Raypak HD101 6000.59 New RP2100 User Manual To The Dd4e96e0 A89d 4d10 83ef A62088aad806

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INSTALLATION & OPERATING
INSTRUCTIONS

Models HD101–HD401
Types H & WH

L
W

WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
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. 1000.52B

Effective: 11-19-09

Replaces: 09-25-09

P/N 241356 Rev. 3

Rev. 3 reflects the following:
Changes to: Updated Table E on page 14, Table G on page 18, Troubleshooting flowchart on page 35, Table
O on page 38.
Additions: Commonwealth of Massachusetts information on page 45
Deletions: None
2

CONTENTS
Flow Switch
High and Low Gas Pressure Switches
(Optional)
Low Water Cut Off (Optional)
WIRING DIAGRAM—MODELS
HD101–HD401
HD TROUBLESHOOTING
PRE-START-UP
Filling System-Heating Heaters
Domestic Hot Water Heaters
Inspect Venting System
Pre-Start-Up Check
INITIAL START-UP
Tools Needed
Preparation for Start-Up
Start-Up
Main Burner Adjustment
Gas Valve Adjustment
Gas Type Conversion on Valve
Safety Inspection
Follow-Up
POST START-UP CHECK
Air Filter Inspection/Removal
Heat Exchanger Removal
MAINTENANCE
Suggested Minimum Maintenance
Schedule
APPENDIX
Inside Combustion Air Contamination
Important Instructions for the
Commonwealth of Massachusetts

WARNINGS
4
Pay Attention to These Terms
4
BEFORE INSTALLATION
5
Product Receipt
5
Model Identification
5
Ratings and Certifications
5
Installations at Elevation
5
Component Locations
6
General Information
7
GENERAL SAFETY
8
Time/Temperature Relationships in Scalds 8
INSTALLATION
9
Installation Codes
9
Equipment Base
9
Clearances
9
Combustion and Ventilation Air
11
Conventional Combustion
Air Supply
11
Water Piping
12
Hydronic Heating
14
Domestic Hot Water Piping
16
Gas Supply
17
Electrical Power Connections
19
Venting
21
Outdoor Installation
31
CONTROLS
32
Ignition Control Module
32
Modulating Temperature Control
(Optional)
32
High Limit (Manual Reset)
32
High Limit — Auto Reset (Optional)
32

33
33

34
35
36
36
36
36
36
36
36
36
38
38
38
39
39
39
40
40
41
42
42
43
43
45

WARNINGS —
DANGER:
WARNING:
CAUTION:
NOTE:

Pay Attention to These Terms

Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
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: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
•

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.

•

WARNING: Risk of electrical shock. More than one
disconnect switch may be required to deenergize the
equipment before servicing.

Heater should never be covered or have any
blockage to the flow of fresh air to the heater.

WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.

WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.

CAUTION: Operation of this heater in lowtemperature systems requires special piping.
Harmful internal condensation will occur if the inlet
water temperature does not exceed 105°F. Warranty
claims will be denied when condensation occurs.

WARNING: This unit contains refractory ceramic
fiber (RCF) insulation in the combustion chamber.
RCF, as manufactured, does not contain respirable
crystalline silica. However, following sustained
exposure to very high temperatures (>2192F), the
RCF can transform into crystalline silica
(cristabolite). The International Agency for Research
on Cancer (IARC) has classified the inhalation of
crystalline silica (cristabolite) as carcinogenic to
humans.

When removing the burners or heat exchangers,
take precautions to avoid creating airborne dust and
avoid inhaling airborne fibers. When cleaning spills,
use wet sweeping or High Efficiency Particulate Air
(HEPA) filtered vacuum to minimize airborne dust.
Use feasible engineering controls such as local
exhaust ventilation or dust collecting systems to
minimize airborne dust. Wear appropriate personal
protective equipment including gloves, safety
glasses with side shields, and appropriate NIOSH
certified respiratory protection, to avoid inhalation of
airborne dust and airborne fiber particles.

Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.

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.
CAUTION: If this heater is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
CAUTION: This heater requires forced water
circulation when the burner is operating. See
minimum and maximum flow rates. Severe damage
will occur if the heater is operated without proper
water flow circulation.

BEFORE INSTALLATION

Model Identification

The model identification number and heater serial
number are found on the heater data plate located on
the right side jacket of the heater. The model number
will have the form H3-HD101 or similar depending on
the heater size and configuration. The first character of
the model number identifies application (H = Hydronic
Heating System, WH = Hot Water Supply System).
The second character identifies the firing mode (3 two stage firing, 4 - On/Off firing ). The next three
places identify the size of the heater.

Raypak strongly recommends that this manual be reviewed 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 the gas supplier.
If, after reviewing this manual, you still have questions
which this manual does not answer, please contact
your local Raypak representative or visit our website at
www.raypak.com.

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:
•

Product Receipt

•

WARNING: Pump motors should NOT be
supported by any type of stand or support from
above due to possible misalignment of pump and
motor which may occur.

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 receipt of your heater it is suggested that you visually check for external damage to the shipping crate. If
the crate is damaged, make a note to that effect on the
Bill of Lading when signing for the shipment. Next,
remove the heater from the shipping packaging.
Report any damage to the carrier immediately.

WARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube
bundle headers, or any ASME parts not
manufactured 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.

On occasion, items are shipped loose. Be sure that
you receive the correct number of packages as indicated on the Bill of Lading.

Claims for shortages and damages must be filed with
the carrier by consignee. Permission to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.

Installations at Elevation

Rated inputs are suitable for up to 2000 feet elevation
without de-rate. Consult the Factory for installations at
any altitude in excess of 2000 feet.

When ordering parts, you must specify the model and
serial number of the heater. When ordering under warranty conditions, you must also specify the date of
installation.

Purchased parts are subject to replacement only
under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted. Parts will
be replaced in kind only per Raypak’s standard warranties.

Gas-Fired Low Pressure Steam and Hot Water
Heaters, ANSI Z21-13 • CSA 4.9 - latest edition
Industrial and Commercial Gas-Fired Package
Heaters, CAN 3.1 - latest edition
Gas Water Heaters, ANSI Z21.10.3 • CSA 4.3 - latest edition

Component Locations

Fig. 1: Component Locations — Angle View

Fig. 2: Component Locations — Left Side

Fig. 3: Component Locations — Front (Panels removed for clarity)

General Information
Model
No.

Quantity of Burners

HD151

HD101

HD201

HD251
HD301
HD401

5
6
8

Table A: Basic Data

Vent Size (in.)

Flue
4

Intake

4
5
5

5
6

Fig. 4: Air Shutter Adjustment

Fig. 5: Gas Valves

GENERAL SAFETY
To meet commercial hot water use needs, the high
limit safety control on this water heater will shut off the
main gas valve before the outlet temperature reaches
210°F. However, water temperatures over 125°F can
cause instant severe burns or death from scalds.
When supplying general purpose hot water, the recommended initial setting for the temperature control is
125°F.

Safety and energy conservation are factors to be considered 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
cause instant severe burns or death
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 setting temperature at water heater.

Feel water before bathing or showering.
Temperature limiting valves are available.

Feel water before bathing or showering.

NOTE: When this water heater is supplying general
purpose hot water for use by individuals, a
thermostatically 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
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.

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.

Water
Temp.

Time to Produce Serious
Burn

120°F

More than 5 minutes

125°F

1-1/2 to 2 minutes

130°F

About 30 seconds

135°F

About 10 seconds

140°F

Less than 5 seconds

145°F

Less than 3 seconds

150°F

About 1-1/2 seconds

155°F

About 1 second

Table courtesy of The Shriners Burn Institute

Table B: Time to Produce Serious Burn

Equipment Base

The temperature of the water in the heater can be regulated by using the optional temperature control. To
comply with safety regulations, the optional temperature control will be set at the lowest setting when
shipped from the factory.

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 control and turn the wheel to the desired
setting (See Fig. 6).

CAUTION: The heater should be located in an area
where water leakage will not result in damage to the
area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable catch pan, adequately
drained, be installed under the appliance. The pan
must not restrict air flow.
In addition, the heater shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation or service (circulator replacement, control
replacement, etc.).
WARNING: This product must be installed by a
licensed plumber or gas fitter when installed within
the Commonweatlh of Massachusetts.

Fig. 6: Temperature Control

CAUTION: Hotter water increases the risk of scaldINSTALLATION
ing! There is a hot water scald potential if the

Clearances

thermostat is set too high.

Indoor/Closet Installations

INSTALLATION
Installation Codes

Minimum Installed
Service Clearance

Rear

2”

Front

Installations must follow these codes:

Heater Side

Floor*

Local, state, provincial, and national codes, laws,
regulations and ordinances.
National Fuel Gas Code, ANSI Z223.1- latest edition (NFGC).
National Electrical Code, ANSI/NFPA 70 - latest
edition (NEC).
Standard for Controls and Safety Devices for
Automatically Fired Heaters, ANSI/ASME CSD-1,
when required (CSD-1).
For Canada only: CAN/CGA B149 Installation
Code (B149) and C.S.A. C22. 1 C.E.C. Part 1
(C22. 1).

