INSTALLATION & OPERATING INSTRUCTIONS Models 992B–2342B Types H, WH & P 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 combustable 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. 7 reflects the following: Changes to: Fig. 3 on page 6; the UDB Diagnostic Board and UDB Fault History sections on page 44; the Wiring Diagrams on pages 50 and 51.
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 4 5 5 5 5 5 6 7 8 Venting
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 H9 1262B 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 follows 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 Quantity of Vent Size (in.) Model No. Burners Gas Blowers Flue Intake Valves 992B 11 2 + 1* 2 10 10 1262B 14 3 + 1* 2 12 10 1532B 17 4 2 12 10 1802B 20 4 2 14 10 2002B 23 5 3 14 10 2072B 23 5 3 14 10 2342B 26 5 3 16 10 *Hidden solenoid valve located inside of air plenum. Table A: Basic Data Burners per Valve 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.) Direct Vent Fig.
three or four sheet metal screws (not supplied) equally distributed around the circumference of the duct. All ducting should be self-supported. The filter housing is not designed to support the air duct. 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.
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. b.
Hydrostatic Test 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. Unlike many types of heaters, this heater does not require hydrostatic testing prior to being placed in operation. The heat exchanger has already been factory-tested and is rated for 160 psi operating pressure.
system, such as a three-way proportional valve or a modulating two-way valve to control the bypass, should be utilized. Failure to exceed 105ºF (41ºC) within 7 minutes may result in the premature failure of the hot surface igniter, remote flame sensor, burners and heat exchanger. It can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the vent system.
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 Pool Heating 3.
circulate water through the heater from the main system piping. slowly throttle Valve B closed to increase the inlet water temperature to 105°F. To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return water line, upstream of the heater. This will ensure that the heater will be energized at the right time.
Total Dissolved Solids shut-off. Close isolation valves and remove water piping from the in/out header on the heater. Drain the heater and any piping of all water that may experience below-freezing temperatures. Total dissolved solids (TDS) is the measure of all minerals and solids that are dissolved in the water. The concentration of total dissolved solids is usually expressed in parts per million (ppm) as measured in a water sample.
Gas Supply Connection 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. CAUTION: The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa). Reversing Gas Supply Connection Reversing the standard fuel connection from the lefthand to the right-hand side is a simple field operation.
Electrical Power Connections 9. Install a coupling, nipple, union and sediment trap onto the right-hand end of the main gas line and then install the gas line, making sure that a manual shut-off valve has been installed within 10 ft of the heater. Installations must follow these codes: • 10. Replace the left and right front panels on the heater. • • Gas Supply Pressure • A minimum of 5.0 in. WC and a maximum of 10.5 in.
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. BLACK prior to working with any electrical connections or components. 3. Observe proper wire colors while making electrical connections.
DANGER: SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components. Fig. 21: On-Off Wiring Connections Fig. 23: 3-Stage Wiring Connections Fig. 24: 4-Stage Wiring Connection 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.
SINGLE STAGE TANKSTAT ured to operate in an on-off firing mode. This means that you will connect a single-pole control to stage one of the CPW board. Then jumper the remaining firing stages. For example, if your heater is a Model 1532B, you will jumper stages two, three and four. Then your heater will either be on at full fire, or it will be off. STAGE 1 CONNECTION 2. For 2-stage controller connections, connect each stage of the control to the corresponding stage of the CPW board in the heater, i.e.
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. Use insulated vent pipe spacers where the vent passes through combustible roofs and walls. NOTE: During winter months check the vent cap and make sure no blockage occurs from build-up of snow or ice.
8. Locate and guard vent termination to prevent accidental contact by people or pets. Canadian Installations Refer to latest edition of B149 Installation code. 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. A vent shall not terminate: 10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations. 1.
5. Remove the screws, retaining ring and rain gasket from top of heater. The maximum and minimum venting length for Category I appliances shall be determined per the NFGC (U.S.) or B149 (Canada). 6. Remove the screws, flue collar and gasket from the run side of the tee located in the flue box on top of the heater. The diameter of vent flue pipe should be sized according to the NFGC (U.S.) and B149 (Canada).
