Raypak Boiler 399B 2339B User Guide

INSTALLATION & OPERATING

INSTRUCTIONS

Models 399B–2339B

Types H & WH

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 gasoline or other flammable vapors and

liquids or other combustible materials in the vicinity of this or any other appliance. 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 installer, service agency or

the gas supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for

future reference.

CATALOG NO. 1000.60A

Effective: 01-06-09

Replaces: 09-28-07

P/N 241330 Rev. 2

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CONTENTS

WARNINGS

BEFORE INSTALLATION

Product Receipt

4 APPENDIX

Inside Air Contamination

5 WARRANTY

5 START-UP CHECKLIST

Model Identification

Ratings and Certifications

Installations at Elevation

Component Locations

General Information

GENERAL SAFETY

Time/Temperature Relationships in

Scalds

INSTALLATION

Installation Codes

Equipment Base

Stacking

Clearances

Combustion and Ventilation Air

Conventional Combustion Air Supply 12

Water Piping

Hydronic Heating

Gas Supply

Electrical Power Connections

Field Wiring Connection

Venting

Changing the Flue Outlet

Venting Installation Tips

Venting Configurations

Outdoor Installation

Controls

Heater Sequence of Operation

Wiring Diagrams

START-UP

Pre Start-up

Start-Up

OPERATION

Lighting Instructions

To Turn Off Gas To Appliance

TROUBLESHOOTING

MAINTENANCE

Suggested Minimum

Maintenance Schedule

Preventative Maintenance Schedule 47

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WARNINGS

Pay Attention to These Terms

Indicates the presence of immediate hazards which will cause severe

DANGER:

WARNING:

CAUTION:

NOTE:

personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause

severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause

minor personal injury or product or property damage if ignored.

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: 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: 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: To minimize the possibility of improper

operation, serious personal injury, fire, or damage 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.

•

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: 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.

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.

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.

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.

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number will have the form H8 1259B or similar

depending on the heater size and configuration. The

letter(s) in the first group of characters identifies the

application (H = Hydronic Heating, WH = Domestic

Hot Water (DHW)). The number which fol-lows identi-

fies the firing mode (1 or 4 = on-off, 3 = 2-stage, 8 =

3-stage and 9 = 4-stage). The second group of char-

acters identifies the size of the heater (four numbers

representing the approximate MBTUH input), and,

where applicable, a letter, indicating the manufacturing

series.

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. (Refer to the warranty at the back of this

manual.) Installation and service must be performed

by a qualified installer, service agency or gas supplier.

If, after reviewing this manual, you still have questions

which this manual does not answer, please contact the

manufacturer or your local Raypak representative.

Ratings and Certifications

Standards:

Thank you for purchasing a Raypak product. We hope

you will be satisfied with the high quality and durability

of our equipment.

•

ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired

Hot Water Boilers

CAN 3.1

latest edition, Industrial and

Product Receipt

Commercial Gas-Fired Package Boilers

ANSI Z21.10.3 · CSA 4.3 - latest edition Gas

Water Heaters

On receipt of your heater it is suggested that you visu-

ally check for external damage to the shipping crate. If

the crate is damaged, make a note to that effect on the

Bill of Lading when signing for the shipment. Remove

the heater from the shipping packaging. Report any

damage to the carrier immediately.

All Raypak heaters are National Board Approved, and

design-certified and tested by the Canadian Standards

Association (CSA) for the U.S. and Canada. Each

heater is constructed in accordance with Section IV of

the American Society of Mechanical Engineers

(ASME) Heater Pressure Vessel Code and bears the

ASME stamp. The heater also complies with the latest

edition of ASHRAE 90.1 Standard.

On occasion, items are shipped loose. Be sure that

you receive the correct number of packages as indi-

cated on the Bill of Lading.

Claims for shortages and damages must be filed with

the carrier by consignee. Permission to return goods

must be received from the factory prior to shipping.

Goods returned to the factory without an authorized

Returned Goods Receipt number will not be accepted.

All returned goods are subject to a restocking charge.

WARNING: Altering any Raypak pressure vessel

by installing replacement heat exchangers, tube

bundle headers, or any ASME parts not

manufactured and/or approved by Raypak will

instantly void the ASME and CSA ratings of the

vessel and any Raypak warranty on the vessel.

Altering the ASME or CSA ratings of the vessel also

violates national, state, and local approval codes.

When ordering parts, you must specify the model and

serial number of the heater. When ordering under war-

ranty conditions, you must also specify the date of

installation.

Installations at Elevation

Purchased parts are subject to replacement only

under the manufacturer’s warranty. Debits for defec-

tive replacement parts will not be accepted and will be

replaced in kind only per Raypak’s standard war-

ranties.

Rated inputs are suitable for up to 5,000 ft elevation

without de-rating. Consult the factory for installations

at altitudes over 5,000 ft above sea level.

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

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Component Locations

OPTIONAL FLUE

CONNECTION

Fig. 1: Component Locations – Back

Fig. 2: Component Locations – Left Side

Panels removed for clarity

Fig. 3: Component Locations – Front

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General Information

Quantity of

Vent Size (in.)

Model

No.

Burners Gas Valves Blowers Flue

Intake

399B

499B

649B

749B

899B

989B

1259B

1529B

1799B

1999B

2069B

2339B

Table A: Basic Data

Burners per Valve

Stages

% Fire at Stage

Model

No.

399B

499B

100

1, 2

50 100

54 100

53 100

66 100

54 100

649B

749B

1, 2

899B

1, 2

1, 2, 3

1, 2

989B

1259B

1529B

1799B

1999B

2069B

2339B

1, 2

1, 2, 3

100

1, 2

1, 2, 3, 4

82 100

75 100

83 100

81 100

1, 2

1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 39

1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 42

Table B: Manifold Data

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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 for the temperature control is

125°F.

Safety and energy conservation are factors to be con-

sidered when setting the water temperature on the

thermostat. The most energy-efficient operation will

result when the temperature setting is the lowest that

satisfies the needs of the application.

Water temperature over 125°F can

causeinstantsevereburnsordeath

from scalds.

Water temperature over 125°F can cause instant

severe burns or death from scalds. Children, disabled

and elderly are at highest risk of being scalded.

Children, disabled, and elderly are

at highest risk of being scalded.

See instruction manual before set-

ting temperature at water heater.

•

Feel water before bathing or showering.

Temperature limiting valves are available.

Feel water before bathing or show-

ering.

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.

Temperature limiting valves are

available, see manual.

Time/Temperature

Relationships in Scalds

Maximum water temperatures occur just after the

heater’s burner has shut off. To determine the water

temperature being delivered, turn on a hot water

faucet and place a thermometer in the hot water

stream and read the thermometer.

The following chart details the relationship of water

temperature and time with regard to scald injury and

may be used as a guide in determining the safest

water temperature for your applications.

Water

Temp.

Time to Produce Serious

Burn

120°F

125°F

130°F

135°F

140°F

145°F

150°F

155°F

More than 5 minutes

1-1/2 to 2 minutes

About 30 seconds

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1-1/2 seconds

About 1 second

Table courtesy of The Shriners Burn Institute

Table C: Time to Produce Serious Burn

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The temperature of the water in the heater can be reg-

ulated by using the temperature controller. To comply

with safety regulations, the temperature controller is

set at the lowest setting when shipped from the facto-

ry.

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 parking garages must be located at least

18 in. above the floor.

To adjust the water temperature, insert a small straight

screwdriver into the adjustment screw on the front of

temperature controller and turn the wheel to the

desired setting (See Fig. 4.).

Stacking

Delta Limited units can be stacked two units high with

an optional stacking rack. A stacking kit is available

from Raypak for this type of installation.

CAUTION: The heaters should be located in an

area where water leakage will not result in damage

to the area adjacent to the appliances or to the

structure. When such locations cannot be avoided, it

is recommended that a suitable catch pan,

adequately drained, be installed under the

appliance. The pan must not restrict air flow.

Fig. 4: Temperature Control

CAUTION: Hotter water increases the risk of scald-

INSTALLATION

ing! There is a hot water scald potential if the

thermostat is set too high.

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)

Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1,

when required (CSD-1)

For Canada only: CAN/CGA B149 Installation

Code (B149) and CSA C22.1 C.E.C. Part 1

(C22.1)

REQUIRES OPTIONAL VENT TEE.

•

REQUIRES OPTIONAL VENT TEE IF VENTED OUT BACK

OF HEATER.

Fig. 5: Typical Stacked Installation

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Fig. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

U.S. Installations¹

Canadian Installations²

Clearance above grade, veranda, porch,

deck, or balcony

1 ft (30 cm)

4 ft (1.2m) below or to side

of opening; 1 foot (30 cm)

above opening

Clearance to window or door that may be

opened

3 ft (91 cm)

Clearance to permanently closed window

Vertical clearance to ventilated soffit located

above the terminal within a horizontal dis-

tance of 2 ft (61cm) from the centerline of the

terminal

5 ft (1.5m)

Clearance to unventilated soffit

Clearance to outside corner

Clearance to inside corner

6 ft (1.83m)

3 ft (91 cm) within a height

15 ft above the me-

ter/regulator assembly

Clearance to each side of center line ex-

tended above meter/regulator assembly

Clearance to service regulator vent outlet

6 ft (1.83m)

Clearance to non-mechanical air supply inlet 4 ft (1.2m) below or to side

to building or the combustion air inlet to any

of opening; 1 ft (30 cm)

3 ft (91 cm)

other appliance

above opening

3 ft (91 cm) above if within

10 ft (3m) horizontally

Clearance to mechanical air supply inlet

6 ft (1.83m)

7 ft (2.13m) t

Clearance above paved sidewalk or paved

driveway located on public property

7 ft (2.13m)

Clearance under veranda, porch, deck or

balcony

12 in. (30 cm) TT

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code

In accordance with the current CAN/CGA-B149 Installation Codes

Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves

both dwellings

TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and

underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)

Clearances in accordance with local installation codes and the requirements of the gas supplier

Table D: Vent/Air Inlet Termination Clearances

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In addition, the heater shall be installed such that the When installed according to the listed minimum clear-

gas ignition system components are protected from ances from combustible construction, these heaters

water (dripping, spraying, rain, etc.) during appliance can still be serviced without removing permanent

operation or service (circulator replacement, control structural construction around the heater. However, for

replacement, etc.).

ease of servicing, we recommend a clearance of at

least 24 in. in front, and at least 12 in. on the water

connection side. This will allow the heater to be serv-

iced in its installed location without movement or

removal of the heater.

