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Raypak Raypak Delta Limited 1259B, Installation & Operating Instructions Manual

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Raypak Raypak Delta Limited 1259B Installation & Operating Instructions Manual Download Page 3

WARNINGS 4

BEFORE INSTALLATION 

5

Product Receipt 

5

Model Identification 

5

Ratings and Certifications 

5

Installations at Elevation 

5

Component Locations 

6

General Information 

7

GENERAL SAFETY 

8

Time/Temperature Relationships in 

Scalds 

8

INSTALLATION 

9

Installation Codes 

9

Equipment Base 

9

Stacking 

9

Clearances 

11

Combustion and Ventilation Air 

12

Conventional Combustion 

Air Supply 

12

Water 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

TROUBLESHOOTING 

46

MAINTENANCE 

47

Suggested Minimum 

Maintenance Schedule 

47

Preventive Maintenance Schedule 

47

APPENDIX 

49

Inside Air Contamination 

49

WARRANTY 50

START-UP CHECKLIST 

51

CONTENTS

3

APPROVED 

UNCONTROLLED DOCUMENT IF PRINTED 

 

Summary of Contents for Raypak Delta Limited 1259B

Page 1: ...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 inst...

Page 2: ...n page 31 for vent and intake pipe material certified standards Updated the Horizontal Through the Wall Venting Category III Installation section adding a third point on page 31 Updated the Periodical...

Page 3: ...eating 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...

Page 4: ...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 engineeri...

Page 5: ...s will not be accepted and will be replaced in kind only per Raypak s standard warran ties Model Identification The model identification number and heater serial number are found on the heater rating...

Page 6: ...L 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 APPROVED UNCONTROLLED DOCUMENT IF...

Page 7: ...o 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 54 100 125...

Page 8: ...ermometer 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 recommende...

Page 9: ...Hotter water increases the risk of scalding 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 str...

Page 10: ...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 dri...

Page 11: ...vement 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 heat er must be i...

Page 12: ...t 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 si...

Page 13: ...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 spac...

Page 14: ...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...

Page 15: ...CAUTION Damaging internal condensation may occur if the heater inlet water temperature does not exceed 105 F 41 C within 7 minutes of start up Models 399B 899B Models 989B 2339B 15 APPROVED UNCONTROLL...

Page 16: ...ess than 20 gpm Temperature Pressure Gauge The temperature and pressure gauge is factory mount ed in the in out header Hydronic Heating Pump Selection In order to ensure proper performance of your hea...

Page 17: ...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 separato...

Page 18: ...ing control must be set no higher than 130F for scale free operation For operating tempera tures above 130F a water softener must be utilized Model No Soft 0 4 grains per gallon Medium 5 15 grains per...

Page 19: ...s 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 L...

Page 20: ...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 pan...

Page 21: ...r 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 Sour...

Page 22: ...facturers 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...

Page 23: ...23 Fig 20 2 Stage Wiring Connections Fig 21 3 Stage Wiring Connections Fig 22 4 Stage Wiring Connection APPROVED UNCONTROLLED DOCUMENT IF PRINTED...

Page 24: ...at er 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 contro...

Page 25: ...e is acceptable as shown in the NFGC The weights on the damper should be adjusted per the damper manufacturer s instructions for proper operation Appliance Categories Heaters are divided into four cat...

Page 26: ...less 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 pi...

Page 27: ...de 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 i...

Page 28: ...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 determined per the NFGC U S or B14...

Page 29: ...ng connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused opening in the common v...

Page 30: ...C U S or B149 Canada CAT III CERTIFIED INSULATED EXHAUST VENTING Fig 26 Horizontal Through the Wall Venting Category III Requires optional vent tee The total length of the horizontal through the wall...

Page 31: ...e vent terminal 2 The vent must be insulated through the length of the horizontal run 3 The horizontal portions of the venting system shall be adequately supported to prevent sagging For installations...

Page 32: ...vents offered by Heat Fab Inc 800 772 0739 Protech System Inc 800 766 3473 Z Flex 800 654 5600 or American Metal Products 800 423 4270 Pipe joints must be positively sealed Follow the vent manufacture...

Page 33: ...tays energized for more than 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 saf...

Page 34: ...24 VAC safety connector 33 24 VAC is now sent to the pressure switch P Switch terminal on the ignition module 34 Once the pressure switch signal is received at the ignition module the hot surface ign...

Page 35: ...VAC signal is sent to pin P3 16 of J 5 on the CPW board 14 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...

Page 36: ...remote sensor is now trying to sense the flame If the flame is not sensed within 4 seconds the ignition module will shut down the gas valve and retry the hot surface igniter During ignition retry the...

Page 37: ...oses 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 he...

Page 38: ...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 G...

Page 39: ...Wiring Diagram Models 399B 1259B 39 APPROVED UNCONTROLLED DOCUMENT IF PRINTED...

Page 40: ...Wiring Diagram Models 1529B 2339B 40 APPROVED UNCONTROLLED DOCUMENT IF PRINTED...

Page 41: ...l 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 p...

Page 42: ...e 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...

Page 43: ...t 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 energi...

Page 44: ...o 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 heate...

Page 45: ...ve 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 infor ma tion on the front cover of this manual If you d...

Page 46: ...00 627 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 h...

Page 47: ...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 vi...

Page 48: ...ull fire Carbon di oxide should be 7 5 to 8 5 at full fire for natu ral 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 le...

Page 49: ...ed ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners chlorine ba...

Page 50: ...ENT 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 warra...

Page 51: ...toff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size _______________ Vent Termination...

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 APPROVED UNCONTROLLED DOCUMENT IF PRINTED...

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