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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.

NOTE: 

Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.

DANGER:

Make sure the gas on which the heater

will operate is the same type as that specified on the
heater rating plate.

WARNING:

Should overheating occur or the gas

supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.

WARNING:

Do not use this heater if any part has

been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.

WARNING:

To minimize the possibility of improper

operation, serious personal injury, fire, or damage to
the heater:

Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.

Heater should never be covered or have any
blockage to the flow of fresh air to the heater.

WARNING - CALIFORNIA PROPOSITION
65: 

This product contains chemicals known to the

State of California to cause cancer, birth defects 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.

CAUTION: 

If this heater is to be installed above

radiation level, it must be provided with a low water
cut-off device at the time of heater installation.

CAUTION: 

If this heater is to be installed in a

negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.

WARNINGS

Pay Attention to These Terms

4

WARNING:

This unit contains refractory ceramic

fiber (RCF) insulation in the combustion chamber.
RCF, as manufactured, does not contain respirable
crystalline silica.  However, following sustained
exposure to very high temperatures (>2192F), the
RCF can transform into crystalline silica
(cristabolite). The International Agency for Research
on Cancer (IARC) has classified the inhalation of
crystalline silica (cristabolite) as carcinogenic to
humans.

When removing the burners or heat exchangers,
take precautions to avoid creating airborne dust and
avoid inhaling airborne fibers. When cleaning spills,
use wet sweeping or High Efficiency Particulate Air
(HEPA) filtered vacuum to minimize airborne dust.
Use feasible engineering controls such as local
exhaust ventilation or dust collecting systems to
minimize airborne dust. Wear appropriate personal
protective equipment including gloves, safety
glasses with side shields, and appropriate NIOSH
certified respiratory protection, to avoid inhalation of
airborne dust and airborne fiber particles.

Summary of Contents for 399B-2339B

Page 1: ...o 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...

Page 2: ...es 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...

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 Out...

Page 4: ...fects 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 t...

Page 5: ...ec 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 fou...

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: ...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...

Page 8: ...tream 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 temp...

Page 9: ...ing 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...

Page 10: ...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...

Page 11: ...ed 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...

Page 12: ...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...

Page 13: ...all 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 connecto...

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...

Page 15: ...41 C within 7 minutes of start up Failure to exceed 105 F 41 C within 7 minutes may result in the premature failure of the hot surface ignit er remote flame sensor burners and heat exchanger It can ca...

Page 16: ...hereby 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...

Page 17: ...alves 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 heat...

Page 18: ...per 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 M...

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 Maxi...

Page 20: ...ove 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...

Page 21: ...aced 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 sourc...

Page 22: ...h 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 grou...

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

Page 24: ...e 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...

Page 25: ...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...

Page 26: ...ll 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 U...

Page 27: ...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...

Page 28: ...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...

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...

Page 30: ...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 h...

Page 31: ...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 ve...

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 man...

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...

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...

Page 35: ...4 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...

Page 36: ...in 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 igni...

Page 37: ...am 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 bu...

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 heat...

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

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

Page 41: ...lding 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 caus...

Page 42: ...re 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...

Page 43: ...rvised 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 a...

Page 44: ...re 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...

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...

Page 46: ...utside 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 ha...

Page 47: ...ors 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 sho...

Page 48: ...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...

Page 49: ...n extremely contaminated ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxe...

Page 50: ...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...

Page 51: ..._______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size ____________...

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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