft (30 cm)  
1 ft (30 cm)  
4 ft (1.2m) below or to side  
of opening; 1 foot (30 cm)  
above opening  
Clearance to window or door that may be  
opened  
B
C
3 ft (91 cm)  
Clearance to permanently closed window  
*
*
Vertical clearance to ventilated soffit located  
above the terminal within a horizontal dis-  
tance of 2 ft (61cm) from the centerline of the  
terminal  
D
5 ft (1.5m)  
*
E
F
Clearance to unventilated soffit  
Clearance to outside corner  
Clearance to inside corner  
*
*
*
*
*
G
6 ft (1.83m)  
3 ft (91 cm) within a height  
15 ft above the me-  
ter/regulator assembly  
Clearance to each side of center line ex-  
tended above meter/regulator assembly  
H
I
*
*
Clearance to service regulator vent outlet  
6 ft (1.83m)  
Clearance to non-mechanical air supply inlet 4 ft (1.2m) below or to side  
to building or the combustion air inlet to any  
of opening; 1 ft (30 cm)  
J
3 ft (91 cm)  
other appliance  
above opening  
3 ft (91 cm) above if within  
10 ft (3m) horizontally  
K
L
Clearance to mechanical air supply inlet  
6 ft (1.83m)  
7 ft (2.13m) t  
Clearance above paved sidewalk or paved  
driveway located on public property  
7 ft (2.13m)  
Clearance under veranda, porch, deck or  
balcony  
M
*
12 in. (30 cm) TT  
1
2
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code  
In accordance with the current CAN/CGA-B149 Installation Codes  
t
Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves  
both dwellings  
TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and  
underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)  
*
Clearances in accordance with local installation codes and the requirements of the gas supplier  
Table G: Vent/Air Inlet Termination Clearances  
11  
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Reversing Air Filter  
Follow these instructions to change the air duct con-  
nection from the left-hand side (standard) to the right-  
hand side:  
1. Remove the four screws and the dust cover from  
the right-hand side of the heater.  
2. Remove the four screws and the air filter bracket  
from the left-hand side of the heater.  
3. Reverse the components and reattach in the new  
location, making sure that the air filter locking  
bracket is on the bottom. (The air filter locking  
bracket is reversible.)  
Direct Vent  
Fig. 8: Minimum Clearances from Combustible  
Surfaces – Outdoor Installations  
If outside air is drawn through the intake pipe directly  
to the unit for combustion:  
1. Install combustion air direct vent in accordance  
with Fig. 26 (horizontal) or Fig. 27 (vertical) of this  
manual (pages 31 and 32, respectively).  
Combustion and Ventilation Air  
NOTE: Use of the heater in construction areas  
where fine particulate matter, such as concrete or  
drywall dust, is present may result in damage to the  
heater that is not covered by the warranty. If operat-  
ed in a construction environment, a clean source of  
combustion air must be provided directly to the  
heater.  
2. Provide adequate ventilation of the space occu-  
pied by the heater(s) by an opening(s) for ventila-  
tion air at the highest practical point communicat-  
ing with the outdoors. The total cross-sectional  
area shall be at least 1 in.2 of free area per 20,000  
BTUH (111 mm2 per kW) of total input rating of all  
equipment in the room when the opening is com-  
municating directly with the outdoors or through  
vertical duct(s). The total cross-sectional area  
shall be at least 1 in.2 of free area per 10,000  
BTUH (222 mm2 per kW) of total input rating of all  
equipment in the room when the opening is com-  
municating with the outdoors through horizontal  
duct(s).  
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 sup-  
plied via conventional means where combustion air is  
drawn from the area immediately surrounding the  
heater, or via direct vent, where combustion air is  
drawn directly from outside. All installations must com-  
ply with the requirements of the NFGC (U.S.) and  
B149.1 (Canada), and all local codes.  
3. In cold climates, and to mitigate potential freeze-  
up, Raypak highly recommends the installation of  
a motorized sealed damper to prevent the circula-  
tion of cold air through the heater during the non-  
operating hours.  
CAUTION: Combustion air must not be contami-  
nated by corrosive chemical fumes which can dam-  
age the heater and void the warranty. (See the  
Appendix.)  
Direct-Ducted Combustion Air  
In certain applications it may be desirable to duct the  
combustion air directly to the heater. This should be  
done with PVC, CPVC or single-wall galvanized duct-  
ing. The duct will attach directly to the collar on the air  
filter housing located on the side of the heater. The  
ducting is attached to the air filter housing collar using  
NOTE: It is recommended that the intake vent be  
insulated to minimize sweating.  
12  
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three or four sheet metal screws (not supplied) equal- space shall be considered in making this determina-  
ly distributed around the circumference of the duct. All tion. Each opening shall have a minimum free area of  
ducting should be self-supported. The filter housing is 1 in.2 per 1,000 BTUH (2,225 mm2 per kW) of the total  
not designed to support the air duct.  
input rating of all gas utilization equipment in the con-  
fined space, but not less than 100 in.2 (645 cm2). One  
opening shall commence within 12 in. (305 mm) of the  
top, and one opening shall commence within 12 in.  
(305 mm) of the bottom of the enclosure. The mini-  
mum dimension of air openings shall be not less than  
3 in. (76 mm) in any direction.  
CAUTION: Use TrueSeal combustion air if damag-  
ing airborne contaminants are or will be present in  
the heater area. See the Appendix regarding air con-  
tamination.  
TruSeal™ Combustion Air  
All Air from Outdoors  
In certain applications it may be necessary to utilize  
the TruSeal option (sales order option D-21 or D-22)  
and duct the combustion air directly to the blower.  
Combustion air may be ducted directly to the heater by  
using PVC, CPVC or sealed single-wall galvanized  
ducting. The duct will attach directly to the air collar lo-  
cated on the side of the heater, using three or four  
sheet metal screws (not supplied) equally positioned  
around the circumference of the duct. The screws and  
duct connection point must be sealed with RTV (not  
supplied). An in-line intake air filter kit (sales order  
option D-17) must be installed in the combustion air  
duct. TruSeal is generally used when damaging con-  
taminants are present in the mechanical room.  
The confined space shall communicate with the out-  
doors in accordance with one of the methods below.  
The minimum dimension of air openings shall not be  
less than 3 in. (76 mm) in any direction. Where ducts  
are used, they shall be of the same cross-sectional  
area as the net free area of the openings to which they  
connect.  
1. Two permanent openings, one commencing  
within 12 in. (305 mm) of the top, and one com-  
mencing within 12 in. (305 mm) of the bottom of  
the enclosure, shall be provided. The openings  
shall communicate directly, or by ducts, with the  
outdoors or spaces (crawl or attic) that freely com-  
municate with the outdoors.  
TruSeal heater connection points are available as fol-  
lows:  
a. Where directly communicating with the out-  
doors or where communicating to the out-  
doors through vertical ducts, each opening  
shall have a minimum free area of 1 in.2 per  
4,000 BTUH (550 mm2 per kW) of total input  
rating of all equipment in the enclosure.  
302A & 402A Right side only  
502A to 902A Left side - standard  
Right side - optional  
CAUTION: This type of installation is recommend-  
ed if damaging airborne contaminants are or will be  
present in the heater area. See the Appendix regard-  
ing air contamination.  
b. Where communicating with the outdoors  
through horizontal ducts, each opening shall  
have a minimum free area of 1 in.2 per 2,000  
BTUH (1,100 mm2 per kW) of total input rat-  
ing of all equipment in the enclosure.  
Conventional Combustion Air  
Supply  
2. One permanent opening, commencing within 12  
in. (305 mm) of the top of the enclosure, shall be  
permitted where the equipment has clearances of  
at least 1 in. (25 mm) from the sides and back and  
6 in. (152 mm) from the front of the appliance. The  
opening shall directly communicate with the out-  
doors or shall communicate through a vertical or  
horizontal duct to the outdoors or spaces that  
freely communicate with the outdoors, and shall  
have a minimum free area of:  
U.S. Installations  
All Air from Inside the Building  
The confined space shall be provided with TWO per-  
manent openings communicating directly with an addi-  
tional room(s) of sufficient volume so that the com-  
bined volume of all spaces meets the criteria for a  
room large in comparison (NFGC). The total input of all  
gas utilization equipment installed in the combined  
a. 1 in.2 per 3,000 BTUH (740 mm2 per kW) of  
the total input rating of all equipment located in  
the enclosure, and  
13  
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b. Not less than the sum of the areas of all vent  
connectors in the confined space.  
of not less than 1 in.2 for each 30,000 BTUH mm2  
per kW) of total rated input of the burner(s), and  
the location of the opening(s) shall not interfere  
with the intended purpose of the opening(s) for  
ventilation air referred to in (1). This opening(s)  
can be ducted to a point not more than 18 in. (450  
mm) nor less than 6 in. (152 mm) above the floor  
level. The duct can also “goose neck” through the  
roof. The duct is preferred to be straight down 18  
in. (450 mm) from the floor, but not near piping.  
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.  
Canadian Installations  
CAUTION: All combustion air must be drawn from  
the air outside of the building; the mechanical equip-  
ment room must communicate directly with the out-  
doors.  
4. Refer to B149.1 for additional information.  
Water Piping  
NOTE: For 87%-efficiency boilers, see special  
instructions on page 39.  
1. Ventilation of the space occupied by the heater  
shall be provided by an opening(s) for ventilation  
air at the highest practical point communicating  
with the outdoors. The total cross-sectional area of  
such an opening(s) shall be at least 10% of the  
area required in 2. and 3. (below), but in no case  
shall the cross-sectional area be less than 10 in.2  
(65 cm2).  
General  
The heater should be located so that any water leaks  
will not cause damage to the adjacent area or struc-  
tures.  
2. For heaters using a barometric damper in the vent  
system there shall be a permanent air supply  
opening(s) having a cross section area of not less  
than 1 in.2 per 7,000 BTUH (320 mm2 per kW) up  
to and including 1 million BTUH, plus 1 in.2 per  
14,000 BTUH (160 mm2 per kW) in excess of 1  
million BTUH. This opening(s) shall be either  
located at or ducted to a point not more than 18 in.  
(450 mm) nor less than 6 in. (152 mm) above the  
floor level. The duct can also “goose neck” through  
the roof. The duct is preferred to be straight down  
and terminated 18 in. (450 mm) from the floor, but  
not near piping. This air supply opening require-  
ment shall be in addition to the air opening for ven-  
tilation air required in 1. (above).  
CAUTION: This heater requires forced water circu-  
lation when the burner is operating. See Table H and  
Table I for minimum and maximum flow rates and  
water pump selection. The pump must be interlocked  
with the heater to prevent heater operation without  
water circulation.  
NOTE: Minimum pipe size for in/out connections is  
2 in. Verify proper flow rates and ΔT as instructed in  
this manual.  
Reversing Water Connections  
Follow these instructions to change the water connec-  
tions from the left-hand side (standard) to the right-  
hand side.  
WARNING: Care must be taken to ensure that the  
equipment room is not under negative pressure con-  
ditions or that the equipment is not common-vented  
with other gas-fired appliances.  
1. Disconnect all electrical power from the heater (if  
applicable).  
2. Label all electrical connections and conduit lines.  
This may include the flow switch, low water cut-off  
probe and/or pump.  
3. For heaters not using a barometric damper in the  
vent system, and when air supply is provided by  
natural air flow from outdoors for a power burner  
and there is no draft regulator, drafthood or similar  
flue gas dilution device installed in the same  
space, in addition to the opening for ventilation air  
required in 1., there shall be a permanent air sup-  
ply opening(s) having a total cross-sectional area  
3. Disconnect or isolate the main gas pipe from the  
heater (if applicable).  
4. Remove both in/out and return header access  
panels by removing all sheet metal screws.  
14  
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5. Remove all plumbing fittings to the header. This  
will include both inlet and outlet water pipe unions  
and the pressure relief valve and drain piping.  
Hydrostatic Test  
Unlike many types of heaters, this heater does not re-  
quire hydrostatic testing prior to being placed in opera-  
tion. The heat exchanger has already been factory-  
tested and is rated for 160 psi operating pressure.  
However, Raypak does recommend hydrostatic test-  
ing of the piping connections to the heater and the rest  
of the system prior to operation. This is particularly  
true for hydronic systems using expensive glycol-  
based anti-freeze. Raypak recommends conducting  
the hydrostatic test before connecting gas piping or  
electrical supply.  
6. Remove limits, control bulbs and/or thermocou-  
ples.  
7. Remove the eight flange nuts and the in/out head-  
er from the left-hand side.  
8. Remove the eight flange nuts and the return head-  
er from the right-hand side.  
9. Reverse the headers to the new location.  
Leaks must be repaired at once to prevent damage to  
the heater. NEVER use petroleum-based stop-leak  
compounds.  
10. Install NEW red beveled O-rings flush against both  
tube sheets with the bevel facing outward.  
11. Push the header firmly against the O-rings. Install  
and tighten the flange nuts onto the stud bolts until  
finger tight.  
To perform hydrostatic test:  
1. Connect fill water supply. With bleed valve open,  
fill heater with water. When water flows from bleed  
valve, shut off water. Close bleed valve. Carefully  
fill the rest of the system, making sure to eliminate  
any entrapped air by using high-point vents. Close  
feed valve. Test at standard operating pressure for  
at least 24 hours.  
12. Slowly tighten the flange nuts, starting from the  
center nut (number 1) in Fig. 9 and working se-  
quentially around the header as indicated. Torque  
all nuts to 25 ft/lb. DO NOT OVER-TIGHTEN.  
13. Re-route the capillary(s), wiring etc. to the new  
location, adding thermal paste and shim to the  
capillary well.  
2. Make sure constant gauge pressure has been  
maintained throughout test.  
3. Check for leaks. Repair if found.  
Cold Water Operation  
CAUTION: Damaging internal condensation may  
occur if the heater inlet water temperature does not  
exceed 105ºF (41ºC) within 7 minutes of start-up.  
