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  5. Installation & Operating Instructions Manual

Raypak 1259B Installation & Operating Instructions Manual

Manual is about: Series H & WH

Summary of 1259B

  • Page 1

    Installation & operating instructions catalog 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 your safety: do not store or use gasolin...

  • Page 2

    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

    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 ...

  • Page 4

    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. Caut...

  • Page 5

    Before installation 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....

  • 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

    General information table a: basic data table b: manifold data model no. Quantity of vent size (in.) burners gas valves 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 ...

  • Page 8

    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...

  • Page 9

    Installation installation installation codes installations must follow these codes: • local, state, provincial, and national codes, laws, regulations and ordinances • national fuel gas code, ansi z223.1/nfpa 54 – latest edition (nfgc) • national electrical code, ansi/nfpa 70 - latest edition (nec) •...

  • Page 10

    U.S. Installations 1 canadian installations 2 a clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) b clearance to window or door that may be opened 4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) c clearance to permanently closed wind...

  • Page 11

    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 side minimum clearance f...

  • Page 12

    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. Conventional combustion air supply u.S. Installations all air from inside the building the con...

  • Page 13

    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 ...

  • Page 14

    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. Remo...

  • Page 15

    Fig. 9: torque 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. To perform hydrostatic test: 1. Connect fill water supply. With bleed valve open, fill heater...

  • Page 16

    Cold water run cold water run differs from cold water start in that the system water entering the heater remains below 105ºf (41ºc) continuously. Typically, 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 na...

  • Page 17

    Pressure drop in feet of head feedwater regulator 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 ...

  • Page 18

    18 potable water 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. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space...

  • Page 19

    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 ...

  • Page 20

    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 pressure ...

  • Page 21

    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. • in canad...

  • Page 22

    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...

  • Page 23

    23 fig. 20: 2-stage wiring connections fig. 21: 3-stage wiring connections fig. 22: 4-stage wiring connection.

  • Page 24

    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 vac transformer. Do not attach any voltage to the stage-selector terminals. Before starting the heater, c...

  • Page 25

    25 venting 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. Caution: proper installation of flue venti...

  • Page 26

    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. 11....

  • Page 27

    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 l...

  • Page 28

    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 b...

  • Page 29

    29 table l: category i vertical venting * vent 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 duc...

  • 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

    Table m: category iii horizontal and direct venting *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 inha...

  • Page 32

    Freeze 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 exc...

  • Page 33

    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, ...

  • Page 34

    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” connection (normally jumpered). 19. ...

  • Page 35

    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...

  • Page 36

    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. 31. When the coil on relay k-4 (n.O.) is powered, the re...

  • Page 37

    37 the optional single-try ignition module will lock out after failing to light one time. To 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). Turning off the power to the heater w...

  • Page 38

    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. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. F...

  • Page 39

    Wiring diagram - models 399b–1259b 39.

  • Page 40

    Wiring diagram - models 1529b–2339b 40

  • Page 41

    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

    Preparation check power supply with multi-meter at incoming power, check voltage between: hot - common (≈120 vac) hot - ground (≈120 vac) common - ground ( attach manometers to measure pressures 1. Turn off main gas valve. 2. Attach 24” scale manometer to the first main gas shut-off valve pressure t...

  • Page 43

    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. Open test point b and connect a rubber tube to it. Connect the other end of the tub...

  • Page 45

    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. 12. Check that the heater i...

  • Page 46

    Troubleshooting step 7 step 6 step 5 step 1 step 2 step 3 step 4 is enable/disable jumper intact (j1)? Is there a call for heat? Is there 120vac at j8 connector 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 modul...

  • Page 47

    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 f...

  • Page 48

    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. Check flue, vent, stack, or outlet da...

  • Page 49

    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 stainle...

  • Page 50

    Limited parts warranty delta limited – types h and wh models 399b–2339b 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 s...

  • Page 51: Raypak Products

    Start-up checklist for fan-assisted raypak products 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. Additiona...

  • Page 52: Www.Raypak.Com

    Www.Raypak.Com raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (805) 278-5468 litho in u.S.A..