Raypak 399B-2339B Installation & Operating Instructions Manual
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Raypak 399B-2339B Installation & Operating Instructions Manual

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INSTALLATION & OPERATING
Models
399B–2339B
Types H & WH
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.
• 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. 1000.60A
INSTRUCTIONS
Effective: 01-06-09
L
W
.
Replaces: 09-28-07
P/N 241330 Rev. 2

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Summary of Contents for Raypak 399B-2339B

  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 399B–2339B Types H & WH 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.
  • Page 2 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.

  • Page 3: Table Of 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 12 Water Piping Hydronic Heating Gas Supply Electrical Power Connections...

  • Page 4: Pay Attention To These Terms

    WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored.

  • Page 5: Before Installation

    If, after reviewing this manual, you still have questions which this manual does not answer, please contact the manufacturer or your local Raypak representative. Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.

  • Page 6: Component Locations

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

  • Page 7: General Information

    General Information Quantity of Model Burners Gas Valves Blowers 399B 499B 649B 749B 899B 989B 1259B 1529B 1799B 1999B 2069B 2339B Table A: Basic Data Burners per Valve Model 399B 499B 649B 749B 899B 989B 1259B 1529B 1799B 1999B 2069B 2339B Vent Size (in.) Flue...

  • Page 8: General Safety

    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 rec- ommended initial setting for the temperature control is 125°F.

  • Page 9: Installation

    Delta Limited units can be stacked two units high with an optional stacking rack. A stacking kit is available from Raypak for this type of installation. CAUTION: The heaters should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the structure.
  • Page 10 Fig. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- tance of 2 ft (61cm) from the centerline of the terminal...

  • Page 11: Clearances

    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 Minimum Clearance Heater from Combustible Side Surfaces Floor*...

  • Page 12: Combustion And Ventilation Air

    Fig. 8: Minimum Clearances from Combustible Surfaces – Outdoor Installations Combustion and Ventilation Air NOTE: Use of the heater in construction areas where fine particulate matter, such as concrete or dry-wall dust, is present may result in damage to the heater that is not covered by the warranty.

  • Page 13: Canadian Installations

    space shall be considered in making this determina- tion. Each opening shall have a minimum free area of 1 in. per 1,000 BTUH (2,225 mm input rating of all gas utilization equipment in the con- fined space, but not less than 100 in. opening shall commence within 12 in.

  • Page 14: Water Piping

    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 rest of the system prior to operation. This is particularly true for hydronic systems using expensive glycol- based anti-freeze.

  • Page 15: Cold Water Operation

    This piping is like a pri- mary/secondary boiler installation with a bypass acting as the secondary boiler piping. Raypak strongly rec- ommends that thermometer(s) be placed into the heater piping next to the in/out header to facilitate tem- perature adjustment.

  • Page 16: 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.
  • Page 17 Raypak heaters are high-recovery, low-mass 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.) Fig.

  • Page 18: Gas Supply

    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.

  • Page 19: Gas Supply Connection

    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.

  • Page 20: Gas Supply Pressure

    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. Reversing Gas Supply Connection Reversing the standard fuel connection from the left- hand to the right-hand side is a simple field operation.

  • Page 21: Electrical Power Connections

    Electrical Power 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.

  • Page 22: Field Wiring Connection

    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 as required by local and state code.
  • Page 23 Fig. 21: 3-Stage Wiring Connections Fig. 22: 4-Stage Wiring Connection Fig. 20: 2-Stage Wiring Connections...
  • Page 24 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.

  • Page 25: Venting

    Venting CAUTION: Proper installation of flue venting is criti- cal for the safe and efficient operation of the heater. General Flue Exhaust Tee An optional Flue Exhaust Tee is available to facilitate horizontal venting. Any reference to horizontal venting that exits the back of the heater requires this tee. Refer to Table J for the appropriate kit for your model.

  • Page 26: Vent Terminal Location

    Use insulated vent pipe spacers where the vent pass- es through combustible roofs and walls. Vent Terminal Location 1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 2. Give special attention to the location of the vent termination to avoid possibility of property dam- age or personal injury.

  • Page 27: Changing The Flue Outlet

    5. Terminate vent at least 6 ft away from adjacent walls. 6. DO NOT terminate vent closer than 5 ft below roof overhang. 7. The vent terminal requires a 12 in. vent terminal clearance from the wall. 8. Terminate vent at least 1 ft above grade, including normal snow line.

  • Page 28: Venting Configurations

    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.
  • Page 29 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. 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.
  • Page 30 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.
  • Page 31 The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved stainless steel flue direct vent cap must be used (sales order option D-15).

  • Page 32: Outdoor Installation

    Outdoor Installation Outdoor models are self-venting when installed with the optional factory-supplied outdoor vent kit and re- quire no additional vent piping. A special vent cap, flow switch cover and air intake hood are provided in accor- dance with CSA requirements, which must be installed directly on the heater.

  • Page 33: Heater Sequence Of Operation

    Fig. 27: Status LED Indicator Decal External Lights Light Color Power On Green Call For Heat Amber Burner Firing Blue Service Req’d Table N: Status LED Indicators Heater Sequence of Operation Models 399B–899B 1. The black (hot) wire lead goes directly to the main power switch.
  • Page 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 VAC signal is sent to the green power light on the front of the unit and the “enable/disable”...
  • Page 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 VAC is applied to the 120 VAC termi- nal block on the circuit board and the 120/24 VAC transformer is powered.
  • Page 36 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.). 30. The 120 VAC signal continues to the 120 VAC safety terminals located at J-13 on the circuit board.

  • Page 37: Ignition Module

    connection close after 5 seconds. 56. The stage 4 temperature controller contacts close. 57. Power is sent to gas valve 4. 58. The heater is now operating at full fire. Ignition Module Fig. 28: Ignition Module When additional heat is needed, the combustion air blower starts to purge air from the combustion cham- ber for about 15 seconds.
  • Page 38 sheets supplied with your heater paperwork. See the General Safety Section for safety precautions con- cerning domestic hot water applications. Fig. 31: 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.

  • Page 39: Wiring Diagrams

    Wiring Diagram - Models 399B–1259B...
  • Page 40 Wiring Diagram - Models 1529B–2339B...

  • Page 41: Start-Up

    START-UP Pre Start-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.

  • Page 42: Start-Up

    Preparation WARNING: Do not turn on gas at this time. Check Power Supply With multi-meter at incoming power, check voltage between: Hot - Common (≈120 VAC) Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) WARNING: If Common - Ground is > 1 VAC, STOP: Contact electrician to correct ground failure.

  • Page 43: Safety Inspection

    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.
  • Page 44 1. Manually close the downstream leak test valve. 2. Open test point A and connect a manometer to it. Verify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in. WC). 3.

  • Page 45: Operation

    10. To restart system, follow lighting instructions in the Operation section. 11. 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.

  • Page 46: Troubleshooting

    TROUBLESHOOTING Does the power switch provide power to the control panel? Step 1 Is enable/disable jumper intact (J1)? Step 2 Is there a call for heat? Do the combustion air Step 3 blowers come on? Step 4 Is 24VAC at PS on ignition module? Is connecting plug secure?

  • Page 47: Maintenance

    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 flammable vapors and liquids.

  • Page 48: Semi-Annually

    Weekly 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.

  • Page 49: Inside Air Contamination

    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- ciency systems.

  • Page 50: Product Receipt 5 Warranty

    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 Wa rranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but a re the owner’s responsibility.

  • Page 51: Model Identification 5 Start-Up Checklist

    START-UP CHECKLIST FOR FAN-ASSISTED 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.
  • Page 52 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

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