A heater operated with an inlet temperature of less  
than 105ºF (41ºC) must have a manual bypass or an  
approved low-temperature operation system to pre-  
vent problems with condensation. A manual bypass,  
shown in Fig. 15, must be piped into the system at the  
time of installation. This piping is like a primary/sec-  
ondary boiler installation with a bypass acting as the  
secondary boiler piping. Raypak strongly recommends  
that thermometer(s) be placed into the heater piping  
next to the in/out header to facilitate temperature  
adjustment. Inlet water temperatures below 105ºF  
(41ºC) can excessively cool the products of combus-  
tion, resulting in condensation on the heat exchanger  
and in the flue.  
Fig. 9: Torque Sequence  
Relief Valve Piping  
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.  
15  
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Failure to exceed 105ºF (41ºC) within 7 minutes may shutting down the heater. Thus an automatic valve  
result in the premature failure of the hot surface ignit- system, such as a three-way proportional valve or a  
er, remote flame sensor, burners and heat exchanger. modulating two-way valve to control the bypass,  
It can cause operational problems, bad combustion, should be utilized.  
sooting, flue gas spillage and reduced service life of  
the vent system. The bypass allows part of the heater Cold Water Run  
discharge water to be mixed with the cooler heater  
return water to increase the heater inlet temperature Cold water run differs from cold water start in that the  
above 105ºF (41ºC). This precautionary measure system water entering the heater remains below 105ºF  
should prevent the products of combustion from con- (41ºC) continuously. Typically, this is the case in swim-  
densing in most installations. Warranty claims will be ming pool heating and water source heat pump appli-  
denied when condensation occurs.  
cations as well as some others. If the system water is  
kept in a narrow temperature range, a permanent  
Cold water operation issues are applicable to both manual bypass can be employed and manually adjust-  
cold water start and cold water run applications. Cold ed to achieve an inlet temperature of 105ºF (41ºC) or  
water operation for 7 minutes or less on start-up is higher. An injector pump arrangement may also be uti-  
acceptable. Where cold water starts will last longer lized to keep the heater loop at or above 105ºF (41ºC).  
than 7 minutes or where cold water operation is con- An injector pump approach has the added value of  
tinuous, provisions must be made to mix higher tem- being able to adjust to changes in the system water  
perature outlet water with the colder inlet water and coming back to the heater take-off.  
thereby raise the inlet temperature to at least 105ºF  
(41ºC) within the 7-minute time limit.  
Temperature & Pressure Gauge  
Cold Water Starts  
The temperature and pressure gauge is factory-  
mounted in the in/out header.  
Frequent (more than once a week) cold water starts,  
wherein the inlet water temperature remains below  
105ºF (41ºC) for more than 7 minutes, must have cold  
water start protection. Known protection methods con-  
sist of mixing heated outlet water with the inlet water  
with a bypass to raise the inlet to 105ºF (41ºC) or high-  
er. Once the system is heated up and has return water  
temperatures of 105ºF (41ºC) or higher, the mixing of  
outlet water with inlet water is no longer needed and  
the bypass can be shut off. If the bypass is not shut off  
as the system heats up, the outlet temperature may  
continue to climb and actuate the high limit, thereby  
Hydronic Heating  
Pump Selection  
In order to ensure proper performance of your heater  
system, you must install a correctly sized pump. Ray-  
pak recommends using a 20°F ΔT as design ΔT. (ΔT is  
the temperature difference between the inlet and out-  
let water when the heater is firing at full rate). If a ΔT  
of larger than 20°F is necessary, see Table H and  
Table I for flow rate requirements.  
Min. Flow  
Max Flow  
10°F T  
20°F T  
30°F T  
40°F T  
Model  
No.  
gpm  
gpm  
gpm  
gpm  
gpm  
gpm  
P (ft)  
P (ft)  
P (ft)  
P (ft)  
P (ft)  
T
P (ft)  
T
302A  
402A  
502A  
50  
67  
84  
3.1  
5.5  
25  
34  
42  
55  
63  
76  
0.8  
1.4  
2.3  
4.1  
5.7  
8.3  
N/A  
22  
28  
36  
42  
50  
N/A  
0.6  
1.1  
1.8  
2.6  
3.8  
N/A  
N/A  
21  
N/A  
N/A  
0.6  
1.1  
1.5  
2.2  
20  
20  
21  
27  
32  
38  
0.5  
0.5  
0.6  
1.1  
1.5  
2.2  
25 90  
34 90  
40 90  
40 90  
40 90  
40 90  
9.8  
6
10.0  
10.4  
7
9
9.1  
652A N/A  
752A N/A  
902A N/A  
N/A  
N/A  
N/A  
27  
10.8 12  
11.3 14  
11.7 17  
32  
38  
Notes:  
1. Basis for minimum flow is 20 gpm or 40°F ΔT. Basis for maximum flow is 90 gpm. Flow switch will not operate if flow is less  
than 20 gpm.  
2. Rear-mounted pumps may provide higher flow rates on smaller models than the system requirements.  
Table H: Heater Rates of Flow and Pressure Drops  
16  
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heaters which are not subject to thermal shock.  
Raypak offers a full line of electronic sequencers that  
produce direct reset of heater water temperature.  
Pressure Drop in Feet of Head  
Feedwater Regulator  
(Refer to the Controls section of the Raypak Catalog.)  
Raypak recommends that a feedwater regulator be in-  
stalled and set at 12 psi minimum pressure at the high-  
est point of the system. Install a check valve or back  
flow device upstream of the regulator, with a manual  
shut-off valve as required by local codes.  
Piping  
All high points should be vented. Purge valves and a  
bypass valve should be installed. A heater installed  
above radiation level must be provided with a low wa-  
ter cut-off device (sales order option F-10). The heater,  
when used in connection with a refrigeration system,  
must be installed so that the chilled medium is piped in  
parallel with the heater with appropriate valves to pre-  
vent the chilled medium from entering the heater.  
The piping system of a hot water heater connected to  
heating coils located in air handling units where they  
may be exposed to circulating refrigerated air, must be  
equipped with flow control valves or other automatic  
means to prevent gravity circulation of the heater  
water during the cooling cycle. It is highly recommend-  
ed that the piping be insulated.  
Fig. 11: Single Heater - Low-Temperature (Heat Pump)  
Application with Primary/Secondary Piping  
Air-Separation/Expansion Tank  
All heaters should be equipped with a properly sized  
expansion tank and air separator fitting as shown in  
Fig. 10.  
Fig. 12: Dual Heaters (Reverse/Return)  
with Primary/Secondary Piping  
Domestic Hot Water  
Fig. 10: Air-Separation/Expansion Tank  
Three-Way Valves  
When designing the water piping system for domestic  
hot water applications, water hardness should be con-  
sidered. Table I indicates the suggested flow rates for  
soft, medium and hard water. Water hardness is ex-  
pressed in grains per gallon.  
Valves designed to blend water temperatures or  
reduce water circulation through the heater should not  
be used. Raypak heaters are high-recovery, low-mass  
17  
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Potable Water and Space Heating  
CAUTION: When this heater is used for both  
potable water and space heating, observe the follow-  
ing to ensure proper operation.  
1. All piping materials and components connected to  
the water heater for the space heating application  
shall be suitable for use with potable water.  
2. Toxic chemicals, such as used for boiler treatment,  
shall not be introduced into the potable water used  
for space heating.  
Fig. 13: Single Domestic Hot Water Heater and Storage  
Tank  
Pool Heating  
3. If the heater will be used to supply potable water,  
it shall not be connected to any heating system or  
components previously used with a non-potable  
water heating appliance.  
CAUTION: Power to the heater should be inter-  
locked 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 instructions to make sure your heater is prop-  
erly installed.  
4. When the system requires water for space heating  
at temperatures higher than 140°F, a means such  
as a mixing valve shall be installed to temper the  
water in order to reduce scald hazard potential.  
The Hi Delta pool heater is equipped with an external  
pump and bypass arrangement as standard equip-  
ment. This arrangement blends outlet water with the  
inlet water to increase the inlet water temperature,  
thereby reducing the likelihood of condensation form-  
ing on the heat exchanger. The pump also serves to  
Soft (0-4 grains per gallon) Medium (5-15 grains per gallon) Hard* (16+ grains per gallon)  
Model  
No.  
gpm  
MTS SHL  
gpm  
MTS  
SHL  
gpm  
MTS SHL  
T
P
T
P
T
P
302A 13  
402A 17  
502A 21  
652A 28  
752A 30  
902A 30  
40 2.0  
40 2.0  
40 2.1  
40 2.2  
42 2.6  
51 3.9  
2
2
2
2
2
2
4.3 10  
4.4 13  
4.5 16  
4.6 20  
5.2 20  
7.6 20  
52  
52  
52  
55  
63  
76  
3.3  
3.4  
3.5  
4.1  
5.7  
8.4  
2
2
2
2
2
2
7.1  
7.2  
7.4  
8.4  
6
90  
90  
90  
90  
90  
90  
9.8  
2
2
2
2
2
2
20.3  
20.5  
20.9  
21.3  
21.8  
22.2  
8
9
10.0  
10.4  
10.8  
11.3  
11.7  
12  
11.1 14  
16.1 17  
ΔT = Temperature rise, °F  
ΔP = Pressure drop through heat exchanger, ft  
SHL = System head loss, ft (based on heater and tank placed no more than 5 ft apart and equivalent length pipe/fittings of 2” tube = 25 ft)  
gpm = Gallons per minute, flow rate  
MTS = Minimum tubing size  
* Must use optional cupro-nickel tubes. If over 25 grains per gallon, a water softening system must also be used  
Table I: Domestic Water Heater Flow Rate Requirements  
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circulate water through the heater from the main sys-  
tem piping.  
perature to 105°F and Valve A is fully open, then  
slowly throttle Valve B closed to increase the inlet  
water temperature to 105°F.  
To complete the installation of the pool heater, the pool  
thermostat needs to be installed in the main return wa-  
ter line, upstream of the heater. This will ensure that  
the heater will be energized at the right time. If the  
main water line is too far away from the heater and the  
capillary bulb will not reach it, locate the pool thermo-  
stat adjacent to the main line and run wires back to the  
heater.  
Fig. 15: “H” Bypass Setting  
Automatic Chlorinators and Chemical  
Feeders  
Fig. 14: Single Pool Heater Application  
CAUTION: Combustion air must not be contami-  
nated by corrosive chemical fumes which can dam-  
age the heater and void the warranty.  
Adjustment of the manual bypass valve is critical to  
proper operation of the heater. The manual bypass  
valve should be adjusted to achieve a minimum inlet  
water temperature of 105°F and an outlet water tem- All chemicals must be introduced and completely di-  
perature below 140°F. When starting with a cold pool, luted into the pool or spa water before being circulated  
make initial adjustments. Make final adjustments when through the heater. Do not place chlorine tablets or  
pool water approaches desired temperature.  
bromine sticks in the skimmer. High chemical concen-  
trations will result when the pump is not running (e.g.  
The use of a bypass is required for proper operation in overnight).  
a pool heating application. Use the following instruc-  
tions to set the manual bypass:  
Chlorinators must feed downstream of the heater and  
have an anti-siphoning device to prevent chemical  
open position, and back-up into the heater when the pump is shut off.  
1
1. Set Valve A (the bypass) to ⁄  
2
Valve B to fully open position.  
NOTE: High chemical concentrates from feeders  
and chlorinators that are out of adjustment will cause  
very rapid corrosion of the heat exchanger in the  
heater. Such damage is not covered under the war-  
ranty.  
2. Turn on pump.  
3. Turn on heater and wait until heater goes to full  
fire.  
4. Adjust Valve A until the inlet water temperature is  
105°F. NOTE: Opening the valve will increase the Winterizing Your Heater  
temperature and closing the valve will decrease  
the temperature.  
Heaters installed outdoors in freezing climate areas  
should be shut down for the winter. To shut down  
heater, turn off manual main gas valve and main gas  
5. If this process does not raise the inlet water tem-  
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shut-off. Close isolation valves and remove water pip- Total Dissolved Solids  
ing from the in/out header on the heater. Drain the  
heater and any piping of all water that may experience Total dissolved solids (TDS) is the measure of all min-  
below-freezing temperatures.  
erals and solids that are dissolved in the water. The  
concentration of total dissolved solids is usually ex-  
pressed in parts per million (ppm) as measured in a  
water sample. Water with a high TDS concentration  
will greatly accelerate lime and scale formation in the  
hot water system. Most high TDS concentrations will  
precipitate out of the water when heated. This can  
generate a scale accumulation on the heat transfer  
surface that will greatly reduce the service life of a  
water heater. This scale accumulation can also  
Pool/Spa Water Chemistry  
NOTE: Chemical imbalance can cause severe dam-  
age to your heater and associated equipment.  
Water Hardness  
Water hardness is mainly due to the presence of cal- impede adequate flow of water and may totally block  
cium and magnesium salts dissolved in the water. The the water passages in the tubes of the heat exchang-  
concentration of these salts is expressed in mg/l, ppm er. A heat exchanger that is damaged or blocked by  
or grains per gallon, as a measure of relative hardness lime/scale accumulation must be replaced. Failure of a  
of water. Grains per gallon is the common reference water heater due to lime scale build up on the heating  
measurement used in the U.S. water heater industry. surface is non-warrantable. The manufacturer of the  
Hardness expressed as mg/L or ppm may be divided water heater has no control of the water quality, espe-  
by 17.1 to convert to grains per gallon. Water may be cially the TDS levels in your system. Total dissolved  
classified as very soft, slightly hard, moderately hard solids in excess of 2,500 ppm will accelerate lime and  
or hard based on its hardness number. The salts in scale formation in the heat exchanger. Heat exchang-  
water will precipitate out when the water is heated and er failure due to total dissolved solids in excess of  
will cause accelerated lime and scale accumulation on 2,500 ppm is a non-warrantable condition. Raypak  
a heat transfer surface.  
offers basic temperature guidelines for operation of a  
potable water heater on normal to moderate levels of  
Raypak water heaters can operate lime/scale-free hardness and solids but levels of hardness and total  
using potable water with a hardness not exceeding 25 dissolved solids beyond normal limits for operation will  
grains per gallon. Proper operation is achieved by set- require special setup and operation.  
ting the temperature rise/water flow per the guidelines  
in the installation instructions. If the hardness of the  
NOTE: Failure of a heat exchanger due to lime  
water exceeds the maximum level of 25 grains per gal-  
scale build-up on the heating surface, low pH or  
lon special measures must be taken to adjust flow and  
other chemical imbalance is non-warrantable.  
temperature rise. Water should be softened to a hard-  
ness level no lower than 5 grains per gallon. Water  
softened as low as 0 to 1 grain per gallon may be  
under-saturated with respect to calcium carbonate  
Gas Supply  
resulting in water that is aggressive and corrosive.  