24”
0”

Top

24”

Right**

6”

Left**

Water Side

*DO NOT install on carpeting.
**When water connections are on other side.

12”
24”

Table C: Clearances — Indoor/Closet Installations

Fig. 7: Minimum Installed Service Clearances — Indoor/Closet Installations

hang. Roof water drainage must be diverted away
from heaters installed under overhangs.

CAUTION: Service clearances less than the
minimums may require removal of the heater to
service either the heat exchanger or the burners.
The heater must be installed in a manner that will
enable the heater to be serviced without removing any
structure around the heater.

Heater Side

Minimum Installed
Service Clearance

Rear

12”

Front

Outdoor Installations

These heaters are design-certified for outdoor installation. Heaters must not be installed under an overhang
unless clearances are in accordance with local installation codes and the requirements of the gas supplier.
Three sides must be open in the area under the over-

24”

Top

Unobstructed

Water Side

36”

Other Side

36”

Table D: Clearances — Outdoor Installations

Fig. 8: Minimum Installed Service Clearance — Outdoor Installations

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.

area per 20,000 BTUH (111 mm2 per kW) of total
input rating of all equipment in the room when the
opening is communicating 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 communicating with the outdoors
through horizontal duct(s).

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 job site.

3. In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of
a motorized sealed damper to prevent the circulation of cold air through the heater during
non-operating hours.

Combustion and Ventilation Air
Combustion Air Filter

This heater is supplied with an integral combustion air
filter. This filter will reduce the amount of particulates
passed through the combustion system and heat
exchanger but will not protect against chemical inside
air contamination (See Appendix). The filter must be
checked periodically to verify that adequate combustion air is being supplied to the heater. See the
Maintenance section of this manual for information on
checking the filter and establishing service intervals.

Conventional Combustion Air
Supply
U.S. Installations

All Air from Inside the Building

The confined space shall be provided with TWO permanent openings communicating directly with an
additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an
unconfined space. The total input of all gas utilization
equipment installed in the combined space shall be
considered in making this determination. Each opening shall have a minimum free area of 1 in.2 per 1,000
BTUH (22 cm² per kW) of the total input rating of all
gas utilization equipment in the confined space, but
not less than 100 in.² (645 cm²). One opening shall
commence within 6-3/4 in. of the top, and one opening
shall commence within 6-3/4 in. of the bottom, of the
enclosure. The minimum dimension of air openings
shall be not less than 3 in. (8 cm) in any direction.

Indoor Units

The heater must be supplied with sufficient quantities
of non-contaminated air to support proper combustion
and equipment ventilation. Combustion air can be supplied via conventional 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 comply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty. (See
the Appendix.)

All Air from Outdoors

The confined space shall communicate with the outdoors in accordance with methods 1 or 2 below. The
minimum dimension of air openings shall not be less
than 3 in. (8 cm) in any direction. Where ducts are
used, they shall be of the same cross-sectional area
as the free area of the openings to which they connect.

Direct Combustion Air

If outside air is drawn through the intake pipe directly
to the unit for combustion:

1. Install combustion air direct vent in accordance
with the venting section of this manual.

2. Provide adequate ventilation of the space occupied by the heater(s) by an opening(s) for
ventilation air at the highest practical point communicating with the outdoors. The total
cross-sectional area shall be at least 1 in.2 of free

1. Two permanent openings, one commencing
within 12 in. (30 cm) of the top, and one commencing within 12 in. (30 cm) 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
communicate with the outdoors.

a. Where directly communicating with the outdoors or where communicating to the
outdoors through vertical ducts, each opening
shall have a minimum free area of 1 in.2 per
4000 BTUH (5.5 cm2 per kW) of total input rating of all equipment in the enclosure.

ral air flow from the outdoors for natural draft, partial fan assisted, fan-assisted or power
draft-assisted burners, there shall be a permanent
air supply opening(s) having a cross section area
of not less than 1 in.2 per 7000 BTUH (310 mm2
per kW) up to and including 1 million BTUH, plus
1 in.2 per 14000 BTUH (155 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. (150 mm)
above the floor level. The duct can also "Goose
Neck" through the roof. The duct is preferred
straight down 18” from floor, but do not place near
piping. This air supply opening requirement shall
be in addition to the air opening for ventilation air
required in (1).

b. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in.2 per 2000
BTUH (11 cm2 per kW) of total input rating of
all equipment in the enclosure.

2. One permanent opening, commencing within 12
in. (30 cm) of the top of the enclosure, shall be
permitted where the equipment has clearances of
at least 1 in. (2.5 cm) from the sides and back and
6 in. (16 cm) from the front of the appliance. The
opening shall directly communicate with the outdoors or shall communicate through a vertical or
horizontal duct to the outdoors or spaces (crawl or
attic) that freely communicate with the outdoors,
and shall have a minimum free area of:

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 supply opening(s) having a total cross-sectional area
of not less than 1 in.2 for each 30,000 BTUH (70
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 (1). This opening(s)
can be ducted to a point not more than 18 in. (450
mm) nor less than 6 in. (150 mm) above the floor
level. The duct can also "Goose Neck" through the
roof. The duct is preferred to be straight down 18”
from floor, but do not place near piping.

a. 1 in.2 per 3000 BTUH (7 cm2 per kW) of the
total input rating of all equipment located in the
enclosure, and

b. Not less than the sum of the areas of all vent
connectors in the confined space.
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.

4. Refer to the latest version of the B149 for additional information.

Installations in Canada

Water Piping

CAUTION: All combustion air must be drawn from
the air outside of the building; the mechanical
equipment room must communicate directly with the
outdoors.

General

The heater should be located so that any water leaks
will not cause damage to the adjacent area or structures.

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 outdoors. The total cross-sectional area of
such an opening(s) shall be at least 10% of the
area required in (2) and (3), but in no case shall
the cross-sectional area be less than 10 in.2 (6500
mm2.).

2. For heaters using a barometric damper in the vent
system, and when air supply is provided by natu-

CAUTION: This heater requires forced water
circulation when the burner is operating. See Table E
and Table F 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.
12

Reversing Water Connections

Follow these instructions to change the water connections from the left-hand side (standard) to the
right-hand side.

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. Disconnect or isolate the main gas pipe from the
heater (if applicable).

Fig. 9: Torque Sequence

4. Remove both in/out and return header access
panels by removing all sheet metal screws.

Relief Valve Piping

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.

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.

6. Remove limits, control bulbs and/or sensors.

7. Remove the six flange nuts and the in/out header
from the left-hand side.

8. Remove the six flange nuts and the return header
from the right-hand side.
9. Remove the header stud bolts from each tube
sheet.
10. Reverse the headers and stud bolts to the new
location.

11. Install NEW red beveled O-rings flush against both
tube sheets with the bevel facing outward.

12. Push the header firmly against the O-rings. Install
and tighten the flange nuts onto the stud bolts until
finger tight.

13. Slowly tighten the flange nuts, starting from the
center nut (number 1) in Fig. 9 and working
sequentially around the header as indicated.
Torque all nuts to 25 ft/lb. DO NOT OVER-TIGHTEN.

14. Re-route the capillary(s), wiring, etc., to the new
location, adding thermal paste and shim to the
capillary well.

Hydrostatic Test

Low Temperature System

Unlike many other types of heaters, Raypak heaters
do not require hydrostatic testing prior to being placed
in operation. The heat exchanger has already been
factory-tested and is rated for 160 PSI maximum operating pressure. However, Raypak does recommend
hydrostatically testing 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 antifreeze. Raypak recommends conducting the hydrostatic test before
connecting gas piping or electrical supply.

Heater requires minimum inlet temperature of 105°F.
Consult the following sections for piping details.

Temperature & Pressure Gauge

The temperature and pressure gauge is shipped loose
for field installation.

Hydronic Heating
Pump Selection

Leaks must be repaired at once to prevent damage to
the heater. NEVER use petroleum-based stop-leak
compounds.

In order to ensure proper performance of your boiler
system, you must install a properly sized pump.
Raypak recommends using a 20°F ∆T as design ∆T.
(∆T is the temperature difference between the inlet
and outlet water when the heater is firing at full rate).
If a ∆T other than 20°F is necessary, see Table E for
flow rate requirements.

1. Connect fill water supply. Fill heater with water (be
sure bleed valve is open). When water flows from
bleed valve, shut off water. Close bleed valve.
Carefully fill the rest of the system, being sure to
eliminate any entrapped air by using high point
vents. Close feed valve. Test at standard operating
pressure for at least 24 hours.

Pressure Drop in Feet of Head
Feedwater Regulator

2. Make sure constant gauge pressure has been
maintained throughout test.

Raypak recommends that a feedwater regulator be
installed and set at 12 psi minimum pressure at the
highest point of system. Install a check valve or back
flow device upstream of the regulator, with a manual
shut off valve as required by local codes.

