Raypak Boiler 302BD 2342BD User Guide

SUPPLEMENTAL INSTALLATION AND  
OPERATING INSTRUCTIONS  
FlexGas™  
For Hi Delta Models  
302BD–2342BD  
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.  
NOTE: THIS MANUAL IS SUPPLEMENTAL FOR THE FLEXGAS MODELS OF  
THE HI DELTA HEATERS. THIS MANUAL ADDRESSES THE SPECIFIC DIF-  
FERENCES BETWEEN THESE HEATERS AND STANDARD HI DELTA  
MODELS. Please refer to the standard Installation and Operating Instruction manuals  
(Catalogs 1000.501 and 1000.511 as appropriate) for installation requirements which are not  
related to the gas supply.  
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. 1000.58B  
Effective: 06-24-08  
Replaces: 02-22-07  
P/N 241295 Rev. 3  
Patent No. 6,904,873; Other patent pending  
 
2-stage, 8 = 3-stage and 9 = 4-stage). NOTE: Not all  
these firing options are available on all heaters.  
Refer to the Hi Delta manual for available firing  
options. The second group of characters identifies the  
size of the heater (four numbers representing the  
approximate MBTUH input), and, where applicable, a  
letter, indicating the manufacturing series. The final  
character is the letter “D” which designates the heater  
as a FlexGas equipped heater.  
WARNING: Do not use this heater if any part has  
been under water. Immediately call a qualified serv-  
ice technician to inspect the heater and to replace  
any part of the control system and any gas control  
which has been under water.  
WARNING: Should overheating occur or the gas  
supply valve fail to shut off, do not turn off or discon-  
nect the electrical supply to the heater. Instead, shut  
off the gas supply at a location external to the heater.  
Input  
Pipe Size  
(Nat)  
Pipe Size  
(LP)  
Model  
(MBTUH)  
1
3
302BD  
402BD  
502BD  
652BD  
752BD  
902BD  
992BD  
1262BD  
1532BD  
1802BD  
2072BD  
2342BD  
300  
399  
1- ⁄  
4
4
WARNING: Risk of electrical shock. More than one  
disconnect switch may be required to de-energize  
the equipment before servicing.  
1
3
1- ⁄  
4
4
1
3
500  
1- ⁄  
4
4
1
3
650  
1- ⁄  
4
4
WARNING: This FlexGas heater is intended for  
operation on Natural Gas as the primary fuel. DO  
NOT use this heater on Propane Gas as the primary  
fuel.  
1
1
750  
1- ⁄  
4
1- ⁄  
4
1
1
900  
1- ⁄  
2”  
2”  
2”  
2”  
2”  
2”  
4
1- ⁄  
4
1
990  
1- ⁄  
4
1
1260  
1530  
1800  
2070  
2340  
1- ⁄  
4
Raypak strongly recommends that this manual be  
reviewed thoroughly before installing your Hi Delta  
heater equipped with FlexGas. Raypak also recom-  
mends that the appropriate Hi Delta Installation and  
Operating Instruction manual (1000.501 for 302B-  
902B or 1000.511 for 992B – 2342B) be thoroughly  
read before attempting to install these heaters. Fac-  
tory warranty does not apply to heaters that have been  
improperly installed or operated. (Refer to the warran-  
ty at the back of the standard Hi Delta manuals.)  
Installation and service must be performed by a quali-  
fied installer, service agency or gas supplier. If, after  
reviewing these manuals, you still have questions  
which these manuals do not answer, please contact  
the manufacturer or your local Raypak representative.  
1
1- ⁄  
4
1
1- ⁄  
4
1
1- ⁄  
4
1
1- ⁄  
4
Table 1: FlexGas Specifications  
Ratings and Certifications  
Standards:  
ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired  
Hot Water Boilers  
CAN 3.1 - latest edition, Industrial and Commer-  
cial Gas-Fired Package Boilers  
Thank you for purchasing a Raypak product. We hope  
you will be satisfied with the high quality and durability  
of our equipment.  
ANSI Z21.56 · CSA 4.7 - latest edition, Gas-Fired  
Pool Heaters  
ANSI Z21.10.3 · CSA 4.3 - latest edition, Gas  
Water Heaters  
Model Identification  
The model identification number and heater serial  
number are found on the heater rating plate located on  
the lower right outside jacket of the heater. The model  
number will have the form H9 1262BD or similar  
depending on the heater size and configuration. The  
letter(s) in the first group of characters identifies the  
application (H = Hydronic Heating, WH = Domestic  
Hot Water (DHW), P = Pool). The number which fol-  
lows identifies the firing mode (1 or 4 = on-off, 3 =  
3
 
