Raypak 399B-2339B manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 1000.60A Effective: 01-06-09 Replaces: 09-28-07 P/N 241330 Rev . 2 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property damage, personal injury or death . FOR Y OUR SAFETY : Do not store or use gasoline or other flammable vapors and liqu[...]

2 Rev . 2 reflects the following: Changes to: Paragraph one of the Stacking section on page 9; T able G on page 16; T able 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.[...]

WARNINGS 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 T ime/T emperature Relationships in Scalds 8 INST ALLA TION 9 Installation Codes 9 Equipment Base 9 Stacking 9 Clearances 1 1 Combustion and V entilation A[...]

D ANGER: 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. CA UTION: Indicates the presence of hazards or unsa[...]

BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your Delta Limited 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 ma[...]

OPTIONAL FLUE CONNECTION Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front 6[...]

General Infor mation T able A: Basic Data T able B: Manifold Data Model No. Quantity of V ent Size (in.) Burners Gas V alves 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 [...]

GENERAL SAFETY T o 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 rec- ommended initial setting for the temperature control is 125°F . Saf[...]

INST ALLA TION INST ALLA TION Installation Codes Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances • National Fuel Gas Code, ANSI Z223.1/NFP A 54 – latest edition (NFGC) • National Electrical Code, ANSI/NFP A 70 - latest edition (NEC) • Standard for Controls and Safety [...]

U.S. Installations 1 Can adian I nstalla tions 2 A Clearance abov e grade , veranda, porch , deck, or balcony 1 ft ( 30 cm) 1 ft ( 30 cm) B Clearance to window or door that may b e opened 4 f t ( 1 .2 m) b elo w o r to s ide of openin g; 1 foot (30 c m) above op ening 3 ft (91 c m) C Clearance to per manen tly closed wind ow ** D Ver tical clearan [...]

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.). Clearances Indoor Installations Heater Sid e Mini mu m Clea ranc e from Com bustible Surf a ce s Recom mende d Se[...]

three or four sheet metal screws (not supplied) equal- ly distributed around the circumference of the duct. All ducting should be self-supported. The filter housing is not designed to support the air duct. Con v entional Combustion Air Supply U .S. Installations All Air from Inside the Building The confined space shall be provided with TWO per- man[...]

space shall be considered in making this determina- tion. Each opening shall have a minimum free area of 1 in. 2 per 1,000 BTUH (2,225 mm 2 per kW) of the total input rating of all gas utilization equipment in the con- fined space, but not less than 100 in. 2 (645 cm 2 ). One opening shall commence within 12 in. (305 mm) of the top, and one opening[...]

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. 6. Remove limits, control bulbs and/or thermocou- ples. 7. Remove the six (or 8) flange nuts and the in/out header from the left-hand side. 8. Remove the six (or 8) flange nuts and the return head[...]

Fig. 9: T orque Sequence the hydrostatic test before connecting gas piping or electrical supply . Leaks must be repaired at once to prevent damage to the heater . NEVER use petroleum-based stop-leak compounds. T o perform hydrostatic test: 1. Connect fill water supply . With bleed valve open, fill heater with water . When water flows from bleed val[...]

Cold Wa ter Run Cold water run differs from cold water start in that the system water entering the heater remains below 105ºF (41ºC) continuously . T ypically , this is the case in swim- ming pool heating and water source heat pump applications as well as some others. If the system water is kept in a narrow temperature range, a perma- nent manual[...]

Pressur e Dr op in F eet of Head F eedwater R e gulator Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the highest point of the system. Install a check valve or back flow device upstream of the regulator , with a manual shut-off valve as required by local codes. Piping All high points should be ven[...]

18 P ota ble Wa ter and Space Heating 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. T oxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating. 3. If the heater will be used to su[...]

19 Gas Supply Connection The heater must be isolated from the gas supply pip- ing system by closing the manual shut-off valve 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 va[...]

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 manu- al shut-off valve has been installed within 10 ft of the heater . 10. Replace the left and right front panels on the heater . Gas Supply Pr essur e A minimum of 5.0 in. WC and a maximum of 10.5 [...]

Electrical P ow er Connections Installations must follow these codes: • National Electrical Code and any other national, state, provincial or local codes or regulations hav- ing 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. The heater [...]

prior to working with any electrical connections or components. 3. Observe proper wire colors while making electri- cal connections. Many electronic controls are polarity sensitive. Components damaged by improper electrical installation are not covered by warranty . 4. Provide overload protection and a disconnect means for equipment serviceability [...]

23 Fig. 20: 2-Stage Wiring Connections Fig. 21: 3-Stage Wiring Connections Fig. 22: 4-Stage Wiring Connection[...]

Consult the wiring diagram shipped with the heater in the instruction packet or at the end of this section. The stage-selector terminals are for the remote tank con- trol through the heater ’s 24 V AC transformer . DO NOT attach any voltage to the stage-selector terminals. Before starting the heater , check to ensure proper volt- age to the heate[...]

25 V enting General Flue Exhaust T ee An optional Flue Exhaust T ee is available to facilitate horizontal venting. Any reference to horizontal venting that exits the back of the heater requires this tee. Refer to T able J for the appropriate kit for your model. CA UTION: Proper installation of flue venting is criti- cal for the safe and efficient o[...]

8. Locate and guard vent termination to prevent acci- dental contact by people or pets. 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. 10. DO NOT terminate above any door , window , or gravity air intake. Condensate can freeze, causing ice formations. 1 1. Locate or guard vent to prevent condensate fro[...]