DANGER: Make sure the gas on which the heater  
will operate is the same type as specified on the  
heater’s rating plate.  
pH of Water  
pH is a measure of relative acidity, neutrality or alka-  
linity. Dissolved minerals and gases affect water’s pH.  
The pH scale ranges from 0 to 14. Water with a pH of  
7.0 is considered neutral. Water with a pH lower than  
7 is considered acidic. Water with a pH higher than 7  
is considered alkaline. A neutral pH (around 7) is desir-  
able for most potable water applications. Corrosion  
damage and water heater failures resulting from water  
pH levels of lower than 6 or higher than 8 are non-war-  
rantable. The ideal pH range for water used in a stor-  
age tank or a copper water heater system is 7.2 to 7.8.  
Gas piping must have a sediment trap ahead of the  
heater gas controls, and a manual shut-off valve lo-  
cated outside the heater jacket. It is recommended  
that a union be installed in the gas supply piping adja-  
cent to the heater for servicing. A pounds-to-inches  
regulator must be installed to reduce the gas supply  
pressure to a maximum of 10.5 in. WC for natural gas  
and 13.0 in. WC for propane gas. The regulator should  
be placed a minimum distance of 10 times the pipe  
diameter up-stream of the heater gas controls. Refer  
to Table J for maximum pipe lengths.  
20  
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Gas Supply Connection  
CAUTION: Support gas supply piping with hang-  
ers, not by the heater or its accessories. Make sure  
the gas piping is protected from physical damage  
and freezing, where required.  
CAUTION: The heater 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).  
Reversing Gas Supply Connection  
Reversing the standard fuel connection from the left-  
hand to the right-hand side is a simple field operation.  
The heater must be isolated from the gas supply pip-  
ing system by closing the manual shut-off valve during  
any pressure testing of the gas supply piping system  
at test pressures equal to or less than 1/2 psi (3.45  
kPa). Relieve test pressure in the gas supply line prior  
to reconnecting the heater and its manual shut-off  
valve to the gas supply line. FAILURE TO FOLLOW  
THIS PROCEDURE MAY DAMAGE THE GAS  
VALVES. Over pressurized gas valves are not cov-  
ered by warranty. The heater and its gas connections  
shall be leak-tested before placing the appliance in  
operation. Use soapy water for leak test. DO NOT use  
an open flame.  
1. Disconnect all electrical power from the heater (if  
applicable).  
2. Disconnect the main gas pipe from the heater (if  
applicable).  
3. Remove the left and right front panels from the  
heater.  
4. Locate the main gas line that traverses across the  
heater above the manifold risers.  
5. Remove the pipe cap from the right-hand end of  
the main gas line.  
6. Reinstall the pipe cap on the left-hand end of the  
main gas line.  
CAUTION: Do not use Teflon tape on main gas line  
pipe thread. A pipe compound rated for natural and  
propane gases is recommended. Apply sparingly  
only on male pipe ends leaving the two end threads  
bare.  
Fig. 16: Gas Supply Connection  
CAUTION: Do not use Teflon tape on gas line pipe  
thread. A pipe compound rated for use with natural  
and propane gases is recommended. Apply sparing-  
ly only on male pipe ends, leaving the two end  
threads bare.  
7. Remove plastic cap from the right-hand side panel  
and reinstall into the standard main gas opening  
located on the left-hand side of the heater.  
3/4"  
1”  
1-1/4”  
1-1/2”  
2”  
2-1/2”  
Model  
No.  
N
P
25  
15  
--  
N
35  
25  
--  
P
N
P
N
P
--  
--  
N
--  
--  
P
--  
--  
--  
--  
N
P
--  
--  
--  
--  
--  
--  
302A  
402A  
502A  
652A  
752A  
902A  
15  
--  
85 150 380 360  
60 100 260 250  
--  
--  
--  
--  
--  
--  
--  
--  
--  
--  
65 150 130 360 500  
45 100 95 250 340  
--  
--  
--  
--  
--  
--  
35  
20  
80  
45  
75 180 260 600  
--  
--  
--  
45 110 150 360 400  
Natural gas – 1,000 BTU per ft3, .60 specific gravity at 0.5 in. WC pressure drop  
Propane gas – 2,500 BTU per ft3, 1.53 specific gravity at 0.6 in. WC pressure drop  
Table J: Maximum Equivalent Pipe Length  
21  
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8. Remove the rubber grommet from the left-hand-  
side panel and reinstall into the standard main gas  
opening, located on the right-hand side of the  
heater.  
Electrical Power Connections  
Installations must follow these codes:  
•
National Electrical Code and any other national,  
state, provincial or local codes or regulations hav-  
ing jurisdiction.  
Safety wiring must be NEC Class 1.  
Heater must be electrically grounded as required  
by the NEC.  
9. Install a coupling, nipple, union and sediment trap  
onto the right-hand end of the main gas line and  
then install the gas line, making sure that a manu-  
al shut-off valve has been installed within 10 ft of  
the heater.  
•
•
•
In Canada, CSA C22. 1 C.E.C. Part 1.  
10. Replace the left and right front panels on the  
heater.  
The heater is wired for 120 VAC, 8 amps. The voltage  
is indicated on the tie-in leads. Consult the wiring dia-  
gram shipped with the heater in the instruction packet.  
The remote tank control stat, thermostat, or electronic  
heater control (as applicable) may be connected to the  
stage selector terminal (See wiring diagram). 24 VAC  
is supplied to this connection through the heater trans-  
former. DO NOT attach any voltage to the stage se-  
lector terminals. Before starting the heater check to  
ensure proper voltage to the heater and pump.  
Gas Supply Pressure  
A minimum of 5.0 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 11.0  
in. WC and a maximum of 13.0 in. WC is required for  
propane gas. The gas pressure regulator(s) supplied  
on the heater is for low-pressure service. If upstream  
pressure exceeds 14.0 in. WC, an intermediate gas  
pressure regulator, of the lockup type, must be  
installed.  
Install a separate disconnect means for each load.  
Use appropriately sized wire as defined by NEC, CSA  
and/or local code. All primary wiring should be 125% of  
minimum rating.  
When connecting additional gas utilization equipment  
to the gas piping system, the existing piping must be  
checked to determine if it has adequate capacity for  
the combined load.  
If any of the original wire as supplied with the heater  
must be replaced, it must be replaced with 105°C wire  
or its equivalent.  
The gas valve pressure regulator(s) on the heater are  
nominally preset at 3.5 in. WC for natural gas, and  
10.5 in. WC for propane gas. The pressure at the gas  
valve outlet tap, measured with a manometer, while in  
operation should be 3.5 0.1 in. WC for natural gas  
and 10.5 in. 0.1 in. WC for propane gas. If an adjust-  
ment is needed, remove the adjustment screw cover  
and turn the adjustment screw clockwise to increase  
pressure or counter-clockwise to lower pressure.  
Field-Connected Controllers  
It is strongly recommended that all individually-pow-  
ered control modules and the heater should be sup-  
plied from the same power source.  
NOTE: Field-supplied isolation relays should be  
installed when field-connected controllers are  
mounted more than 50 equivalent feet (18 Ga) from  
heater.  
Check the Power Source  
WARNING: Using a multi-meter, check the follow-  
ing voltages at the circuit breaker panel prior to con-  
necting any equipment. Make sure proper polarity is  
followed and house ground is proven. (See Fig. 18.)  
Fig. 17: Gas Valve  
22  
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prior to working with any electrical connections or  
components.  
BLACK  
CIRCUIT  
BREAKER  
3. Observe proper wire colors while making electri-  
cal connections. Many electronic controls are po-  
larity sensitive. Components damaged by improp-  
er electrical installation are not covered by warran-  
ty.  
WHITE  
GREEN  
GROUND  
4. Provide overload protection and a disconnect  
means for equipment serviceability as required by  
local and state code.  
A
B
C
Fig. 18: Wiring Connections  
5. Install heater controls, thermostats, or building  
management systems in accordance with the  
applicable manufacturers’ instructions.  
Check the power source:  
AC = 108 VAC Minimum, 132 VAC MAX  
AB = 108 VAC Minimum, 132 VAC MAX  
BC = <1 VAC Maximum  
6. Conduit should not be used as the earth ground.  
NOTE: A grounding electrode conductor shall be  
used to connect the equipment grounding conduc-  
tors, the equipment enclosures, and the grounded  
service conductor to the grounding electrode.  
Field Wiring Connection  
Fig. 19: Multi-meter  
If the heater does not have a factory-wired stage con-  
troller, it is factory-wired in an on-off configuration with  
other stage terminals jumpered.  
To field-connect a stage controller, remove factory-  
installed jumper and wire stage controller as shown in  
Fig. 21.  
Making the Electrical Connections  
Fig. 20: Wiring Location  
Refer to Fig. 18-23.  
1. Verify that circuit breaker is properly sized by  
referring to heater rating plate. A dedicated circuit  
breaker should be provided.  
CAUTION: Label all wires prior to disconnection  
when servicing controls. Wiring errors can cause im-  
proper and dangerous operation. Verify proper oper-  
ation after servicing.  
2. Turn off all power to the heater. Verify that power  
has been turned off by testing with a multi-meter  
23  
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DANGER: SHOCK HAZARD  
Make sure electrical power to the heater is discon-  
nected to avoid potential serious injury or damage to  
components.  
Fig. 21: Wiring Connections  
24  
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Installer action is required to electrically enable your  
heater to operate after making the power connections.  
You must make a closed contact connection on Stage  
1 connector of the Central Point Wiring (CPW) board  
for temperature control connections. This will be done  
based on the controller option selected with your  
heater order.  
SINGLE  
STAGE  
TANKSTAT  
STAGE 1  
CONNECTION  
1. For Pool and Closed-Loop Water-Source Heat  
Pump applications, your heater should be config-  
ured to operate in an on-off firing mode. This  
means that you will connect a single-pole control  
to stage one of the CPW board. Then jumper the  
remaining firing stages. For example, if your  
heater is a Model 1532A, you will jumper stages  
two, three and four. Then your heater will either be  
on at full fire, or it will be off.  
ATTACH STAGE 1 CONNECTIONS  
ON HEATER TO THE SINGLE STAGE  
TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.  
Fig. 23: Single-Stage Tankstat  
Consult the wiring diagram shipped with the heater in  
the instruction packet or at the end of this section. The  
stage-selector terminals are for the remote tank con-  
trol through the heater’s 24 VAC transformer. DO NOT  
attach any voltage to the stage-selector terminals.  
Before starting the heater, check to ensure proper volt-  
age to the heater and pump.  
2. For 2-stage controller connections, connect each  
stage of the control to the corresponding stage of  
the CPW board in the heater, i.e., stage 1 of the  
heater to stage 1 of the control; stage 2 of the  
heater to stage 2 of the control, as shown in Fig.  
21 and 22. Set the operating control to the set-  
point at which you want the heater to maintain.  
Ensure that the sensing bulb of the control is at the  
point in the system that will best maintain the tem-  
perature you want. For example, when you are  
heating a tank of water, you want the operating  
control sensor bulb in the tank.  
NOTE: If any of the original wire supplied with the  
heater must be replaced, it must be replaced with  
similar sized 105°C wire or its equivalent.  
Venting  
3. For single-stage controller connections, attach the  
stage 1 connections on heater 1 to the tankstat per  
Fig. 23.  
NOTE: For 87%-efficiency boilers, see special  
instructions on page 39.  
Heater must be electrically grounded in accordance  
with the NEC, and CSA C22.1 C.E.C. Part 1 in  
Canada.  
CAUTION: Proper installation of flue venting is criti-  
cal for the safe and efficient operation of the heater.  
General  
2-STAGE  
TANKSTAT  
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.  
STAGE 2 CONNECTION OR  
STAGE 1 CONNECTION  
STAGE 1  
CONNECTION  
OF HEATER 2  
Category I – A heater which operates with a non-pos-  
itive vent static pressure and with a vent gas tempera-  
ture that avoids excessive condensate production in  
the vent.  
ATTACH STAGE 1 CONNECTIONS ON HEATER  
TO STAGE 1 CONNECTION ON TANKSTAT.  
ATTACH STAGE 2 CONNECTIONS OR  
STAGE 1 CONNECTION OF HEATER 2  
TO STAGE 2 CONNECTIONON TANKSTAT  
AS SHOWN IN THE DIAGRAM.  
Category II – A heater which operates with a non-pos-  
itive vent static pressure and with a vent gas tempera-  
ture that may cause excessive condensate production  
in the vent.  
Fig. 22: 2-Stage Tankstat  
25  
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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.  
Vent Terminal Location  
NOTE: During winter months check the vent cap  
and make sure no blockage occurs from build-up of  
snow or ice.  
Category IV – A heater which operates with a positive  
vent pressure and with a vent gas temperature that  
may cause excessive condensate production in the  
vent.  
1. Condensate can freeze on the vent cap. Frozen  
condensate on the vent cap can result in a blocked  
flue condition.  
See Table K for appliance category requirements.  
2. Give special attention to the location of the vent  
termination to avoid possibility of property dam-  
age or personal injury.  
NOTE: For additional information on appliance cat-  
egorization, see appropriate ANSI Z21 Standard and  
the NFGC (U.S.), or B149.1 (Canada), or applicable  
provisions of local building codes.  
3. Gases may form a white vapor plume in winter.  
The plume could obstruct a window view if the ter-  
mination is installed near windows.  
CAUTION: When condensate traps are installed,  
condensate must be routed to an appropriate con-  
tainer for neutralization before disposal, as required  
by local codes.  
4. Prevailing winds, in combination with below-freez-  
ing temperatures, can cause freezing of conden-  
sate and water/ice build-up on buildings, plants or  
roofs.  
WARNING: Contact the manufacturer of the vent  
material if there is any question about the appliance  
categorization and suitability of a vent material for  
application on a Category III or IV vent system.  