Clearances

Indoor Installations

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.

Minimum Clearance Recommended

Heater

Side

from Combustible

Service

Surfaces

Clearance

Floor*

Rear

0”

1”

0”

24”

1”

Outdoor Installations

Water Side

Other Side

Top

12”

1”

These heaters are design-certified for outdoor installa-

tion. Heaters must not be installed under an overhang

that is less than 3 ft from the top of the heater. Three

sides must be open in the area under the overhang.

Roof water drainage must be diverted away from

heaters installed under overhangs.

1”

Front

Open

2”

24”

2”

Vent

* DO NOT install on carpeting.

Recommended

Service

Table E: Clearances – Indoor Installations

Min. Clearance

from Combustible

Surfaces

Heater

Side

Clearance

Front

Rear

Open

24”

36”

N/A

12”

36”

Water Side

Other Side

Top

36”

Unobstructed

N/A

Vent

Table F: Clearances – Outdoor Installations

TOP VIEW

These clearances are required when the outdoor

vent cap is used. If installing the heater outdoors

with a vent stack, the indoor clearances may be

utilized.

The combustion air intake hood MUST be used for

outdoor installations. The hood is shipped loose and

installed on the side of the heater over the filter box at

the jobsite.

FRONT VIEW

Venting not shown for clarity. Heater must be vented

per instructions in this manual

Fig. 7: Minimum Clearances from Combustible

Surfaces – Indoor Installations

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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 the components and reattach in the new

location, making sure that the air filter locking

bracket is on the bottom. (The air filter locking

bracket is reversible.)

Fig. 8: Minimum Clearances from Combustible

Surfaces – Outdoor Installations

Direct-Ducted Combustion Air

In certain applications it may be desirable to duct the

combustion air directly to the heater. This should be

done with PVC, CPVC or single-wall galvanized duct-

ing. The duct will attach directly to the collar on the air

filter housing located on the side of the heater. The

ducting is attached to the air filter housing collar using

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.

Combustion and Ventilation Air

NOTE: Use of the heater in construction areas

where fine particulate matter, such as concrete or

dry-wall dust, is present may result in damage to the

heater that is not covered by the warranty. If

operated in a construction environment, a clean

source of combustion air must be provided directly to

the heater.

Conventional Combustion Air

Supply

Indoor Units

The heater must be supplied with sufficient quantities U.S. Installations

of non-contaminated air to support proper combustion

and equipment ventilation. Combustion air can be sup-

plied via conventional means where combustion air is

drawn from the area immediately surrounding the

heater, or via direct vent, where combustion air is

drawn directly from outside. All installations must com-

ply with the requirements of the NFGC (U.S.) and

B149 (Canada), and all local codes.

All Air from Inside the Building

The confined space shall be provided with TWO per-

manent openings communicating directly with an

additional room(s) of sufficient volume so that the com-

bined volume of all spaces meets the criteria for a

room large in comparison (NFGC). The total input of all

gas utilization equipment installed in the combined

CAUTION: Combustion air must not be

contaminated by corrosive chemical fumes which

can damage the heater and void the warranty. (See

the Appendix.)

CAUTION: This type of installation is

recommended if damaging airborne contaminants

are or will be present in the heater area. See the

Appendix regarding air contamination.

NOTE: It is recommended that the intake vent be

insulated to minimize sweating.

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space shall be considered in making this determina-

tion. Each opening shall have a minimum free area of

1 in.²per 1,000 BTUH (2,225 mm²per kW) of the total

input rating of all gas utilization equipment in the con-

fined space, but not less than 100 in.²(645 cm²). One

opening shall commence within 12 in. (305 mm) of the

top, and one opening shall commence within 12 in.

(305 mm) of the bottom of the enclosure. The mini-

mum dimension of air openings shall be not less than

3 in. (76 mm) in any direction.

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.

Canadian Installations

CAUTION: All combustion air must be drawn from

the air outside of the building; the mechanical equip-

ment room must communicate directly with the

outdoors.

All Air from Outdoors

The confined space shall communicate with the out-

doors in accordance with one of the methods below.

The minimum dimension of air openings shall not be

less than 3 in. (76 mm) in any direction. Where ducts 1. Ventilation of the space occupied by the heater

are used, they shall be of the same cross-sectional

area as the net free area of the openings to which they

connect.

shall be provided by an opening(s) for ventilation

air at the highest practical point communicating

with the outdoors. The total cross-sectional area of

such an opening(s) shall be at least 10% of the

area required in 2. and 3. (below), but in no case

shall the cross-sectional area be less than 10 in.²

(65 cm²).

1. Two permanent openings, one commencing

within 12 in. (305 mm) of the top, and one com-

mencing within 12 in. (305 mm) of the bottom of

the enclosure, shall be provided. The openings

shall communicate directly, or by ducts, with the

outdoors or spaces (crawl or attic) that freely com-

municate with the outdoors.

2. For heaters using a barometric damper in the vent

system there shall be a permanent air supply

opening(s) having a cross section area of not less

than 1 in.²per 7,000 BTUH (320 mm²per kW) up

to and including 1 million BTUH, plus 1 in.²per

14,000 BTUH (160 mm²per kW) in excess of 1

million BTUH. This opening(s) shall be either

located at or ducted to a point not more than 18 in.

(450 mm) nor less than 6 in. (152 mm) above the

floor level. The duct can also “goose neck” through

the roof. The duct is preferred to be straight down

and terminated 18 in. (450 mm) from the floor, but

not near piping. This air supply opening require-

ment shall be in addition to the air opening for

ventilation air required in 1. (above).

a. Where directly communicating with the out-

doors or where communicating to the

outdoors through vertical ducts, each opening

shall have a minimum free area of 1 in.²per

4,000 BTUH (550 mm²per kW) of total input

rating of all equipment in the enclosure.

b. Where communicating with the outdoors

through horizontal ducts, each opening shall

have a minimum free area of 1 in.²per 2,000

BTUH (1,100 mm²per kW) of total input rat-

ing of all equipment in the enclosure.

WARNING: Care must be taken to ensure that the

equipment room is not under negative pressure

conditions or that the equipment is not common-

vented with other gas-fired appliances.

2. One permanent opening, commencing within 12

in. (305 mm) of the top of the enclosure, shall be

permitted where the equipment has clearances of

at least 1 in. (25 mm) from the sides and back and

6 in. (152 mm) from the front of the appliance. The

opening shall directly communicate with the out-

doors or shall communicate through a vertical or

horizontal duct to the outdoors or spaces that

freely communicate with the outdoors, and shall

have a minimum free area of:

3. For heaters not using a barometric damper in the

vent system, and when air supply is provided by

natural air flow from outdoors for a power burner

and there is no draft regulator, drafthood or similar

flue gas dilution device installed in the same

space, in addition to the opening for ventilation air

required in 1., there shall be a permanent air sup-

ply opening(s) having a total cross-sectional area

a. 1 in.²per 3,000 BTUH (740 mm²per kW) of

the total input rating of all equipment located in

the enclosure, and

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of not less than 1 in.²for each 30,000 BTUH mm²5. Remove all plumbing fittings to the header. This

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

will include both inlet and outlet water pipe unions

and the pressure relief valve and drain piping.

ventilation air referred to in (1). This opening(s) 6. Remove limits, control bulbs and/or thermocou-

can be ducted to a point not more than 18 in. (450

mm) nor less than 6 in. (152 mm) above the floor

ples.

level. The duct can also “goose neck” through the 7. Remove the six (or 8) flange nuts and the in/out

roof. The duct is preferred to be straight down 18

in. (450 mm) from the floor, but not near piping.

header from the left-hand side.

8. Remove the six (or 8) flange nuts and the return

header from the right-hand side.

4. Refer to B149 Installation code for additional infor-

mation.

9. Remove the header stud bolts from each tube

sheet.

Water Piping

10. Reverse the headers and stud bolts to the new

location.

General

The heater should be located so that any water leaks

will not cause damage to the adjacent area or struc-

tures.

11. Install NEW red beveled O-rings flush against both

tube sheets with the bevel facing outward.

12. Push the header firmly against the O-rings. Install

and tighten the flange nuts onto the stud bolts until

finger tight.

CAUTION: This heater requires forced water

circulation when the burner is operating. See Table

G and Table H for minimum and maximum flow rates

and water pump selection. The pump must be

interlocked with the heater to prevent heater

operation without water circulation.

13. Slowly tighten the flange nuts, starting from the

center nut (number 1) in Fig. 9 and working se-

quentially around the header as indicated. Torque

all nuts to 25 ft/lb. DO NOT OVER-TIGHTEN.

NOTE: Minimum pipe size for in/out connections is

14. Re-route the capillary(s), wiring etc. to the new

location, adding thermal paste and shim to the

capillary well.

2 ⁄

in (2 in. for 399B–899B). Verify proper flow rates

and ΔT as instructed in this manual.

Relief Valve Piping

Reversing Water Connections

Follow these instructions to change the water connec-

tions from the left-hand side (standard) to the

right-hand side.

WARNING: Pressure relief valve discharge piping

must be piped near the floor and close to a drain to

eliminate the potential of severe burns. Do not pipe

to any area where freezing could occur. Refer to

local codes.

1. Disconnect all electrical power from the heater (if

applicable).

2. Label all electrical connections and conduit lines.

This may include the flow switch, low water cut-off

probe and/or pump.

Hydrostatic Test

Unlike many types of heaters, this heater does not re-

quire hydrostatic testing prior to being placed in

operation. The heat exchanger has already been fac-

tory-tested and is rated for 160 psi operating pressure.

However, Raypak does recommend hydrostatic test-

ing of the piping connections to the heater 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

3. Disconnect or isolate the main gas pipe from the

heater (if applicable).

4. Remove both in/out and return header access

panels by removing all sheet metal screws.

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Cold Water Operation

CAUTION: Damaging internal condensation may

occur if the heater inlet water temperature does not

exceed 105ºF (41ºC) within 7 minutes of start-up.

A heater operated with an inlet temperature of less

than 105ºF (41ºC) must have a manual bypass or an

approved low-temperature operation system to pre-

vent problems with condensation. A manual bypass,

shown in Fig. 15, must be piped into the system at the

time of installation. This piping is like a pri-

mary/secondary boiler installation with a bypass acting

as the secondary boiler piping. Raypak strongly rec-

ommends that thermometer(s) be placed into the

heater piping next to the in/out header to facilitate tem-

perature adjustment. Inlet water temperatures below

105ºF (41ºC) can excessively cool the products of

combustion, resulting in condensation on the heat

exchanger and in the flue.

