Raypak HI DELTA 302B Installation & Operating Instructions Manual

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Raypak HI DELTA 302B Installation & Operating Instructions Manual Manual pdf 15 page image

155. Remove all plumbing fittings to the header. Thiswill include both inlet and outlet water pipe unionsand the pressure relief valve and drain piping.6. Remove limits, control bulbs and/or thermocou-ples.7. Remove the six flange nuts and the in/out headerfrom the left-hand side.8. Remove the six flange nuts and the return headerfrom the right-hand side.9. Remove the header stud bolts from each tubesheet.10. Reverse the headers and stud bolts to the newlocation.11. Install NEW red beveled O-rings flush against bothtube sheets with the bevel facing outward.12. Push the header firmly against the O-rings. Installand tighten the flange nuts onto the stud bolts untilfinger tight.13. Slowly tighten the flange nuts, starting from thecenter nut (number 1) in Fig. 9 and working se-quentially around the header as indicated. Torqueall nuts to 25 ft/lb. DO NOT OVER-TIGHTEN.14. Re-route the capillary(s), wiring etc. to the newlocation, adding thermal paste and shim to thecapillary well.Fig. 9: Torque SequenceRelief Valve PipingWARNING: Pressure relief valve discharge pipingmust be piped near the floor and close to a drain toeliminate the potential of severe burns. Do not pipeto any area where freezing could occur. Refer tolocal codes.Hydrostatic TestUnlike many types of heaters, this heater does not re-quire hydrostatic testing prior to being placed inoperation. The heat exchanger has already been fac-tory-tested and is rated for 160 psi operating pressure.However, Raypak does recommend hydrostatic test-ing of the piping connections to the heater and the restof the system prior to operation. This is particularlytrue for hydronic systems using expensive glycol-based anti-freeze. Raypak recommends conductingthe hydrostatic test before connecting gas piping orelectrical supply.Leaks must be repaired at once to prevent damage tothe heater. NEVER use petroleum-based stop-leakcompounds.To perform hydrostatic test:1. Connect fill water supply. With bleed valve open,fill heater with water. When water flows from bleedvalve, shut off water. Close bleed valve. Carefullyfill the rest of the system, making sure to eliminateany entrapped air by using high-point vents. Closefeed valve. Test at standard operating pressure forat least 24 hours.2. Make sure constant gauge pressure has beenmaintained throughout test.3. Check for leaks. Repair if found.Cold Water OperationA heater operated with an inlet temperature of lessthan 105ºF (41ºC) must have a manual bypass or anapproved low-temperature operation system to pre-vent problems with condensation. A manual bypass,shown in Fig. 15, must be piped into the system at thetime of installation. This piping is like a primary/sec-ondary boiler installation with a bypass acting as thesecondary boiler piping. Raypak strongly recommendsthat thermometer(s) be placed into the heater pipingnext to the in/out header to facilitate temperatureadjustment. Inlet water temperatures below 105ºF(41ºC) can excessively cool the products of combus-tion, resulting in condensation on the heat exchangerand in the flue.CAUTION: Damaging internal condensation mayoccur if the heater inlet water temperature does notexceed 105ºF (41ºC) within 7 minutes of start-up.NOTE: See Raypak Catalog No. 1000.57 for infor-mation on Cold Water Protection.