Using improper venting materials can result in per-  
sonal injury, death or property damage.  
5. The bottom of the vent terminal and the air intake  
shall be located at least 12 in. above grade, includ-  
ing normal snow line.  
6. Un-insulated single-wall metal vent pipe shall not  
be used outdoors in cold climates for venting gas-  
fired equipment.  
Support of Vent Stack  
7. Through-the-wall vents for Category II and IV  
appliances and non-categorized condensing appli-  
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.  
The weight of the vent stack or chimney must not rest  
on the heater vent connection. Support must be pro-  
vided in compliance with applicable codes. The vent  
should also be installed to maintain proper clearances  
from combustible materials.  
Use insulated vent pipe spacers where the vent pass-  
es through combustible roofs and walls.  
Combustion  
Air Supply  
Exhaust  
Configuration  
Heater Venting  
Category  
Certified  
Materials  
Combustion Air  
Inlet Material  
Vertical Natural  
Draft Venting  
I
“B” Vent  
From Inside Building  
(Non-Direct Venting)  
Horizontal Through-  
the-Wall Venting  
Stainless Steel  
(Gas Tight)  
III  
I
Vertical Natural  
Draft Venting  
Galvanized Steel  
PVC  
“B” Vent  
From Outside Building  
(Direct Venting)  
ABS  
CPVC  
Horizontal Through-  
the-Wall Venting  
Stainless Steel  
(Gas Tight)  
III  
Table K: Venting Category Requirements  
26  
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8. Locate and guard vent termination to prevent acci- Canadian Installations  
dental contact by people or pets.  
Refer to latest edition of B149.1.  
9. DO NOT terminate vent in window well, stairwell,  
alcove, courtyard or other recessed area.  
A vent shall not terminate:  
10. DO NOT terminate above any door, window, or 1. Directly above a paved sidewalk or driveway  
gravity air intake. Condensate can freeze, causing  
ice formations.  
which is located between two single-family dwell-  
ings and serves both dwellings.  
11. Locate or guard vent to prevent condensate from 2. Less than 7 ft (2.13 m) above a paved sidewalk or  
damaging exterior finishes. Use a rust-resistant  
sheet metal backing plate against brick or mason-  
ry surfaces.  
paved driveway located on public property.  
3. Within 6 ft (1.8 m) of a mechanical air supply inlet  
to any building.  
12. DO NOT extend exposed vent pipe outside of  
building. Condensate could freeze and block vent 4. Above a meter/regulator assembly within 3 ft (915  
pipe.  
mm) horizontally of the vertical centre-line of the  
regulator.  
U.S. Installations  
5. Within 6 ft (1.8 m) of any gas service regulator  
vent outlet.  
Refer to the latest edition of the National Fuel Gas  
Code.  
6. Less than 1 ft (305 mm) above grade level.  
Vent termination requirements are as follows:  
7. Within the 3 ft (915 mm) of a window or door which  
can be opened in any building, any non-mechani-  
cal air supply inlet to any building or the combus-  
tion air inlet of any other appliance.  
1. Vent must terminate at least 4 ft below, 4 ft hori-  
zontally from or 1 ft above any door, window or  
gravity air inlet to the building.  
2. The vent must not be less than 7 ft above grade 8. Underneath a verandah, porch or deck, unless the  
when located adjacent to public walkways.  
verandah, porch or deck is fully open on a mini-  
mum of two sides beneath the floor, and the dis-  
tance between the top of the vent termination and  
the underside of the verandah, porch or deck is  
greater than 1 ft (305 mm).  
3. Terminate vent at least 3 ft above any forced air  
inlet located within 10 ft.  
4. Vent must terminate at least 4 ft horizontally, and  
in no case above or below unless 4 ft horizontal  
distance is maintained, from electric meters, gas  
meters, regulators, and relief equipment.  
Changing the Flue Outlet  
Follow these instructions to change the flue connec-  
tion from the standard top location to the rear of the  
heater.  
5. Terminate vent at least 6 ft away from adjacent  
walls.  
1. Disconnect all electrical power from the heater (if  
applicable).  
6. DO NOT terminate vent closer than 5 ft below roof  
overhang.  
2. Disconnect or isolate the main gas pipe from the  
heater (if applicable).  
7. The vent terminal requires a 12 in. vent terminal  
clearance from the wall.  
3. Remove the screws, gasket and dustcover from  
the rear of the heater.  
8. Terminate vent at least 1 ft above grade, including  
normal snow line.  
4. Remove the screws, stainless steel flue cover and  
gasket from the branch side of the tee located in  
the flue box at the rear of the heater.  
9. Multiple direct vent installations require a 4 ft  
clearance between the ends of vent caps located  
on the same horizontal plane.  
27  
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5. Remove the screws, retaining ring and rain gasket The maximum and minimum venting length for Cate-  
from top of heater.  
gory I appliances shall be determined per the NFGC  
(U.S.) or B149.1 (Canada).  
6. Remove the screws, flue collar and gasket from  
the run side of the tee located in the flue box on The diameter of vent flue pipe should be sized accord-  
top of the heater.  
ing to the NFGC (U.S.) and B149.1 (Canada). The  
minimum flue pipe diameter for conventional negative  
7. Reverse the components and reattach in the new draft venting using double-wall Type B vent is: 5 in. for  
location.  
Model 302A, 6 in. for Models 402A and 502A, and 8 in.  
for Models 652A, 752A and 902A.  
8. Make sure that the stainless steel cover, now lo-  
cated on the run side of the tee, is sealed to avoid  
any flue gas spillage.  
NOTE: A vent adapter (field-supplied) must be used  
to connect Type B vent to the unit.  
CAUTION: The silicone vent gaskets must be prop-  
erly reinstalled to prevent flue gas leakage. Replace  
any torn or worn vent gaskets.  
Venting Installation Tips  
Support piping:  
•
•
•
horizontal runs - at least every 5 ft  
vertical runs - use braces  
under or near elbows  
WARNING: Examine the venting system at least  
once a year. Check all joints and vent pipe connec-  
tions for tightness, corrosion or deterioration.  
Venting Configurations  
For heaters connected to gas vents or chimneys, vent  
installations shall be in accordance with the NFGC  
(U.S.), or B149.1 (Canada), or applicable provisions of  
local building codes.  
Natural Draft Vertical Venting  
(Category I)  
Fig. 24: Natural Draft Vertical Venting  
(Category I)  
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 nega-  
tive draft must be within the range of -.01 to -.08 in.  
WC as measured 12 in. above the appliance flue out-  
let to ensure proper operation. Vent material must be  
listed by a nationally recognized test agency.  
The connection from the appliance vent to the stack  
must be as direct as possible and shall be the same di-  
ameter as, or larger than, the vent outlet. The horizon-  
tal breaching of a vent must have an upward slope of  
not less than 1/4 inch per linear foot from the heater to  
the vent terminal. The horizontal portions of the vent  
shall also be supported for the design and weight of  
the material employed to maintain clearances and to  
prevent physical damage or separation of joints.  
28  
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Termination  
WARNING: Vent connectors serving appliances  
vented by natural draft shall not be connected into  
any portion of mechanical draft systems operating  
under a positive pressure.  
The vent terminal should be vertical and should termi-  
nate outside the building at least 2 ft above the high-  
est point of the roof that is within 10 ft. The vent cap  
should have a minimum clearance of 4 ft horizontally  
from and in no case above or below (unless a 4 ft hori-  
zontal distance is maintained) electric meters, gas me-  
ters, regulators and relief equipment. The distance of  
CAUTION: Vent connectors for natural draft vent-  
ing systems must be Type B or better.  
the vent terminal from adjacent public walkways, adja- Common venting systems may be too large once an  
cent buildings, open windows and building openings existing unit is removed. At the time of removal of an  
must be consistent with the NFGC (U.S.) or B149.1 existing appliance, the following steps must be fol-  
(Canada). Gas vents supported only by flashing and lowed with each appliance remaining connected to the  
extended above the roof more than 5 ft should be se- common venting system placed in operation, while the  
curely guyed or braced to withstand snow and wind other appliances remaining connected to the common  
loads.  
venting system are not in operation.  
1. Seal any unused opening in the common venting  
system.  
CAUTION: A listed vent cap terminal, adequately  
sized, must be used to evacuate the flue products  
from the heaters.  
2. Visually inspect the venting system for proper size  
and horizontal pitch and verify there is no block-  
age, restriction, leakage, corrosion or other unsafe  
condition.  
Common Venting System  
Manifolds that connect more than one heater to a com-  
mon chimney must be sized to handle the combined 3. Insofar as is practical, close all building doors and  
load. Consult available guides for proper sizing of the  
manifold and the chimney. At no time should the area  
of the common vent be less than the area of the  
largest heater exhaust outlet.  
windows and all doors between the space in which  
the appliances remaining connected to the com-  
mon venting system are located and other spaces  
of the building. Turn on clothes dryers and any ap-  
pliance not connected to the common vent sys-  
tem. Turn on any exhaust fans, such as range  
hoods and bathroom exhausts, at maximum  
Vertical Venting  
Height*  
Air Inlet  
Max. Length**  
Certified  
Model Venting  
Material  
Combustion Air  
Intake Pipe  
Material  
Vent Size  
Min.  
Max.  
6”  
8”  
302A  
402A  
Cat. I  
502A  
5”  
6”  
100’  
N/A  
Galvanized Steel,  
PVC,  
75’  
40’  
(Type B  
Equivalent)  
5’  
25’  
ABS,  
CPVC  
652A  
752A  
902A  
100’  
8”  
* Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. When  
vertical height exceeds 25 ft, consult factory prior to installation.  
** Subtract 10 ft per elbow. Max. 3 elbows.  
Maximum combustion air duct length terminated at 100 equivalent ft.  
Table L: Category I Vertical Venting  
29  
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speed. Do not operate summer exhaust fan. Close The total length of the horizontal through-the-wall flue  
fireplace dampers.  
system should not exceed 70 equivalent ft in length. If  
horizontal run exceeds 70 equivalent ft, an appropri-  
4. Place in operation the appliances being inspected. ately sized extractor must be used. Each elbow used  
Follow the manufacturer’s instructions for lighting is equal to 10 ft of straight pipe. This will allow installa-  
each appliance. Adjust thermostat so appliance tion in one of the four following arrangements:  
will operate continuously.  
•
•
•
•
70’ of straight flue pipe  
5. 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 -0.01  
and -0.08 in. WC.  
60’ of straight flue pipe and one elbow  
50’ of straight flue pipe and two elbows  
40’ of straight pipe and three elbows  
The vent cap is not considered in the overall length of  
6. After it has been determined that each appliance the venting system.  
remaining connected to the common venting sys-  
tem properly vents when tested as outlined above, The vent must be installed to prevent flue gas leakage.  
return doors, windows, exhaust fans, fireplace Care must be taken during assembly to ensure that all  
dampers and other gas burning appliances to their joints are sealed properly and are airtight. The vent  
previous conditions of use.  
must be installed to prevent the potential accumulation  
of condensate in the vent pipes. It is required that:  
7. Any improper operation of the common venting  
system should be corrected so that the installation 1. The vent must be installed with a slight downward  
conforms with the NFGC (U.S.) or B149.1  
(Canada). When re-sizing any portion of the com-  
mon venting system, the common venting system  
slope of not more than 1/4 inch per foot of hori-  
zontal run to the vent terminal.  
should be re-sized to approach the minimum size 2. The vent must be insulated through the length of  
as determined using the appropriate tables in Ap-  
pendix G in the NFGC (U.S.) or B149.1 (Canada).  
the horizontal run.  
For installations in extremely cold climate, it is re-  
quired that:  
Horizontal Through-the-Wall Venting  
(Category III)  
1. The vent must be installed with a slight upward  
slope of not more than 1/4 inch per foot of hori-  
zontal run to the vent terminal. In this case, an ap-  
proved condensate trap must be installed per ap-  
plicable codes.  
2. The vent must be insulated through the length of  
the horizontal run.  
Termination  
The flue direct vent cap MUST be mounted on the ex-  
terior of the building. The direct vent cap cannot be  
installed in a well or below grade. The direct vent cap  
must be installed at least 1 ft above ground level and  
above normal snow levels. The Raypak-approved  
stainless steel flue direct vent cap must be used (sales  
order option D-15).  
Fig. 25: Horizontal Through-the-Wall Venting  
(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 installed horizontally through the wall to the out-  
doors. Adequate combustion and ventilation air must  
be supplied to the equipment room in accordance with  
the NFGC (U.S.) or B149.1 (Canada).  
WARNING: No substitutions of flue pipe or vent  
cap material are allowed. Such substitutions would  
jeopardize the safety and health of inhabitants.  
30  
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Combustion  
Air  
Intake Pipe  
Material  
Air Inlet  
Max. Length  
Certified  
Venting  
Material  
Maximum  
Vent Size Equivalent  
Vent Length*  
Model  
No.  
6”  
8”  
302A  
402A  
502A  
652A  
752A  
902A  
5”  
70’  
Room Air  
100’  
75’  
N/A  
Galvanized  
Steel,  
6”  
40’  
Ducted  
Combustion  
PVC,  
ABS,  
CPVC  
Category III  
100’  
80’  
40’  
8”  
Air  
30’  
* Subtract 10 ft per elbow. Max. 3 elbows.  
Maximum combustion air duct length terminated at 100 equivalent ft.  
Table M: Category III Horizontal and Direct Venting  
The total length of the through-the-wall flue cannot  
exceed 40 equivalent ft in length for the flue outlet.  
Each elbow used is equal to 10 ft of straight pipe. This  
will allow installation in one of the three following  
arrangements:  
Use only the special gas vent pipes listed for use with  
Category III gas burning heaters, such as the AL29-4C  
stainless steel vents offered by Heat Fab Inc. (800-  
772-0739), Protech System, Inc. (800-766-3473) or Z-  
Flex (800-654-5600). Pipe joints must be positively  
sealed. Follow the vent manufacturer’s installation  
instructions carefully.  
•
•
•
40’ of straight flue pipe  
30’ of straight flue pipe and one elbow  
20’ of straight flue pipe and two elbows.  
