Raypak 1259B Installation & Operating Instructions Manual Download Page 41 | Manualshive

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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.

Air Purge (Domestic Hot Water
Heaters)

Purge all air from system before lighting heater. This
can be normally accomplished by opening a down-
stream valve.

Venting System Inspection

1.

Check all vent pipe connections and flue pipe ma-
terial.

2.

Make sure vent terminations are installed per code
and are clear of all debris or blockage.

For Your Safety

This appliance has a hot surface igniter. It is equipped
with an ignition device which automatically lights the
burners. Do not try to light the burners by hand.

BEFORE OPERATING, smell all around the appliance
area for gas. Be sure to smell near the floor because
some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

•

Do not try to light any appliance.

•

Do not touch any electrical switch; do not use any
telephone in your building.

•

Immediately call your gas supplier from a neigh-
bor’s telephone. Follow the gas supplier’s
instructions.

WARNING:

If you do not follow these instructions

exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.

•

If you cannot reach your gas supplier, call the fire
department.

•

Use only your hand to push in or turn the gas con-
trol knob. Never use tools. If the knob will not turn
by hand, do not try to repair it, call a qualified serv-
ice technician. Forced or attempted repair may
result in a fire or explosion.

•

Do not use this appliance if any part has been
under water, immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.

•

Check around unit for debris and remove com-
bustible products, i.e. gasoline, etc.

Pre Start-up Check

1. Verify heater is filled with water.

2. Check system piping for leaks. If found, repair

immediately.

3. Vent air from system. Air in system can interfere

with water circulation.

4. Purge air from gas line up to heater.

Initial Start-up

Tools Needed

•

(1) 12-0-12, 24” scale U-tube manometer

•

(4) 6-0-6, 12” scale U-tube manometers (mini-
mum)

•

(1) Screwdriver

•

(1) Multi-meter

•

(1) 3/16” Allen wrench

NOTE:

Digital manometers are not recommended.

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Summary of Contents for 1259B

Page 1: ...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 in...

Page 2: ...ges 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: ... Piping 14 Hydronic Heating 16 Gas Supply 18 Electrical Power Connections 21 Field Wiring Connection 22 Venting 25 Changing the Flue Outlet 27 Venting Installation Tips 27 Venting Configurations 28 Outdoor Installation 32 Controls 32 Heater Sequence of Operation 33 Wiring Diagrams 39 START UP 41 Pre Start up 41 Start Up 42 OPERATION 45 Lighting Instructions 45 To Turn Off Gas To Appliance 45 TROUB...

Page 4: ...efects or other reproductive harm WARNING Risk of electrical shock More than one disconnect switch may be required to deenergize the equipment before servicing CAUTION Operation of this heater in low temperature systems requires special piping Harmful internal condensation will occur if the inlet water temperature does not exceed 105 F Warranty claims will be denied when condensation occurs CAUTIO...

Page 5: ...fec tive replacement parts will not be accepted and will be replaced in kind only per Raypak s standard war ranties Model Identification The model identification number and heater serial number are found on the heater rating plate located on the lower right outside jacket of the heater The model number will have the form H8 1259B or similar depending on the heater size and configuration The letter...

Page 6: ...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 ...

Page 7: ...B 26 5 3 16 10 Model No Burners per Valve Stages Fire at Stage 1 1A 2 3 4 1 2 3 4 1 2 3 4 399B 8 1 100 499B 5 5 1 1 2 50 100 649B 7 6 1 1 2 54 100 749B 8 7 1 1 2 53 100 899B 6 6 6 1 2 1 2 3 66 100 989B 6 5 1 1 2 54 100 1259B 5 3 6 1 1 2 1 2 3 36 57 100 1529B 6 4 4 3 1 1 2 1 2 3 1 2 3 4 35 59 82 100 1799B 6 4 5 5 1 1 2 1 2 3 1 2 3 4 30 50 75 100 1999B 4 5 5 5 4 1 1A 1 1A 2 1 1A 2 3 1 1A 2 3 4 39 61...

