Page 3 - CONTENTS
WARNINGS 4 BEFORE INSTALLATION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 Time/Temperature Relationships inScalds 8 INSTALLATION 9 Installation Codes 9 Equipment Base 9 Stacking 9 C...
Page 4 - WARNINGS; Pay Attention to These Ter ms
DANGER: Indicates the presence of immediate hazards which will cause severepersonal injury, death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could causesevere personal injury, death or substantial property damage if ignored. CAUTIO...
Page 5 - BEFORE INSTALLATION; Product Receipt; Altering any Raypak pressure vessel
BEFORE INSTALLATION Raypak strongly recommends that this manual be re-viewed thoroughly before installing your Delta Limitedheater. Please review the General Safety informationbefore installing the heater. Factory warranty does notapply to heaters that have been improperly installed oroperated. (Ref...
Page 6 - Component Locations
OPTIONAL FLUE CONNECTION Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front 6
Page 7 - General Infor mation
General Infor mation Table A: Basic Data Table B: Manifold Data Model No. Quantity of Vent Size (in.) Burners Gas Valves Blowers Flue Intake 399B 8 1 1 6 6 499B 10 2 1 6 6 649B 13 2 1 8 6 749B 15 2 1 8 6 899B 18 3 1 8 6 989B 11 2 2 10 10 1259B 14 3 2 12 10 1529B 17 4 2 12 10 1799B 20 4 2 14 10 1999B...
Page 8 - GENERAL SAFETY; Feel water before bathing or showering.
GENERAL SAFETY To meet commercial hot water use needs, the highlimit safety control on this water heater is adjustable upto 210°F. However, water temperatures over 125°Fcan cause instant severe burns or death from scalds.When supplying general purpose hot water, the rec-ommended initial setting for ...
Page 9 - Installation Codes; Installations must follow these codes:; Equipment Base; The heaters should be located in an
INSTALLATION INSTALLATION Installation Codes Installations must follow these codes: • Local, state, provincial, and national codes, laws,regulations and ordinances • National Fuel Gas Code, ANSI Z223.1/NFPA 54 –latest edition (NFGC) • National Electrical Code, ANSI/NFPA 70 - latestedition (NEC) • St...
Page 11 - Clearances; Indoor Installations; Outdoor Installations
In addition, the heater shall be installed such that thegas ignition system components are protected fromwater (dripping, spraying, rain, etc.) during applianceoperation or service (circulator replacement, controlreplacement, etc.). Clearances Indoor Installations Heater Side Minimum Clearance from ...
Page 12 - All Air from Inside the Building; TWO; Combustion and Ventilation Air; Indoor Units
three or four sheet metal screws (not supplied) equal-ly distributed around the circumference of the duct. Allducting should be self-supported. The filter housing isnot designed to support the air duct. Conventional Combustion AirSupply U.S. Installations All Air from Inside the Building The confine...
Page 13 - All Air from Outdoors; Two permanent openings; Canadian Installations
space shall be considered in making this determina-tion. Each opening shall have a minimum free area of1 in. 2 per 1,000 BTUH (2,225 mm 2 per kW) of the total input rating of all gas utilization equipment in the con-fined space, but not less than 100 in. 2 (645 cm 2 ). One opening shall commence wit...
Page 14 - Water Piping; General
5. Remove all plumbing fittings to the header. Thiswill include both inlet and outlet water pipe unionsand the pressure relief valve and drain piping. 6. Remove limits, control bulbs and/or thermocou-ples. 7. Remove the six (or 8) flange nuts and the in/outheader from the left-hand side. 8. Remove t...
Page 15 - To perform hydrostatic test:; Cold Water Operation; Damaging internal condensation may; Warranty claims will be; Cold Water Star ts
Fig. 9: Torque Sequence the hydrostatic test before connecting gas piping orelectrical supply. Leaks must be repaired at once to prevent damage tothe heater. NEVER use petroleum-based stop-leakcompounds. To perform hydrostatic test: 1. Connect fill water supply. With bleed valve open,fill heater wit...
Page 16 - Cold Water Run; Temperature & Pressure Gauge; Hydronic Heating; Pump Selection
Cold Water Run Cold water run differs from cold water start in that thesystem water entering the heater remains below 105ºF(41ºC) continuously. Typically, this is the case in swim-ming pool heating and water source heat pumpapplications as well as some others. If the systemwater is kept in a narrow ...
Page 18 - Potable Water and Space Heating; When this heater is used for both; Gas Supply; Make sure the gas on which the heater
18 Potable Water and Space Heating 1. All piping materials and components connected tothe water heater for the space heating applicationshall be suitable for use with potable water. 2. Toxic chemicals, such as used for boiler treatment,shall not be introduced into the potable water usedfor space hea...
Page 19 - Gas Supply Connection; FAILURE TO FOLLOW; . Over pressurized gas valves are not cov-; Table I: Maximum Equivalent Pipe Length; Model
19 Gas Supply Connection The heater must be isolated from the gas supply pip-ing system by closing the manual shut-off valve duringany pressure testing of the gas supply piping systemat test pressures equal to or less than 1/2 psi (3.45kPa). Relieve test pressure in the gas supply line priorto recon...
Page 20 - Replace the left and right front panels on the; Gas Supply Pressure; Support gas supply piping with; Adjustment
9. Install a coupling, nipple, union and sediment traponto the right-hand end of the main gas line andthen install the gas line, making sure that a manu-al shut-off valve has been installed within 10 ft ofthe heater. 10. Replace the left and right front panels on the heater. Gas Supply Pressure A mi...