Models 399B–899B

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

return water to increase the heater inlet temperature

above 105ºF (41ºC). This precautionary measure

should prevent the products of combustion from con-

densing in most installations. Warranty claims will be

denied when condensation occurs.

Models 989B–2339B

Fig. 9: Torque Sequence

the hydrostatic test before connecting gas piping or

electrical supply.

Cold water operation issues are applicable to both

cold water start and cold water run applications. Cold

water operation for 7 minutes or less on start-up is

acceptable. Where cold water starts will last longer

than 7 minutes or where cold water operation is con-

tinuous, provisions must be made to mix higher

temperature outlet water with the colder inlet water

and thereby raise the inlet temperature to at least

105ºF (41ºC) within the 7-minute time limit.

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 with water. When water flows from bleed

valve, shut off water. Close bleed valve. Carefully

fill the rest of the system, making sure to eliminate

any entrapped air by using high-point vents. Close

feed valve. Test at standard operating pressure for

at least 24 hours.

Cold Water Starts

Frequent (more than once a week) cold water starts,

wherein the inlet water temperature remains below

105ºF (41ºC) for more than 7 minutes, must have cold

water start protection. Known protection methods con-

sist of mixing heated outlet water with the inlet water

with a bypass to raise the inlet to 105ºF (41ºC) or high-

er. Once the system is heated up and has return water

temperatures of 105ºF (41ºC) or higher, the mixing of

outlet water with inlet water is no longer needed and

the bypass can be shut off. If the bypass is not shut off

2. Make sure constant gauge pressure has been

maintained throughout test.

3. Check for leaks. Repair if found.

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as the system heats up, the outlet temperature may

continue to climb and actuate the high limit, thereby

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

Cold Water Run

Pump Selection

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 narrow temperature range, a perma-

nent manual bypass can be employed and manually

adjusted to achieve an inlet temperature of 105ºF

(41ºC) or higher. An injector pump arrangement may

also be utilized to keep the heater loop at or above

105ºF (41ºC). An injector pump approach has the

added value of being able to adjust to changes in the

system water coming back to the heater take-off.

In order to ensure proper performance of your heater

system, you must install a correctly sized pump. Ray-

pak recommends using a 20°F ΔT as design ΔT. (ΔT is

the temperature difference between the inlet and out-

let water when the heater is firing at full rate). If a ΔT

of larger than 20°F is necessary, see Table G and

Table H for flow rate requirements.

10°F ΔT

20°F ΔT

30°F ΔT

Min. Flow

Max. Flow

Model

No.

gpm ΔP (ft) gpm ΔP (ft) gpm ΔP (ft) gpm ΔP (ft)

ΔT

gpm ΔP (ft) ΔT

399B

499B

5.5

9.1

1.4

2.3

4.1

5.7

8.3

5.2

9.6

15.7

0.6

1.1

0.5

0.6

1.1

1.5

2.2

1.3

2.4

4.0

6.0

7.9

8.5

12.1

10.0

10.4

10.8

11.3

11.7

13.1

14.8

16.5

18.3

19.0

21.4

649B

1.8

749B

2.6

899B

3.8

989B

2.3

132

1259B

1529B

1799B

1999B

2069B

2339B

106

129

4.3

7.1

101

112

116

132

10.7

13.8

14.8

21.4

Notes:

1. Basis for minimum flow: Models 399–899, 20 gpm or 40°F ΔT. Models 989–2339, 30 gpm or 40°F ΔT.

Basis for maximum flow: Models 399–899, 90 gpm. Models 989–2339, 132 gpm.

2. Flow switch will not operate if flow is less than 20 gpm.

Table G: Heater Rates of Flow and Pressure Drops

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heaters which are not subject to thermal shock.

Raypak offers a full line of electronic sequencers that

produce direct reset of heater water temperature.

Pressure Drop in Feet of Head

Feedwater Regulator

(Refer to the Controls section of the Raypak Catalog.)

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 codes.

Piping

All high points should be vented. Purge valves and a

bypass valve should be installed. A heater installed

above radiation level must be provided with a low wa-

ter cut-off device (sales order option F-10). The heater,

when used in connection with a refrigeration system,

must be installed so that the chilled medium is piped in

parallel with the heater with appropriate valves to pre-

vent the chilled medium from entering the heater.

The piping system of a hot water heater connected to

heating coils located in air handling units where they

may be exposed to circulating refrigerated air, must be

equipped with flow control 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.

Fig. 11: Single Heater - Low-Temperature (Heat Pump)

Application with Primary/Secondary Piping

Air-Separation/Expansion Tank

All heaters should be equipped with a properly sized

expansion tank and air separator fitting as shown in

Fig. 10.

Fig. 12: Dual Heaters (Reverse/Return)

with Primary/Secondary Piping

Domestic Hot Water

Fig. 10: Air-Separation/Expansion Tank

Three-Way Valves

When designing the water piping system for domestic

hot water applications, water hardness should be con-

sidered. Table H indicates the suggested flow rates for

soft, medium and hard water. Water hardness is ex-

pressed in grains per gallon.

Valves designed to blend water temperatures or

reduce water circulation through the heater should not

be used. Raypak heaters are high-recovery, low-mass

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Potable Water and Space Heating

CAUTION: When this heater is used for both

potable water and space heating, observe the

following to ensure proper operation.

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 heating.

Fig. 13: Single Domestic Hot Water Heater and Storage

Tank

Gas Supply

3. If the heater will be used to supply potable water,

it shall not be connected to any heating system or

components previously used with a non-potable

water heating appliance.

DANGER: Make sure the gas on which the heater

will operate is the same type as specified on the

heater’s rating plate.

4. When the system requires water for space heating

at temperatures higher than 140°F, a means such

as a mixing valve shall be installed to temper the

water in order to reduce scald hazard potential.

Gas piping must have a sediment trap ahead of the

heater gas controls, and a manual shut-off valve lo-

cated outside the heater jacket. It is recommended

that a union be installed in the gas supply piping adja-

cent to the heater for servicing. A pounds-to-inches

Soft (0–4 grains per gallon)

Medium (5–15 grains per gallon) Hard* (16–25** grains per gallon)

Model

No.

ΔT gpm ΔP MTS SHL ΔT gpm

ΔP

3.4

3.5

4.1

5.7

8.4

MTS

SHL

7.2

ΔT gpm

ΔP

MTS

SHL

20.5

20.9

21.3

21.8

22.2

21.0

22.7

24.4

26.1

26.9

29.3

399B

499B

649B

749B

899B

989B

2.0

2.1

2.2

2.6

3.9

4.4

4.5

4.6

5.2

7.6

10.0

10.4

10.8

11.3

11.7

7.4

8.4

11.1

16.1

8.6

2.7 2 1/2 4.6

4.4 2 1/2 7.0

5.2 2 1/2

132 13.1 2 1/2

132 14.8 2 1/2

132 16.5 2 1/2

132 18.3 2 1/2

132 19.0 2 1/2

132 21.4 2 1/2

1259B 30

1529B 30

1799B 30

1999B 30

2069B 30

2339B 30

106

9.6 2 1/2 14.8

7.1 2 1/2 10.7 20

132 16.5 2 1/2 24.4

132 18.3 2 1/2 26.1

132 19.0 2 1/2 26.9

132 21.4 2 1/2 29.3

101 10.7 2 1/2 15.5 23

112 13.9 2 1/2 19.7 26

116 14.8 2 1/2 21.0 27

132 21.4 2 1/2 29.3 30

ΔT = Temperature rise, °F.

ΔP = Pressure drop through heat exchanger, ft.

SHL = System head loss, ft. (System head loss based on heater and tank placed no more than 5 ft apart and equivalent length pipe/fittings as fol-

lows: 2 in. tube = 25 ft; 2 1/2 in. tube = 80 ft.

gpm = Gallons per minute, flow rate.)

MTS = Minimum tubing size.

*Must utilize optional cupro-nickel tubes.

**With Hard Water (16-25 grains 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.

Table H: Domestic Water Heater Flow Rate Requirements

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regulator must be installed to reduce the gas supply

pressure to a maximum of 10.5 in. WC for natural gas

and 13.0 in. WC for propane gas. The regulator should

be placed a minimum distance of 10 times the pipe

diameter up-stream of the heater gas controls. Refer

to Table I for maximum pipe lengths.

Gas Supply Connection

CAUTION: The heater must be disconnected from

the gas supply during any pressure testing of the gas

supply system at test pressures in excess of 1/2 psi

(3.45 kPa).

Fig. 14: 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 reconnecting the heater and its manual shut-off

valve to the gas supply line. FAILURE TO FOLLOW

THIS PROCEDURE MAY DAMAGE THE GAS

VALVES. Over pressurized gas valves are not cov-

ered by warranty. The heater and its gas connections

shall be leak-tested before placing the appliance in

operation. Use soapy water for leak test. DO NOT use

an open flame.

CAUTION: Do not 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.

3/4”

1”

1-1/4”

1-1/2”

2”

2-1/2”

3”

4”

Model

No.

399B

499B

60 100 260 250

65 150 130 360 500

45 100 95 250 340

649B

749B

75 180 260 600

899B

45 110 150 360 400

120 300 300

989B

1259B

1529B

1799B

1999B

2069B

2339B

75 180 170 325 560

50 120 125 250 400

40 100 100 225 340

75 175 260

55 135 160 400 600

Natural gas – 1,000 BTU per ft , .60 specific gravity at 0.5 in. WC pressure drop

Propane gas – 2,500 BTU per ft , 1.53 specific gravity at 0.6 in. WC pressure drop

Table I: Maximum Equivalent Pipe Length

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pressure regulator, of the lockup type, must be

installed.

CAUTION: Support gas supply piping with

hangers, not by the heater or its accessories. Make

sure the gas piping is protected from physical

damage and freezing, where required.

When connecting additional gas utilization equipment

to the gas piping system, the existing piping must be

checked to determine if it has adequate capacity for

the combined load.

Reversing Gas Supply Connection

Reversing the standard fuel connection from the left-

hand to the right-hand side is a simple field operation.

The gas valve pressure regulator(s) on the heater are

nominally preset at 3.5 in. WC for natural gas, and

10.5 in. WC for propane gas. The pressure at the gas

valve outlet tap, measured with a manometer, while in

operation should be 3.5 0.1 in. WC for natural gas

and 10.5 in. 0.1 in. WC for propane gas. If an adjust-

ment is needed, remove the adjustment screw cover

and turn the adjustment screw clockwise to increase

pressure or counter-clockwise to lower pressure.