Page 8: ...stream and read the thermometer NOTE When this water heater is supplying general purpose hot water for use by individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further information Water temperature over 125 F can cause instant severe burn...

Page 9: ...ting See Fig 4 CAUTION Hotter water increases the risk of scald ing There is a hot water scald potential if the thermostat is set too high Fig 4 Temperature Control Equipment Base 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 park...

Page 10: ...4 ft 1 2m below or to side of opening 1 ft 30 cm above opening 3 ft 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t M Clearance under veranda porch deck or balcony 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 Natio...

Page 11: ...led location without movement or removal of the heater Service clearances less than the minimums may require removal of the heater to service either the heat exchanger or the burner tray In either case the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater Outdoor Installations These heaters are design certified for outd...

Page 12: ...m ply with the requirements of the NFGC U S and B149 Canada and all local codes Reversing Air Filter Follow these instructions to change the air duct con nection 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...

Page 13: ...hall have a minimum free area of a 1 in 2 per 3 000 BTUH 740 mm2 per kW of the total input rating of all equipment located in the enclosure and b Not less than the sum of the areas of all vent connectors in the confined space WARNING Do not use one permanent opening method if the equipment room is under negative pressure conditions or the equipment is common vented with other gas fired appliances ...

Page 14: ...ter and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based anti freeze Raypak recommends conducting 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 o...

Page 15: ... 41ºC within 7 minutes of start up Failure to exceed 105ºF 41ºC within 7 minutes may result in the premature failure of the hot surface ignit er 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 The bypass allows part of the heater discharge water to be mixed with the cooler heater r...

Page 16: ...y 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 Temperature Pressure Gauge The temperature and pressure gauge is factory mounted in the in out header Hydronic Heating Pump Selection In order to ensure proper performance of your heater system you must install a correctly sized pum...

Page 17: ...valves or other automatic means to prevent gravity circulation of the heater water during the cooling cycle It is highly recommend ed that the piping be insulated Air Separation Expansion Tank All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig 10 Three Way Valves Valves designed to blend water temperatures or reduce water circulation throu...

Page 18: ...er gallon the operating control must be set no higher than 130F for scale free operation For operating temper atures above 130F a water softener must be utilized Model No Soft 0 4 grains per gallon Medium 5 15 grains per gallon Hard 16 25 grains per gallon ΔT gpm ΔP MTS SHL ΔT gpm ΔP MTS SHL ΔT gpm ΔP MTS SHL 399B 17 40 2 0 2 4 4 13 52 3 4 2 7 2 8 90 10 0 2 20 5 499B 21 40 2 1 2 4 5 16 52 3 5 2 7 ...

Page 19: ... use Teflon tape on gas line pipe thread A pipe compound rated for use with natural and propane gases is recommended Apply sparingly only on male pipe ends leaving the two end threads bare Table I Maximum Equivalent Pipe Length Natural gas 1 000 BTU per ft3 60 specific gravity at 0 5 in WC pressure drop Propane gas 2 500 BTU per ft3 1 53 specific gravity at 0 6 in WC pressure drop Model No 3 4 1 1...

Page 20: ...move the left and right front panels from the heater 4 Locate the main gas line that traverses across the heater above the manifold risers 5 Remove the pipe cap from the right hand end of the main gas line 6 Reinstall the pipe cap on the left hand end of the main gas line 7 Remove plastic cap from the right hand side panel and reinstall into the standard main gas opening located on the left hand s...

Page 21: ...laced with 105 C wire or its equivalent Field Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source Check the Power Source NOTE Field supplied isolation relays should be installed when field connected controllers are mounted more than 50 equivalent feet 18 Ga from heater WARNING Using a multi met...

