Rheem Raypak Delta Limited 399B, Installation And Operation Manual

Page 1: ...ns 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 maintaine...

Page 2: ...2 Revision 8 reflects the following changes Added two warnings regarding carbon monoxide to Warnings section per ANSI Z21 13_22 Chapters 4 33 1 b and 4 34 i...

Page 3: ...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 4...

Page 4: ...ction to avoid inhalation of airborne dust and airborne fiber particles AWARNING Do not use this heater if any part has been under water Immediately call a qualified service technician to inspect the...

Page 5: ...ec tive replacement parts 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 fou...

Page 6: ...ENTER CONTROL COMBUSTION BLOWER IGNITER REMOTE SENSOR BURNER GROUP HEAT EXCHANGER PRESSURE RELIEF VALVE Component Locations Fig 1 Component Locations Back Fig 2 Component Locations Left Side Panels re...

Page 7: ...356 10 254 2069B 23 5 3 14 356 10 254 2339B 26 5 3 16 406 10 254 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 74...

Page 8: ...r 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 t...

Page 9: ...ee Fig 4 ACAUTION 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 mount...

Page 10: ...liance 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 abov...

Page 11: ...serviced in its installed location without movement or removal of the heater Service clearances less than the minimums may re quire removal of the heater to service either the heat exchanger or the b...

Page 12: ...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...

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: ...d 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 opening s can be ducted to a point no...

Page 15: ...Fig 9 Torque Sequence ACAUTION 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 2339...

Page 16: ...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 heater system you must install a correctly si...

Page 17: ...culation of the heater water during the cooling cycle It is highly recommended that the piping be insulated Air Separation Expansion Tank All heaters should be equipped with a properly sized expansion...

Page 18: ...grains per gallon the operating 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...

Page 19: ...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 1 4 1 1 2 2 2 1 2 3 4 N P N P N P N P N P N P N P N P 399B 15 25 60 100 260 250...

Page 20: ...o less than 10 pipe diameters of straight smooth pipe downstream of the regulator discharge and to have no less than 10 linear feet not including fittings between the regulator and the inlet to the ap...

Page 21: ...uivalent Field Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be sup plied from the same power source Check the Power Source NOTE...

Page 22: ...ers instructions 6 Conduit should not be used as the earth ground Field Wiring Connection Fig 19 Wiring Location ADANGER SHOCK HAZARD Make sure electrical power to the heater is disconnect ed to avoid...

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

Page 24: ...r example if your heat 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...

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 p...

Page 26: ...Wall 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 CPV...

Page 27: ...at 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 Flu...

Page 28: ...System ACAUTION A listed vent cap terminal ade quately 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: ...lianc es vented by natural draft shall not be connected into any portion of mechanical draft systems op erating under a positive pressure 1 Seal any unused opening in the common venting system 2 Visua...

Page 30: ...or B149 Canada CAT III CERTIFIED INSULATED EXHAUST VENTING Fig 27 Horizontal Through the Wall Venting Category III Requires optional vent tee The total length of the horizontal through the wall flue s...

Page 31: ...t of horizontal run to the 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...

Page 32: ...he AL29 4C stainless steel 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...

Page 33: ...unless the circuit stays 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 opera...

Page 34: ...is then sent to the 24 VAC safe ty 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...

Page 35: ...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: ...gas valve and retry the hot surface igniter During ignition retry the heater must per form a 15 second pre purge and an approximate ly 30 second igniter warm up before opening gas valve 1 again The s...

Page 37: ...the combustion cham 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 ver...

Page 38: ...in 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 h...

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

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

Page 41: ...ilding Immediately call your gas supplier from a neigh bor s telephone Follow the gas supplier s instruc tions AWARNING If you do not follow these instructions exactly a fire or explosion may result c...

Page 42: ...V 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 f...

Page 43: ...supervised pilot to light 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 s...

Page 44: ...37 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 di...

Page 45: ...inutes 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 ga...

Page 46: ...5 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...

Page 47: ...d liq uids 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 b...

Page 48: ...ct a combustion test at full fire Carbon diox ide 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...