3. Check for leaks. Repair if found.

Model
No.

Input
MBTUH

Output
MBTUH

HD151

150

128

250

213

HD101
HD201
HD251
HD301
HD401

100
199
299
399

169
254
335

10°F ∆T

20°F ∆T

30°F ∆T

Min. Flow

gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft)
17

1.3

5.3

26
44

3.0

0.7

9.2

2.1

1.0

5.6

2.5

17
25
34

1.3
3.1

0.7

3.4

1.4

*Flow switch will not activate at less than 12 gpm.
NOTE: Basis for minimum flow — 13 gpm or 40°F ∆T maximum flow — gpm, except for header.

13
13
17

Table E: Heater Rates of Flow and Pressure Drops

0.7
0.7
0.8
1.4

Max. Flow

∆T gpm ∆P (ft) ∆T
14

8.8

8.9

20
34
40
40

44
44
44
44

8.8

9.2

9.8

9.4

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Fig. 10: Single Boiler — Low Temperature Application (Heat Pump) Primary/Secondary Piping

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Fig. 11: Dual Boiler—Primary/Secondary Piping

Piping—Heating Boilers

Three-Way Valves

All high points should be vented. Purge valves and a
bypass valve should be installed. A boiler installed
above radiation level must be provided with a low
water cut-off device. The boiler, when used in connection with a refrigeration system, must be installed so
the chilled medium is piped in parallel with the boiler
with appropriate valves to prevent the chilled medium
from entering the boiler.

Valves designed to blend water temperatures or
reduce water circulation through the boiler should not
be used. Raypak boilers are high recovery low mass
boilers not subject to thermal shock. Raypak offers a
full line of electric sequencers that produce direct reset
of boiler water temperature. Refer to the Controls
Section in our Complete Catalog.

Domestic Hot Water Piping

The boiler piping system of a hot water heating boiler
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
boiler water during the cooling cycle. It is highly recommended that the piping be insulated.

When designing the water piping system for domestic
water applications, water hardness should be considered. Table F indicates the suggested flow rates for
soft, medium and hard water. Hardness is specified as
grains per gallon.

Air-Separation/Expansion Tank

All boilers should be equipped with a properly sized
expansion tank and air separator fitting as shown in
the piping diagrams (Fig. 10–12).
Model
No.

Input
MBTUH

Output
MBTUH

HD101

100

HD201

199

HD151
HD251
HD301
HD401

Soft (0–4 grains per gallon)

∆T

gpm
20

150

128

250

213

299
399

169
254
339

17
25
34

∆P

MTS

SHL

∆T

gpm

1-1/2

3.8

3.9

1.8

1-1/2

1.9

1-1/2

20
20
20

1.8
1.9
1.9
2.0

Medium (5–15 grains per gallon)

1-1/2
1-1/2
1-1/2

3.8
3.9
3.9
4.0

13
20
26

∆P

MTS

SHL

∆T

gpm

1-1/2

6.3

3.0

1-1/2

3.2

1-1/2

26
26
26

3.1
3.2
3.2
3.3

Hard* (16–25** grains per gallon)

1-1/2
1-1/2
1-1/2

6.3
6.4
6.5
6.5
6.6

4
8
9

∆P

MTS

SHL

1-1/2

18.1

9.2

1-1/2

9.4

1-1/2

45
45
45

9.2
9.6
9.8

10.3

1-1/2
1-1/2
1-1/2

18.0
18.2
18.5
18.7
19.1

∆T = Temperature rise, °F.
∆P = Pressure drop through heat exchanger, ft.
SHL = System head loss, ft. (System head loss is based on the heater and tank placed no more than 5 feet apart and 50 feet equivalent length
of tubing and fittings.)
gpm = Gallons per minute, flow rate.
MTS = Minimum tubing size.
*Must utilize optional cupro-nickel tubes.
**With Hard Water (16-25 grains per gallon), the operating control must be set no higher than 130°F for scale free operation. For operating temperatures above 130°F, a water softener must be utilized.

Table F: Domestic Water Heater Flow Rate Requirements

Gas Supply

Fig. 12: Single Heater — Domestic Hot Water with One Storage Tank

Gas Supply Connection

DANGER: Make sure the gas on which the heater
will operate is the same type as specified on the
heater’s rating plate.

CAUTION: The heater and its manual shutoff valve
must be disconnected from the gas supply during
any pressure testing of the gas supply system at test
pressures in excess of 1/2 psi (3.45 kPa). The heater
must be isolated from the gas supply piping system
by closing the manual shutoff valve during any
pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 psi. Relieve
test pressure in the gas supply line before
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 covered 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 open flame.

Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve located outside the heater jacket. A pounds to inches
regulator must be installed to reduce the natural gas
supply pressure to under 10.5 in. WC (13.0 in. WC for
propane gas). The regulator should be placed a minimum distance of 10 times the pipe diameter upstream
of the heater gas controls. All gas piping must be tested after installation in accordance with local codes.
The heater and its gas connection must be leak-tested
before placing it in operation.

Fig. 13: Sediment Trap Orientation

Gas Pressure Regulator

CAUTION: Do not use Teflon tape on gas line pipe
thread. A pipe compound rated for use with gas
systems is recommended. Apply sparingly only on
male pipe ends.

The gas valve pressure regulator(s) on the heater are
nominally preset at 3 in. WC for natural gas, and 10.0
in. WC for propane gas manifold pressure. The pressure at the gas valve outlet tap, measured with a
manometer, while in operation should be as indicated
in Table G. If an adjustment is needed, turn the adjustment screw clockwise to increase pressure or
counter-clockwise to decrease pressure.

CAUTION: Support gas supply piping with
hangers, not by the heater or its accessories. Ensure
the gas piping is protected from physical damage
and freezing where required.

Gas Supply Pressure

Electrical Power Connections

A minimum of 4 in. WC and a maximum of 10.5 in. WC
upstream gas pressure is required under load and no
load conditions for natural gas. A minimum of 11 in.
WC and a maximum of 13 in. WC is required for
propane gas. The gas pressure regulator supplied on
the heater is for low pressure service. If upstream
pressure exceeds 14 in. WC, an intermediate gas
pressure regulator, of the lockup type, must be
installed.

Installations must follow these codes:
·
·
·
·

When connecting additional gas utilization equipment
to the gas piping system, the existing piping must be
checked to determine if it has adequate capacity.
Firing
Stage
Hi-Fire
Lo-Fire

Gas Valve
Invensys

Honeywell or
White-Rodgers
Invensys

Honeywell or
White-Rodgers

The heater is wired for 120 VAC, less than 12 AMPS.
The voltage is indicated on the tie-in leads. Consult the
wiring diagram shipped with the heater in the instruction packet. The remote tank control stat, thermostat,
or electronic heater control as applicable, may be connected to stage selector terminal (See wiring diagram).
24 Volts are supplied to this connection through the
heater transformer. DO NOT attach line voltage to
the stage connections. Before starting the heater
check to ensure proper voltage to the heater and
pump.

Gas Type
Natural
LP/Propane
+/- 0.1"WC +/- 0.1"WC
3.3" WC
3.1" WC

9.6" WC

1.4" WC

3.6" WC

1.2" WC

Table G: Pressure at Gas Valve Outlet Tap

National Electrical Code and any other national,
state, provincial or local codes or regulations having jurisdiction
Safety wiring must be N.E.C. Class 1
Heater must be electrically grounded as required
by N.E.C.
In Canada, C22.1

WARNING: Connecting line voltage to the stage
connection terminal block will cause damage to the
unit that is not covered by warranty.

Input

Model
No.

(KBTUH)

HD151

150

HD101
HD201
HD251
HD301
HD401

3/4”
N

1”
P

160

530

600

230

240

100

105

385

340

199

250
299
399

50
20
15
5

180
50
35
20

1-1/4”

45
25

355
170
80

1-1/2”

550

360

360
170
100

365

Table H: Maximum Equivalent Pipe Length

210

Natural gas – 1,000 BTUH per ft3, .60 specific gravity at 0.5 in. WC pressure drop
Propane gas – 2,500 BTUH per ft3, 1.50 specific gravity at 0.5 in. WC pressure drop

Install a separate disconnect means for each load.
Use appropriate-sized wire as defined by NEC, CSA
and/or local code. All primary wiring should be 125% of
minimum rating.

It is strongly recommended that all individually-powered control modules and the heater should be
supplied from the same power source.

Surge Protection

Microprocessor-based and solid state controls are vulnerable to damage from voltage and amperage
fluctuations in the power supply. All sensitive control
components should be protected by a suitable commercial-grade surge protection device.

AC = 108 Volts AC Minimum, 132 Volts AC MAX
AB = 108 Volts AC Minimum, 132 Volts AC MAX
BC = < 1 Volt AC
Fig. 14: Check Power Source

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.