Page 22: ...th the applicable manufacturers instructions 6 Conduit should not be used as the earth ground Field Wiring Connection 22 NOTE A grounding electrode conductor shall be used to connect the equipment grounding conductors the equipment enclosures and the grounded service conductor to the grounding electrode Fig 18 Wiring Location DANGER SHOCK HAZARD Make sure electrical power to the heater is discon n...

Page 23: ...23 Fig 20 2 Stage Wiring Connections Fig 21 3 Stage Wiring Connections Fig 22 4 Stage Wiring Connection ...

Page 24: ...le if your heater is a Model 1529B you will jumper stages two three and four Then your heater will either be on at full fire or it will be off 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 stage 1 of the heater to stage 1 of the control stage 2 of the heater to stage 2 of the control as shown in Fig 22 and Fig 2...

Page 25: ...r vertical runs of vent pipe as necessary Installation in a bull head tee is acceptable as shown in the NFGC The weights on the damper should be adjusted per the damper manufacturer s instructions for proper opera tion Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent Category I A heat...

Page 26: ...all Venting III Stainless Steel Gas Tight Vertical Natural Draft Venting I B Vent From Outside Building Horizontal Through the Wall Venting III Stainless Steel Gas Tight Galvanized Steel PVC ABS CPVC 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 i...

Page 27: ...t least 1 ft above grade including normal snow line 9 Multiple sidewall vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane Changing the Flue Outlet Follow these instructions to change the flue connec tion from the standard top location to the rear of the heater with optional flue exhaust tee 1 Disconnect all electrical power from the heat...

Page 28: ...f more than 5 ft should be se curely guyed or braced to withstand snow and wind loads Common Venting System Manifolds that connect more than one heater to a com mon chimney must be sized to handle the combined CAUTION A listed vent cap terminal adequately sized must be used to evacuate the flue products from the heaters The maximum and minimum venting length for Cate gory I appliances shall be det...

Page 29: ... natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure CAUTION Vent connectors for natural draft venting systems must be Type B or better 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 block age restriction leakage corrosion or ot...

Page 30: ...h the minimum size as determined using the appropriate tables in the NFGC U S or B149 Canada Fig 26 Horizontal Through the Wall Venting Category III Requires optional vent tee 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 appropri ately sized extractor must be used Each elbow used is equal ...

Page 31: ...1 4 inch per foot of hori zontal run to the vent terminal 2 The vent must be insulated through the length of the horizontal run For installations in extremely cold climate it is re quired that 1 The vent must be installed with a slight upward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal In this case an approved condensate trap must be installed per applicable co...

Page 32: ... may be required to de energize the equipment before servicing 1 Outdoor models must be installed outdoors and must use the outdoor vent cap flow switch cover and air intake hood available from the manufac turer sales order option D 11 2 Periodically check venting system The heater s venting areas must never be obstructed in any way and minimum clearances must be observed to prevent restriction of...

Page 33: ... 5 seconds 11 Power is output from terminal J5 24V of the CPW board to all of the safeties All safeties are verified to ensure that it is safe to operate the heater The safety components wired into the diagnostic board are Manual reset high limit low water cut off optional blocked vent switch low gas pressure switch optional and high gas pressure switch optional 12 Once all safeties have been veri...

Page 34: ... switch P Switch terminal on the ignition module 34 Once the pressure switch signal is received at the ignition module the hot surface igniter is ener gized by a 120 VAC signal from S 1 on the ignition module The hot surface igniter must draw greater than 3 2 amps while being energized or the ignition module red LED will flash 4 times and ignition lockout will occur after three tries 35 Once the i...

Page 35: ...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 termi nal P1 4 of J 5 on the CPW board 15 Power is applied to terminal 24V of the pump delay relay to energize the timing circuit 16 Relay K 1 N C will now be energized and opens the N C contacts to disable the alarm optional and turn off the red safety shutdo...