All Raypak heaters are National Board Approved, and  
design-certified and tested by the Canadian Stan-  
dards 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) Pressure Vessel Code, and bears either the  
ASME “H” stamp for boilers or “HLW” stamp for water  
heaters. The heater also complies with the latest edi-  
tion of ASHRAE 90.1 Standard.  
Installation Codes  
Installations must follow these codes:  
Local, state, provincial, and national codes, laws,  
regulations and ordinances  
National Fuel Gas Code, ANSI Z223.1/NFPA 54 –  
latest edition (NFGC)  
National Electrical Code, ANSI/NFPA 70 - latest  
edition (NEC)  
WARNING: Altering any Raypak pressure vessel  
by installing replacement heat exchangers, tube  
bundle headers, or any ASME parts not manufac-  
tured and/or approved by Raypak will instantly void  
the ASME and CSA ratings of the vessel and any  
Raypak warranty on the vessel. Altering the ASME or  
CSA ratings of the vessel also violates national,  
state, and local approval codes.  
For Canada only: CAN/CGA B149 Installation Code  
(B149.1) and CSA C22.1 C.E.C. Part 1 (C22.1)  
Gas Supply  
This heater will be connected to 2 different gas sup-  
plies (Natural Gas and Propane Gas).  
Each gas piping must have a separate sediment trap  
ahead of the gas controls. Pounds-to-inches regula-  
tors must be installed to reduce the gas supply  
pressure to a maximum of 10.5 in. WC for natural gas  
and 13.0 in. WC for propane gas. The regulator should  
be placed a minimum distance of 10 times the pipe  
diameter upstream of the heater gas controls.  
Rated inputs are suitable for up to 4,500 ft elevation  
without de-rating. Consult the factory for installations  
at altitudes over 4,500 ft above sea level.  
Component Locations  
NOTE: Maintain upright orientation of all compo-  
nents as shown in Fig. 1.  
CAUTION: The heater must be disconnected from  
the gas supply during any pressure testing of the gas  
supply system at test pressures in excess of 1/2 psi  
(3.45 kPa).  
The heater must be isolated from the gas supply pip-  
ing system by closing the manual shut-off valves  
during any pressure testing of the gas supply piping  
system at test pressures equal to or less than 1/2 psi  
(3.45 kPa). Relieve test pressure in the gas supply line  
prior to reconnecting the heater and its manual shut-off  
valves to the gas supply lines. FAILURE TO FOLLOW  
THIS PROCEDURE MAY DAMAGE THE GAS  
VALVES. Over-pressurized gas valves are not cov-  
ered by warranty. The heater and its gas connections  
shall be leak-tested before placing the appliance in  
operation. Use soapy water for leak test. DO NOT use  
an open flame.  
FlexGas cover not shown for clarity  
Fig. 1: Component Locations – Back  
4
 