Making the Electrical Connections
Refer to Fig. 14 and the Wiring Diagram.

Check the Power Source

1. Verify circuit breaker is properly sized by referring
to heater rating plate. A dedicated circuit breaker
should be provided.

WARNING: Using a volt-ohm meter (VOM), check
the following voltages at the terminal block inside the
unit. Make sure proper polarity is followed and house
ground is proven.

2. Turn off all power to the heater. Verify that power
has been turned off by testing with a volt-ohm
meter prior to working with any electrical connections or components.
3. Observe proper wire colors while making electrical
connections. Many electronic controls are polarity
sensitive. Components damaged by improper
electrical installation are not covered by warranty.

4. Provide an external surge suppressor capable of
maintaining system integrity.

5. Provide overload protection and a disconnect
means for equipment serviceability as required by
local and state code.

6. Install heater controls, thermostats, or building
management systems in accordance with the
applicable manufacturer’s instructions.

STAGE 1

USE COPPER
CONDUCTORS ONLY

P/N 901935 REV 1

NOTE: A grounding electrode conductor shall be
used to connect the equipment grounding
conductors, the equipment enclosures, and the
grounded service conductor to the grounding
electrode.

INTERLOCK /
LOUVER SW

ALARM
DRY
CONTACTS

(OPTIONAL) JUMPERED
WHEN NOT USED

JUMPERED
WHEN NOT USED

7. Conduit should not be used as the ground. There
must be a solidly wired ground.

ENABLE /
DISABLE OR
SEQUENCER

STAGE 2

HOT

COM

HOT

COM

HOT

POWER IN

SAFETY VALVE

24V
24VR
CWS / CWR
FAN / DAMPER
(PILOT DUTY)
(OPTIONAL)

PUMP

Fig. 15: Terminal Block Connections

Consult the wiring diagram shipped with the heater in
the instruction packet. The Stage 1 connections are for
the remote tank control through the heaters 24 volt
transformer. DO NOT attach line voltage to the
Stage 1 connection. Before starting heater, check to
ensure proper voltage to heater and pump.

Electrical Connections — Domestic
Hot Water
DANGER—SHOCK HAZARD: Make sure
electrical power to the heater is disconnected to
avoid potential serious injury or damage to
components.

SINGLE
STAGE
TANKSTAT

CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper
operation after servicing.
NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.

STAGE 1
CONNECTION

Installer action is required to electrically enable your Hi
Delta heater to operate after making the power connections. You must use Terminal Block connections 1
through 4 for the temperature controller, as shown in
Fig. 15. This will be done based on the controller
option selected with your heater order.

ATTACH STAGE 1 CONNECTIONS
ON HEATER TO THE SINGLE STAGE
TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.
Fig. 16: Single Stage Tankstat

For operation with a Temp-Tracker controller, refer to
the Temp-Tracker Installation and Operating
Instructions, Raypak Catalog number 5000.66 (P/N
241177).

2-STAGE
TANKSTAT

STAGE 1
CONNECTION

Category II. A heater which operates with a non-positive vent static pressure and with a vent gas
temperature that may cause excessive condensate
production in the vent.

Category III. A heater which operates with a positive
vent pressure and with a vent gas temperature that
avoids excessive condensate production in the vent.

STAGE 2 CONNECTION OR
STAGE 1 CONNECTION
OF HEATER 2

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.
See Table I for appliance category requirements for
the Hi Delta.

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 CONNECTION ON TANKSTAT
AS SHOWN IN THE DIAGRAM.

NOTE: For additional information on appliance
categorization, see appropriate ANSI Z21 Standard
and the NFGC (U.S.), or B149 (Canada), or
applicable provisions of local building codes.

Fig. 17: 2-Stage Tankstat

Heater must be electrically grounded in accordance
with NEC and C22.1(in Canada).

Determination of Appliance
Category for Venting Purposes and
Venting Arrangements

NOTES:
1. Field installed ground to inside of junction box.

2. 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.

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
personal injury, death or property damage.

Venting
General

CAUTION: Proper installation of flue venting is
critical for the safe and efficient operation of the
heater.
Definition of Appliance Categories

Heaters are divided into four categories based on the
pressure produced in the exhaust and the likelihood of
condensate production in the vent.

Category I. A heater which operates with a non-positive vent static pressure and with a vent gas
temperature that avoids excessive condensate production in the vent.

Combustion Air
Supply
From Inside
Building (Non-Direct
Venting)

From Outside
Building (Direct
Venting)

Exhaust
Configuration

Venting Category

Vertical Natural
Draft Venting

Certified
Appliance Material
Type B or any
Category I Venting
System*

Horizontal
Thru-wall
Venting

III

Vertical Venting

Horizontal
Thru-wall
Venting

Type B or any
Category I Venting
System*

III

Stainless Steel
(Gas Tight)

Combustion Air
Inlet Material

Stainless Steel
(Gas Tight)

Galvanized Steel
PVC
ABS
CPVC

*As defined in the latest edition of the NFGC, or in Canada, the B149.

Barometric Damper

Table I: Venting Category Requirements

Vent Terminal Location

A barometric damper may be required when vent
heights exceed 25 feet or when the draft is greater
than -0.08 in. WC. In these installations, a barometric
damper (single acting) is required.

NOTE: During winter months check the vent cap
and make sure no blockage occurs from build up of
snow.

The damper should be installed NO CLOSER than 18
in. from the discharge of the unit and no closer than 18
in. from a combustible ceiling. The damper can be
installed in horizontal or vertical runs of vent pipe as
necessary. Installation in a bull-head tee is acceptable
as shown in the NFGC.

1. Condensate can freeze on the vent cap. Frozen
condensate on the vent cap can result in a blocked
flue condition.

2. Give special attention to the location of the vent
termination to avoid possibility of property damage
or personal injury.

The weights on the damper should be adjusted per the
damper manufacturer’s instructions for proper operation, to maintain –0.01 to –0.08 in. WC, 12 in. from the
heater outlet, at all firing conditions.

3. Gases may form a white vapor plume in winter.
The plume could obstruct a window view if the termination is installed in close proximity to windows.

Support of Vent Stack

4. Prevailing winds, in combination with below freezing temperatures, can cause freezing of
condensate and water/ice build-up on buildings,
plants or roofs.

The weight of the vent stack or chimney must not rest
on the heater vent connection. Support must be provided in compliance with applicable codes. The vent
should also be supported to maintain proper clearances from combustible materials.

5. The bottom of the vent terminal and the air intake
shall be located at least 12 in. above grade, including normal snow line.

Use insulated vent pipe spacers where the vent passes through combustible roofs and walls.

6. Un-insulated single-wall metal vent pipe shall not
be used outdoors on cold climates for venting gas
utilization equipment.

7. Through-the-wall vents for Category II and IV
appliances and non-categorized condensing appli-

Fig. 18: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
1

1
2

t
TT
*

U.S. Installations

Canadian Installations

Clearance above grade, veranda, porch,
deck, or balcony

1 ft (30 cm)

Clearance to window or door that may be
opened

4 ft (1.2m) below or to side
of opening; 1 foot (30 cm)
above opening

3 ft (91 cm)

Clearance to permanently closed window

Vertical clearance to ventilated soffit located
above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the
terminal

5 ft (1.5m)

Clearance to unventilated soffit

Clearance to outside corner

Clearance to inside corner

6 ft (1.83m)

3 ft (91 cm) within a height
15 ft above the meter/regulator assembly

Clearance to each side of center line extended above meter/regulator assembly

Clearance to service regulator vent outlet

6 ft (1.83m)

Clearance to non-mechanical air supply inlet
to building or the combustion air inlet to any
other appliance

4 ft (1.2m) below or to side
of opening; 1 ft (30 cm)
above opening

3 ft (91 cm)

Clearance to mechanical air supply inlet

3 ft (91 cm) above if within
10 ft (3m) horizontally

6 ft (1.83m)

Clearance above paved sidewalk or paved
driveway located on public property

7 ft (2.13m)

7 ft (2.13m) t

Clearance under veranda, porch, deck or
balcony

12 in. (30 cm) TT

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
In accordance with the current CAN/CGA-B149 Installation Codes
Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves
both dwellings
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 J: Vent/Air Inlet Termination Clearances

ances shall not terminate over public walkways or
over an area where condensate or vapor could
create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or
other equipment. Where local experience indicates that condensate is a problem with Category
I and III appliances, this provision shall also apply.

g) The vent terminal of a direct vent appliance with
an input over 50,000 BTUH per hour shall require
a 12-inch vent terminal clearance.
h) Terminate vent at least one (1) foot above grade,
including normal snow line.
i)

8. Locate and guard vent termination to prevent accidental contact by people or pets.

Installations in Canada

9. DO NOT terminate vent in window well, stairwell,
alcove, courtyard or other recessed area.

Refer to latest edition of CAN/CGA-B149.

10. DO NOT terminate above any door, window, or
gravity air intake. Condensate can freeze, causing
ice formations.

A vent shall not terminate:

a) Directly above a paved sidewalk or driveway
which is located between two single family
dwellings and serves both dwellings.