1. Disconnect all electrical power from the heater (if

applicable).

2. Disconnect the main gas pipe from the heater (if

applicable).

3. Remove 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 side of the heater.

8. Remove the rubber grommet from the left-hand-

side panel and reinstall into the standard main gas

opening, located on the right-hand side of the

heater.

Models 399B–2339B

Adjustment

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

A minimum of 5.0 in. WC and a maximum of 10.5 in.

WC upstream gas pressure is required under load and

no-load conditions for natural gas. A minimum of 11.0

in. WC and a maximum of 13.0 in. WC is required for

propane gas. The gas pressure regulator(s) supplied

on the heater is for low-pressure service. If upstream

pressure exceeds 14.0 in. WC, an intermediate gas

Models 989B–2339B

Fig. 15: Gas Valves

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Electrical Power Connections

BLACK

CIRCUIT

BREAKER

Installations must follow these codes:

WHITE

•

National Electrical Code and any other national,

state, provincial or local codes or regulations hav-

ing jurisdiction.

GREEN

GROUND

•

Safety wiring must be NEC Class 1.

Heater must be electrically grounded as required

by the NEC.

•

In Canada, CSA C22. 1 C.E.C. Part 1.

Fig. 16: Wiring Connections

The heater is wired for 120 VAC, <12 amps. The volt-

age is indicated on the tie-in leads. Consult the wiring

diagram shipped with the heater in the instruction

packet. The remote tank control stat, thermostat, or

electronic heater control (as applicable) may be con-

nected to the stage selector terminal (See wiring

diagram). 24 VAC is supplied to this connection

through the heater transformer. DO NOT attach any

voltage to the stage selector terminals. Before

starting the heater check to ensure proper voltage to

the heater and pump.

Check the power source:

AC = 108 VAC Minimum, 132 VAC MAX

AB = 108 VAC Minimum, 132 VAC MAX

BC = <1 VAC Maximum

Install a separate disconnect means for each load.

Use appropriately sized wire as defined by NEC, CSA

and/or local code. All primary wiring should be 125% of

minimum rating.

If any of the original wire as supplied with the heater

must be replaced, it must be replaced with 105°C wire

or its equivalent.

Field-Connected Controllers

Fig. 17: Multi-meter

It is strongly recommended that all individually-pow-

ered control modules and the heater should be

supplied from the same power source.

If the heater does not have a factory-wired stage con-

troller, it is factory-wired in an on-off configuration with

other stage terminals jumpered.

NOTE: Field-supplied isolation relays should be

installed when field-connected controllers are

mounted more than 50 equivalent feet (18 Ga) from

heater.

To field-connect a stage controller, remove factory-

installed jumpers and wire stage controller as shown in

Fig. 19–22.

Making the Electrical Connections

Check the Power Source

Refer to Fig. 16–22.

1. Verify that circuit breaker is properly sized by

referring to heater rating plate. A dedicated circuit

breaker should be provided.

WARNING: Using a multi-meter, check the

following voltages at the terminal block inside the

unit. Make sure proper polarity is followed and house

ground is proven. (See Fig. 18.)

2. Turn off all power to the heater. Verify that power

has been turned off by testing with a multi-meter

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prior to working with any electrical connections or

components.

DANGER: SHOCK HAZARD

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.

CAUTION: Label all wires prior to disconnection

when servicing controls. Wiring errors can cause im-

proper and dangerous operation. Verify proper

operation after servicing.

4. Provide overload protection and a disconnect

means for equipment serviceability as required by

local and state code.

Make sure electrical power to the heater is discon-

nected to avoid potential serious injury or damage to

components.

5. Install heater controls, thermostats, or building

management systems in accordance with the

applicable manufacturers’ instructions.

6. Conduit should not be used as the earth ground.

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.

Field Wiring Connection

Fig. 19: On-Off Wiring Connections

Fig. 18: Wiring Location

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Fig. 21: 3-Stage Wiring Connections

Fig. 22: 4-Stage Wiring Connection

Fig. 20: 2-Stage Wiring Connections

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Installer action is required to electrically enable your 3. For single-stage controller connections, attach the

heater to operate after making the power connections.

You must make a closed contact connection on Stage

1 connector of the Central Point Wiring (CPW) board

stage 1 connections on heater 1 to the tankstat per

Fig. 26.

for temperature control connections. This will be done Heater must be electrically grounded in accordance

based on the controller option selected with your with the NEC, and CSA C22.1 C.E.C. Part 1 in

heater order.

Canada.

1. For Closed-Loop Water-Source Heat Pump appli-

cations with fixed bypass, your heater should be

configured to operate in an on-off firing mode. This

means that you will connect a single-pole control

to stage one of the CPW board. Then jumper the

remaining firing stages. For example, 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.

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, check to ensure proper volt-

age to the heater and pump.

NOTE: If any of the original wire supplied with the

heater must be replaced, it must be replaced with

similar sized 105°C wire or its equivalent.

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. 25. Set the operating control to the

set-point at which you want the heater to maintain.

Ensure that the sensing bulb of the control is at the

point in the system that will best maintain the tem-

perature you want. For example, when you are

heating a tank of water, you want the operating

control sensor bulb in the tank.

SINGLE

STAGE

TANKSTAT

2-STAGE

TANKSTAT

STAGE 1

CONNECTION

ATTACH STAGE 1 CONNECTIONS

ON HEATER TO THE SINGLE STAGE

TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.

STAGE 2 CONNECTION OR

STAGE 1 CONNECTION

STAGE 1

CONNECTION

OF HEATER 2

Fig. 24: Single-Stage Tankstat

ATTACH STAGE 1 CONNECTIONS ON HEATER

TO STAGE 1 CONNECTION ON TANKSTAT.

ATTACH STAGE 2 CONNECTIONS OR

STAGE 1 CONNECTION OF HEATER 2

TO STAGE 2 CONNECTIONON TANKSTAT

AS SHOWN IN THE DIAGRAM.

Fig. 23: 2-Stage Tankstat

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Category IV – A heater which operates with a positive

vent pressure and with a vent gas temperature that

may cause excessive condensate production in the

vent.

Venting

CAUTION: Proper installation of flue venting is criti-

cal for the safe and efficient operation of the heater.

See Table K for appliance category requirements.

NOTE: For additional information on appliance

categorization, see appropriate ANSI Z21 Standard

and the NFGC (U.S.), or B149 (Canada), or

applicable provisions of local building codes.

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: When condensate traps are installed,

condensate must be routed to an appropriate

container for neutralization before disposal, as

required by local codes.

Model

Diameter

Order Number

WARNING: Contact the manufacturer of the vent

material if there is any question about the appliance

categorization and suitability of a vent material for

application on a Category III or IV vent system.

Using improper venting materials can result in

personal injury, death or property damage.

399B–499B

6”

011839

649B, 749B,

899B

8”

011840

989B

10”

12”

011841

011842

Support of Vent Stack

1259B, 1529B

The weight of the vent stack or chimney must not rest

on the heater vent connection. Support must be pro-

vided in compliance with applicable codes. The vent

should also be installed to maintain proper clearances

from combustible materials.

1799B, 1999B,

2069B

14”

16”

011843

011844

2339B

Table J: Flue Exhaust Tee Kits

NOTE: During winter months check the vent cap

and make sure no blockage occurs from build-up of

snow or ice.

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.

Barometric Damper

A barometric damper may be required when vent

heights exceed 25 feet or when the draft is greater

than -0.08 in. WC. In these installations, a barometric

damper (single or double acting) is recommended.

Category I – A heater which operates with a non-pos-

itive vent static pressure and with a vent gas

temperature that avoids excessive condensate pro-

duction in the vent.

The damper should be installed NO CLOSER than 18

in. from the discharge of the unit and no closer than 18

in. from a combustible ceiling. The damper can be

installed in horizontal or vertical runs of vent pipe as

necessary. Installation in a bull-head tee is acceptable

as shown in the NFGC.

Category II – A heater which operates with a non-pos-

itive vent static pressure and with a vent gas

temperature that may cause excessive condensate

production in the vent.

Category III – A heater which operates with a positive

vent pressure and with a vent gas temperature that

avoids excessive condensate production in the vent.

The weights on the damper should be adjusted per the

damper manufacturer’s instructions for proper opera-

tion.

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Use insulated vent pipe spacers where the vent pass- 8. Locate and guard vent termination to prevent acci-

es through combustible roofs and walls.

dental contact by people or pets.

9. DO NOT terminate vent in window well, stairwell,

alcove, courtyard or other recessed area.

Vent Terminal Location

1. Condensate can freeze on the vent cap. Frozen

condensate on the vent cap can result in a blocked

flue condition.

10. DO NOT terminate above any door, window, or

gravity air intake. Condensate can freeze, causing

ice formations.

2. Give special attention to the location of the vent

termination to avoid possibility of property dam-

age or personal injury.

11. Locate or guard vent to prevent condensate from

damaging exterior finishes. Use a rust-resistant

sheet metal backing plate against brick or mason-

ry surfaces.

3. Gases may form a white vapor plume in winter.

The plume could obstruct a window view if the ter-

mination is installed near windows.

12. DO NOT extend exposed vent pipe outside of

building. Condensate could freeze and block vent

pipe.

4. Prevailing winds, in combination with below-freez-

ing temperatures, can cause freezing of

condensate and water/ice build-up on buildings,

plants or roofs.

U.S. Installations

Refer to the latest edition of the National Fuel Gas

Code.

5. The bottom of the vent terminal and the air intake

shall be located at least 12 in. above grade, includ-

ing normal snow line.

Vent termination requirements are as follows:

1. Vent must terminate at least 4 ft below, 4 ft hori-

zontally from or 1 ft above any door, window or

gravity air inlet to the building.

6. Un-insulated single-wall metal vent pipe shall not

be used outdoors in cold climates for venting gas-

fired equipment.

2. The vent must not be less than 7 ft above grade

when located adjacent to public walkways.

7. Through-the-wall vents for Category II and IV

appliances and non-categorized condensing appli-

ances shall not terminate over public walkways or

over an area where condensate or vapor could

create a nuisance or hazard or could be detrimen-

tal to the operation of regulators, relief valves, or

other equipment. Where local experience indi-

cates that condensate is a problem with Category

I and III appliances, this provision shall also apply.

3. Terminate vent at least 3 ft above any forced air

inlet located within 10 ft.

4. Vent must terminate at least 4 ft horizontally, and

in no case above or below unless 4 ft horizontal

distance is maintained, from electric meters, gas

meters, regulators, and relief equipment.