Low Gas Pressure Switch  
(Optional on 302BD-902BD)  
Fig. 2: Gas Supply Connection - Top View  
Gas Supply Pressure  
CAUTION: DO NOT adjust the individual heater  
gas valve pressure settings when firing with  
propane gas. Propane adjustments (if neces-  
sary) should ONLY be made to the FlexGas  
propane regulator.  
A minimum of 5.0 in. WC and a maximum of 10.5 in.  
WC upstream gas pressure is required under load and  
no-load conditions for natural gas. A minimum of 8.0  
in. WC and a maximum of 13.0 in. WC is required for  
propane gas. The gas pressure regulator(s) supplied  
on the heater is for low-pressure service. If upstream  
gas pressures exceed 14.0 in. WC, intermediate gas  
pressure regulators, of the lockup type, must be  
installed.  
NOTE: DO NOT adjust the FlexGas propane regu-  
lator setting without verifying proper operation  
including the use of a flue gas analyzer.  
Bleeds/Vents  
CAUTION: Do not use Teflon tape on gas line pipe  
thread. A pipe compound rated for use with natural  
and propane gases is recommended. Apply sparing-  
ly only on male pipe ends, leaving the two end  
threads bare.  
This FlexGas gas train is equipped with an propane  
gas regulator and low gas pressure switch (optional on  
302BD-902BD) which may need to be vented to the  
outdoors as required by state and local codes. If these  
components are required to be vented, the cover must  
be removed and vent lines installed into the compo-  
nents and ran to a suitable location outside the  
building in compliance with the NFGC. See Fig.3.  
CAUTION: Support gas supply piping with hang-  
ers, not by the heater or its accessories. Make sure  
the gas piping is protected from physical damage  
and freezing, where required.  
When connecting additional gas utilization equipment  
to the gas piping system, the existing piping must be  
checked to determine if it has adequate capacity for  
the combined load.  
The gas valve pressure regulator(s) on the Hi Delta  
heater are nominally preset at 3.5 in. WC. The pres-  
sure regulator on the FlexGas propane system is  
nominally set at 2.2 0.1 in. WC. This can be verified  
by measuring the propane gas pressure at the upper  
manifold pressure tap shown in Fig. 5. The pressure at  
the gas valve(s) outlet tap, measured with a manome-  
ter, while in operation should be 3.5 0.1 in. WC for  
natural gas. A nominal pressure of 1.3 in. WC will be  
observed at the individual heater gas valve outlet taps  
on propane gas. See Fig. 5 for gas pressure measure-  
ment locations.  
Fig. 3: FlexGas Cover Removal & Vent Locations  
5
 
Propane Supply Pressure  
Test Point  
Gas Valve  
Output Tap  
Models: 302BD-902BD  
Models: 992BD-  
2342BD  
Fig. 4: FlexGas Gas Pressure Measurement Locations  
any part of the control system and any gas control  
which has been under water.  
Check around unit for debris and remove combus-  
tible products, i.e. gasoline, etc.  
Start-up  
For Your Safety  
Pre Start-up Check  
WARNING: If you do not follow these instructions  
exactly, a fire or explosion may result causing prop-  
erty damage, personal injury or loss of life.  
1. Verify heater is filled with water.  
2. Check system piping for leaks. If found, repair  
immediately.  
This appliance has a hot surface igniter(s). It is  
equipped with an ignition device(s) which automatical-  
ly lights the burners. Do not try to light the burners by 3. Vent air from system. Air in system can interfere  
hand.  
with water circulation.  
BEFORE OPERATING, smell all around the appli- 4. Purge air from gas lines up to FlexGas gas train.  
ance area for gas. Be sure to smell near the floor  
because some gas is heavier than air and will settle on  
the floor.  
Initial Start-up  
Tools Needed:  
WHAT TO DO IF YOU SMELL GAS:  
(1) 12-0-12, 24” scale U-tube manometer  
(4) 6-0-6, 12” scale U-tube manometers (min.)  
(1) Screwdriver  
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any  
telephone in your building.  
(1) Multi-meter  
Immediately call your gas supplier from a neigh-  
bor’s telephone. Follow the gas supplier’s  
instructions.  
If you cannot reach your gas supplier, call the fire  
department.  
Use only your hand to push in or turn the gas con-  
trol knob. Never use tools. If the knob will not turn  
by hand, do not try to repair it, call a qualified serv-  
ice technician. Forced or attempted repair may  
result in a fire or explosion.  
Do not use this appliance if any part has been  
under water, immediately call a qualified service  
technician to inspect the appliance and to replace  
(1) 3/16” Allen wrench  
NOTE: Digital manometers are not recommended.  
6
 