Direct Vent - Horizontal Through-  
the-Wall  
The total length of air supply pipe cannot exceed the  
distances listed in Table M. Each elbow used is equal  
to 10 ft of straight pipe. This will allow installation in  
any arrangement that does not exceed the lengths  
shown in Table M.  
The flue direct vent cap is not considered in the over-  
all length of the venting system.  
Care must be taken during assembly that all joints are  
sealed properly and are airtight.  
The vent must be installed to prevent the potential ac-  
cumulation of condensate in the vent pipes. It is re-  
quired that:  
Note: When vertical height exceeds 25 ft,  
consult factory prior to installation.  
1. The vent must be installed with a slight downward  
slope of not more than 1/4 inch per foot of hori-  
zontal run to the vent terminal.  
Fig. 26: Direct Vent - Horizontal Through-the-Wall  
2. The vent must be insulated through the length of  
the horizontal run.  
Installation  
These installations utilize the heater-mounted blower  
to draw combustion air from outdoors and vent com-  
bustion products to the outdoors.  
31  
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For installations in extremely cold climate, it is re-  
quired that:  
Direct Vent - Vertical  
1. The vent must be installed with a slight upward  
slope of not more than 1/4 inch per foot of hori-  
zontal run to the vent terminal. In this case, an ap-  
proved condensate trap must be installed per ap-  
plicable codes.  
2. The intake vent must be insulated through the  
length of the horizontal run.  
Termination  
The flue direct vent cap MUST be mounted on the ex-  
terior of the building. The direct vent cap cannot be  
installed in a well or below grade. The direct vent cap  
must be installed at least 1 ft above ground level and  
above normal snow levels.  
Note: When vertical height exceeds 25 ft, consult  
factory prior to installation.  
Fig. 27: Direct Vent - Vertical  
The direct vent cap MUST NOT be installed with any  
combustion air inlet directly above a direct vent cap.  
This vertical spacing would allow the flue products  
from the direct vent cap to be pulled into the combus-  
tion air intake installed above.  
Installation  
These installations utilize the heater-mounted blower  
to draw combustion air from outdoors and force the  
heated flue products through the vent pipe under posi-  
tive pressure. The vent material must be in accor-  
dance with the above instructions for vent materials.  
Vent material must be listed by a nationally recognized  
test agency.  
This type of installation can cause non-warrantable  
problems with components and poor operation of the  
heater due to the recirculation of flue products. Multi-  
ple direct vent caps should be installed in the same  
horizontal plane with a 4 ft clearance from the side of  
one vent cap to the side of the adjacent vent cap(s).  
The connection from the appliance flue to the stack  
must be as direct as possible and should be the same  
size or larger than the vent outlet.  
Combustion air supplied from outdoors must be free of  
particulate and chemical contaminants. To avoid a  
blocked flue condition, keep the vent cap clear of  
snow, ice, leaves, debris, etc.  
See Table L for Category I venting guidelines.  
It is recommended that in colder climates, the intake  
vent be insulated.  
WARNING: No substitutions of flue pipe or vent  
cap material are allowed. Such substitutions would  
jeopardize the safety and health of inhabitants.  
Termination  
The flue terminal should be vertical and should termi-  
nate outside the building at least 2 ft above the high-  
est point of the roof within 10 ft. The vent cap should  
have a minimum clearance of 4 ft horizontally from and  
in no case above or below (unless a 4 ft horizontal dis-  
tance is maintained) electric meters, gas meters, reg-  
ulators and relief equipment. The distance of the vent  
terminal from adjacent public walkways, adjacent  
buildings, open windows and building openings must  
be consistent with the NFGC (U.S.) or B149.1  
(Canada).  
The stainless steel flue direct vent cap must be fur-  
nished by the heater manufacturer in accordance with  
its listing (sales order option D-15).  
Use only the special gas vent pipes listed for use with  
Category III gas burning heaters, such as the AL29-4C  
stainless steel vents offered by Heat Fab Inc. (800-  
772-0739), Protech System, Inc. (800-766-3473) or Z-  
Flex (800-654-5600). Pipe joints must be positively  
sealed. Follow carefully the vent manufacturer’s instal-  
lation instructions.  
32  
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Flues supported only by flashing and extended above  
the roof more than 5 ft should be securely guyed or  
braced to withstand snow and wind loads.  
NOTE: Condensate can freeze on the vent cap.  
Frozen condensate on the vent cap can result in a  
blocked flue condition.  
The air inlet opening MUST be installed 1 ft above the  
roof line or above normal snow levels that might ob-  
struct combustion air flow. This dimension is critical to  
the correct operation of the heater and venting system  
and reduces the chance of blockage from snow. The  
vent cap must have a minimum 3 ft vertical clearance  
from the air inlet opening.  
NOTE: The vent cap, flow switch cover and air  
intake hood must be furnished by the heater manu-  
facturer in accordance with its listing (sales order  
option D-11).  
Freeze Protection  
Outdoor Installation  
When installing this heater in an outdoor location that  
is susceptible to freezing, sales order option B-22  
must be ordered. The B-22 option energizes the  
heater pump at a preset temperature drop to circulate  
water and reduces the possibility of freezing and dam-  
aging the heat exchanger or headers.  
Outdoor models are self-venting when installed with  
the optional factory-supplied outdoor vent kit and re-  
quire no additional vent piping. A special vent cap, flow  
switch cover and air intake hood are provided in accor-  
dance with CSA requirements, which must be installed  
directly on the heater. Correct clearances can be  
found earlier in this section.  
Controls  
Care must be taken when locating the heater out-  
doors, because the flue gases discharged from the  
vent cap can condense as they leave the cap.  
Improper location can result in damage to adjacent  
structures or building finish. For maximum efficiency  
and safety, the following precautions must be  
observed:  
WARNING: 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. Failure to do so  
may result in control damage, heater malfunction,  
property damage, personal injury, or death.  
1. Outdoor models must be installed outdoors and  
must use the outdoor vent cap, flow switch cover  
and air intake hood available from the manufac-  
turer (sales order option D-11).  
WARNING: Turn off the power to the heater before  
installation, adjustment or service of the CPW board  
or any heater controls. Failure to do so may result in  
board damage, heater malfunction, property dam-  
age, personal injury, or death.  
2. Periodically check venting system. The heater’s  
venting areas must never be obstructed in any  
way and minimum clearances must be observed  
to prevent restriction of combustion and ventilation  
air. Keep area clear and free of combustible and  
flammable materials.  
CAUTION: This appliance has provisions to be  
connected to more than one supply source. To  
reduce the risk of electric shock, disconnect all such  
connections before servicing.  
3. Do not locate adjacent to any window, door walk-  
way, or gravity air intake. The vent must be lo-  
cated a minimum of 4 ft horizontally from such ar-  
eas.  
CAUTION: Risk of electric shock: More than one  
disconnect switch may be required to de-energize  
the equipment before servicing.  
4. Install above grade level and above normal snow  
levels.  
5. Vent terminal must be at least 3 ft above any  
forced air inlet located within 10 ft.  
6. Adjacent brick or masonry surfaces must be pro-  
tected with a rust-resistant sheet metal plate.  
33  
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und unless the circuit stays energized for more  
than 5 seconds.  
12. Power is applied to terminal P1-1 of the U-2  
Board. All safeties are verified to ensure that it is  
safe to operate the heater. The safety compo-  
nents wired into the diagnostic board are: low  
water cut-off (optional), blocked vent switch, man-  
ual vent temp switch (optional), manual reset high  
limit, low gas pressure switch (optional), high gas  
pressure switch (optional), and auto-reset high  
limit (optional).  
Fig. 28: External LED Indicator Decal  
13. Power is applied to terminal TP-1 of the  
Economaster II pump delay to energize the circuit  
board.  
Heater Sequence of Operation  
Models 302A, 402A, 502A, 652A,  
752A and 902A  
14. Once all safeties have been verified to be closed,  
a 24 VAC signal is output from pin P3-16 of the U-  
2 Board.  
1. The black (hot) wire lead goes directly to the main  
power switch. This black toggle switch is located  
at the middle front of the control compartment.  
15. Relay K-1 (N.C.) will now be energized, and opens  
the N.C. contacts to disable the alarm (optional)  
and turns off the red safety shutdown light.  
2. When the main power switch is placed in the “ON”  
position, 120 VAC is applied to the 120 VAC termi-  
nal block on the circuit board and the 120/24 VAC  
transformer is powered.  
16. Pin P1-4 on the diagnostic board will now output a  
24 VAC signal to pin 1 of the “standby switch”.  
17. The “standby switch” (rocker switch) located at the  
lower left front of the control compartment is now  
powered. If the switch is “ON” and there is no call  
for heat (CFH), the heater is in standby mode.  
3. 120 VAC is waiting at the N.O. contacts of the  
Economaster II pump delay.  
4. Terminals L1 and F1 of the ignition module are  
powered with 120VAC.  
18. After the standby switch is placed into the “ON”  
position, a 24 VAC signal is sent to the  
“enable/disable” connection (normally jumpered).  
5. 120 VAC power is also applied to the control  
power connector on the circuit board.  
19. 24 VAC switched power is applied to the S24V ter-  
minal on the ignition module.  
6. 120 VAC power is waiting at relay contacts K-3 to  
energize the heater blower.  
20. When the “enable/disable” contacts are closed,  
the 24 VAC signal travels to pin 1 of the stage 1  
connection and waits for a CFH.  
7. The 120/24 VAC transformer outputs 24 VAC.  
8. 24 VAC is sent to the low water cut-off (optional)  
and the red power light is energized.  
21. When a CFH occurs, a 24 VAC signal is sent to the  
CFH light on the diagnostics panel located on the  
lower left front of the control compartment.  
9. 24 VAC is applied to the blue power light located  
on the diagnostic display board.  
22. Power is now sent to terminal TP4 of the  
Economaster II to energize the relay and close the  
contacts.  
10. 24 VAC is also applied to the red LED safety shut-  
down light on the front diagnostic board.  
11. 24 VAC is applied to the alarm circuit (optional). If  
the E-5 sales option (Alarm) is included a 5 sec-  
ond time delay relay will not allow the alarm to so-  
23. The heater pump is energized upon relay closure  
of the Economaster II.  
34  
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External Lights  
Color  
Light  
Indication  
Power  
Blue  
Main power is on  
Thermostat is closed  
Call For Heat  
Yellow  
One or more safeties is inopera-  
tive  
Safety  
Red  
Ignition  
Flow  
Red  
Ignition module is inoperative  
Flow is present  
Green  
Green  
Green  
Green  
Blower 1  
Stage 1  
Stage 2  
Blower 1 is on  
Stage 1 is on  
Stage 2 is on  
Internal Lights  
Color  
Light  
Indication  
Board power is on  
Low water cut-off is open  
Vent is blocked  
Board Power  
Yellow  
Red  
Low Water Cut-Off  
Blocked Vent  
Manual Reset Hi-Limit  
Red  
Red  
Manual reset is open  
Low Gas Pressure  
Switch  
Red  
Low gas pressure  
High gas pressure  
High Gas Pressure  
Switch  
Red  
Red  
Red  
Red  
(Not Used)  
Vent temperature exceeds  
limits  
PVC Vent Limit  
Auto Reset High Limit  
Auto reset option  
Table N: LED Indicators  
24. Upon sufficient flow from the heater pump, the 30. When the coil on relay K-3 (N.O.) is powered, the  
flow switch contacts will close.  
relay contacts (K-3) close and energizes the blow-  
er from the J-8 connections on the CPW board.  
25. The flow light is energized; located on the diag-  
nostics panel.  
31. After proper air pressure is received in the air  
plenum, the air pressure switch will close.  
26. A 24 VAC signal is also sent to the “TH” terminal  
located on the ignition module.  
32. A 24 VAC signal is now sent to the blower LED on  
the diagnostics board.  
27. Once the 24 VAC “TH” signal is received at the  
ignition module, a 120 VAC signal is sent from F2 33. Power is applied to the optional equipment inter-  
on the ignition module to the 120 VAC pilot duty  
terminals, located at J-14 on the circuit board.  
lock connection (normally jumpered).  
34. The 24 VAC signal is then sent to the 24 VAC safe-  
ty connector.  
28. The 120 VAC signal continues to the coil of the  
blower relay K-3 (N.O.).  
35. 24 VAC is now sent to the pressure switch (P.S.)  
terminal on the ignition module.  
29. The 120 VAC signal continues to the 120 VAC  
safety terminals located at J-13 on the circuit  
board.  
35  
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36. Once the pressure switch signal is received at the  
ignition module the hot surface igniter is energized  
by a 120 VAC signal from S-1 on the ignition mod-  
ule. (The hot surface igniter must draw greater  
than 3.1 amps while being energized or ignition  
lockout will occur after three tries.)  
Ignition Module  
When additional heat is needed, the combustion air  
blower starts to purge air from the combustion cham-  
ber for about 15 seconds. On proof-of-air flow, the air-  
37. Once the ignition module determines that the hot  
surface igniter amp draw is within specs and oper-  
ating properly, a 24 VAC signal is output from pin  
GV on the module.  
38. 24 VAC signal is received to gas valve 1 thus ener-  
gizing it.  
39. The stage 1 LED on the diagnostics display board  
is now illuminated.  
40. The coil of relay K-2 (N.O.) is now energized with  
the (K-2) contacts closing downstream of the  
stage 2 connections.  
Fig. 29: Ignition Module  
proving switch closes and the igniter is energized. To  
ensure safe operation, the gas valve cannot open until  
the igniter is verified. The main burner is automatically  
lit when the device is powered and pre-purged. The  
heater performs its own safety check and opens the  
main valve only after the igniter is proven to be capa-  
ble of ignition.  
41. The gas coming through the burners should ignite  
from the heat of the hot surface igniter and the  
flame should carry over from one burner to the  
other burners of stage 1. The remote sensor is  
now trying to sense the flame. If the flame is not  
sensed within 4 seconds, the ignition module will  
shut down the gas valve and retry the hot surface  
igniter. During ignition retry the heater must per-  
form a 15-second pre-purge and an approximate-  
ly 30-second igniter warm-up before opening gas  
valve 1 again. The standard ignition module will  
attempt ignition a maximum of three times prior to  
ignition lockout.  
The standard ignition module will attempt to light three  
times before locking out. To reset it, turn off power to  
the heater, wait 30 seconds and re-apply power.  