Page 49: ...e In extremely contaminated areas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated wa...

Page 50: ...899B 1 S 7 S 1 C 2 C 4 C 9 S 13 S 14 S 9 S 1 V 11 M 2 S 6 S 8 S 10 S 9 S 14 S 15 S 13 S 9 S 12 S 11 S 12 M 11 S 1 R 1 M 5 C 2 R 4 M 2 M 6 M 5 G 1 B SEE DETAIL 1 H SEE DETAIL DIAGNOSTIC SEE DETAIL 4 S...

Page 51: ...51 DIAGNOSTIC DETAIL 12 J 7 J 6 J 5 J 3 0 2 0 16 S 1 F 2 F 3 F 4 F BLOWER DETAIL...

Page 52: ...52 1 G 5 G 6 G 4 G 2 G 3 G 6 B 13 M 14 M 7 B 4 B 3 B 1 B 5 B 4 M 9 H 2 H 5 H 6 H 1 O 8 H 1 M 5 C 4 H 6 M 3 H 7 H HEAT EXCHANGE DETAIL BURNER ASSEMBLY DETAIL 3 G 4 G 2 G 7 G 8 B...

Page 53: ...53 13 J 8 J 10 J 11 J 4 J 2 J 3 J 6 C 14 J 9 J 1 J CONTROL BOX DETAILS...

Page 54: ...007424F 007424F Gas Valve Pro 3 4 Honeywell 601563 007425F 007425F 007425F 007425F 007425F 4 G Switch Low Gas Pressure w o Bracket optional 007187F 007187F 007187F 007187F 007187F 5 G Switch High Gas...

Page 55: ...007400F 007400F 13 M Touch up Paint Green 750125 750125 750125 750125 750125 Dark Gray 750126 750126 750126 750126 750126 Cool Dark Gray 750256 750256 750256 750256 750256 14 M Sight Window Plug 0084...

Page 56: ...S Left Right Heat Exchanger Support 010251F 010251F 010251F 010251F 010251F 15 S Support Horizontal 009778F 009779F 009780F 009781F 009782F 16 S Support Assy Controls and Flue Exhaust 009886F 009783F...

Page 57: ...57 ILLUSTRATED PARTS LIST MODELS 989B 2339B 10 J 3 O 5 O...

Page 58: ...58 12 H 6 H 7 H 8 H 2 H 9 H 3 H 5 H 1 H 4 H 1 P HEAT EXCHANGER DETAILS BURNER ASSEMBLY DETAILS...

Page 59: ...59 CONTROL BOX DETAILS 9 J 8 J 23 S 13 J 10 J 3 O 10 J 3 O 5 O FRONT SWITCH DETAILS...

Page 60: ...6F 010786F 010786F 010786F 010786F 7 C Sensor Water 010787F 010787F 010787F 010787F 010787F 010787F 010787F 8 C Controller RayTemp B 25 010252F 010252F 010252F 010252F 010252F 010252F 010252F 9 C Sens...

Page 61: ...F 007735F 007736F 007737F 007738F 007738F 007739F Heat Exchange Tube Cupronickel 007740F 007741F 007742F 007743F 007744F 007744F 007745F 7 H Stud Bolt Kit 007828F 007828F 007828F 007828F 007828F 00782...

Page 62: ...5F 015895F 015895F 015895F 19 M Gas Valve Wire Harness Honeywell 015896F 015896F 015896F 015896F 015896F 015896F 015896F 20 M Power Pump Wire Harness 015898F 015898F 015898F 015898F 015898F 015898F 01...

Page 63: ...rizontal 009671F 009672F 009673F 009674F 009675F 009675F 009676F 17 S Support Assy Controls and Flue Exhaust 009677F 009677F 009677F 009677F 009677F 009677F 009677F 18 S Flue Collector Top 009678F 009...

Page 64: ...Manual on your smart device The QR Code will take you to the most current version of the installation manual Previous versions of manuals can be found in the document library at Raypak com P N 241330...

Page 65: ...additives to 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...

Page 66: ...66...

Page 67: ...67 Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Litho in U S A NOTES...