Combustion

Air Supply

Exhaust

Configuration

Heater Venting

Category

Certified

Materials

Combustion Air

Inlet Material

Vertical Natural

Draft Venting

“B” Vent

From Inside Building

Horizontal Through-

the-Wall Venting

Stainless Steel

(Gas Tight)

III

Vertical Natural

Draft Venting

Galvanized Steel

PVC

“B” Vent

From Outside Building

ABS

CPVC

Horizontal Through-

the-Wall Venting

Stainless Steel

(Gas Tight)

III

Table K: Venting Category Requirements

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5. Terminate vent at least 6 ft away from adjacent

walls.

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).

6. DO NOT terminate vent closer than 5 ft below roof

overhang.

7. The vent terminal requires a 12 in. vent terminal

clearance from the wall.

1. Disconnect all electrical power from the heater (if

applicable).

8. Terminate vent at least 1 ft above grade, including

normal snow line.

2. Disconnect or isolate the main gas pipe from the

heater (if applicable).

9. Multiple sidewall vent installations require a 4 ft

clearance between the ends of vent caps located

on the same horizontal plane.

3. Remove the screws, gasket and dustcover from

the rear of the heater.

4. Remove the screws, stainless steel flue cover and

gasket from the branch side of the tee located in

the flue box at the rear of the heater.

Canadian Installations

Refer to latest edition of B149 Installation code.

A vent shall not terminate:

5. Remove the screws, retaining ring and rain gasket

from top of heater.

1. Directly above a paved sidewalk or driveway

which is located between two single-family dwell-

ings and serves both dwellings.

6. Remove the screws, flue collar and gasket from

the run side of the tee located in the flue box on

top of the heater.

2. Less than 7 ft (2.13 m) above a paved sidewalk or

paved driveway located on public property.

7. Reverse the components and reattach in the new

location.

3. Within 6 ft (1.8 m) of a mechanical air supply inlet

to any building.

8. Make sure that the stainless steel cover, now lo-

cated on the run side of the tee, is sealed to avoid

any flue gas spillage.

4. Above a meter/regulator assembly within 3 ft (915

mm) horizontally of the vertical centre-line of the

regulator.

CAUTION: The silicone vent gaskets must be prop-

erly reinstalled to prevent flue gas leakage. Replace

any torn or worn vent gaskets.

5. Within 6 ft (1.8 m) of any gas service regulator

vent outlet.

Venting Installation Tips

6. Less than 1 ft (305 mm) above grade level.

7. Within the 3 ft (915 mm) of a window or door which

can be opened in any building, any non-mechani-

cal air supply inlet to any building or the

combustion air inlet of any other appliance.

Support piping:

•

horizontal runs - at least every 5 ft

vertical runs - use braces

under or near elbows

8. Underneath a verandah, porch or deck, unless the

verandah, porch or deck is fully open on a mini-

mum of two sides beneath the floor, and the

distance between the top of the vent termination

and the underside of the verandah, porch or deck

is greater than 1 ft (305 mm).

WARNING: Examine the venting system at least

once a year. Check all joints and vent pipe

connections for tightness, corrosion or deterioration.

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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 buoyancy of the

heated flue products to create a thermal driving head

that expels the exhaust gases from the flue. The nega-

tive draft must be within the range of -.01 to -.08 in.

WC as measured 12 in. above the appliance flue out-

let to ensure proper operation. Vent material must be

listed by a nationally recognized test agency.

The maximum and minimum venting length for Cate-

gory I appliances shall be determined per the NFGC

(U.S.) or B149 (Canada).

The diameter of vent flue pipe should be sized accord-

ing to the NFGC (U.S.) and B149 (Canada). The

minimum flue pipe diameter for conventional negative

draft venting using double-wall Type B vent is: 6 in. for

Models 399B and 499B, 8 in. for Models 649B, 749B

and 899B, 10 in. for Model 989B, 12 in. for Models

1259B and 1529B, 14 in. for Models 1799B, 1999B

and 2069B, and 16 in. for 2339B.

Fig. 25: Natural Draft Vertical Venting

(Category I)

Termination

The vent terminal should be vertical and should termi-

nate outside the building at least 2 ft above the highest

point of the roof that is within 10 ft. The vent cap

should have a minimum clearance of 4 ft horizontally

from and in no case above or below (unless a 4 ft hori-

zontal distance is maintained) electric meters, gas

meters, regulators and relief equipment. The distance

of the vent terminal from adjacent public walkways,

adjacent buildings, open windows and building open-

ings must be consistent with the NFGC (U.S.) or B149

(Canada). Gas vents supported only by flashing and

extended above the roof more than 5 ft should be se-

curely guyed or braced to withstand snow and wind

loads.

NOTE: A vent adapter (field-supplied) must be used

to connect Type B vent to the unit.

The connection from the appliance vent to the stack

must be as direct as possible and shall be the same di-

ameter as, or larger than, the vent outlet. The

horizontal breaching of a vent must have an upward

slope of not less than 1/4 inch per linear foot from the

heater to the vent terminal. The horizontal portions of

the vent shall also be supported for the design and

weight of the material employed to maintain clear-

ances and to prevent physical damage or separation

of joints.

CAUTION: A listed vent cap terminal, adequately

sized, must be used to evacuate the flue products

from the heaters.

Common Venting System

Manifolds that connect more than one heater to a com-

mon chimney must be sized to handle the combined

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load. Consult available guides for proper sizing of the 1. Seal any unused opening in the common venting

manifold and the chimney. At no time should the area

of the common vent be less than the area of the

largest heater exhaust outlet.

system.

2. Visually inspect the venting system for proper size

and horizontal pitch and verify there is no block-

age, restriction, leakage, corrosion or other unsafe

condition.

WARNING: Vent connectors serving appliances

vented by natural draft shall not be connected into

any portion of mechanical draft systems operating

under a positive pressure.

3. Insofar as is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the com-

mon venting system are located and other spaces

of the building. Turn on clothes dryers and any ap-

pliance not connected to the common vent

system. Turn on any exhaust fans, such as range

hoods and bathroom exhausts, at maximum

CAUTION: Vent connectors for natural draft

venting systems must be Type B or better.

Common venting systems may be too large once an

existing unit is removed. At the time of removal of an

existing appliance, the following steps must be fol-

lowed with each appliance remaining connected to the

common venting system placed in operation, while the

other appliances remaining connected to the common

venting system are not in operation.

Combustion

Air Inlet Max. Length**

Air

Vertical Venting

Certified

Model

No.

Vent

Size

Height*

Venting

Material

Intake Pipe

Min.

Max.

6”

8”

10”

12”

Material

399B

499B

100’

75’

6”

8”

649B

100’

749B

40’

899B

Galvanized

Steel,

PVC, ABS,

CPVC

Category I

(Type B

Equivalent)

989B

10”

12”

5’

25’

1259B

1529B

1799B

1999B

2069B

2339B

75’

40’

100’

75’

14”

16”

* 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 duct length terminated at 100 equivalent ft.

Table L: Category I Vertical Venting

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speed. Do not operate summer exhaust fan. Close

fireplace dampers.

Horizontal Through-the-Wall Venting

(Category III)

4. Place in operation the appliances being inspected.

Follow the manufacturer’s instructions for lighting

each appliance. Adjust thermostat so appliance

will operate continuously.

Installation

These installations utilize the heater-mounted blower

to vent the combustion products to the outdoors.

Combustion air is taken from inside the room and the

vent is installed horizontally through the wall to the out-

doors. Adequate combustion and ventilation air must

be supplied to the equipment room in accordance with

the NFGC (U.S.) or B149 (Canada).

5. Check the pressure at a pressure tap located 12

in. above the bottom joint of the first vertical vent

pipe. Pressure should be anywhere between -0.01

and -0.08 in. WC.

6. After it has been determined that each appliance

remaining connected to the common venting sys-

tem properly vents when tested as outlined above,

return doors, windows, exhaust fans, fireplace

dampers and other gas burning appliances to their

previous conditions of use.

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 to 10 ft of straight pipe. This will allow installa-

tion in one of the four following arrangements:

7. Any improper operation of the common venting

system should be corrected so that the installation

conforms with the NFGC (U.S.) or B149 (Canada).

When re-sizing any portion of the common venting

system, the common venting system should be re-

sized to approach the minimum size as

determined using the appropriate tables in the

NFGC (U.S.) or B149 (Canada).

•

70’ of straight flue pipe

60’ of straight flue pipe and one elbow

50’ of straight flue pipe and two elbows

40’ of straight pipe and three elbows

The vent cap is not considered in the overall length of

the venting system.

*Requires optional vent tee.

Fig. 26: Horizontal Through-the-Wall Venting (Category III)

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Combustion

Air

Intake Pipe

Material

Certified

Venting

Material

Maximum

Equivalent

Vent Length*

Air Inlet Max. Length*

Model

No.

Vent

Size

6”

8”

10”

12”

399B

499B

100’

75’

6”

8”

649B

100’

80’

40’

30’

749B

899B

70’Room Air

Galvanized

Steel,

PVC, ABS,

CPVC

989B

10”

12”

Category III

40’ Ducted

Combustion Air

1259B

1529B

1799B

1999B

2069B

2339B

75’

40’

100’

75’

14”

16”

*Subtract 10 ft per elbow. Max. 3 elbows.

Maximum combustion air duct length terminated at 100 equivalent ft.

Table M: Category III Horizontal and Direct Venting

The vent must be installed to prevent flue gas leakage. Termination

Care must be taken during assembly to ensure that all

joints are sealed properly and are airtight. The vent The flue direct vent cap MUST be mounted on the ex-

must be installed to prevent the potential accumulation terior of the building. The direct vent cap cannot be

of condensate in the vent pipes. It is required that:

installed in a well or below grade. The direct vent cap

must be installed at least 1 ft above ground level and

1. The vent must be installed with a slight downward above normal snow levels. The Raypak-approved

slope of not more than 1/4 inch per foot of hori- stainless steel flue direct vent cap must be used (sales

zontal run to the vent terminal.

order option D-15).

2. The vent must be insulated through the length of

the horizontal run.

WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

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 codes.

Use only the special gas vent pipes listed for use with

Category III gas burning heaters, such as the 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.

Follow the vent manufacturer’s installation instructions

carefully.

2. The vent must be insulated through the length of

the horizontal run.

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Outdoor Installation

NOTE: Condensate can freeze on the vent cap.

Frozen condensate on the vent cap can result in a

blocked flue condition.