11. Locate or guard vent to prevent condensate from
damaging exterior finishes. Use a rust resistant
sheet metal backing plate against brick or masonry surfaces.

b) Less than 7 ft. (2.1m) above a paved sidewalk or
paved driveway located on public property.

12. DO NOT extend exposed vent pipe outside of
building. Condensate could freeze and block vent
pipe.

c) Within 6 ft. (1.8m) of a mechanical air supply inlet
to any building.

d) Above a meter/regulator assembly within 3 ft.
(914mm) horizontally of the vertical center-line of
the regulator.

US Installations

Refer to latest edition of the National Fuel Gas Code.

e) Within 6 ft. (1.8m) of any gas service regulator
vent outlet.

Vent termination requirements are as follows:

a) Vent must terminate at least four (4) feet below,
four (4) feet horizontally, or one (1) foot above any
door, window or gravity air inlet to the building.

Less than 1 ft. (305mm) above grade level.

g) Within the 3 ft. (914mm) of a window or door which
can be opened in any building, any non-mechanical air supply inlet to any building or the
combustion air inlet of any other appliance.

b) The vent must not be less than seven (7) feet
above grade when located adjacent to public walkways.

h) Underneath a verandah, porch or deck, unless

c) Terminate vent at least three (3) feet above any
forced air inlet located within ten (10) feet.

(i) the verandah, porch or deck is fully open on a
minimum of two sides beneath the floor, and

d) Vent must terminate at least four (4) feet horizontally, and in no case above or below unless four (4)
feet horizontal distance is maintained, from electric meters, gas meters, regulators, and relief
equipment.

(ii) the distance between the top of the vent termination and the underside of the verandah,
porch or deck is greater than 1 ft. (30 cm).

e) Terminate vent at least six (6) feet away from adjacent walls.

Multiple direct vent installations require a four (4)
foot clearance between vent caps.

DO NOT terminate vent closer than five (5) feet
below roof overhang.

Venting Installation Tips

on, Venting of Equipment, of the latest edition of
NFGC, or in Canada, B149 Installation Code for Gas
Burning Appliances and Equipment, or applicable provisions of local building codes.

Support piping:
·
·
·

horizontal runs- at least every five (5) feet.
vertical runs - use braces:
under or near elbows

Cut nonmetallic intake pipe with fine-toothed hacksaw.
Do not use nonmetallic intake pipe or fittings that
are cracked or damaged.
Do not use nonmetallic intake fittings if they are
cut or altered.
Do not drill holes, or use screws or rivets, in nonmetallic intake pipe or fittings.

Follow items listed below to avoid personal injury or
property damage.
·

To make metallic vent joints:
·

Do not install seams of vent pipe on bottom of
runs.
100% Seal all joints and seams with high temperature silicone sealant.

WARNING: Examine the venting system at least
once a year. Check all joints and vent pipe
connections for tightness, corrosion or deterioration.
NOTE: The words "Flue Exhaust", "Flue" and
"Exhaust Vent" are used interchangeably.

Venting Configurations

Fig. 19: Natural Draft Vertical Venting (Category I)

For heaters connected to gas vents or chimneys, vent
installations shall be in accordance with the section
Model
No.
HD101
HD151
HD201
HD251
HD301
HD401

Appliance
Category

Certified
Venting
Material

Type B or
Equivalent

Minimum
Recommended
Vent Size (inches)
4

Min./Max. Venting Length without
Barometric Damper (feet)**
Min.
6

(HD201) 6
(HD251) 6
(HD301) 11

5
6

Max.

**Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the NFGC for further details. (ANSI Z223.1)

Table K: Natural Draft Vertical Venting

Air Inlet Max.
Length (feet)

100

Natural Draft Vertical Venting
System Installation

CAUTION: Listed vent cap terminal must be used
and sized adequately to evacuate the flue products
from the heaters.

Natural draft venting uses the natural buoyancy of the
heated flue products to create a thermal driving head
that expels the exhaust gases from the flue. The negative draft must be within the range of –0.01 in. to
–0.08 in. WC as measured 12 in. from the appliance
flue outlet to ensure proper operation. Vent material
must be listed by a nationally recognized test agency.

Natural Draft Vertical Venting with
Common Venting System, Category I
Appliance Only
Manifolds that connect more than one heater to a common chimney must be sized to handle the combined
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 heater
exhaust outlet.

The maximum and minimum venting length for
Category I appliance shall be determined per the latest edition of the NFGC (U.S.) or B149 Installation
Code (Canada).

The diameter of vent flue pipe should be sized according to Part 11 of the latest edition of the NFGC (U.S.)
and part 7 and appendix B of the B149 Installation
Code (Canada). The minimum flue pipe diameter for
conventional negative draft venting using double-wall
B type vent is 4” for HD101 and HD151, 5” for HD201,
HD251 and HD301, and 6” for HD401.

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.
CAUTION: Vent connectors for natural draft
venting systems must be type “B” vent or better.

NOTE: Vent Adapter will have to be used to connect
B vent to the unit.

Common venting systems may be too large when an
existing unit is removed. At the time of removal of an
existing appliance, the following steps must be followed with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation.

The connection from the appliance vent to the stack
must be as direct as possible and shall be the same
diameter as, or larger than the vent outlet. The horizontal 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.

a) Seal any unused opening in the common venting
system.

Natural Draft Vertical Vent
Termination

The vent terminal should be vertical and should terminate outside the building at least two (2) feet above the
highest point of the roof that is within 10 feet. The vent
cap should have a minimum clearance of four (4) feet
horizontally from and in no case above or below
(unless a four (4) foot horizontal distance is maintained) electric meters, gas meters, regulators 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, or in Canada, the B149
Installation Code for Gas Burning Appliances and
Equipment. Gas vents supported only by flashing and
extended above the roof more than five feet should be
securely guyed or braced to withstand snow and wind
loads.

b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion or other
unsafe condition.

c) Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common vent system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate summer
exhaust fan. Close fireplace dampers.
d) Place in operation the appliances being inspected.
Follow the manufacturers instructions for lighting

Fig. 20: Horizontal Thru-Wall Venting (Category III)

each appliance. Adjust thermostat so appliance
will operate continuously.

g) Any improper operation of the common venting
system should be corrected so that the installation
conforms with the latest edition of the NFGC (US)
and the B149 Installation Code (Canada). When
re-sizing any portion of the common venting system, the common venting system should be
re-sized to approach the minimum size as determined using the appropriate tables in Appendix G
in the NFGC (US) and Appendix B of the B149
Installation Code (Canada).

e) Check the pressure at a pressure tap located 12
in. above the bottom joint of the first vertical vent
pipe. Pressure should be anywhere between -.01
to -.08 in. WC.
f)

After it has been determined that each appliance
remaining connected to the common venting system properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and other gas burning appliances to their
previous conditions of use.
Model
No.
HD101
HD151
HD201
HD251
HD301
HD401

Appliance
Category

III

Certified
Venting
Material

Vent Size
(inches)

Max. Venting
Length (feet)

Stainless
Steel
(Gas Tight)

5
6

Table L: Horizontal Thru-Wall Venting (Category III)

100

Horizontal Thru-wall Venting
System (Category III) Installation

b) The vent be insulated through the length of the
horizontal run.

These installations utilize the heater-mounted blower
to vent the combustion products to the outdoors.
Combustion air is taken from the space and the vent is
installed horizontally through the wall to the outdoors.
Adequate combustion and ventilation air must be supplied in accordance with the NFGC or, in Canada, the
B149 Installation Code.

Horizontal Thru-wall Direct Vent
Termination

The flue exhaust direct vent cap MUST be mounted on
the exterior 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 one (1) foot above
ground level and above normal snow levels.

The total length of the horizontal thru-wall exhaust
vent system should not exceed one hundred (100) feet
in length. If horizontal run exceeds 100 feet, an appropriately sized extractor must be used. Each elbow
used is equal to ten (10) feet of straight pipe. This will
allow installation in one of the four following combinations.
·
·
·
·
·

Multiple direct vent caps MUST NOT be installed with
one 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
combustion air intake installed above. This type of
installation can cause non warrantable problems with
components and poor operation of the unit due to the
recirculation of flue products. Multiple direct vent caps
should be installed in the same horizontal plane with a
three (3) foot clearance from the side of one vent cap
to the side of the adjacent vent cap(s).

100’ of straight flue pipe.
90' of straight flue pipe and one elbow.
80' of straight flue pipe and two elbows.
70' of straight pipe and three elbows.
60' of straight pipe and four elbows.

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.

The vent cap is not considered in the overall length of
the venting system. The vent must be installed to prevent the flue gas leakage. Care must be taken during
assembly to ensure that all joints are sealed properly
and are airtight.

WARNING: No substitutions of flue pipe or vent
cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants.

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.