Preparation  
4. Check if the service regulator is installed and/or  
adjust the service regulator.  
WARNING: Do not turn on gas at this time.  
WARNING: This FlexGas heater is intended for  
operation on Natural Gas as the primary fuel. DO  
NOT use this heater with Propane Gas as the pri-  
mary fuel.  
Check Power Supply  
With multi-meter at incoming power in Hi Delta heater,  
check voltage between:  
FlexGas System Start-up  
Hot - Common (≈120 VAC)  
Hot - Ground (≈120 VAC)  
Common - Ground (< 1 VAC)  
1. Turn off unit. Ensure that the switch on the  
FlexGas control is in the position marked “NAT”.  
See Fig. 6 for FlexGas control operation. Ensure  
the manual valve on the natural gas supply is open  
and the manual valve on the propane supply is  
closed.  
WARNING: If Common - Ground is > 1 VAC,  
STOP: Contact electrician to correct ground failure.  
Failure to do this may burn out 120V-24V trans-  
former, or may cause other safety control damage or  
failure.  
2. Turn on the unit, wait 15 seconds, and the igniter  
should glow. Look into sight glass located at each  
end of the heater to check igniter operation. Gas  
valves should open in 45-60 seconds.  
Attach Manometers to Measure Pressures  
1. Turn off main gas valves.  
3. If burner does not light on first trial. It will retry, up  
to three times.  
2. Attach 24” scale manometer to the first main gas  
shut-off valve pressure tapping.  
4. Main burner ignition: Check manifold gas pres-  
sure at gas valve outlet pressure tap. This should  
read 3.5 0.1 in. WC for natural gas. If the natural  
gas manifold pressure is not within 3.5 0.1 in.  
WC, follow the instructions in the Hi Delta I&O  
manual for adjusting manifold pressure. If a flue  
gas analyzer is used, the CO2 on natural gas  
3. Attach (1) 12” scale manometer to the outlet side  
of the second main gas shut-off valve pressure  
tapping.  
4. Attach (1) 12” scale manometer near the fan-prov-  
ing switch. Pull black cap from air pressure switch  
tee and connect the manometer. NOTE: Retain  
caps for reinstallation later.  
should be 7.5-8.5% and CO should be less than  
150 ppm.  
NOTE: Do not adjust Hi Delta valve(s) or manifold  
settings when operating on propane. These should  
only be adjusted while firing natural gas.  
NOTE: The fan(s) pressure is already factory set to  
1.4 in. .1 in. WC (up to 4500 ft altitude). If adjust-  
ment(s) is required, consult the appropriate Hi Delta  
manual.  
5. When acceptable operation on Natural Gas is con-  
firmed, turn the gas selector key on the FlexGas  
control to “OFF”.  
Check Gas Supply Pressure  
1. Slowly turn on main gas shut-off valve.  
6. Close the manual valve on the natural gas supply  
then open the manual valve on the propane sup-  
ply. When the heater shuts off, turn the FlexGas  
control key counter-clockwise to the “PRO” posi-  
tion.  
2. Read the gas supply pressure from the manome-  
ter; minimum supply pressure for natural gas is 5.0  
in. WC, recommended supply is 7.0 in. WC, mini-  
mum supply pressure for propane gas is 8.0 in.  
WC (dynamic readings, all stages firing).  
7. Wait 15 seconds, and the igniter should glow. Look  
into sight glass located at each end of the heater  
to check igniter operation. Gas valves should open  
in 45-60 seconds.  
3. If the pressure is > 14.0 in. WC, turn off the valve.  
7
 