Page 36: ...hin 4 seconds the ignition module will shut down the gas valve and retry the hot surface ignit er During ignition retry the heater must perform a 15 second pre purge and an approximately 30 second 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 42 After gas valve 1 opens and flame rectification i...

Page 37: ...ham ber for about 15 seconds On proof of air flow the air proving switch closes and the igniter is energized To ensure safe operation the gas valve cannot open until the igniter is verified The main burner is automatically lit when the device is powered and pre purged The heater performs its own safety check and opens the main valve only after the igniter is proven to be capa ble of ignition Code ...

Page 38: ... WC for propane gas The high gas pressure switch optional connection mounts down stream of the stage 1 gas valve If the gas pressure regulator fails the high gas pressure sheets supplied with your heater paperwork See the General Safety Section for safety precautions con cerning domestic hot water applications Fig 33 High Low Gas Pressure Switch Fig 34 Fan Proving Switch Fig 35 Blocked Vent Switch...

Page 39: ...Wiring Diagram Models 399B 1259B 39 ...

Page 40: ...Wiring Diagram Models 1529B 2339B 40 ...

Page 41: ...ilding Immediately call your gas supplier from a neigh bor s telephone Follow the gas supplier s instructions WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas con trol knob Never use tools If the k...

Page 42: ...ure Failure to do this may burn out 120V 24V transformer or may cause other safety control damage or failure Start Up Blower Adjustment 1 Turn off power 2 Unplug cap at pressure switches and connect ma nometer s to the tee 3 Close all manual firing valves 4 Turn power on 5 Check manometers attached to fan pressure switch The reading should be 1 4 0 1 in WC for propane gas and natural gas If not ad...

Page 43: ...ervised pilot to light the burner sections on either side of it The burn er 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 The pilot turn down test is conducted as follows 1 Turn off ...

Page 44: ...ore electrical power to heater Fig 36 Leak Test This completes leak testing for a single Delta Limited manifold riser Repeat steps 1 8 for each riser Post Start Up Check Check off steps as completed 1 Verify that the heater and heat distribution units or storage tank are filled with water 2 Confirm that the automatic air vent if used was opened two full turns during the venting proce dure 3 Verify...

Page 45: ... on main manual gas valve 7 Wait 5 minutes to clear out any gas Then smell for gas especially near the floor If you then smell gas STOP Follow the steps in the safety informa tion on the front cover of this manual If you do not smell gas go to next step 8 Turn on all electrical power to the appliance 9 Set thermostat to desired setting The appliance will operate The igniter will glow after the pre...

Page 46: ...Outside California 1 800 627 2975 Inside California Replace gas valve Are the gas valve settings correct Replace fan relay Replace fan Replace air pressure switch Correct the air settings or you may have to clean burners heat exchanger and or air filter NO Check the switch and or line voltage YES Does the power switch provide power to the control panel Reattach Unit is in standby mode YES NO NO YE...

Page 47: ...pors and liquids 4 Check for and remove any obstruction to the flow of combustion or ventilation air to heater 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 ig niter and sensor for damage cracking or debris build up 7 Check operation of safety devices Refer to manu facturers instructions 8 Follow ...

Page 48: ...a combustion test at full fire Carbon di oxide should be 7 5 to 8 5 at full fire for natural gas and between 9 2 to 9 8 for propane gas Carbon monoxide should be 150 ppm 5 Check coils for 60 cycle hum or buzz Check for leaks at all valve fittings using a soapy water solu tion Test other operating parts of all safety shut off and control valves and increase or decrease set tings depending on the ty...

Page 49: ...In extremely contaminated ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners chlorine based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varnish removers hydrochloric acid muriatic aci...

Page 50: ...o water PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts not man...

Page 51: ...t _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size _______________ Vent Termination Type __________________ Pump Size _________ boiler Pump HP ______ Combustion Air Openings Low __________ in2 Impeller trim____________ Pump Model___________ Ventilation air High ...

Page 52: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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