The flue exhaust direct vent cap must be furnished
by the heater manufacturer in accordance with its
listing. Use only the special gas vent pipes listed for
use with Category III gas burning heaters, such as the
stainless steel vent by Heat Fab Inc (800-772-0739),
Protech Systems, Inc. (800-766-3473) or Z-Flex (800654-5600). Pipe joints must be positively sealed.
Follow the vent manufacturers installation instructions
carefully.

The vent must be installed to prevent the potential
accumulation of condensate in the vent pipes. It is recommended that:
a) The vent be installed with a slight downward slope
of not more than 1/4" per foot of horizontal run to
the vent terminal.

b) The vent be insulated through the length of the
horizontal run.

For appliances installed in extreme cold climate, it is
recommended that:

a) The vent be installed with a slight upward slope of
not more than 1/4" per foot of horizontal run to the
vent terminal. In this case, an approved condensate trap must be installed per applicable codes.
28

Fig. 21: Direct Vent Horizontal Thru-Wall Venting (Category III)

Model
No.
HD101
HD151
HD201
HD251
HD301
HD401

Appliance
Category

III

Certified
Venting
Material

Vent Size
(inches)

Stainless
Steel
(Gas Tight)

4
5
6

Max.
Venting
Length
(feet)

Combustion
Air Intake
Pipe
Material

Air Inlet
Size
(inches)

Max. Air
Intake
Length
(feet)

100,
4 Elbows
Max.

Galvanized
Steel
PVC
ABS
CPVC

100

Table M: Horizontal Thru-Wall Venting

Fig. 22: Direct Vent—Vertical Venting (Category I)

Model
No.
HD101
HD151
HD201
HD251
HD301
HD401

Appliance
Category

Certified
Venting
Material

Type B
Equivalent

Vent
Size
(inches)
4
5
6

Min./Max. Vertical
Venting Height (feet)
Min.
6

(HD201) 6
(HD251) 6
(HD301) 11

Max.

25*

Combustion
Air Intake
Pipe
Material

Air Inlet
Size
(inches)

Max. Air
Intake
Length
(feet)

Galvanized
Steel
PVC
ABS
CPVC

100

*Over 25 feet, use single acting barometric damper. Consult the factory for additional information.

Table N: Vertical Venting

Vertical Direct Vent System
Installation

blockage from snow. The vent cap must have a minimum 3 foot clearance from the air inlet opening.

Outdoor Installation

These installations utilize the heater mounted blower
to draw combustion air from outdoors and uses the
natural buoyancy of the heated flue products to create
a thermal driving head that expels the exhaust gases
from the flue. The negative draft must be within the
range of -0.01 to -0.08 in. WC as measured 12 in. from
the appliance outlet to ensure proper operation. The
vent material must be in accordance with the above
instructions for vent materials. Vent material must be
listed by a nationally recognized test agency.

Outdoor models are self-venting when installed with
the factory-supplied vent assembly and air intake
cover and require no additional vent piping. This special vent assembly is provided with the heater in
accordance with CSA requirements. It must be
installed directly on the heater. See the Venting section for correct clearances.
Care must be taken when locating the outdoor unit
because the flue gases discharged from the vent
assembly can condense as they leave the assembly.
Improper location can result in damage to adjacent
structures or building finish. For maximum efficiency
and safety, the following precautions must be
observed:

The maximum and minimum venting length for
Category I appliance shall be determined per the latest edition of the NFGC (U.S.) and B149 Installation
Code (Canada).

The connection from the appliance exhaust vent to the
stack must be as direct as possible and should be the
same as or larger than the vent outlet. The vent must
be installed to prevent accumulation of condensate
and, where necessary, have means provided for
drainage of condensate. The horizontal 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.

a) Outdoor models must be installed outdoors and
must use the outdoor vent assembly and air intake
cover supplied by the manufacturer.

b) 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.

Vertical Direct Vent Termination

c) Do not locate adjacent to any window, door walkway, or gravity air intake. The vent must be located
a minimum of four (4) feet horizontally, or four (4)
feet below, or one (1) foot above such areas.

The exhaust vent terminal should be vertical and
should terminate outside the building at least two (2)
feet above the highest point of the roof within 10 feet.
The vent cap should have a minimum clearance of
four (4) feet horizontally from and in no case above or
below (unless a four (4) foot horizontal distance is
maintained) electric meters, gas meters, regulators
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, or in Canada, the B149
Installation Code. Gas vents supported only by flashing and extended above the roof more than five feet
should be securely guyed or braced to withstand snow
and wind loads.

The vertical direct vent cap is designed for roof top
mounting only. The air inlet opening MUST be installed
one (1) foot above the roof line or above normal snow
levels that might obstruct combustion air flow. This
dimension is critical to the correct operation of the
heater and venting system and reduces the chance of

d) Install above grade level and above normal snow
levels.

e) Vent must be at least 3 feet above any forced air
inlet located within 10 feet.
f)

Adjacent brick or masonry surfaces must be protected with a rust-resistant sheet metal plate.

g) Multiple Outdoor Vent installations require a four
(4) feet clearance between vent assemblies.
NOTE: Condensate can freeze on the vent
assembly. Frozen condensate on the vent assembly
can result in a blocked flue condition.

The vent assembly must be furnished by the
heater manufacturer in accordance with its listing.

CONTROLS

Modulating Temperature
Control (Optional)

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.

This heater can be equipped with a Raypak modulating temperature control. For operation with this control,
refer to the Temp-Tracker Installation and Operating
Instructions, Raypak Catalog number 5000.66 (P/N
241177).

WARNING: Turn off the power to the heater before
installation, adjustment or service of the heater
controls. Failure to do so may result in heater
malfunction, property damage, personal injury, or
death.
CAUTION: This appliance has provisions to be
connected to more than one (1) supply source. To
reduce the risk of electric shock, disconnect all such
connections before servicing.
CAUTION: Risk of electric shock. More than one
(1) disconnect switch may be required to deenergize the equipment before servicing.

Fig. 24: Modulating Temperature Control

High Limit (Manual Reset)

Ignition Control Module

The heater is equipped with a manual reset high limit
temperature device. If the optional adjustable limit is
used, push the reset button and adjust the setting to
30°F or 40°F above desired operating temperature.

The interrupted proved ignition device conserves energy. When additional heat is needed, the combustion air
blower starts to purge all air from the combustion
chamber for about 15 seconds. On proof of air flow,
the air proving switch closes and the igniter is energized, eliminating the fuel costs of maintaining a
constant pilot.
To ensure safe operation, the gas valve cannot open
until the igniter is verified as capable of igniting the
gas. The ignition module is an electronic device which
closes the main gas valve within 8/10 of a second
whenever the flame is interrupted. The main burner is
automatically lit when the device is powered and prepurged. The unit performs its own safety check.

Fig. 25: Manual Reset High Limit

High Limit — Auto Reset
(Optional)
Fig. 23: Ignition Module

This heater may be equipped with an optional adjustable auto reset high limit temperature device.
32

The optional adjustable auto reset high limit is located
behind the front panel (see Fig. 3). Adjust the setting
to approx. 20°F (10°C) above desired outlet temperature.

cient gas pressure is present for proper regulator performance. The low gas pressure switch automatically
shuts down the heater if gas supply drops below the
recommended setting of 4.0 in. WC for natural gas,
and 9.0 in. WC for propane gas.

The high gas pressure switch (optional) connection
mounts down-stream of the gas valve. If the gas pressure regulator fails, the high gas pressure switch
automatically shuts down the burner. The high gas
pressure switch automatically shuts down the heater if
gas manifold pressure rises above the recommended
setting of 4.0 in. WC for natural gas, and 10.5 in. WC
for propane gas.

Fig. 26: High Limit — Auto Reset (Optional)

Flow Switch

Dual-purpose control shuts off heater in case of pump
failure or low water flow. Mounted and wired in series
with the main gas valve.
NOTE: Flow switch will not operate if flow is less
than 12 gpm.

Fig. 28: Gas Pressure Switch

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
premature lockout due to temporary conditions such
as power fluctuations or air pockets.

Fig. 27: Flow Switch

High and Low Gas Pressure
Switches (Optional)

The low gas pressure switch (optional) connection
mounts upstream of the gas valve to ensure that suffi-

Fig. 29: Low Water Cut Off

WIRING DIAGRAM—MODELS HD101–HD401

HD101-HD401 Troubleshooting
Step 1

Does the main power switch provide
power to the green power LED?
YES

Check the switch, transformer
and/or line voltage
NO

Is Disable connection intact?

Reattach.

YES

Step 2

Is there a Call For Heat?

Is temperature controller
installed?

Install.

YES

Step 3

Does the Pump come on?

Is there 120VAC at the pump or
pump relay contacts?

Is there120 VAC at the blower,
between the red & white leads?

Check and correct power
connections at main terminal
block, circuit breaker panel or
pump relay.

YES

Step 4

Does the combustion air
blower come on?
NO

Check safeties, I.E. Flow switch, high
limit, vent switch, thermostat, etc.