8. If burner does not light on first trial. It will retry, up  
to three times.  
NOTE: Reset Low Gas Pressure Switch (when  
equipped) if necessary. Refer to Fig. 2 for location.  
9. Main burner ignition: Check upper manifold gas  
pressure.  
From PRO to NAT:  
1. Turn the boiler off (power switch on front control  
panel).  
10. If the pressure readings differ by more than 0.1  
in. WC, remove screw cover from the gas pres-  
sure regulator on the FlexGas fuel train and adjust  
until upper manifold pressure is nominally 2.2  
0.1 in. WC (manifold pressure 1.3 0.1 in. WC). If  
a flue gas analyzer is used, the CO2 on propane  
2. Turn FlexGas key to “OFF”.  
3. Close PRO manual valve.  
4. Open NAT manual valve.  
5. Turn FlexGas key to “NAT”.  
6. Turn the boiler on.  
should be 9.0-10.0% and CO should be less than  
150 ppm.  
CAUTION: Once the natural gas pressures are  
established, DO NOT adjust the Hi Delta gas valves  
to attain the required propane pressures.  
Adjustments must be made to the FlexGas propane  
regulator.  
Safety Inspection  
1. Check all thermostats and high limit settings.  
11. Replace the screw cover.  
2. During the following safety checks leave ma-  
nometers hooked up, check and record.0  
CAUTION: Special manifold and air settings may  
be required. Verify rating plate and blower housing.  
3. If other gas-fired appliances in the room are on the  
same gas main, check all pressures on the Hi  
Delta with all other equipment running.  
12. Turn the gas selector key on the FlexGas control  
panel to “OFF”.  
4. Check thermostats for ON-OFF operation.  
5. Check high limits for ON-OFF operation.  
6. While in operation, check flow switch operation.  
13. Close the manual valve on the propane gas supply  
and open the manual valve on the natural gas  
supply. Turn the gas selector key on the FlexGas  
control clockwise to “NAT”. The heater is now  
ready for operation.  
7. Check the low gas pressure switch. (For proper  
adjustment, use the attached manometers, if  
available, to set pressure. The scales on the  
switch are approximate only.) Low gas pressure  
switch (if equipped) must be set at 5.0 in. WC for  
natural gas.  
FlexGas Operation - Changing Fuels  
From NAT to PRO:  
1. Turn the boiler off (power switch on front control  
panel).  
Follow-Up  
Safety checks must be recorded as performed.  
Turn heater on. After main burner ignition:  
1. Check manometer for proper reading.  
2. Cycle heater several times and re-check readings.  
3. Turn unit off.  
2. Turn FlexGas key to “OFF”.  
3. Close NAT manual valve.  
4. Open PRO manual valve.  
5. Turn FlexGas key to “PRO”.  
6. Turn the boiler on.  
8
 
4. Remove all manometers and replace caps and  
screws.  
5. Replace all gas pressure caps.  
6. Check for gas leaks one more time.  
7. Restart unit.  
Fig. 5: FlexGas Control Panel  
Wiring Diagram  
*
*Optional on  
302BD–902BD  
Fig. 6 Wiring Diagram  
9
 
10  
 
DESCRIPTION  
KEY SWITCH ASSY  
RELAY-SPDT 120 VAC  
CONNECTOR-WIRE BONDING  
GAS SOLENOID VALVE (NAT)  
GAS SOLENOID VALVE (PRO)  
MANUAL GAS VALVE (NAT)  
MANUAL GAS VALVE (PRO)  
GAS REGULATOR VALVE  
BLEEDLE VALVE  
302BD-652BD 752BD-902BD 992BD-1262BD 1532BD-2342BD  
CALL OUT  
1-C  
2-C  
3-C  
1-G  
2-G  
4-G  
5-G  
6-G  
7-G  
8-G  
1-S  
2-S  
011943F  
012126F  
007155F  
011910F  
012125F  
011945F  
011944F  
011946F  
007423F  
007187F  
011949F  
011951F  
011943F  
012126F  
007155F  
011910F  
011910F  
011945F  
011945F  
011947F  
007423F  
007187F  
011949F  
011951F  
011943F  
012126F  
007155F  
011911F  
011910F  
007665F  
011945F  
011947F  
007423F  
007187F  
011950F  
011951F  
011943F  
012126F  
007155F  
011911F  
011910F  
007665F  
011945F  
011948F  
007423F  
007187F  
011950F  
011951F  
LOW GAS PRESSURE SWITCH  
GAS TRAIN COVER  
CONTROL BOX w/COVER  
11  
 
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468  
Litho in U.S.A.  
 

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