Code  
On  
Condition  
System OK;  
No faults present  
42. (Models 302A-402A only) 24 VAC is now waiting  
at pin 3 of the stage 2 connection on the CPW  
board.  
Possible control fault;  
Check power  
Off  
43. (Models 502A-902A only) After gas valve 1 opens  
and flame rectification is received, time delay relay  
1 (TD-1) starts a 5-second countdown.  
Low air pressure, brief flash-  
ing normal on start-up  
1 Flash  
Flame in combustion  
chamber; No call for heat  
2 Flashes  
3 Flashes  
4 Flashes  
5 Flashes  
6 Flashes  
44. (Models 502A-902A only) After the 5 second  
countdown from TD-1, 24 VAC is waiting at pin 3  
of the stage 2 connection on the CPW board.  
Ignition lockout  
Low igniter current  
45. After closure of the stage 2 contacts Gas valve 2  
in energized.  
Low 24VAC, check control  
supply voltage  
46. The stage 2 LED on the diagnostics display board  
is now illuminated.  
Internal fault;  
Replace control  
47. The heater is now operating at full fire.  
Table O: Ignition Module  
Diagnostic LED Codes  
36  
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The optional single-try ignition module will lock out General Safety Section for safety precautions con-  
after failing to light one time. To reset it, press and cerning domestic hot water applications.  
release the small, recessed black push button located  
inside of the cut-out on the lower right-hand corner of  
the ignition module case. Turning off the power to the  
heater WILL NOT reset the ignition module.  
Fig. 32: Operating Control  
Low Water 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 5-second time delay prevents  
Fig. 30: High Limit (Manual Reset)  
premature lockout due to temporary conditions such  
High Limit (Manual Reset)  
as power fluctuations or air pockets.  
The heater is equipped with a manual reset high limit  
temperature device. Push the reset button and adjust  
the setting to 40 - 50°F above desired operating tem-  
perature.  
Fig. 33: Low Water Cut-Off  
High and Low Gas Pressure Switches  
The low gas pressure switch (standard) connection  
Fig. 31: Flow Switch  
mounts upstream of the gas valve to ensure that suffi-  
cient gas pressure is present for proper regulator per-  
formance. The low gas pressure switch automatically  
shuts down the heater if gas supply drops below the  
factory setting of 5.0 in. WC for natural gas, and 10.0  
in. WC for propane gas.  
Flow Switch  
This dual-purpose control, mounted and wired in  
series with the main gas valve, shuts off heater in case  
of pump failure or low water flow.  
The high gas pressure switch (optional) connection  
mounts down-stream of the stage-1 gas valve. If the  
gas pressure regulator fails, the high gas pressure  
switch automatically shuts down the burner.  
Operating Control  
The heater may be equipped with different types of  
operating controls. Consult the individual control data  
sheets supplied with your heater paperwork. See the  
37  
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Fig. 34: High/Low Gas Pressure Switch  
Fig. 35: Fan-Proving Switch  
Fig. 36: Blocked Vent Switch  
38  
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ends that a thermometer be placed into the boiler inlet  
piping next to the in/out header to facilitate tempera-  
ture adjustment. Inlet water temperatures below 120ºF  
(49ºC) can excessively cool the products of combus-  
tion, resulting in condensation on the heat exchanger.  
87%-Efficiency Boilers –  
Special Instructions  
NOTE: The constructions of the 84%- (standard)  
and 87%-efficiency (optional) boilers are very similar,  
and they are installed to the same requirements,  
except as noted in this section.  
Venting  
CAUTION: Proper installation of flue venting is criti-  
cal for the safe and efficient operation of the boiler.  
Water Piping  
An 87%-efficiency boiler requires a minimum inlet  
water temperature of 120ºF (49ºC) to prevent exces-  
sive condensation in the combustion chamber. An  
87%-efficiency boiler operated with an inlet tempera-  
ture of less than 120ºF (49ºC) must have a manual  
bypass or an approved low-temperature operation  
system to prevent problems with condensation. A man-  
ual bypass, shown in Fig. 15, must be piped into the  
system at the time of installation. This piping is like a  
primary/secondary boiler installation with a bypass in  
the secondary boiler piping. Raypak strongly recomm-  
Appliance Categories  
See Table Q for appliance category requirements for  
the 87%-efficiency Hi Delta.  
NOTE: For additional information on appliance cat-  
egorization, see appropriate code NFGC (U.S.) and  
B149.1 (Canada), or applicable local building codes.  
10°F T  
20°F T  
30°F T  
Min. Flow  
P (ft)  
Max Flow  
P (ft)  
Model  
No.  
gpm P (ft) gpm  
P (ft) gpm  
P (ft) gpm  
T
gpm  
T
302AE  
402AE  
502AE  
652AE  
752AE  
902AE  
52  
69  
3.3  
6.0  
26  
<1.0  
1.5  
2.5  
4.4  
6.1  
8.9  
N/A  
N/A  
<1.0  
1.1  
20  
20  
22  
28  
33  
39  
<1.0  
<1.0  
<1.0  
1.1  
26  
35  
40  
40  
40  
40  
90  
90  
90  
90  
90  
90  
9.8  
6
35  
44  
57  
65  
78  
23  
29  
38  
44  
52  
10.0  
10.4  
10.8  
11.3  
11.7  
8
87  
9.7  
10  
13  
15  
17  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
2.0  
2.8  
1.6  
4.1  
2.3  
Note: Basis for minimum flow is 20 gpm or 40°F ΔT. Basis for maximum flow is 90 gpm.  
Table P: Heater Rate of Flow and Pressure Drop  
Combustion  
Air Supply  
Exhaust  
Configuration  
Heater Venting  
Category  
Certified  
Materials  
Combustion Air  
Inlet Material  
Vertical Natural Draft  
Venting  
Stainless Steel  
(Gas Tight)  
II  
IV  
II  
From Inside Building  
(Non-Direct Venting)  
Horizontal Through-  
the-Wall Venting  
AL29-4C  
Vertical Natural Draft  
Venting  
Stainless Steel Galvanized Steel  
(Gas Tight)  
PVC  
From Outside Building  
(Direct Venting)  
Horizontal Through-  
the-Wall Venting  
ABS  
CPVC  
IV  
AL29-4C  
Table Q: Category Determination for Venting Purpose and Venting Arrangement  
39  
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11. Locate or guard vent to prevent condensate from  
damaging exterior finishes. Install a rust-resistant  
sheet metal backing plate against brick or mason-  
ry surfaces.  
WARNING: Contact the vent material manufactur-  
er if there are any questions about the appliance cat-  
egory or suitability of a vent material for Category II,  
III or IV applications. Using improper venting materi-  
als can result in personal injury, death or property  
damage.  
12. DO NOT extend exposed vent pipe outside of  
building. Condensate could freeze and block vent  
pipe.  
Vent Terminal Location  
Condensate Management  
NOTE: During winter months check the vent cap  
and make sure no blockage occurs from build-up of  
snow or ice.  
Condensate must be routed from the condensate trap  
to an appropriate container for neutralization before  
disposal, as required by local codes.  
1. Condensate can freeze on the vent cap. Frozen  
condensate on the vent cap can result in a blocked  
flue condition.  
Vertical Venting (Category II)  
2. Give special attention to the location of the vent  
termination to avoid possibility of property dam-  
age or personal injury.  
3. Gases may form a white vapor plume in winter.  
The plume could obstruct a window view if the ter-  
mination is installed near windows.  
4. Prevailing winds, in combination with below-freez-  
ing temperatures, can cause freezing of con-den-  
sate and water/ice build-up on building, plants or  
roof.  
5. The bottom of the vent terminal and the air intake  
shall be located at least 12 in. above grade, includ-  
ing normal snow line.  
6. Un-insulated single-wall metal vent pipe shall NOT  
be used outdoors in cold climates for venting gas  
utilization equipment.  
7. Through-the-wall vents for Category II and IV  
appliances shall not terminate over public walk-  
ways or areas where condensate or vapor could  
create a nuisance or hazard, or be detrimental to  
the operation of regulators, relief valves or other  
equipment.  
Note: When vertical height exceeds 25 ft,  
consult factory prior to installation.  
Fig. 37: Vertical Venting (Category II)  
CAUTION: A properly sized listed vent cap termi-  
nal must be used to evacuate the flue products from  
the boilers.  
8. Locate and guard vent termination to prevent acci-  
dental contact by people or pets.  
Common Venting System  
9. DO NOT terminate vent in window well, stairwell,  
alcove, courtyard or other recessed area, unless  
previously approved by local authority.  
Manifolds that connect more than one boiler to a com-  
mon chimney must be engineered to handle the com-  
bined load. Consult available guides for proper sizing  
of the manifold and the chimney. At no time should the  
area of the vent be less than the area of the largest  
boiler exhaust outlet.  
10. DO NOT terminate above any door, window, or  
gravity air intake. Condensate can freeze, causing  
ice formations.  
40  
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pressure reading must be between -0.01 and -0.1 in.  
WC as measured 12 in. from the appliance flue outlet.  
Each elbow used is equal to 10 ft of straight pipe. This  
will allow installation in one of the four following com-  
binations:  
WARNING: Vent connectors serving appliances  
vented by natural draft shall not be connected into  
any portion of mechanical draft systems operating  
under a positive pressure.  
•
•
•
•
70’ of straight flue pipe  
Horizontal Through-the-Wall Venting  
(Category IV)  
60’ of straight flue pipe and one elbow  
50’ of straight flue pipe and two elbows  
40’ of straight pipe and three elbows  
The vent cap is not considered in the overall length of  
the venting system.  
The vent must be installed to prevent flue gas leakage.  
Care must be taken during assembly to ensure that all  
joints are sealed properly and are airtight. The vent  
must be installed to prevent the potential accumulation  
of condensate in the vent pipes. It is recommended  
that:  
Fig. 38: Horizontal Through-the-Wall Venting  
(Category IV)  
1. The vent must be installed with a slight upward  
slope of not more than 1/4 in per foot of horizontal  
run to the vent terminal.  
Installation  
2. The vent must be insulated through the length of  
the horizontal run.  
These installations utilize the boiler-mounted blower to  
vent the combustion products to the outdoors.  
Combustion air is taken from inside the room and the  
vent is installed horizontally through the wall to the out-  
doors. Adequate combustion and ventilation air must  
be supplied to the mechanical room in accordance  
with the NFGC (U.S.) and B149.1 (Canada).  
Common Venting System  
Common venting of Category IV systems is not al-  
lowed.  
WARNING: No substitutions of flue pipe or vent  
cap material are allowed. Such substitutions would  
jeopardize the safety and health of inhabitants.  
The total length of the horizontal through-the-wall ex-  
haust vent system should not exceed 70 ft in length. If  
horizontal run exceeds 70 ft, an appropriately sized  
extractor must be used. To maintain proper operation,  
Air Inlet  
Max. Length*  
Certified  
Venting  
Material  
Maximum  
Equivalent  
Vent Length  
Combustion Air  
Intake Pipe  
Material  
Model  
Vent Size  
6”  
8”  
302AE  
402AE  
502AE  
652AE  
752AE  
902AE  
5”  
6”  
70’  
Room Air  
100’  
N/A  
Galvanized Steel,  
PVC,  
75’  
40’  
30’  
Category II  
or IV  
40’  
Ducted  
Combustion  
Air  
ABS,  
CPVC  
100’  
80’  
8”  
* Subtract 10 ft per elbow. Max. 3 elbows.  
Maximum combustion air duct length terminated at 100 equivalent ft.  
Table R: Category II and IV Venting  
41  
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The stainless steel direct vent cap must be furnished The flue exhaust direct vent cap is not considered in  
by the boiler manufacturer in accordance with its list- the overall length of the venting system.  
ing (sales order option D-15).  
Care must be taken during assembly that all joints are  
Use only double-wall vent pipe and the special gas sealed properly and are airtight.  
vent pipes listed for use with category II or IV gas burn-  
ing boilers, such as the stainless steel Saf-T vent by The vent must be installed to prevent the potential ac-  
Heat Fab Inc. (800-772-0739), Protech Systems Inc. cumulation of condensate in the vent pipes. It is rec-  
(800-766-3473), or Z-Flex (800-654-5600). Pipe joints ommended that:  
must be positively sealed. Follow the vent manufactur-  
er’s installation instructions carefully.  
1. The vent must be installed with a slight downward  
slope of not more than 1/4 inch per foot of hori-  
zontal run to the vent terminal.  
Direct Vent - Horizontal Through-  
the-Wall  
2. The vent must be insulated through the length of  
the horizontal run.  
For installations in extremely cold climate, it is rec-  
ommended that:  
1. The vent must be installed with a slight upward  
slope of not more than 1/4 inch per foot of hori-  
zontal run to the vent terminal. In this case, an ap-  
proved condensate trap must be installed per ap-  
plicable codes.  
2. The intake vent must be insulated through the  
length of the horizontal run.  
Common Venting System  
Fig. 39: Direct Vent - Horizontal Through-the-Wall  
Common venting of Category IV systems is not al-  
lowed.  
Installation  
These installations utilize the boiler-mounted blower to  
draw combustion air from outdoors and vent combus-  
tion products to the outdoors.  
WARNING: No substitutions of flue pipe or vent  
cap material are allowed. Such substitutions would  
jeopardize the safety and health of inhabitants.  
The total length of the direct vent through-the-wall  
exhaust vent cannot exceed 40 ft in length for the flue  
outlet. Each elbow used is equal to 10 ft of straight  
pipe. This will allow installation in one of the three fol-  
lowing combinations:  
The stainless steel flue exhaust direct vent cap must  
be furnished by the boiler manufacturer in accordance  
with its listing (sales order option D-15).  
Use only double-wall vent pipe and the special gas  
vent pipes listed for use with category II or IV gas burn-  
ing boilers, such as the stainless steel Saf-T vent by  
Heat Fab Inc. (800-772-0739), Protech Systems Inc.  
(800-766-3473), or Z-Flex (800-654-5600). Pipe joints  
must be positively sealed. Follow the vent manufactur-  
er’s installation instructions carefully.  