YES

Step 5

Check and correct power
connections at main terminal
block, ignition module, circuit
breaker panel or blower relay.

Is blower pressure setting
correct? Should be about 0.5”
W.C. (low speed)

Is 24VAC at the NO side of
the air pressure switch?

YES

Correct the blower
shutter setting.

Is the air filter or
air intake blocked?

YES

Replace low air pressure switch.

Step 6

Is 24VAC at PS on ignition module?
Is connecting plug secure?

Step 7

Does igniter prove?

YES

Is Amp draw during heatup for HSI greater than
3.1 Amps?

Step 8

Is the flame sensor signal to the ignition
module greater than 1 Micro Amp (µA) DC?

YES

The unit is okay

YES

Correct inlet gas supply pressure

Is manifold gas
pressure correct?

Yes

Adjust manifold gas
pressure.
Replace gas valve
YES

Does the unit run at least
5 seconds?
NO

Step 10

Is inlet gas supply pressure
correct?
YES

Does the unit run longer
than 10 seconds?

Replace HSI

Is air switch bouncing?

YES

Step 9

YES

Remove blockage
and/or replace filter

Correct wiring.

YES

Does the air pressure
reach 0.9” W.C.?
NO

Is the air filter or air
intake blocked?

Is the polarity of incoming
power supply correct?
NO

Correct supply wiring

YES

Replace high air pressure switch

Replace blower

Remove blockage
and/or replace filter

Is sensor probe grounded?
Call our Technical Service Department
1-800-947-2975 Outside California
1-800-627-2975 Inside California

YES

Replace Sensor

PRE-START-UP

NOTE: Digital manometers are not recommended.

Filling System-Heating Heaters

Preparation for Start-Up

Fill system with water. Purge all air from the system
using purge valve sequence. After system is purged of
air, lower system pressure. Open valves for normal
system operation, fill system through feed pressure.
Manually open air vent on the compression tank until
water appears, then close vent.

WARNING: Do not turn on gas at this time.

Check Power Supply

Domestic Hot Water Heaters

Purge all air from system before lighting heater. This
can be normally be accomplished by opening a downstream valve.

Inspect Venting System:

Fig. 30: Check Power Source

1. Check all vent pipe connections and flue pipe
material.

With volt meter at incoming power check voltage
between:

2. Ensure vent terminations are installed per code
and are clear of all debris or blockage.

Hot - Common (~120 VAC)
Hot - Ground (~120 VAC)
Common - Ground (< 1 VAC)

Pre-Start-Up Check

WARNING: If Common - Ground is > 1 VAC,
STOP: Contact electrician to correct ground failure.
Failure to do this may burn out 120V-24V
transformer, or may cause other safety control
damage or failure.

1. Verify heater is filled with water.

2. Check system piping for leaks. If found, repair
immediately.

3. Vent air from system. Air in system can interfere
with water circulation.

Attach Manometers to Measure
Pressures

4. Purge air from gas line up to heater.

INITIAL START-UP

•

Tools Needed

•
•
•
•
•
•
•
•
•
•
•

One 8–0–8, 16” scale manometer
Two 6–0–6, 12” scale manometers
7/16” open end wrench
1/2” open end wrench
Screwdriver (Standard & Phillips)
3/8” open end wrench
Multi-meter
3/16” Allen wrench
3/32” Allen wrench (Honeywell or White-Rodgers
gas valve)
5/32” Allen wrench (Invensys gas valve)
#10 Torx driver w/center hole (Invensys gas valve)

•

Attach 16" scale manometer to the main gas shutoff valve supply pressure tapping.
Attach one 12" scale manometer to the manifold
gas pressure tapping. (See gas valve detail on
page 7.)
Attach one 12" scale manometer to the tee near
the blower housing.

Check the Gas Supply Pressure

6. If the pressure reading differs by more than the tolerance given, adjust the gas valve accordingly.
See gas valve adjustment section below for
instructions.

1. Slowly turn on main gas shut-off valve.

2. Read the gas supply pressure from the manometer; minimum supply pressure is 4 in. WC,
recommended supply is 7 in. WC for natural gas
(minimum 11.0 in. WC for LP gas).

Gas Valve Adjustment
Firing
Stage

3. If pressure is > 14 in. WC, turn off the valve.

4. Check if the service regulator is installed and/or
adjust the service regulator.

Hi-Fire

Start-Up

Lo-Fire

Blower Adjustment

Gas Valve
Invensys

Honeywell or
White-Rodgers
Invensys

Honeywell or
White-Rodgers

Gas Type
Natural
LP/Propane
+/- 0.1"WC +/- 0.1"WC
3.3" WC
3.1" WC

9.6" WC

1.4" WC

3.6" WC

1.2" WC

Table O: Gas Valve Pressures

1. A nylon tee fitting is connected with hoses in-line
with the air pressure switches. Disconnect the
plugged side and connect a manometer.

Honeywell Gas Valve

2. Close the gas valve.

1. While the heater is running, remove plastic cap
located behind ON/OFF knob.

3. Turn power on.

2. Locate the HI or LO screw to adjust.

4. During startup or Lo-Fire, the air pressure should
read 0.5±0.05 in. WC. During Hi-Fire, the reading
should be between 0.9 in. WC and 1.0 in. WC. If
these are not the obvserved manometer readings,
adjust the air shutter on the blower to attain the
correct values. (See Fig. 4, air shutter adjustment,
on page 7).

3. Using a small flat screwdriver, turn clockwise to
increase and counterclockwise to decrease manifold pressure. See nominal gas valve manifold
settings in Table O above.
4. Replace plastic cap when pressure is set.

5. Turn power off.

White Rodgers Gas Valve

6. Reinstall rubber plug on tee.

1. While the heater is running, locate the HI or LO
cap located adjacent to ON/OFF switch.

Main Burner Adjustment

2. Remove the appropriate cap.

1. Turn off unit.

3. Using a flat screwdriver, turn clockwise to increase
and counterclockwise to decrease manifold pressure. See nominal gas valve manifold settings
above.

2. Open manual firing valve.

3. Turn on the unit, wait 15 seconds, and the igniter
should glow. There’s a sight glass to check igniter
at both ends of the heater. Gas valve should be
open after 45 seconds.

4. Replace cap(s) when pressure is set.

Invensys (Model HD401 Natural
Only)

4. If burner does not light on first trial. It will retry, up
to 3 times.

1. Turn heater off.

5. Main burner ignition – check manifold gas pressure at gas valve manifold pressure tap. (See
Table O).
38

2. Locate and remove the Torx tamper resistant
screw. (Shown in Fig. 31)

3. Carefully remove 2-stage solenoid.

2. Remove the pressure regulator cover assembly.

5. Locate and remove Lo-fire adjustment cap.

4. Insert the replacement stem/spring assembly.

4. Skip to Step 9 for LO-fire adjustment only.

3. Remove the existing stem/spring assembly.

6. Carefully remove the spring & weight.

5. Replace the pressure regulator cover assembly
and tighten screws.

7. Using an allen wrench, turn clockwise to increase
and counterclockwise to decrease the HI-fire manifold pressure. Heater will not run while adjusting
HI-fire pressure.

6. Mount conversion labels on the gas valve.

8. Carefully place the spring & weight back in before
replacing LO-fire adjustment cap.
9. For LO-fire adjustment, tighten the cap to increase
the pressure, loosen to decrease.

10. When correct settings are set, replace the solenoid and tamper screw in place.

Fig. 32: Gas Type Conversion on Honeywell Valve

Safety Inspection
•
•
•
•
•
•
•
•

Fig. 31: Gas Valve Adjustment (Invensys Valve)

Gas Type Conversion on Valve

WARNING: Burner orifices must be changed when
changing gas type.

NOTE: Model HD401 requires replacement of
valve.

•

1. Turn off gas supply at the appliance service level.

•
39

Replace main gas manifold adjustment screw cap.
Check all thermostats and high limit settings.
During the following safety checks leave manometers hooked up, check and record.
If other gas fired equipment are in the room and on
same gas main check all pressures on the Hi Delta
SS with all other equipment running.
Check thermostats for ON/OFF operation.
Check High limits for ON/OFF operation.
While in operation, check flow switch operation.
Check the low gas pressure switches (For proper
adjustment, if available, use the attached
manometers to set pressure. The scales on the
switch are approximate only); Low gas pressure
switch (optional) must be set at 3.5 in. WC for natural gas and 10.5 in. WC for LP gas.
High gas pressure switch (optional) at 1 in. WC
above manifold pressure.
Insert ignition control lockout tests as safety
check.

Follow-Up
•
•

Safety checks must be recorded as performed.
Turn unit on.

•
•
•

Check Manometer(s) for proper reading(s).
Cycle unit several times and recheck readings.
Re-analyze with unit running record or print
results.
Remove all Manometers and replace hose,
replace all gas pressure caps.
Check for gas leaks one more time.