Termination WARNING: Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure. The vent terminal should be vertical and should terminate outside the building at least 2 ft above the highest point of the roof that is within 10 ft.
speed. Do not operate summer exhaust fan. Close fireplace dampers. The total length of the horizontal through-the-wall flue system should not exceed 70 equivalent ft in length. If horizontal run exceeds 70 equivalent ft, an appropriately sized extractor must be used. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in one of the four following arrangements: 4. Place in operation the appliances being inspected.
Model No. Certified Venting Material 992B Maximum Vent Size Equivalent Vent Length* 1532B 12” 70’ Room Air 14” 40’ Ducted Combustion Air 1802B Category III 2072B 2342B Air Inlet Max. Length* 10” 12” 75’ 100’ 40’ 75’ 10” 1262B 2002B Combustion Air Intake Pipe Material Galvanized Steel, PVC, ABS, CPVC 16” * Subtract 10 ft per elbow. Max. 3 elbows. Maximum combustion air duct length terminated at 100 equivalent ft.
Direct Vent - Vertical For installations in extremely cold climate, it is required that: 1. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of horizontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes. 2. The intake vent must be insulated through the length of the horizontal run. Termination The flue direct vent cap MUST be mounted on the exterior of the building.
Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. NOTE: Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that might obstruct combustion air flow.
12. Power is applied to terminal P1-1 of the Universal Diagnostics Board. 24 VAC power is then applied in series to all typically closed safeties wired into the heater. All safeties are verified to ensure that it is safe to operate the heater.
External Lights Light Color Indication Power Blue Main power is on Yellow Thermostat is closed Safety Red One or more safeties is inoperative Ignition Red Ignition module is inoperative Flow Green Flow is present Blower 1 Green Blower 1 is on Blower 2 Green Blower 2 is on Blower 3 Green Blower 3 is on Stage 1 Green Stage 1 is on Stage 2 Green Stage 2 is on Stage 3 Green Stage 3 is on Stage 4 Green Stage 4 is on Call For Heat Table M: Status LED Indicators 24.
gized by a 120 VAC signal from S-1 on the ignition module for approximately 30 seconds. (The hot surface igniter must draw greater than 3.1 amps while being energized or ignition lockout will occur after three tries.) 54. After closure of the stage 3 contacts, power is applied to TD-2. 55. After a 5 second countdown TD-2 contacts close. 56. Gas valve 3 then receives 24 VAC and is energized. 43.
9. 24 VAC is applied to the blue power light located on the status display board. 21. 24 VAC switched power is applied to the S24V terminal on ignition modules 1 and 2. 10. 24 VAC is also applied to the red LED safety shutdown light on the front status board until the safeties have been proven. 22. When the “enable/disable” contacts are closed, the 24 VAC signal travels to pin 1 of the stage 1 connection and waits for a CFH. 11. 24 VAC is applied to the alarm circuit (optional).
36. After proper air pressure is received in the air plenum, the air pressure switches will close. 48. If ignition module one locks out, a signal will be sent to the Universal Diagnostics Board and to the status display board to indicate an ignition fault. 37. If there is insufficient air pressure and the air pressure switch does not close, a 24 VAC signal is sent to the Universal Diagnostics Board to indicate the fault. 49.
60. If ignition module two locks out, a signal will be sent to the Universal Diagnostics Board and to the status display board to indicate an ignition fault. 11. 24 VAC is applied to the alarm circuit (optional). If the E-5 sales option (Alarm) is included a 5 second time delay relay will not allow the alarm to sound unless a safety or limit circuit stays energized for more than 5 seconds. 61. The coil of relay K-5 (N.O.
23. When a CFH occurs, a 24 VAC signal is sent to the CFH light on the status panel located on the lower left front of the control compartment. 38. A 24 VAC signal is now sent to the blower LED’s on the status board. 39. Power is applied to the optional equipment interlock connection (normally jumpered). 24. Power is also sent from pin 2 of the stage 1 connection to pin P1-3 of the universal diagnostic board. 40. The 24 VAC signal is then sent to the 24 VAC safety connector. 25.