Outdoor models are self-venting when installed with

the optional factory-supplied outdoor vent kit and re-

quire no additional vent piping. A special vent cap, flow

switch cover and air intake hood are provided in accor-

dance with CSA requirements, which must be installed

directly on the heater. Correct clearances can be

found earlier in this section.

NOTE: The vent cap, flow switch cover and air

intake hood must be furnished by the heater

manufacturer in accordance with its listing (sales

order option D-11).

Care must be taken when locating the heater out-

doors, because the flue gases discharged from the

vent cap can condense as they leave the cap.

Improper location can result in damage to adjacent

structures or building finish. For maximum efficiency

and safety, the following precautions must be

observed:

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 exchanger or headers.

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).

Controls

WARNING: Installation, adjustment and service of

heater controls, including timing of various operating

functions, must be performed by a qualified installer,

service agency or the gas supplier. Failure to do so

may result in control damage, heater malfunction,

property damage, personal injury, or death.

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 combustion and ventilation

air. Keep area clear and free of combustible and

flammable materials.

3. Do not locate adjacent to any window, door walk-

way, or gravity air intake. The vent must be

located a minimum of 4 ft horizontally from such

areas.

WARNING: Turn off the power to the heater before

installation, adjustment or service of the CPW board

or any heater controls. Failure to do so may result in

board damage, heater malfunction, property

damage, personal injury, or death.

4. Install above grade level and above normal snow

levels.

CAUTION: This appliance has provisions to be

connected to more than one supply source. To

reduce the risk of electric shock, disconnect all such

connections before servicing.

5. Vent terminal must be at least 3 ft above any

forced air inlet located within 10 ft.

6. Adjacent brick or masonry surfaces must be pro-

tected with a rust-resistant sheet metal plate.

CAUTION: Risk of electric shock: More than one

disconnect switch may be required to de-energize

the equipment before servicing.

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3. 120 VAC is waiting at the N.O. contacts of the

pump delay relay.

4. Terminals L1 and F1 of the ignition module are

powered with 120VAC.

5. 120 VAC power is also applied to the control

power connector on the circuit board.

6. 120 VAC power is waiting at relay contacts K-3 to

energize the heater blower.

7. The 120/24 VAC transformer outputs 24 VAC.

8. 24 VAC is sent to power terminal L1 of the low

water cut-off board (optional).

9. 24 VAC is applied to the red LED safety shutdown

light on the front of the unit.

Fig. 27: Status LED Indicator Decal

External Lights

10. 24 VAC is applied to the alarm circuit (optional). If

the E-5 sales option (Alarm) is included a 5 sec-

ond time delay relay will not allow the alarm to

sound 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 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).

Light

Color

Indication

24 VAC

switched on

Power On

Green

Thermostat is

closed

Call For Heat

Amber

Burner(s) are

firing

12. Once all safeties have been verified to be closed a

24 VAC signal is sent to pin P3-16 of J-5 on the

CPW board.

Burner Firing

Service Req’d

Blue

Red

Service

required

13. 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.

Table N: Status LED Indicators

Heater Sequence of Operation

Models 399B–899B

14. Power is applied to terminal 24V of the pump

delay relay to energize the timing circuit .

15. 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 shutdown light.

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.

16. Pin P1-4 on the diagnostic board will now output a

24 VAC signal to pin 1 of the “standby switch”.

2. When the main power switch is placed in the “ON”

position, 120 VAC is applied to the 120 VAC termi-

nal block on the circuit board and the 120/24 VAC

transformer is powered.

17. The “standby switch” (rocker switch) located at the

lower left front of the control compartment is now

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powered. If the switch is “ON” and there is no call 33. 24 VAC is now sent to the pressure switch (P

for heat (CFH), the heater is in standby mode. Switch) terminal on the ignition module.

18. After the standby switch is placed into the “ON” 34. Once the pressure switch signal is received at the

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).

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).

19. 24 VAC switched power is applied to the 24VAC

terminal on the ignition module.

20. When the “enable/disable” contacts are closed, 35. Once the ignition module determines that the hot

the 24 VAC signal travels to pin 1 of the stage 1

connection and waits for a CFH.

surface igniter is operating properly, a 24 VAC sig-

nal is output from terminal “valve” of the module.

21. When a CFH occurs, a 24 VAC signal is sent from 36. A 24 VAC signal is sent to gas valve 1.

J-5 CFH on the CPW board to the amber CFH light

on the front of the unit.

37. The blue LED on the front of the unit is now illumi-

nated.

22. Power is now sent to terminal TRIG of the pump

delay relay to energize it and close the contacts.

38. The coil of relay K-2 (N.O.) is now energized with

the (K-2) contacts closing downstream of the

stage 2 and upstream of the stage 3 connections.

23. The heater pump is energized.

24. Upon sufficient flow from the heater pump, the 39. The gas coming through the burners should ignite

flow switch contact will close.

from the heat of the hot surface igniter and the

flame should carry over from one burner to the

other burners of stage 1. The 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 heater must per-

form 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.

25. A 24 VAC signal is then sent to the “TH” terminal

located on the ignition module.

26. Once the 24 VAC “TH” signal is received, a 120

VAC signal is sent from F2 on the ignition module

to the 120 VAC pilot duty terminals, located at J-14

on the circuit board.

27. The 120 VAC signal continues to the coil of relay

K-3 (N.O.).

28. The 120 VAC signal continues to the 120 VAC 40. After gas valve 1 opens and flame rectification is

safety terminals located at J-13 on the circuit

board.

received, time delay relay 1 (TD-1) is powered and

starts a 5-second countdown.

29. When the coil on relay K-3 (N.O.) is powered, the 41. After the 5 second countdown from TD-1, 24 VAC

relay contacts (K-3) close and energize the blow-

er(s) from the J-8 connections on the CPW board.

is waiting at pin 3 of the stage 2 connection on the

CPW board.

30. After proper air pressure is received in the air 42. After closure of the stage 2 contacts Gas valve 2

plenum, the air pressure switch(s) will close. in energized.

31. Power is applied to the optional equipment inter- 43. After a 5 second countdown from TD-2, 24 VAC is

lock connection (normally jumpered).

waiting at pin 5 of the stage 3 connection on the

CPW board.

32. The 24 VAC signal is then sent to the 24 VAC safe-

ty connector.

44. After closure of the stage 3 contacts Gas valve 2

is energized.

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45. The Heater is now operating at full fire.

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 termi-

nal P1-4 of J-5 on the CPW board.

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.

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 shutdown light.

2. When the main power switch is placed in the “ON”

position, 120 VAC is applied to the 120 VAC termi-

nal block on the circuit board and the 120/24 VAC

transformer is powered.

17. Terminal J4-24 on the CPW board will now output

a 24 VAC signal to pin 1 of the “standby switch”.

3. 120 VAC is waiting at the N.O. contacts of the

pump delay relay.

18. The “standby switch” (rocker switch) located at the

lower left front of the control compartment is now

powered. If the switch is “ON” and there is no call

for heat (CFH), the heater is in standby mode.

4. Terminals L1 and F1 of the ignition module 1 are

powered with 120VAC.

5. 120 VAC power is also applied to the control

power connector on the circuit board.

19. The “standby switch” (rocker switch) located at the

lower left front of the control compartment is now

powered. If the switch is “ON” and there is no call

for heat (CFH), the heater is in standby mode.

6. Terminals L1 and F1 of the ignition module 2 are

powered with 120VAC (1529B-2349B only).

20. Power is applied to the coil of K-3. (If an ignition

lockout occurs, ignition module 1 closes contacts

allowing the 24VAC from K-3 to go to ground and

closes the contacts to allow the unit to fire at stage

3.)

7. 120 VAC power is waiting at relay contacts K-4 to

energize the heater blowers.

8. The 120/24 VAC transformer outputs 24 VAC.

9. 24 VAC is sent to power terminal L1 of the low

water cut-off board (optional).

21. After the standby switch is placed into the “ON”

position, a 24 VAC signal is sent to the

“enable/disable” connection (normally jumpered).

10. 24 VAC is applied to the red LED safety shutdown

light on the front of the unit.

22. 24 VAC switched power is applied to the 24VAC

terminals on ignition modules 1 and 2.

11. 24 VAC is applied to the alarm circuit (optional). If

the E-5 sales option (Alarm) is included a 5 sec-

ond time delay relay will not allow the alarm to

sound unless the circuit stays energized for more

than 5 seconds.

23. When the “enable/disable” contacts are closed,

the 24 VAC signal travels to pin 1 of the stage 1

connection and waits for a CFH.

24. Power is now sent to terminal TRIG of the pump

delay relay to energize it.

12. 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, and high gas pressure switch(s) (optional).

25. The heater pump is energized.

26. Upon sufficient flow from the heater pump, the

flow switch contact will close.

27. A 24 VAC signal is now sent to the “TH” terminal

located on ignition module 1 and to the N.O. con-

tacts of K-2 and K-3.

13. Once all safeties have been verified to be closed a

24 VAC signal is sent to pin P3-16 of J-5 on the

CPW board.

28. Once the 24 VAC “TH” signal is received, a 120

VAC signal is sent from F2 on ignition module 1 to

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the 120 VAC pilot duty terminals, located at J-14

on the circuit board.

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.

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 42. After gas valve 1 opens and flame rectification is

safety terminals located at J-13 on the circuit

board.

received, time delay relay 1 (TD-1) is powered and

starts a 5-second countdown.

31. When the coil on relay K-4 (N.O.) is powered, the 43. After the 5 second countdown from TD-1, the con-

relay contacts (K-4) close and energize the blow-

ers from the J-8 connections on the CPW board.

tacts close time delay relay 2 receives 24 VAC.

44. After 5 seconds gas valve 1a is now energized

allowing the remainder of stage 1 to fire.

32. After proper air pressure is received in the air

plenum, the air pressure switches will close.

45. After the 5-second countdown from TD-2 the inter-

nal contacts close allowing 24 VAC to sit at pin 3

of the stage 2 connection on the CPW board.

33. Power is applied to the optional equipment inter-

lock connection (normally jumpered).

34. The 24 VAC signal is then sent to the 24 VAC safe- 46. The temperature controller closes the stage 2 con-

ty connector. tacts and gas valve 2 in energized.

35. 24 VAC is now sent to the pressure switch (P 47. The temperature controller closes the stage 3 con-

Switch) terminal on the ignition modules. tacts at J-3 on the CPW board.