·
·

After main burner ignition:

•

When the unit is in operation. Disconnect
combustion air blower pressure switch, burner
should go off immediately.
Wait 5 minutes.
Reconnect combustion air pressure switch,
burner should reignite after pre-purge time
delay.

10. To restart system, follow lighting instructions in the
Operation section.

11. High limit control set to design temperature
requirements of system? For multiple zones: flow
adjusted as required in each zone?

12. Heater cycled with thermostat? Raise to highest
setting and verify heater goes through normal
start-up cycle. Reduce to lowest setting and verify
heater goes off.

POST START-UP CHECK
Check off steps as completed:

13. Observed several operating cycles for proper
operation?

1. Heater and heat distribution units or storage tank
filled with water?

14. Set room thermostat or tankstat to desired temperature?

2. Automatic air vent, if used, open two full turns during venting procedure?

15. Reviewed all instructions shipped with this heater
with owner or maintenance person, returned to
envelope and given to owner?

3. Air purged from system?

4. Air purged from gas piping? Piping checked for
leaks?

Air Filter Inspection/Removal

5. Followed start-up procedure for proper start-up?

1. Turn power off.

6. Is burner flame visible?

2. Locate the Air Filter panel below the air intake
duct.

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 controls are tested. When safety devices are restored,
burners should reignite after pre-purge time delay.

8. Test limit control: While burner is operating, move
indicator on high limit control below actual heater
water temperature. Burner should go off while
blower and circulator continue to operate. Raise
setting on limit control above heater water temperature and burner should reignite after pre-purge
time delay. NOTE: This test doesn’t apply to fixed
setting high limits.

9. Test ignition system safety device:
·
·

Turn on manual gas valve. Turn power on.
Set thermostat to call for heat.

Fig. 33: Locate the Air Filter Panel

Heat Exchanger Removal

3. Remove the (4) screws holding the panel in place.

Refer to Fig. 36 for the following procedure.

1. Before beginning, make sure the heater is cool to
the touch. Shut water, gas and electricity off, close
valves and relieve pressure, then remove the relief
valve. Remove side inspection panels.
2. Remove screw behind inspection panels holding
the jacket top down.
3. Remove the front panel. Remove two additional
screws holding the jacket top to the top support.

4. Disconnect vent pipe from the flue exhaust and set
aside.
5. Remove jacket top, then disconnect vent switch
hose.

6. Remove two rows of screws holding the flue collector to the combustion chamber. Remove two
additional screws located on the front combustion
panel. Cut any silicone holding the flue collector
and heat exchanger in place.

Fig. 34: Remove the Screws and Panel

4. Pull the air filter out for inspection. Replace if necessary.

7. Carefully lift and remove the flue collector.

8. Lift heat exchanger straight up being careful not to
damage the refractory.
9. Reverse the above procedure to re-install. Make
sure sufficient high temperature silicone sealant
(RTV) is placed along the vertical sides of the tube
sheet and flue collector.

Fig. 35: Inspect the Air Filter

5. When replacing, note the direction of the air flow
defined on the side of the filter. The arrow should
be pointing downward.

6. Replace the panel and screws before operating.

JACKET TOP
REMOVAL

FLUE COLLECTOR
REMOVAL

ACCESS
PANEL
REMOVAL

MAINTENANCE

Fig. 36: Heat Exchanger Removal

heater operating efficiency. Maintenance as outlined
below may be performed by the owner.

Suggested Minimum
Maintenance Schedule:

Yearly (Beginning of each heating
season):

1. Annual service call by qualified service agency.

Regular service by a qualified service agency and
maintenance must be performed to ensure maximum
42

2. Visually check top of vent for soot. Call service
person to clean. Some sediment at bottom of vent
is normal.

2. Visually inspect burner flame.

3. Visually inspect venting system for proper function, deterioration or leakage.

4. Check air vents for leakage.

Quarterly:

4. Check that heater area is free from combustible
materials, gasoline, and other flammable vapors
and liquids.

1. Check relief valve. Refer to manufacturer’s
instructions on valve.

5. Check for and remove any obstruction to the flow
of combustion or ventilation air to heater.

2. Test low water cut-off, if used. Refer to manufacturer’s instructions.

6. Follow pre-start-up check in the Initial Start-up
section.

3. Check the air filter; replace if necessary.

APPENDIX

7. Visually inspect burner flame. Should see light
blue flame. Visually inspect hot surface igniter for
damage, cracking or debris build-up.

Inside Combustion Air
Contamination:

8. Check operation of safety devices. Refer to manufacturer’s instructions.

All heaters experience some condensation during
start-up. The condensate from flue gas is slightly
acidic. In most cases the pH level is not harmful to
vents or drains. When combustion air is contaminated
by vapors from products in areas listed below, the
acidic levels in the condensate increase. Higher acidic
levels attack many materials, including stainless steel
commonly used in high efficiency systems.

9. Follow oil-lubricating instructions on circulator (if
required). Over-oiling will damage circulator.
Water-lubricated circulators do not need oiling.

10. To avoid potential of severe burn, DO NOT REST
HANDS ON OR GRASP PIPES. Use a light touch
- return piping will heat up quickly.
11. Check blower and blower motor. Clean and oil as
necessary.

The heater can use special corrosion-resistant nonmetallic intake vent material. You may, however,
choose to use outside combustion air for one or more
of these reasons:

12. Check for piping leaks around circulators, relief
valves and other fittings. Repair, if found. DO NOT
use petroleum based stop leak.

•

13. Check air filter and replace if necessary.

•

Daily:

•

1. Check that heater area is free from combustible
materials, gasoline, and other flammable vapors
and liquids.

Products causing contaminated combustion air:

2. Check for and remove any obstruction to the flow
of combustion or ventilation air to heater.

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.

installation is in an area containing contaminants
listed below which will induce acidic condensation.
you want to reduce infiltration into your building
through openings around windows and doors.
you are using AL29-4C stainless steel vent pipe,
which is more corrosion-resistant than standard
metallic vent pipe. In extremely contaminated
areas, this may also experience deterioration.

•
•
•
•
•
•
•
•

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
... and other similar products.

•
•
•
•
•
•
•
•
•
•

dry cleaning/laundry areas and establishments
metal fabrication plants
beauty shops
refrigeration repair shops
photo processing plants
auto body shops
plastic manufacturing plants
furniture refinishing areas and establishments
new building construction
remodeling areas.

•
•

remove products permanently, OR
provide outdoor combustion air.

Areas causing contaminated combustion air:

Check for areas and products as listed above before
installing heater. If found:

Important Instructions for the Commonwealth of Massachusetts

The Commonwealth of Massachusetts requires compliance
with regulation 248 CMR 4.00 and 5.00 for installation of
through – the – wall vented gas appliances as follows:

(b) EXEMPTIONS: The following equipment is exempt from
248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled "Equipment
Not Required To Be Vented" in the most current edition of
NFPA 54 as adopted by the Board; and

(a) For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7) feet
above finished grade in the area of the venting, including but
not limited to decks and porches, the following requirements
shall be satisfied:

2. Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the
manufacturer of Product Approved side wall horizontally
vented gas equipment provides a venting system design or
venting system components with the equipment, the instructions provided by the manufacturer for installation of the
equipment and the venting system shall include:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS.
At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level
where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery
operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the
property owner to secure the services of qualified licensed
professionals for the installation of hard wired carbon
monoxide detectors

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the
manufacturer of a Product Approved side wall horizontally
vented gas fueled equipment does not provide the parts for
venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the
manufacturer:

a. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an attic, the
hard wired carbon monoxide detector with alarm and battery
back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the
above requirements; provided, however, that during said
thirty (30) day period, a battery operated carbon monoxide
detector with an alarm shall be installed.

1. The referenced "special venting system" instructions shall
be included with the appliance or equipment installation
instructions; and
2. The "special venting systems" shall be Product Approved
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.

2. APPROVED CARBON MONOXIDE DETECTORS. Each
carbon monoxide detector as required in accordance with
the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified.

(e) A copy of all installation instructions for all Product
Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting
instructions, and/or all venting design instructions shall
remain with the appliance or equipment at the completion of
the installation.

3. SIGNAGE. A metal or plastic identification plate shall be
permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with
the exhaust vent terminal for the horizontally vented gas
fueled heating appliance or equipment. The sign shall read,
in print size no less than one-half (1/2) inch in size, "GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS".

GAS PRESSURE SUPERVISION

The Commonwealth of Massachusetts requires listed high
and low gas pressure switches (manual reset) for any model
with a maximum firing input greater than 1,000,000 Btu/Hr in
accordance with 248 CMR 7.04(11)(d).

4. INSPECTION. The state or local gas inspector of the side
wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.

A gas pressure regulator (field supplied) is required in the
gas train ahead of the heater, for heaters having input rates
greater than 1,000,000 Btu/Hr, in accordance with 248 CMR
7.04 Figure 3B requirements.

NOTES:
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www.raypak.com
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468
Litho in U.S.A.

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