•
•
•
40’ of straight flue pipe  
30’ of straight flue pipe and one elbow  
20’ of straight flue pipe and two elbows  
The total length air supply duct cannot exceed the dis-  
tances listed. Each elbow used is equal to 10 ft of  
straight pipe. This will allow installation in one of the  
three following combinations:  
•
•
•
40’ of straight combustion air pipe  
30’ of straight combustion air pipe and one elbow  
20’ of straight combustion air pipe and two elbows  
42  
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Direct Vent - Vertical  
Note: When vertical height exceeds 25 ft, consult  
factory prior to installation.  
Fig. 40: Direct Vent - Vertical  
Vertical Venting  
Height*  
Air Inlet  
Max. Length**  
Certified  
Model Venting Vent Size  
Combustion Air  
Intake Pipe  
Material  
Material  
Min.  
Max.  
6”  
8”  
302A  
402A  
502A  
652A  
752A  
902A  
5”  
6”  
100’  
N/A  
Galvanized Steel,  
PVC,  
75’  
40’  
Category II  
or IV  
5’  
25’  
ABS,  
CPVC  
100’  
8”  
* Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details.  
When vertical height exceeds 25 ft, consult factory prior to installation.  
** Subtract 10 ft per elbow. Max. 3 elbows.  
Maximum combustion air duct length terminated at 100 equivalent ft.  
Table S: Category II or IV Vertical Venting  
43  
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Wiring Diagram  
44  
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•
•
If you cannot reach your gas supplier, call the fire  
department.  
START-UP  
Use only your hand to push in or turn the gas con-  
trol knob. Never use tools. If the knob will not turn  
by hand, do not try to repair it, call a qualified serv-  
ice technician. Forced or attempted repair may  
result in a fire or explosion.  
Pre Start-up  
Filling System (Heating Boilers)  
Fill system with water. Purge all air from the system.  
Lower system pressure. Open valves for normal sys-  
tem operation, and fill system through feed pressure.  
Manually open air vent on the compression tank until  
water appears, then close vent.  
•
•
Do not use this appliance if any part has been  
under water, immediately call a qualified service  
techni-cian to inspect the appliance and to replace  
any part of the control system and any gas control  
which has been under water.  
Air Purge (Domestic Hot Water  
Heaters)  
Check around unit for debris and remove com-  
bustible products, i.e. gasoline, etc.  
Purge all air from system before lighting heater. This  
can be normally accomplished by opening a down-  
stream valve.  
Pre Start-up Check  
1. Verify heater is filled with water.  
Venting System Inspection  
2. Check system piping for leaks. If found, repair  
immediately.  
1. Check all vent pipe connections and flue pipe ma-  
terial.  
3. Vent air from system. Air in system can interfere  
with water circulation.  
2. Make sure vent terminations are installed per code  
and are clear of all debris or blockage.  
4. Purge air from gas line up to heater.  
Initial Start-up  
For Your Safety  
WARNING: If you do not follow these instructions  
exactly, a fire or explosion may result causing prop-  
erty damage, personal injury or loss of life.  
Tools Needed  
•
•
(1) 12-0-12, 24” scale U-tube manometer  
This appliance has a hot surface igniter. It is equipped  
with an ignition device which automatically lights the  
burners. Do not try to light the burners by hand.  
(4) 6-0-6, 12” scale U-tube manometers (mini-  
mum)  
•
•
•
(1) Screwdriver  
BEFORE OPERATING, smell all around the appliance  
area for gas. Be sure to smell near the floor because  
some gas is heavier than air and will settle on the floor.  
(1) Multi-meter  
(1) 3/16” Allen wrench  
WHAT TO DO IF YOU SMELL GAS:  
NOTE: Digital manometers are not recommended.  
•
•
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any  
telephone in your building.  
•
Immediately call your gas supplier from a neigh-  
bor’s telephone. Follow the gas supplier’s instruc-  
tions.  
45  
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Preparation  
Start-Up  
WARNING: Do not turn on gas at this time.  
Check Power Supply  
Blower Adjustment  
1. Turn off power.  
2. Unplug cap at pressure switches and connect ma-  
nometer(s) to the tee.  
With multi-meter at incoming power, check voltage  
between:  
3. Close all manual firing valves.  
4. Turn power on.  
Hot - Common (≈120 VAC)  
Hot - Ground (≈120 VAC)  
Common - Ground (< 1 VAC)  
5. Check manometers attached to fan pressure  
switch. The reading should be 1.4 .1 in. WC for  
propane gas and natural gas. If not, adjust the air  
shutter on the blowers to attain the correct value.  
WARNING: If Common - Ground is > 1 VAC,  
STOP: Contact electrician to correct ground failure.  
Failure to do this may burn out 120V-24V trans-  
former, or may cause other safety control damage or  
failure.  
6. Turn power off.  
7. Reconnect this cap.  
Main Burner Adjustment  
1. Turn off unit.  
Attach Manometers to Measure Pressures  
1. Turn off main gas valve.  
2. Open manual firing valves.  
2. Attach 24” scale manometer to the first main gas  
shut-off valve pressure tapping.  
3. Turn on the unit, wait 15 seconds, and the igniter  
should glow. Look into sight glass located at each  
end of the heater to check igniter operation. Gas  
valves should open in 45-60 seconds.  
3. Attach (1) 12” scale manometer to the outlet side  
of the second main gas shut-off valve pressure  
tapping.  
4. If burner does not light on first trial. It will retry, up  
to three times.  
4. Attach (1) 12” scale manometer near the fan-prov-  
ing switch. Pull black cap from air pressure switch  
tee and connect the manometer. NOTE: Retain  
caps for reinstallation later.  
5. Main burner ignition: Check manifold gas pressure  
at gas valve outlet pressure tap. This should read  
3.5 0.1 in. WC for natural gas and 10.5 0.1 in.  
WC for propane gas.  
Check Gas Supply Pressure  
1. Slowly turn on main gas shut-off valve.  
6. If the pressure reading differs by more than 0.1  
in. WC, remove screw cover from the gas pres-  
sure regulator and adjust main burner manifold  
pressure. Replace the screw cover. Repeat steps  
2 to 5 on other valves as necessary.  
2. Read the gas supply pressure from the manome-  
ter; minimum supply pressure for natural gas is 5.0  
in. WC, recommended supply is 7.0 in. WC, mini-  
mum supply pressure for propane gas is 11.0 in.  
WC (dynamic readings, all stages firing).  
CAUTION: Special manifold and air settings may  
be required. Verify rating plate and blower housing.  
3. If the pressure is > 14.0 in. WC, turn off the valve.  
4. Check if the service regulator is installed and/or  
adjust the service regulator.  
46  
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The burner section that is ignited directly by the hot  
surface ignition system serves as a supervised pilot to  
light the burner sections on either side of it. The burn-  
er sections on either side of the supervised section  
(pilot) are electrically interlocked with the supervised  
ignition system so as they are not energized unless  
flame is proven on the center section which is acting  
as a pilot to light the right and left-hand sections.  
Safety Inspection  
1. Check all thermostats and high limit settings.  
2. During the following safety checks leave manome-  
ters hooked up, check and record.  
3. If other gas-fired appliances in the room are on the  
same gas main, check all pressures on the Hi  
Delta with all other equipment running.  
The pilot turn-down test is conducted as follows:  
1. Turn off manual valves on non-supervised burner  
sections.  
4. Check thermostats for ON-OFF operation.  
5. Check high limits for ON-OFF operation.  
6. While in operation, check flow switch operation.  
2. Turn on electrical power and adjust thermostat to  
call for heat.  
3. Wait for completion of ignition sequence to light  
burner section being utilized as a pilot for those  
turned off in step 1 above.  
7. Check the low gas pressure switch. (For proper  
adjustment, use the attached manometers, if  
available, to set pressure. The scales on the  
switch are approximate only.) Low gas pressure  
switch must be set at 5.0 in. WC for natural gas  
and 10.0 in. WC for propane gas.  
4. Gradually reduce manifold pressure (flame) on  
supervised burner section by slowly closing man-  
ual gas valve. Watch for shut-down due to loss of  
supervised flame signal as pressure is being re-  
duced. Flame signal should be lost before mani-  
fold pressure goes below 2.0 in. WC for natural  
gas and 6.0 in. WC for propane gas.  
8. Make sure that the high gas pressure switch (op-  
tional) is set to 1.0 in. WC above manifold pres-  
sure.  
Follow-Up  
Leak Test Procedure: Dual-Seat Gas  
Valves  
Safety checks must be recorded as performed.  
Turn heater on. After main burner ignition:  
1. Check manometer for proper reading.  
Proper leak testing requires three pressure test points  
in the gas train.  
Test point A is upstream of the automatic gas valve. On  
2. Cycle heater several times and re-check readings. the first automatic valve, this is a bleedle valve. On the  
other valves, this is a plugged port. The bleedle valve  
3. Remove all manometers and replace caps and on the first valve may be used for all the other valves  
screws.  
as well.  
4. Replace all gas pressure caps.  
5. Check for gas leaks one more time.  
Pilot Turn-Down Test  
Test point B is a bleedle valve located between the two  
automatic gas valve seats.  
Test point C is located downstream of both automatic  
gas valve seats and upstream of the manual valve. On  
the manual valve, this is a bleedle valve. Identical  
readings will be found at the plugged port labeled as  
Alternate C.  
The Hi Delta heaters, depending on their size, have  
one to three burner sections. Each burner section is  
supplied gas by gas valves incorporated into a single  
valve body. A maximum of three burner sections may  
be controlled by a single hot surface ignition system.  
The middle of the three burner sections is ignited  
directly with a hot surface ignition system.  
Refer to Fig. 41. The numbers on the diagram refer to  
the steps below:  
These tests are to be conducted with the electrical  
power to the heater turned off.  
47  
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1. Manually close the downstream leak test valve.  
This completes leak testing for a single Hi Delta mani-  
fold riser. Repeat steps 1-8 for each riser.  
2. Open test point A and connect a manometer to it.  
Verify that there is gas pressure and that it is with-  
in the proper range (NOTE: must not exceed 14.0  
in. WC).  
Post Start-Up Check  
Check off steps as completed:  
3. Open test point B and connect a rubber tube to it.  
Connect the other end of the tube to a manometer  
and look for a build-up of pressure. Increasing  
pressure indicates a leaking gas valve.  
1. Verify that the heater and heat distribution units or  
storage tank are filled with water.  
2. Confirm that the automatic air vent (if used) was  
opened two full turns during the venting proce-  
dure.  
4. Next, close the upstream manual gas valve and  
remove the manometer from test point A and from  
test point B. Connect a rubber tube from test point  
A to test point B and open the upstream manual  
gas valve. Make sure that test points A & B have  
been opened so as to allow gas to flow. This will  
bring pressure to the second valve seat.  
3. Verify that air has been purged from the system.  
4. Verify that air has been purged from the gas pip-  
ing, and that the piping has been checked for  
leaks.  
5. Open test point C and connect a second rubber  
tube to it. Connect the other end of the tube to a  
manometer and look for a build-up of pressure. In-  
creasing pressure indicates a leaking gas valve.  
5. Confirm that the proper start-up procedures were  
followed.  
6. Inspect burner to verify flame.  
6. Remove rubber tube and manometers. Close  
each test point valve as the tubes are removed.  
7. Test safety controls: If heater is equipped with a  
low water cut-off or additional safety controls, test  
for operation as outlined by manufacturer. Burner  
should be operating and should go off when con-  
trols are tested. When safety devices are restored,  
burners should re-ignite after pre-purge time  
delay.  
7. Connect a manometer to each test point (one at a  
time) and look for a build-up of pressure. If a build-  
up of pressure is detected, check each test point  
valve to see if it is tightly closed. If leak persists,  
replace test point valve(s).  
8. Test limit control: While burner is operating, move  
indicator on high limit control below actual water  
temperature. Burner should go off while blower  
and circulator continue to operate. Raise setting  
on limit control above water temperature and burn-  
er should re-ignite after pre-purge time delay.  
8. After no leakage has been verified at all valve  
seats and test valves, open downstream leak tests  
valve and restore electrical power to heater.  
9. Test ignition system safety device:  
a. Turn on manual gas valve. Turn power on.  
b. Set thermostat to call for heat.  
c. When the heater is in operation, pull cap off of  
tee in air switch hose. The burner should go  
off immediately.  
d. Wait 5 minutes.  
e. Reattach cap on tee. Burner should re-ignite  
after pre-purge time delay.  
Fig. 41: Leak Test  
48  
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10. To restart system, follow lighting instructions in the 9. Set thermostat to desired setting. The appliance  
Operation section.  
will operate. The igniter will glow after the pre-  
purge time delay (15 seconds). After igniter reach-  
es temperature (45 seconds) the main valve will  
open. System will try for ignition three times. If  
flame is not sensed, lockout will commence.  
11. Check to see that the high limit control is set  
above the design temperature requirements of the  
system.  
For multiple zones: Check to make sure the flow is 10. If the appliance will not operate, follow the instruc-  
adjusted as required in each zone.  
tions “To Turn Off Gas To Appliance,” and call your  
service technician or gas supplier.  
12. Check that the heater is cycled with the thermo-  
stat. Raise to the highest setting and verify that the 11. Replace access panel.  
heater goes through the normal start-up cycle. Re-  
duce to the lowest setting and verify that the 12. If heater fails to start, verify the following:  
heater goes off.  
a. There are no loose connections or that the  
13. Observe several operating cycles for proper oper-  
ation.  
service switch is off.  
b. High temperature limit switch is set above wa-  
ter temperature.  
14. Set the room thermostat or tankstat to desired  
temperature.  
c. Thermostat is set above room temperature.  
d. Gas is on at the meter and the heater.  
15. Review all instructions shipped with this heater  
with owner or maintenance person, return to enve-  
lope and give to owner or place the instructions in-  
side front panel on heater.  
e. Incoming gas pressure to the gas valve is  
NOT less than 5.0 in. WC for natural gas, 11.0  
in. WC for propane gas.  
OPERATION  
To Turn Off Gas To Appliance  
Lighting Instructions  
1. Set the thermostat to lowest setting.  
1. Before lighting, make sure you have read all of the  
safety information in this manual.  
2. Turn off all electrical power to the appliance if serv-  
ice is to be performed.  