36. Once the pressure switch signals are received at 48. 24 VAC signal is received at gas valve 3 (Model

both ignition modules, hot surface igniter 1 is ener-

gized by a 120 VAC signal from S-1 on ignition

module 1. (The hot surface igniter must draw

greater than 3.2 amps while being energized or

ignition lockout will occur after three tries.)

1259B only).

Models 1529B–2339B Only

49. Power is applied to the “TH” terminal of ignition

module 2.

37. Once ignition module 1 determines that hot sur-

face igniter 1 has heated up and operating

properly, a 24 VAC signal is output from terminal

“valve” on module 1.

50. Once the “TH” signal is received at ignition module

2, hot surface igniter 2 is energized by a 120 VAC

signal from S-1 on ignition module 2. (The hot sur-

face igniter must draw greater than 3.2 amps while

being energized or ignition lockout will occur after

three tries.)

38. 24 VAC signal is sent to gas valve 1.

39. The blue LED on the front of the unit is now illumi-

nated.

51. Once the ignition module determines that the hot

surface igniter has heated up and operating prop-

erly, a 24 VAC signal is output from pin “valve” on

the module.

40. The coil of relay K-2 (N.O.) is now energized with

the (K-2) contacts closing downstream of the

stage 2 connections and upstream of the stage 3

connections.

52. 24 VAC signal is received at gas valve 3.

41. The gas coming through the burners should ignite

from the heat of hot surface igniter 1 and the flame

should carry over from one burner to the other

burners of stage 1. The remote sensor is now try-

ing 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 ignit-

er. During ignition retry the heater must perform a

53. The coil of relay K-5 (N.O.) is now energized with

the (K-5) contacts closing downstream of the

stage 4 connections.

54. Remote flame sensor 2 is trying to rectify flame.

55. Power is now applied to time delay relay 3 and the

contacts of TD-3 located upstream of the stage 4

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The standard ignition module will attempt to light three

times before locking out. To reset it, turn off power to

the heater, wait 30 seconds and re-apply power.

connection close after 5 seconds.

56. The stage 4 temperature controller contacts close.

57. Power is sent to gas valve 4.

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 WILL NOT reset the ignition mod-

ule.

58. The heater is now operating at full fire.

Ignition Module

High Limit (Manual Reset)

Reset button

on 1-try

module

Fig. 28: Ignition Module

Fig. 29: High Limit (Manual Reset)

When additional heat is needed, the combustion air

blower starts to purge air from 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 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.

The heater is equipped with a manual reset high limit

temperature device. Push the reset button and adjust

the setting to 40 - 50°F above desired operating tem-

perature.

Flow Switch

Code

Condition

System OK;

No faults present

Possible control fault;

Check power

Off

Low air pressure, brief

flashing normal on start-up

1 Flash

Flame in combustion

chamber; No call for heat

2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

Fig. 30: Flow Switch

Ignition lockout

This dual-purpose control, mounted and wired in

series with the main gas valve, shuts off heater in case

of pump failure or low water flow.

Low igniter current

Low 24 VAC, check control

supply voltage

Operating Control

Internal fault;

Replace module

The heater may be equipped with different types of

operating controls. Consult the individual control data

Table O: Ignition Module Diagnostic LED Codes

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sheets supplied with your heater paperwork. See the

switch automatically shuts down the burner. The high

General Safety Section for safety precautions con- gas pressure switch automatically shuts down the

cerning domestic hot water applications.

heater if gas manifold pressure rises above the recom-

mended setting of 5.0 in. WC for natural gas, and 11.5

in. WC for propane gas.

NOTE: Some jurisdictions may require two high gas

pressure switches on models 1529B–2339B due to

two ignition modules.

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.

Fig. 33: High/Low Gas Pressure Switch

Fig. 34: Fan-Proving Switch

Fig. 32: Low Water Cut-Off

High and Low Gas Pressure Switches

The low gas pressure switch (standard on models

989B–2339B, optional on models 399B–899B) con-

nection mounts upstream of the gas valve to ensure

that sufficient gas pressure is present for proper regu-

lator performance. The low gas pressure switch

automatically shuts down the heater if gas supply

drops below the factory setting of 5.0 in. WC for natu-

ral gas, and 10.0 in. WC for propane gas.

Fig. 35: Blocked Vent Switch

NOTE: The wiring diagrams in this manual show all

standard options. Refer to the large wiring diagram

provided with your heater for options installed on

your specific unit(s).

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

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Wiring Diagram - Models 399B–1259B

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Wiring Diagram - Models 1529B–2339B

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•

If you cannot reach your gas supplier, call the fire

department.

START-UP

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.

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.

•

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.

Air Purge (Domestic Hot Water

Heaters)

Check around unit for debris and remove com-

bustible products, i.e. gasoline, etc.

Purge all air from system before lighting heater. This

can be normally accomplished by opening a down-

stream valve.

Pre Start-up Check

1. Verify heater is filled with water.

Venting System Inspection

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

immediately.

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

terial.

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

with water circulation.

2. Make sure vent terminations are installed per code

and are clear of all debris or blockage.

4. Purge air from gas line up to heater.

Initial Start-up

For Your Safety

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

Tools Needed

•

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

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.

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

mum)

•

(1) Screwdriver

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.

(1) Multi-meter

(1) 3/16” Allen wrench

WHAT TO DO IF YOU SMELL GAS:

NOTE: Digital manometers are not recommended.

•

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.

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Preparation

Start-Up

WARNING: Do not turn on gas at this time.

Check Power Supply

Blower Adjustment

1. Turn off power.

2. Unplug cap at pressure switches and connect ma-

nometer(s) to the tee.

With multi-meter at incoming power, check voltage

between:

3. Close all manual firing valves.

4. Turn power on.

Hot - Common (≈120 VAC)

Hot - Ground (≈120 VAC)

Common - Ground (< 1 VAC)

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, adjust the air

shutter on the blowers to attain the correct value.

WARNING: If Common - Ground is > 1 VAC,

STOP: Contact electrician to correct ground failure.

Failure to do this may burn out 120V-24V

transformer, or may cause other safety control

damage or failure.

6. Turn power off.

7. Reconnect this cap.

Main Burner Adjustment

1. Turn off unit.

Attach Manometers to Measure Pressures

1. Turn off main gas valve.

2. Open manual firing valves.

2. Attach 24” scale manometer to the first main gas

shut-off valve pressure tapping.

3. Turn on the unit, wait 15 seconds, and the igniter

should glow. Look into sight glass located at each

end of the heater to check igniter operation. Gas

valves should open in 45-60 seconds.

3. Attach (1) 12” scale manometer to the outlet side

of the second main gas shut-off valve pressure

tapping.

4. If burner does not light on first trial. It will retry, up

to three times.

4. Attach (1) 12” scale manometer near the fan-prov-

ing switch. Pull black cap from air pressure switch

tee and connect the manometer. NOTE: Retain

caps for reinstallation later.

5. Main burner ignition: Check manifold gas pressure

at gas valve outlet pressure tap. This should read

3.5 0.1 in. WC for natural gas and 10.5 0.1 in.

WC for propane gas.

Check Gas Supply Pressure

1. Slowly turn on main gas shut-off valve.

6. If the pressure reading differs by more than 0.1

in. WC, remove screw cover from the gas pres-

sure regulator and adjust main burner manifold

pressure. Replace the screw cover. Repeat steps

2 to 5 on other valves as necessary.

2. Read the gas supply pressure from the manome-

ter; minimum supply pressure for natural gas is 5.0

in. WC, recommended supply is 7.0 in. WC, mini-

mum supply pressure for propane gas is 11.0 in.

WC (dynamic readings, all stages firing).

CAUTION: Special manifold and air settings may

be required. Verify rating plate and blower housing.

3. If the pressure is > 14.0 in. WC, turn off the valve.

4. Check if the service regulator is installed and/or

adjust the service regulator.

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The burner section that is ignited directly by the hot

surface ignition system serves as a supervised 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.

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.

The pilot turn-down test is conducted as follows:

1. Turn off manual valves on non-supervised burner

sections.

4. Check thermostats for ON-OFF operation.

5. Check high limits for ON-OFF operation.

6. While in operation, check flow switch operation.

2. Turn on electrical power and adjust thermostat to

call for heat.

3. Wait for completion of ignition sequence to light

burner section being utilized as a pilot for those

turned off in step 1 above.

7. Check the low gas pressure switch. (For proper

adjustment, use the attached manometers, if

available, to set pressure. The scales on the

switch are approximate only.) Low gas pressure

switch must be set at 5.0 in. WC for natural gas

and 10.0 in. WC for propane gas.

4. Gradually reduce manifold pressure (flame) on

supervised burner section by slowly closing man-

ual gas valve. Watch for shut-down due to loss of

supervised flame signal as pressure is being re-

duced. Flame signal should be lost before

manifold pressure goes below 2.0 in. WC for nat-

ural gas and 6.0 in. WC for propane gas.

8. Make sure that the high gas pressure switch (op-

tional) is set to 1.0 in. WC above manifold

pressure.

Follow-Up

Leak Test Procedure: Dual-Seat Gas

Valves

Safety checks must be recorded as performed.

Turn heater on. After main burner ignition:

1. Check manometer for proper reading.

Proper leak testing requires three pressure test points

in the gas train.

Test point A is upstream of the automatic gas valve. On

2. Cycle heater several times and re-check readings. the first automatic valve, this is a bleedle valve. On the

other valves, this is a plugged port. The bleedle valve

3. Remove all manometers and replace caps and on the first valve may be used for all the other valves

screws.

as well.

4. Replace all gas pressure caps.

5. Check for gas leaks one more time.

Pilot Turn-Down Test

Test point B is a bleedle valve located between the two

automatic gas valve seats.

Test point C is located downstream of both automatic

gas valve seats and upstream of the manual valve. On

the manual valve, this is a bleedle valve. Identical

readings will be found at the plugged port labeled as

Alternate C.

The Delta Limited heaters, depending on their size,

have two to five burner sections. Each burner section

is supplied gas by two gas valves incorporated into a

single valve body. A maximum of three burner sections

may be controlled by a single hot surface ignition sys-

tem. The middle of the three burner sections is ignited

directly with a hot surface ignition system.

Refer to Fig. 36. The numbers on the diagram refer to

the steps below:

These tests are to be conducted with the electrical

power to the heater turned off.

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1. Manually close the downstream leak test valve.

This completes leak testing for a single Delta Limited

manifold riser. Repeat steps 1-8 for each riser.

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).

Post Start-Up Check

Check off steps as completed:

3. Open test point B and connect a rubber tube to it.

Connect the other end of the tube to a manometer

and look for a build-up of pressure. Increasing

pressure indicates a leaking gas valve.

