INSTALLATION & OPERATING INSTRUCTIONS Models 399B–2339B 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.
Rev. 2 reflects the following: Changes to: Paragraph one of the Stacking section on page 9; Table G on page 16; Table H on page 18; Fig. 19 on page 22; Fig. 20–22 on page 23; Fig. 24 on page 24; the Wiring Diagrams on pages 39 and 40. The addition of: A wiring diagram note on page 38.
CONTENTS WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Stacking Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connection Venting Changing the Flue Outlet Venting Installation Tips V
WARNINGS Pay Attention to These Terms DANGER: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
BEFORE INSTALLATION number will have the form H8 1259B 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)). The number which fol-lows identifies the firing mode (1 or 4 = on-off, 3 = 2-stage, 8 = 3-stage and 9 = 4-stage).
Component Locations OPTIONAL FLUE CONNECTION Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig.
General Information Model No. Quantity of Vent Size (in.) Burners Gas Valves Blowers Flue Intake 399B 8 1 1 6 6 499B 10 2 1 6 6 649B 13 2 1 8 6 749B 15 2 1 8 6 899B 18 3 1 8 6 989B 11 2 2 10 10 1259B 14 3 2 12 10 1529B 17 4 2 12 10 1799B 20 4 2 14 10 1999B 23 5 3 14 10 2069B 23 5 3 14 10 2339B 26 5 3 16 10 Table A: Basic Data Burners per Valve Stages % Fire at Stage Model No.
GENERAL SAFETY To meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the 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.
Equipment Base The temperature of the water in the heater can be regulated by using the temperature controller. To comply with safety regulations, the temperature controller is 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.
Fig. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 1 2 t TT * 2 U.S. Installations Canadian Installations A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 ft (1.
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.). When installed according to the listed minimum clearances from combustible construction, these heaters can still be serviced without removing permanent structural construction around the heater. However, for ease of servicing, we recommend a clearance of at least 24 in.
Reversing Air Filter Follow these instructions to change the air duct connection from the left-hand side (standard) to the right-hand side: 1. Remove the four screws and the dust cover from the right-hand side of the heater. 2. Remove the four screws and the air filter bracket from the left-hand side of the heater. 3. Reverse the components and reattach in the new location, making sure that the air filter locking bracket is on the bottom. (The air filter locking bracket is reversible.) Fig.
space shall be considered in making this determination. Each opening shall have a minimum free area of 1 in.2 per 1,000 BTUH (2,225 mm2 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 12 in. (305 mm) of the top, and one opening shall commence within 12 in. (305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 in. (76 mm) in any direction. b.
of not less than 1 in.2 for each 30,000 BTUH mm2 per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere with the intended purpose of the opening(s) for ventilation air referred to in (1). This opening(s) can be ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down 18 in. (450 mm) from the floor, but not near piping. 5.
Cold Water Operation CAUTION: Damaging internal condensation may occur if the heater inlet water temperature does not exceed 105ºF (41ºC) within 7 minutes of start-up. A heater operated with an inlet temperature of less than 105ºF (41ºC) must have a manual bypass or an approved low-temperature operation system to prevent problems with condensation. A manual bypass, shown in Fig. 15, must be piped into the system at the time of installation.
Temperature & Pressure Gauge as the system heats up, the outlet temperature may continue to climb and actuate the high limit, thereby shutting down the heater. Thus an automatic valve system, such as a three-way proportional valve or a modulating two-way valve to control the bypass, should be utilized. The temperature and pressure gauge is factorymounted in the in/out header.
Pressure Drop in Feet of Head Feedwater Regulator heaters which are not subject to thermal shock. Raypak offers a full line of electronic sequencers that produce direct reset of heater water temperature. (Refer to the Controls section of the Raypak Catalog.) Raypak recommends that a feedwater regulator be installed and set at 12 psi minimum pressure at the highest point of the system.
Potable Water and Space Heating CAUTION: When this heater is used for both potable water and space heating, observe the following to ensure proper operation. 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water. 2. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating. Fig. 13: Single Domestic Hot Water Heater and Storage Tank Gas Supply 3.
regulator must be installed to reduce the gas supply pressure to a maximum of 10.5 in. WC for natural gas and 13.0 in. WC for propane gas. The regulator should be placed a minimum distance of 10 times the pipe diameter up-stream of the heater gas controls. Refer to Table I for maximum pipe lengths. Gas Supply Connection 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). Fig.
pressure regulator, of the lockup type, must be installed. CAUTION: Support gas supply piping with hangers, 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.