Canadian Installations Refer to latest edition of B149 Installation code. A vent shall not terminate: 1. Directly above a paved sidewalk or driveway which is located between two single-family dwell- ings and serves both dwellings. 2. Less than 7 ft (2.13 m) above a paved sidewalk or paved driveway located on public property . 3. Within 6 ft (1.8 m)[...]

V enting Configur a tions 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 V er tical V enting (Categor y I) Installation Natural draft venting uses the natural buoyancy of the heated flue products to crea[...]

29 T able L: Category I V ertical V enting * V ent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. When vertical height exceeds 25 ft, consult factory prior to installation. ** Subtract 10 ft per elbow . Max. 3 elbows. Maximum combustion air duct length terminated at 100 equivalent ft. loa[...]

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 . 5. Check the pressure at a pressure tap located 12 in. above the bottom joint of the first vertical[...]

T able M: Category III Horizontal and Direct V enting *Subtract 10 ft per elbow . Max. 3 elbows. Maximum combustion air duct length terminated at 100 equivalent ft. WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants. Model No. Certified V enting Material [...]

F r eeze Protection When installing this heater in an outdoor location that is susceptible to freezing, sales order option B-22 must be ordered. The B-22 option energizes the heater pump at a preset temperature drop to circulate water and reduces the possibility of freezing and dam- aging the heat exchanger or headers. Controls NO TE: Condensate ca[...]

33 Fig. 27: Status LED Indicator Decal Heater Sequence of Operation Models 399B–899B 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. 2. When the main power switch is placed in the “ON” position, 120 V AC is applied to the 120 V AC termi- n[...]

34 powered. If the switch is “ON” and there is no call for heat (CFH), the heater is in standby mode. 18. After the standby switch is placed into the “ON” position, a 24 V AC signal is sent to the green power light on the front of the unit and the “enable/disable” connection (normally jumpered). 19. 24 V AC switched power is applied to [...]

35 45. The Heater is now operating at full fire. 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. 2. When the main power switch is placed in the “ON” position, 120 V AC is applied to the 120 V AC termi- nal block on the ci[...]

36 the 120 V AC pilot duty terminals, located at J-14 on the circuit board. 29. The 120 V AC signal continues to the coil of relay K-4 (N.O.). 30. The 120 V AC signal continues to the 120 V AC safety terminals located at J-13 on the circuit board. 31. When the coil on relay K-4 (N.O.) is powered, the relay contacts (K-4) close and energize the blow[...]

37 The optional single-try ignition module will lock out after failing to light one time. T o 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). T urning off the power to the heater WILL NOT reset the ignition mod- ule. High Limit [...]

Fig. 31: Operating Control Low W ater 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. 32: Low W ater Cut-Off High and Low Gas Press[...]

W iring Dia g r am - Models 399B–1259B 39[...]

W iring Dia g r am - Models 1529B–2339B 40[...]

ST ART -UP Pre Star t-up Filling System (Heating Boilers) Fill system with water . Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. Air Pur ge (Domestic Hot Wa ter Heaters) Purge[...]

Prepar ation Check P ower Supply With multi-meter at incoming power , check voltage between: Hot - Common (≈120 V AC) Hot - Ground (≈120 V AC) Common - Ground (< 1 V AC) Attach Manometers to Measure Pr essur es 1. T urn off main gas valve. 2. Attach 24” scale manometer to the first main gas shut-off valve pressure tapping. 3. Attach (1) 12[...]

Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record. 3. If other gas-fired appliances in the room are on the same gas main, check all pressures on the Delta Limited with all other equipment running. 4. Check thermostats for ON-OFF operation. 5. Chec[...]

1. Manually close the downstream leak test valve. 2. Open test point A and connect a manometer to it. V erify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in. WC). 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 press[...]

10. T o restart system, follow lighting instructions in the Operation section. 1 1. Check to see that the high limit control is set above the design temperature requirements of the system. For multiple zones: Check to make sure the flow is adjusted as required in each zone. 12. Check that the heater is cycled with the thermo- stat. Raise to the hig[...]

TR OUBLESHOO TING Ste p 7 Ste p 6 Ste p 5 Step 1 Step 2 Step 3 Step 4 Is enable/disable j um p er intact ( J1 ) ? Is there a call for heat? Is there 120VAC at J8 Connecto r on the CPW board? Do the combustion air blowers come on? Is 24VAC at present at TH (J3 & J12 on CPW board and orange wire on ignition module)? Check flow switch, all connect[...]

MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency . Maintenance as outlined below may be performed by the owner . Daily 1. Check that the area where the heater is installed is free from combustible materials, gasoline, and other f[...]

W eekl y 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). Monthly 1. Check flue, vent, stack, or outlet dampers. 2. T est fan air pressure. (See “Blower[...]

APPENDIX Inside Air Contamination 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 effi- cie[...]

LIMITED PARTS WARRANTY DELTA LI MITE D – TYPES H AND WH MODELS 399B–2339B SCOP E Ray pak, Inc . (“R ay pak ”) w arr ants to the o r igin al ow ner th at al l par ts o f th is h eat er w hic h a r e ac tu al ly m an uf actur ed by R ay pak w ill be free fro m f ailur e un der n orm al use a nd s erv ic e for th e sp ec if ied w a rra nty per[...]

START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This s tart- u p c he c kli s t is to b e c o mp l ete ly fill ed o ut b y t he s e rv ice tec hn ic ia n sta r tin g up th e Ra y p ak Bo i ler or H ea ter for the first time. All information may be used for warra nty purposes an d to ensure that the installation is corre ct. Addi ti o na lly th [...]

ww w . ray pak.c om Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.[...]