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.

4. Next, close the upstream manual gas valve and

remove the manometer from test point A and from

test point B. Connect a rubber tube from test point

A to test point B and open the upstream manual

gas valve. Make sure that test points A & B have

been opened so as to allow gas to flow. This will

bring pressure to the second valve seat.

3. Verify that air has been purged from the system.

4. Verify that air has been purged from the gas pip-

ing, and that the piping has been checked for

leaks.

5. Open test point C and connect a second rubber

tube to it. Connect the other end of the tube to a

manometer and look for a build-up of pressure. In-

creasing pressure indicates a leaking gas valve.

5. Confirm that the proper start-up procedures were

followed.

6. Inspect burner to verify flame.

6. Remove rubber tube and manometers. Close

each test point valve as the tubes are removed.

7. Test safety controls: If heater is equipped with a

low water cut-off or additional safety controls, test

for operation as outlined by manufacturer. Burner

should be operating and should go off when con-

trols are tested. When safety devices are restored,

burners should re-ignite after pre-purge time

delay.

7. Connect a manometer to each test point (one at a

time) and look for a build-up of pressure. If a build-

up of pressure is detected, check each test point

valve to see if it is tightly closed. If leak persists,

replace test point valve(s).

8. Test limit control: While burner is operating, move

indicator on high limit control below actual water

temperature. Burner should go off while blower

and circulator continue to operate. Raise setting

on limit control above water temperature and burn-

er should re-ignite after pre-purge time delay.

8. After no leakage has been verified at all valve

seats and test valves, open downstream leak tests

valve and restore electrical power to heater.

9. Test ignition system safety device:

a. Turn on manual gas valve. Turn power on.

b. Set thermostat to call for heat.

c. When the heater is in operation, pull cap off of

tee in air switch hose. The burner should go

off immediately.

d. Wait 5 minutes.

e. Reattach cap on tee. Burner should re-ignite

after pre-purge time delay.

Fig. 36: Leak Test

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10. To restart system, follow lighting instructions in the 9. Set thermostat to desired setting. The appliance

Operation section.

will operate. The igniter will glow after the pre-

purge time delay (15 seconds). After igniter

reaches temperature (45 seconds) the main valve

will open. System will try for ignition three times. If

flame is not sensed, lockout will commence.

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 10. If the appliance will not operate, follow the instruc-

adjusted as required in each zone.

tions “To Turn Off Gas To Appliance,” and call your

service technician or gas supplier.

12. Check that the heater is cycled with the thermo-

stat. Raise to the highest setting and verify that the 11. Replace access panel.

heater goes through the normal start-up cycle. Re-

duce to the lowest setting and verify that the 12. If heater fails to start, verify the following:

heater goes off.

a. There are no loose connections or that the

13. Observe several operating cycles for proper oper-

ation.

service switch is off.

b. High temperature limit switch is set above wa-

ter temperature.

14. Set the room thermostat or tankstat to desired

temperature.

c. Thermostat is set above room temperature.

d. Gas is on at the meter and the heater.

15. Review all instructions shipped with this heater

with owner or maintenance person, return to enve-

lope and give to owner or place the instructions

inside front panel on heater.

e. Incoming gas pressure to the gas valve is

NOT less than 5.0 in. WC for natural gas, 11.0

in. WC for propane gas.

OPERATION

To Turn Off Gas To Appliance

Lighting Instructions

1. Set the thermostat to lowest setting.

1. Before lighting, make sure you have read all of the

safety information in this manual.

2. Turn off all electrical power to the appliance if serv-

ice is to be performed.

2. Set the thermostat to the lowest setting.

3. Remove upper front panels.

4. Turn off main manual gas valve.

5. Replace access panel.

3. Turn off all electrical power to the appliance.

4. This appliance is equipped with an ignition device

which automatically lights the burner. Do not try to

light the burner by hand.

5. Remove upper front panel.

6. Turn 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.

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TROUBLESHOOTING

Does the power switch

provide power to the

Check the switch

and/or line voltage

control panel?

Step 1

Replace ignition module

Is enable/disable

jumper intact (J1)?

YES

Reattach

Check all safety limit

devices and voltage from

the transformer to J10 on

CPW board.

Unit is in standby mode.

Step 2

Step 3

Step 4

Is there a call for heat?

YES

Is there 120VAC at J8

Connector on the CPW board?

Does F2 on ignition module

have 120VAC?

Do the combustion air

blowers come on?

YES

Is 24VAC at present at TH (J3 & J12 on CPW

board and orange wire on ignition module)?

Check flow switch, all

connectors on CPW board

and controller.

Is air pressure switch(s) and

J2 of CPW board (N.O.)

powered?

YES

Check the fan relay. Is there

120VAC at K3 relay?

YES

Is there continuity from the

fan relay to fan(s)?

Is 24VAC at PS on

ignition module? Is

connecting plug

secure?

YES

Does air pressure switch(s)

have correct pressure?

(1.4” W.C.)

Replace fan relay

Replace fan

YES

Replace air

pressure switch

Step 5

Does igniter prove?

Correct the air settings or

you may have to clean

burners, heat exchanger

and/or air filter.

YES

Check Amp draw during

heat-up for 3.2 Amps or

greater.

Is air switch

bouncing?

YES

Is the flame

sensor signal to

the ignition

Replace HSI

YES

module greater

than 4 uA DC?

Step 6

Step 7

Readjust to 3.5” W.C.

gas.

Is the unit running?

Are the gas valve

settings correct?

YES

Is the unit running?

Is static and dynamic inlet

manifold gas pressure correct?

Is downdraft present?

Replace gas valve

YES

Call our Technical Service Department

1-800-947-2975 Outside California

1-800-627-2975 Inside California

The unit is okay

Clean or replace flame sensor

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4. Check for and remove any obstruction to the flow

of combustion or ventilation air to heater.

MAINTENANCE

5. Follow pre-start-up check in the Start-up section.

Suggested Minimum

Maintenance Schedule

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.

Regular service by a qualified service agency and

maintenance must be performed to ensure maximum

operating efficiency.

7. Check operation of safety devices. Refer to manu-

facturers’ instructions.

Maintenance as outlined below may be performed by

the owner.

8. Follow oil-lubricating instructions on circulator if

required. Over-oiling will damage circulator.

Water-lubricated circulators do not need oiling.

Daily

1. Check that the area where the heater is installed

is free from combustible materials, gasoline, and

other flammable vapors and liquids.

9. To avoid potential of severe burn, DO NOT REST

HANDS ON OR GRASP PIPES. Use a light touch;

return piping will heat up quickly.

2. Check for and remove any obstruction to the flow

of combustion or ventilation air to heater.

10. Check blower and blower motor.

11. Check for piping leaks around circulators, relief

valves and other fittings. Repair, if found. DO NOT

use petroleum-based stop-leak.

Monthly

1. Check for piping leaks around circulators, mixing

valves, relief valves, and other fittings. If found,

repair at once. DO NOT use petroleum-based

stop-leak compounds.

12. Clean air filter.

Periodically

2. Visually inspect burner flame.

1. Check relief valve. Refer to manufacturer’s in-

structions on valve.

3. Visually inspect venting system for proper func-

tion, deterioration or leakage.

2. Test low water cut-off, if used. Refer to manufac-

turer’s instructions.

4. Check air vents for leakage.

3. Clean screen and air filter in intake.

Yearly (Beginning Of Each Heating

Season)

Preventive Maintenance

Schedule

Schedule annual service call by qualified service

agency.

The following is required procedure in CSD-1 states

and good practice for all Delta Limited installations.

1. Visually check top of vent for soot. Call service

person to clean. Some sediment at bottom of vent

is normal.

Daily

2. Visually inspect venting system for proper func-

tion, deterioration or leakage.

1. Check gauges, monitors and indicators.

2. Check instrument and equipment settings. (See

“Post Start-Up Check” on page 44.)

3. Check that area is free from combustible materi-

als, gasoline, and other flammable vapors and

liquids.

3. Check burner flame. (Should see light blue flame).

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6. Perform leakage test on gas valves. (See Fig. 36.)

Weekly

7. Test air switch in accordance with manufacturer’s

instructions. (Turn panel switch to the “On” posi-

tion until blower is proven, then turn the switch to

“Off”.

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).

8. Inspect and clean burners as necessary.

Monthly

As Required

1. Check flue, vent, stack, or outlet dampers.

1. Recondition or replace low water cut-off device (if

equipped).

2. Test fan air pressure. (See “Blower Adjustment” on

page 42.)

2. Check drip leg and gas strainers.

3. Test high and low gas pressure interlocks (if

equipped). (See “Safety Inspection” on page 43.)

3. Perform flame failure detection and pilot turn-

down tests.

Semi-Annually

4. Check igniter. (Resistance reading should be 42-

70 ohms at ambient temperature.)

1. Recalibrate all indicating and recording gauges.

5. Check flame signal strength. (Flame signal should

be greater than 1 microamp).

2. Check flame failure detection system components.

(See “Pilot Turn-Down Test Procedure,” page 43.)

6. Test safety/safety relief valves in accordance with

ASME Heater and Pressure Vessel Code Sections

VI and VII.

3. Check firing rate control by checking the manifold

pressure. (See “Main Burner Adjustment” on page

42.)

4. Check piping and wiring of all interlocks and shut-

off valves.

Annually

1. Test flame failure detection system and pilot turn-

down. (See “Pilot Turn-Down Test Procedure,”

page 43.)

2. Test high limit and operating temperature. (See

“Post Start-Up Check,” page 44.)

3. Check flame sensors.

4. Conduct 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 type of control) until the

safety circuit opens. Reset to original setting after

each device is tested.

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•

furniture refinishing areas and establishments

new building construction

remodeling areas

APPENDIX

open pit skimmers

Inside Air Contamination

Check for areas and products listed above before in-

stalling heater. If found, remove products permanently.

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

stainless steel, which is commonly used in high effi-

ciency systems. The heater can be supplied with

corrosion-resistant, non-metallic intake air vent materi-

al. You may, however, choose to use outside

combustion air for one or more of these reasons:

1. Installation is in an area containing contaminants

listed below which will induce acidic condensation.

2. You want to reduce infiltration into your building

through openings around windows and doors.

3. You are using AL29-4C stainless steel vent pipe,

which is more corrosion-resistant than standard

metallic vent pipe. 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 acid

cements and glues

antistatic fabric softeners used in clothes dryers

chloride-type bleaches, detergents, and cleaning

solvents found in household laundry rooms

adhesives used to fasten building products