Electrical Power Connections BLACK Installations must follow these codes: CIRCUIT BREAKER WHITE • • • • National Electrical Code and any other national, state, provincial or local codes or regulations having jurisdiction. Safety wiring must be NEC Class 1. Heater must be electrically grounded as required by the NEC. In Canada, CSA C22. 1 C.E.C. Part 1. GREEN GROUND A B C Fig. 16: Wiring Connections The heater is wired for 120 VAC, <12 amps. The voltage is indicated on the tie-in leads.
prior to working with any electrical connections or components. DANGER: SHOCK HAZARD 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. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 4.
Fig. 21: 3-Stage Wiring Connections Fig. 22: 4-Stage Wiring Connection Fig.
Installer action is required to electrically enable your heater to operate after making the power connections. You must make a closed contact connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connections. This will be done based on the controller option selected with your heater order. 3. For single-stage controller connections, attach the stage 1 connections on heater 1 to the tankstat per Fig. 26. 1.
Venting 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. CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the heater. See Table K for appliance category requirements. NOTE: For additional information on appliance categorization, see appropriate ANSI Z21 Standard and the NFGC (U.S.
Use insulated vent pipe spacers where the vent passes through combustible roofs and walls. 8. Locate and guard vent termination to prevent accidental contact by people or pets. Vent Terminal Location 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. 1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 10. DO NOT terminate above any door, window, or gravity air intake.
5. Terminate vent at least 6 ft away from adjacent walls. Changing the Flue Outlet 6. DO NOT terminate vent closer than 5 ft below roof overhang. Follow these instructions to change the flue connection from the standard top location to the rear of the heater (with optional flue exhaust tee). 7. The vent terminal requires a 12 in. vent terminal clearance from the wall. 1. Disconnect all electrical power from the heater (if applicable). 8.
Venting Configurations For heaters connected to gas vents or chimneys, vent installations shall be in accordance with the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes. Natural Draft Vertical Venting (Category I) Installation Natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue. The negative draft must be within the range of -.01 to -.08 in. WC as measured 12 in.
load. Consult available guides for proper sizing of the manifold and the chimney. At no time should the area of the common vent be less than the area of the largest heater exhaust outlet. 1. Seal any unused opening in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and verify there is no blockage, restriction, leakage, corrosion or other unsafe condition.
Horizontal Through-the-Wall Venting (Category III) speed. Do not operate summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliances being inspected. Follow the manufacturer’s instructions for lighting each appliance. Adjust thermostat so appliance will operate continuously. Installation These installations utilize the heater-mounted blower to vent the combustion products to the outdoors.
Model No. Certified Venting Material Vent Size Combustion Air Intake Pipe Material Maximum Equivalent Vent Length* 399B Air Inlet Max. Length* 6” 8” 10” 12” 75’ 100’ 40’ 75’ 100’ 6” 499B 75’ 649B 100’ 40’ 749B 8” 899B 989B 30’ Category III 10” 1259B 12” 70’Room Air Galvanized Steel, PVC, ABS, CPVC 40’ Ducted Combustion Air 80’ 1529B 1799B 1999B 14” 2069B 2339B 16” *Subtract 10 ft per elbow. Max. 3 elbows. Maximum combustion air duct length terminated at 100 equivalent ft.
Outdoor Installation NOTE: Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Outdoor models are self-venting when installed with the optional factory-supplied outdoor vent kit and require no additional vent piping. A special vent cap, flow switch cover and air intake hood are provided in accordance with CSA requirements, which must be installed directly on the heater. Correct clearances can be found earlier in this section.
3. 120 VAC is waiting at the N.O. contacts of the pump delay relay. 4. Terminals L1 and F1 of the ignition module are powered with 120VAC. 5. 120 VAC power is also applied to the control power connector on the circuit board. 6. 120 VAC power is waiting at relay contacts K-3 to energize the heater blower. 7. The 120/24 VAC transformer outputs 24 VAC. 8. 24 VAC is sent to power terminal L1 of the low water cut-off board (optional). 9.
powered. If the switch is “ON” and there is no call for heat (CFH), the heater is in standby mode. 33. 24 VAC is now sent to the pressure switch (P Switch) terminal on the ignition module. 18. After the standby switch is placed into the “ON” position, a 24 VAC signal is sent to the green power light on the front of the unit and the “enable/disable” connection (normally jumpered). 19. 24 VAC switched power is applied to the 24VAC terminal on the ignition module. 34.