49. When power is sent to gas valve 1 it is also sent to time delay relay 1 (TD-1) which starts a 5-second countdown. 63. The coil of relay K-5 (N.O.) is now energized with the (K-5) contacts closing downstream of the stage 4 connections. 50. After the 5-second countdown from TD-1 and the internal contacts close, time delay relay 2 (TD-2 ) receives 24 VAC. 64. Remote flame sensor 2 is trying to rectify flame. 65.
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. Turning off the power to the heater WILL NOT reset the ignition module. Ignition Module When additional heat is needed, the combustion air blower starts to purge air from the combustion chamber for about 15 seconds.
sheets supplied with your heater paperwork. See the General Safety Section for safety precautions concerning domestic hot water applications. 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. Fig. 35: Operating Control Low Water Cut-Off (Optional) The low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe.
Pump Time Delay There are two versions of the Pump Time Delay. The first is the Economaster II. It is an electronic device that allows the operator to set a variable time (3 to 10 minutes) for the pump to run after the boiler shuts off. See Fig. 40 (A) . The time is factory-set at 7 minutes and it can be re-adjusted in the field. The second version is a fully enclosed solid state TDR with a white jumper that selects one of two time delays. See Fig. 40 (B).
87%-Efficiency Boilers – Special Instructions ends that a thermometer be placed into the boiler inlet piping next to the in/out header to facilitate temperature adjustment. Inlet water temperatures below 120ºF (49ºC) can excessively cool the products of combustion, resulting in condensation on the heat exchanger. NOTE: The constructions of the 84%- (standard) and 87%-efficiency (optional) boilers are very similar, and they are installed to the same requirements, except as noted in this section.
11. Locate or guard vent to prevent condensate from damaging exterior finishes. Install a rust-resistant sheet metal backing plate against brick or masonry surfaces. WARNING: Contact the vent material manufacturer if there are any questions about the appliance category or suitability of a vent material for Category II, III or IV applications. Using improper venting materials can result in personal injury, death or property damage. 12. DO NOT extend exposed vent pipe outside of building.
pressure reading must be between -0.01 and -0.1 in. WC as measured 12 in. from the appliance flue outlet. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in one of the four following combinations: WARNING: Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure.
The stainless steel direct vent cap must be furnished by the boiler manufacturer in accordance with its listing (sales order option D-15). The flue exhaust direct vent cap is not considered in the overall length of the venting system. Care must be taken during assembly that all joints are sealed properly and are airtight. Use only double-wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burning boilers, such as the stainless steel Saf-T vent by Heat Fab Inc.
Direct Vent - Vertical Note: When vertical height exceeds 25 ft, consult factory prior to installation. *Requires optional vent tee if vented horizontally out back of heater. Fig. 45: Direct Vent - Vertical Model Certified Venting Material 992BE 1262BE 1532BE Category II 1802BE or IV 2002BE Vertical Venting Height* Vent Size Min. Max. Combustion Air Intake Pipe Material 10” 12” 75’ 100’ 40’ 75’ 10” 12” 5’ 25’ 14” Galvanized Steel, PVC, ABS, CPVC 2072BE 2342BE Air Inlet Max.
SEE PAGE 24 FOR STAGING OPTIONS Wiring Diagram—Models 992B–1262B 50
Wiring Diagram—Models 1532B–2342B 51
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 ± .1 in. WC for propane gas and natural gas.
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 Hi Delta 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 there a Call For Heat? YES Unit is in standby mode. Check all safety limit devices and voltage from the transformer to J10 on CPW board. NO YES Reattach.
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. 46.) 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: 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 HI DELTA – TYPES H AND WH MODELS 992B–2342B SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
LIMITED PARTS WARRANTY HI DELTA – TYPE P MODELS 992B–2342B SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
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.
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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.