2. Set the thermostat to the lowest setting.  
3. Remove upper front panels.  
4. Turn off main manual gas valve.  
5. Replace access panel.  
3. Turn off all electrical 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. Remove upper front panel.  
6. Turn on main manual gas valve.  
7. Wait 5 minutes to clear out any gas. Then smell for  
gas, especially near the floor. If you then smell  
gas, STOP! Follow the steps in the safety informa-  
tion on the front cover of this manual. If you do not  
smell gas, go to next step.  
8. Turn on all electrical power to the appliance.  
49  
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TROUBLESHOOTING  
Does the power switch  
provide power to the  
Check the switch  
and/or line voltage  
control panel?  
NO  
Step 1  
Replace ignition module  
Is there a Call For  
Heat?  
YES  
YES  
Unit is in standby mode.  
Check all safety limit  
devices and voltage from  
the transformer to J10 on  
CPW board.  
NO  
Reattach.  
Step 2  
Step 3  
Step 4  
Is Disable jumper intact? (J1)  
YES  
NO  
NO  
Is there 120VAC at J8  
Connector on the CPW board?  
NO  
Does F2 on ignition module  
have 120VAC?  
NO  
Do the combustion air  
blowers come on?  
YES  
YES  
YES  
Is 24VAC at present at TH (J3 & J12 on CPW  
board and orange wire on ignition module)?  
NO  
YES  
Check flow switch, all  
connectors on CPW board  
and controller.  
Are the blower lights  
illuminated?  
NO  
Is air pressure switch(s) and  
J2 of CPW board (N.O.)  
powered?  
Check the fan relay. Is there  
120VAC at K3 relay?  
YES  
YES  
NO  
YES  
NO  
Is there continuity from the  
fan relay to fan(s)?  
Is 24VAC at PS on  
ignition module? Is  
connecting plug  
secure?  
YES  
Does air pressure switch(s)  
have correct pressure?  
(1.4” W.C.)  
Replace fan relay  
Replace fan  
YES  
Replace air  
pressure switch  
Step 5  
Does igniter prove?  
NO  
NO  
Correct the air settings or  
you may have to clean  
burners, heat exchanger  
and/or air filter.  
YES  
Check Amp draw during  
heat-up for greater than  
3.1 Amps.  
Is air switch  
bouncing?  
YES  
Is the flame  
sensor signal to  
the ignition  
NO  
NO  
Replace HSI  
YES  
module greater  
than 1 uA DC?  
Step 6  
Step 7  
Readjust to 3.5” W.C.  
gas.  
Is the unit running?  
Are the gas valve  
settings correct?  
NO  
NO  
YES  
YES  
NO  
Is the unit running?  
NO  
Is static and dynamic inlet  
manifold gas pressure correct?  
Is downdraft present?  
Replace gas valve  
YES  
YES  
NO  
Call our Technical Service Department  
1-800-927-2975 Outside California  
1-800-627-2975 Inside California  
The unit is okay  
Clean or replace flame sensor  
50  
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4. Check for and remove any obstruction to the flow  
of combustion or ventilation air to heater.  
MAINTENANCE  
5. Follow pre-start-up check in the Start-up section.  
Suggested Minimum  
Maintenance Schedule  
6. Visually inspect burner flame. It should be light  
blue. Remove and visually inspect hot surface ig-  
niter and sensor for damage, cracking or debris  
build-up.  
Regular service by a qualified service agency and  
maintenance must be performed to ensure maximum  
operating efficiency.  
7. Check operation of safety devices. Refer to manu-  
facturers’ instructions.  
Maintenance as outlined below may be performed by  
the owner.  
8. Follow oil-lubricating instructions on circulator if  
required. Over-oiling will damage circulator.  
Water-lubricated circulators do not need oiling.  
Daily  
1. Check that the area where the heater is installed  
is free from combustible materials, gasoline, and  
other flammable vapors and liquids.  
9. To avoid potential of severe burn, DO NOT REST  
HANDS ON OR GRASP PIPES. Use a light touch;  
return piping will heat up quickly.  
2. Check for and remove any obstruction to the flow  
of combustion or ventilation air to heater.  
10. Check blower and blower motor.  
11. Check for piping leaks around circulators, relief  
valves and other fittings. Repair, if found. DO NOT  
use petroleum-based stop-leak.  
Monthly  
1. Check for piping leaks around circulators, mixing  
valves, relief valves, and other fittings. If found,  
repair at once. DO NOT use petroleum-based  
stop-leak compounds.  
12. Clean air filter.  
Periodically  
2. Visually inspect burner flame.  
1. Check relief valve. Refer to manufacturer’s in-  
structions on valve.  
3. Visually inspect venting system for proper func-  
tion, deterioration or leakage.  
2. Test low water cut-off, if used. Refer to manufac-  
turer’s instructions.  
4. Check air vents for leakage.  
3. Clean screen and air filter in intake.  
Yearly (Beginning Of Each Heating  
Season)  
Preventive Maintenance  
Schedule  
Schedule annual service call by qualified service  
agency.  
The following is required procedure in CSD-1 states  
and good practice for all Hi Delta installations.  
1. Visually check top of vent for soot. Call service  
person to clean. Some sediment at bottom of vent  
is normal.  
Daily  
2. Visually inspect venting system for proper func-  
tion, deterioration or leakage.  
1. Check gauges, monitors and indicators.  
2. Check instrument and equipment settings. (See  
“Post Start-Up Check” on page 48.)  
3. Check that area is free from combustible materi-  
als, gasoline, and other flammable vapors and liq-  
uids.  
3. Check burner flame. (Should see light blue flame).  
51  
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2. Test high limit and operating temperature. (See  
“Post Start-Up Check,” page 48.)  
Weekly  
For low-pressure heaters, test low-water cut-off  
device. (With at least one stage of the appliance on,  
depress the low water cut-off test button, appliance  
should shut-off and ignition fault light should come on.  
Depress reset button to reset).  
3. Check flame sensors.  
4. Conduct a combustion test at full fire. Carbon di-  
oxide should be 7.5 to 8.5% at full fire for natural  
gas, and between 9.2 to 9.8% for propane gas;  
Carbon monoxide should be < 150 ppm).  
1. Check igniter. (Resistance reading should be 42-  
70 ohms at ambient temperature.)  
5. Check coils for 60 cycle hum or buzz. Check for  
leaks at all valve fittings using a soapy water solu-  
tion. Test other operating parts of all safety shut-off  
and control valves and increase or decrease set-  
tings (depending on the type of control) until the  
safety circuit opens. Reset to original setting after  
each device is tested.  
2. Check flame signal strength. (Flame signal should  
be greater than 1 microamp).  
3. Check flame failure detection system. (See “Post  
Start-Up Check” on page 48.)  
4. Check firing rate control by checking the manifold  
pressure. (See “Main Burner Adjustment” on page  
46.)  
6. Perform leakage test on gas valves. (See Fig. 41.)  
7. Test air switch in accordance with manufacturer’s  
instructions. (Turn panel switch to the “On” posi-  
tion until blower is proven, then turn the switch to  
“Off”.  
5. Make auditory and visual check of main fuel  
valves.  
Monthly  
As Required  
1. Check flue, vent, stack, or outlet dampers.  
1. Recondition or replace low water cut-off device (if  
equipped).  
2. Test fan air pressure. (See “Blower Adjustment” on  
page 46.)  
2. Check drip leg and gas strainers.  
3. Test high and low gas pressure interlocks (if  
equipped). (See “Safety Inspection” on page 47.)  
3. Perform flame failure detection and pilot turn-  
down tests.  
Semi-Annually  
4. Test safety/safety relief valves in accordance with  
ASME Heater and Pressure Vessel Code Sections  
VI and VII.  
1. Recalibrate all indicating and recording gauges.  
2. Check flame failure detection system components.  
(See “Pilot Turn-Down Test Procedure,” page 47.)  
3. Check firing rate control by checking the manifold  
pressure. (See “Main Burner Adjustment” on page  
46.)  
4. Check piping and wiring of all interlocks and shut-  
off valves.  
5. Inspect burners.  
Annually  
1. Test flame failure detection system and pilot turn-  
down. (See “Pilot Turn-Down Test Procedure,”  
page 47.)  
52  
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•
•
•
•
furniture refinishing areas and establishments  
new building construction  
remodeling areas  
APPENDIX  
open pit skimmers  
Inside Air Contamination  
Check for areas and products listed above before in-  
stalling heater. If found:  
All heaters experience some condensation during  
start-up. The condensate from flue gas is acidic.  
Combustion air can be contaminated by certain vapors  
in the air which raise the acidity of the condensate.  
Higher acidity levels attack many materials including  
stainless steel, which is commonly used in high effi-  
ciency systems. The heater can be supplied with cor-  
rosion-resistant, non-metallic intake air vent material.  
You may, however, choose to use outside combustion  
air for one or more of these reasons:  
•
•
remove products permanently, OR  
install TruSeal direct vent  
1. Installation is in an area containing contaminants  
listed below which will induce acidic condensation.  
2. You want to reduce infiltration into your building  
through openings around windows and doors.  
3. You are using AL29-4C stainless steel vent pipe,  
which is more corrosion-resistant than standard  
metallic vent pipe. In extremely contaminated ar-  
eas, this may also experience deterioration.  
Products causing contaminated combustion air:  
•
•
•
•
•
•
•
•
•
•
•
•
spray cans containing chloro/fluorocarbons  
permanent wave solutions  
chlorinated waxes/cleaners  
chlorine-based swimming pool chemicals  
calcium chloride used for thawing  
sodium chloride used for water softening  
refrigerant leaks  
paint or varnish removers  
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  
similar products  
•
•
Areas where contaminated combustion air commonly  
exists:  
•
•
•
•
•
•
•
dry cleaning/laundry areas  
metal fabrication plants  
beauty shops  
refrigeration repair shops  
photo processing plants  
auto body shops  
plastic manufacturing plants  
53  
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LIMITED PARTS WARRANTY  
HI DELTA – TYPES H AND WH  
MODELS 302A–902A  
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 conditions set forth in this Warranty. Labor  
charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the  
owner’s responsibility.  
HEAT EXCHANGER WARRANTY  
Domestic Hot Water  
Five (5) years from date of heater installation. Includes copper heat exchanger with bronze and cast iron waterways.  
Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways.  
Space Heating (Closed Loop System)  
Ten (10) years from date of heater installation. Includes both cupro-nickel and copper heat exchanger with bronze or cast iron water-  
ways.  
Thermal Shock Warranty  
Twenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large  
changes exceeding 150°F between the water temperature at intake and heater temperature, or operating at heater temperatures exceed-  
ing 230°F).  
ANY OTHER PART MANUFACTURED BY RAYPAK  
One (1) year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records,  
whichever comes first.  
SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE  
VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.  
ADDITIONAL WARRANTY EXCLUSIONS  
This warranty does not cover failures or malfunctions resulting from:  
1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;  
2. Abuse, alteration, accident, fire, flood and the like;  
3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;  
4. High velocity flow exceeding heater design rates;  
5. Failure of connected systems devices, such as pump or controller;  
6. Use of non-factory authorized accessories or other components in conjunction with the heater system;  
7. Failing to eliminate air from, or replenish water in, the connected water system;  
8. Chemical contamination of combustion air or use of chemical additives to water.  
PARTS REPLACEMENT  
Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested,  
with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for  
only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak  
will apply any such warranty as may be provided to it by the parts manufacturer.  
TO MAKE WARRANTY CLAIM  
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the prob-  
lem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service  
Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be  
received from Raypak before replacement of any part.  
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY  
This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN  
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER-  
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST  
RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK  
SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE,  
FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states  
do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above  
limitation or exclusion may not apply to you.  
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that  
you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective  
date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manufacture plus  
thirty (30) days.  
Original Owner  
Mailing Address  
Model Number  
Serial Number  
Date of Installation  
Installation Site  
Contractor/Installer  
City  
State  
Zip Code  
Daytime Telephone Number  
RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  
LIMITED PARTS WARRANTY  
HI DELTA – TYPE P  
MODELS 302A–902A  
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 conditions set forth in this Warranty. Labor  
charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the  
owner’s responsibility.  
HEAT EXCHANGER WARRANTY  
Five (5) years from date of heater installation. Includes cupo-nickel heat exchanger with bronze and cast iron waterways.  
Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways.  
Thermal Shock Warranty  
Twenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large  
changes exceeding 150°F between the water temperature at intake and heater temperature, or operating at heater temperatures exceed-  
ing 230°F).  
ANY OTHER PART MANUFACTURED BY RAYPAK  
One (1) Year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records,  
whichever comes first.  
SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE  
VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.  
ADDITIONAL WARRANTY EXCLUSIONS  
This warranty does not cover failures or malfunctions resulting from:  
1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;  
2. Abuse, alteration, accident, fire, flood and the like;  
3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;  
4. High velocity flow exceeding heater design rates;  
5. Failure of connected systems devices, such as pump or controller;  
6. Use of non-factory authorized accessories or other components in conjunction with the heater system;  
7. Chemical contamination of combustion air or use of chemical additives to water.  
8. Misuse or neglect, including but not limited to freeze-ups, operating the heater with cabinet door off, having flow restrictions or obstruc-  
tions between the heater outlet and pool/spa or not maintaining proper chemical balance (pH level must be between 7.2 and 7.8 and  
total alkalinity between 100 and 150 PPM. Total Dissolved Solids (TDS) must be no greater than 2500 PPM).  
PARTS REPLACEMENT  
Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested,  
with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for  
only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak  
will apply any such warranty as may be provided to it by the parts manufacturer.  
TO MAKE WARRANTY CLAIM  
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the prob-  
lem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service  
Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be  
received from Raypak before replacement of any part.  
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY  
This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN  
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER-  
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST  
RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK  
SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE,  
FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states  
do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above  
limitation or exclusion may not apply to you.  
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that  
you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective  
date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manufacture plus  
thirty (30) days.  
Original Owner  
Mailing Address  
Model Number  
Serial Number  
Date of Installation  
Installation Site  
Contractor/Installer  
City  
State  
Zip Code  
Daytime Telephone Number  
RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  
www.raypak.com  
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468  
Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036  
Litho in U.S.A.  
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