45. The Heater is now operating at full fire. 14. 24 VAC power now leaves pin P3-16 of J-5 on the CPW board and is sent to the auto-reset high limit (optional). If closed the power now goes to terminal P1-4 of J-5 on the CPW board. Models 989B–2339B 1. The black (hot) wire lead goes directly to the main power switch. This black toggle switch is located at the middle front of the control compartment. 15. Power is applied to terminal 24V of the pump delay relay to energize the timing circuit. 16.
the 120 VAC pilot duty terminals, located at J-14 on the circuit board. 29. The 120 VAC signal continues to the coil of relay K-4 (N.O.). 15-second pre-purge and an approximately 30second igniter warm-up before opening gas valve 1 again. The standard ignition module will attempt ignition a maximum of three times prior to ignition lockout. 30. The 120 VAC signal continues to the 120 VAC safety terminals located at J-13 on the circuit board. 42.
The standard ignition module will attempt to light three times before locking out. To reset it, turn off power to the heater, wait 30 seconds and re-apply power. connection close after 5 seconds. 56. The stage 4 temperature controller contacts close. The optional single-try ignition module will lock out after failing to light one time. To reset it, press and release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case (see Fig. 28).
sheets supplied with your heater paperwork. See the General Safety Section for safety precautions concerning domestic hot water applications. 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 5.0 in. WC for natural gas, and 11.5 in. WC for propane gas. NOTE: Some jurisdictions may require two high gas pressure switches on models 1529B–2339B due to two ignition modules. Fig.
Wiring Diagram - Models 399B–1259B 39
Wiring Diagram - Models 1529B–2339B 40
START-UP Pre Start-up • If you cannot reach your gas supplier, call the fire department. • Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not turn by hand, do not try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion.
Start-Up Preparation Blower Adjustment WARNING: Do not turn on gas at this time. Check Power Supply 1. Turn off power. With multi-meter at incoming power, check voltage between: 2. Unplug cap at pressure switches and connect manometer(s) to the tee. Hot - Common (≈120 VAC) 3. Close all manual firing valves. Hot - Ground (≈120 VAC) 4. Turn power on. Common - Ground (< 1 VAC) 5. Check manometers attached to fan pressure switch. The reading should be 1.4 ± 0.1 in.
Safety Inspection The burner section that is ignited directly by the hot surface ignition system serves as a supervised pilot to light the burner sections on either side of it. The burner sections on either side of the supervised section (pilot) are electrically interlocked with the supervised ignition system so as they are not energized unless flame is proven on the center section which is acting as a pilot to light the right and left-hand sections. 1. Check all thermostats and high limit settings. 2.
1. Manually close the downstream leak test valve. This completes leak testing for a single Delta Limited manifold riser. Repeat steps 1-8 for each riser. 2. Open test point A and connect a manometer to it. Verify that there is gas pressure and that it is within the proper range (NOTE: must not exceed 14.0 in. WC). Post Start-Up Check Check off steps as completed: 3. Open test point B and connect a rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up of pressure.
10. To restart system, follow lighting instructions in the Operation section. 9. Set thermostat to desired setting. The appliance will operate. The igniter will glow after the prepurge time delay (15 seconds). After igniter reaches temperature (45 seconds) the main valve will open. System will try for ignition three times. If flame is not sensed, lockout will commence. 11. Check to see that the high limit control is set above the design temperature requirements of the system.
TROUBLESHOOTING Step 1 Does the power switch provide power to the control panel? Check the switch and/or line voltage NO Replace ignition module Is enable/disable jumper intact (J1)? YES Reattach Check all safety limit devices and voltage from the transformer to J10 on CPW board. NO YES Unit is in standby mode.
MAINTENANCE 4. Check for and remove any obstruction to the flow of combustion or ventilation air to heater. Suggested Minimum Maintenance Schedule 5. Follow pre-start-up check in the Start-up section. 6. Visually inspect burner flame. It should be light blue. Remove and visually inspect hot surface igniter and sensor for damage, cracking or debris build-up. Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. 7.
Weekly 6. Perform leakage test on gas valves. (See Fig. 36.) For low-pressure heaters, test low-water cut-off device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance should shut-off and ignition fault light should come on. Depress reset button to reset). 7. Test air switch in accordance with manufacturer’s instructions. (Turn panel switch to the “On” position until blower is proven, then turn the switch to “Off”. 8.
APPENDIX • • • • Inside Air Contamination Check for areas and products listed above before installing heater. If found, remove products permanently. All heaters experience some condensation during start-up. The condensate from flue gas is acidic. Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high efficiency systems.
LIMITED PARTS WARRANTY DELTA LIMITED – TYPES H AND WH MODELS 399B–2339B SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty.
START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. Additionally this form will be used to record all equipment operation functions and required settings.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