Page 21 - Electrical Power Connections; DO NOT attach any; Before; Field-Connected Controllers; Field-supplied isolation relays should be; Check the power source:; Making the Electrical Connections
Electrical Power Connections Installations must follow these codes: • National Electrical Code and any other national,state, provincial or local codes or regulations hav-ing jurisdiction. • Safety wiring must be NEC Class 1. • Heater must be electrically grounded as requiredby the NEC. • In Canada, ...
Page 22 - Conduit should not be used as the earth ground.; Field Wiring Connection; A grounding electrode conductor shall be
prior to working with any electrical connections orcomponents. 3. Observe proper wire colors while making electri-cal connections. Many electronic controls arepolarity sensitive. Components damaged byimproper electrical installation are not covered bywarranty. 4. Provide overload protection and a di...
Page 24 - If any of the original wire supplied with the
Consult the wiring diagram shipped with the heater inthe instruction packet or at the end of this section. Thestage-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, chec...
Page 25 - Venting; Flue Exhaust Tee; Suppor t of Vent Stack; Appliance Categories
25 Venting General Flue Exhaust Tee An optional Flue Exhaust Tee is available to facilitatehorizontal venting. Any reference to horizontal ventingthat exits the back of the heater requires this tee. Referto Table J for the appropriate kit for your model. CAUTION: Proper installation of flue venting ...
Page 26 - Vent Ter minal Location
8. Locate and guard vent termination to prevent acci-dental contact by people or pets. 9. DO NOT terminate vent in window well, stairwell,alcove, courtyard or other recessed area. 10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causingice formations. 11. Lo...
Page 27 - Changing the Flue Outlet
Canadian Installations Refer to latest edition of B149 Installation code. A vent shall not terminate: 1. Directly above a paved sidewalk or drivewaywhich is located between two single-family dwell-ings and serves both dwellings. 2. Less than 7 ft (2.13 m) above a paved sidewalk orpaved driveway loca...
Page 28 - Venting Configurations; Installation
Venting Configurations For heaters connected to gas vents or chimneys, ventinstallations shall be in accordance with the NFGC(U.S.), or B149 (Canada), or applicable provisions oflocal building codes. Natural Draft Ver tical Venting(Categor y I) Installation Natural draft venting uses the natural buo...
Page 31 - No substitutions of flue pipe or vent
Table M: Category III Horizontal and Direct Venting *Subtract 10 ft per elbow. Max. 3 elbows.Maximum combustion air duct length terminated at 100 equivalent ft. WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions wouldjeopardize the safety and health of inhabi...
Page 32 - Freeze Protection; Controls
Freeze Protection When installing this heater in an outdoor location thatis susceptible to freezing, sales order option B-22must be ordered. The B-22 option energizes theheater pump at a preset temperature drop to circulatewater and reduces the possibility of freezing and dam-aging the heat exchange...
Page 33 - Heater Sequence of Operation; External Lights
33 Fig. 27: Status LED Indicator Decal Heater Sequence of Operation Models 399B–899B 1. The black (hot) wire lead goes directly to the mainpower switch. This black toggle switch is locatedat the middle front of the control compartment. 2. When the main power switch is placed in the “ON”position, 120...
Page 37 - Ignition Module; connection close after 5 seconds.
37 The optional single-try ignition module will lock outafter failing to light one time. To reset it, press andrelease the small, recessed black push button locatedinside of the cut-out on the lower right-hand corner ofthe ignition module case (see Fig. 28). Turning off thepower to the heater WILL N...
Page 41 - WHAT TO DO IF YOU SMELL GAS:
START-UP Pre Star t-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 untilwater appears, then close vent. Air...
Page 42 - Blower Adjustment
Preparation Check Power Supply With multi-meter at incoming power, check voltagebetween: Hot - Common (≈120 VAC) Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) Attach Manometers to Measure Pressures 1. Turn off main gas valve. 2. Attach 24” scale manometer to the first main gasshut-off valve p...
Page 45 - OPERATION; Lighting Instructions
10. To restart system, follow lighting instructions in the Operation section. 11. Check to see that the high limit control is set above the design temperature requirements of thesystem. For multiple zones: Check to make sure the flow isadjusted as required in each zone. 12. Check that the heater is ...
Page 46 - TROUBLESHOOTING
TROUBLESHOOTING Step 7 Step 6 Step 5 Step 1 Step 2 Step 3 Step 4 Is enable/disable jumper intact (J1)? Is there a call for heat? Is there 120VAC at J8 Connector on the CPW board? Do the combustion air blowers come on? Is 24VAC at present at TH (J3 & J12 on CPW board and orange wire on ignition m...
Page 47 - MAINTENANCE; Visually inspect burner flame.; Periodically; Clean screen and air filter in intake.; Daily
MAINTENANCE Suggested MinimumMaintenance Schedule Regular service by a qualified service agency andmaintenance must be performed to ensure maximumoperating efficiency. Maintenance as outlined below may be performed bythe owner. Daily 1. Check that the area where the heater is installedis free from c...
Page 48 - Recalibrate all indicating and recording gauges.; Annually; Inspect and clean burners as necessary.; As Required; Check drip leg and gas strainers.
Weekly For low-pressure heaters, test low-water cut-offdevice. (With at least one stage of the appliance on,depress the low water cut-off test button, applianceshould shut-off and ignition fault light should come on.Depress reset button to reset). Monthly 1. Check flue, vent, stack, or outlet damper...
Page 49 - APPENDIX; Inside Air Contamination
APPENDIX Inside Air Contamination All heaters experience some condensation duringstart-up. The condensate from flue gas is acidic.Combustion air can be contaminated by certain vaporsin the air which raise the acidity of the condensate.Higher acidity levels attack many materials includingstainless st...
Page 51 - RAYPAK PRODUCTS
START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. Additiona...
