INSTALLATION & OPERATING
INSTRUCTIONS
Models 992B–2342B
Types H, WH & P
L
W
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 combustable 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. 1000.511F
Effective: 06-23-09
Replaces: 08-21-08
P/N 241259 Rev. 7
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CONTENTS
WARNINGS
BEFORE INSTALLATION
Product Receipt
4
5
5
5
5
5
6
7
Venting Installation Tips
28
28
33
33
34
Venting Configurations
Outdoor Installation
Controls
Model Identification
Ratings and Certifications
Installations at Elevation
Component Locations
General Information
GENERAL SAFETY
Time/Temperature Relationships in
Scalds
Heater Sequence of Operation
87%-Efficiency Boilers –
Special Instructions
Wiring Diagrams
45
50
52
52
53
56
56
56
57
58
8 START-UP
Pre Start-up
Start-Up
9 OPERATION
8
INSTALLATION
Installation Codes
9
9
Lighting Instructions
To Turn Off Gas To Appliance
Equipment Base
Stacking
9 TROUBLESHOOTING
Clearances
11 MAINTENANCE
12
Combustion and Ventilation Air
Suggested Minimum
Conventional Combustion Air Supply 13
Maintenance Schedule
58
Water Piping
Hydronic Heating
Gas Supply
14
Preventative Maintenance Schedule 58
16 APPENDIX
60
60
61
61
62
20
Inside Air Contamination
Electrical Power Connections
Field Wiring Connection
Venting
22 WARRANTIES
23
25
27
Type H and WH
Type P
Changing the Flue Outlet
3
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WARNINGS
Pay Attention to These Terms
Indicates the presence of immediate hazards which will cause severe person-
DANGER:
WARNING:
CAUTION:
NOTE:
al 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: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
•
Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
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.
•
Heater should never be covered or have any
blockage to the flow of fresh air 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.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to deenergize the
equipment before servicing.
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: 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.
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.
4
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number will have the form H9 1262B 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), P = Pool). The number which fol-
lows identifies the firing mode (1 or 4 = on-off, 3 =
2-stage, 8 = 3-stage and 9 = 4-stage). The second
group of characters identifies the size of the heater
(four numbers representing the approximate MBTUH
input), and, where applicable, a letter, indicating the
manufacturing series. An “E” suffix indicates 87% effi-
ciency (Category II or IV venting) (“H” stamped boilers
only).
BEFORE INSTALLATION
Raypak strongly recommends that this manual be re-
viewed thoroughly before installing your Hi Delta
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
Thank you for purchasing a Raypak product. We hope
you will be satisfied with the high quality and durability
of our equipment.
Standards:
•
•
•
•
ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired
Hot Water Boilers
Product Receipt
CAN 3.1
-
latest edition, Industrial and
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.
Commercial Gas-Fired Package Boilers
ANSI Z21.56 · CSA 4.7 - latest edition Gas-Fired
Pool Heaters
ANSI Z21.10.3 · CSA 4.3 - latest edition Gas
Water Heaters
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.
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.
Installations at Elevation
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
5
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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
6
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General Information
Quantity of
Gas
Vent Size (in.)
Model
No.
Burners
Blowers Flue Intake
Valves
992B
1262B
1532B
1802B
2002B
2072B
2342B
11
14
17
20
23
23
26
2 + 1*
2
2
2
2
3
3
3
10
12
12
14
14
14
16
10
10
10
10
10
10
10
3 + 1*
4
4
5
5
5
*Hidden solenoid valve located inside of air plenum.
Table A: Basic Data
Burners per Valve
Stages
3
% Fire at Stage
Model
No.
1
6
5
6
6
4
4
5
1A
2
3
3
4
4
5
5
5
3
2
3
4
5
5
5
5
4
1
1
1
1
1
2
4
1
2
3
4
992B
1262B
1532B
1802B
2002B
2072B
2342B
1, 2
1,2
1,2
1,2
1, 2, 3
1, 2, 3
1, 2, 3
1, 2, 3
54 82 100
3
3
5
4
4
5
1, 2, 3, 4
1, 2, 3, 4
1, 2, 3, 4
36 57 79 100
35 59 82 100
30 50 75 100
5
5
6
1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 39 61 83 100
1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 39 61 83 100
1, 1A 1, 1A, 2 1, 1A, 2, 3 1, 1A, 2, 3, 4 42 62 81 100
Table B: Manifold Data
7
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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
8
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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
Hi Delta units can be stacked two units high with an
optional stacking rack. A seismic-certified 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 Controller
CAUTION: Hotter water increases the risk of scald-
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)
•
Fig. 5: Typical Stacked Installation
9
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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
A
1 ft (30 cm)
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
B
C
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
D
5 ft (1.5m)
*
E
F
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
*
*
*
*
*
G
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
H
I
*
*
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)
J
3 ft (91 cm)
other appliance
above opening
3 ft (91 cm) above if within
10 ft (3m) horizontally
K
L
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
M
*
12 in. (30 cm) TT
1
2
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
In accordance with the current CAN/CGA-B149 Installation Codes
t
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
10
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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”
6”
Outdoor Installations
Water Side
Other Side
Top
12”
1”
24”
24”
6”
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”
24”
36”
36”
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
11
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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.)
Direct Vent
Fig. 8: Minimum Clearances from Combustible
Surfaces – Outdoor Installations
If outside air is drawn through the intake pipe directly
to the unit for combustion:
1. Install combustion air direct vent in accordance
with Fig. 29 (horizontal) or Fig. 30 (vertical) of this
manual (pages 31 and 32, respectively).
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.
2. Provide adequate ventilation of the space occu-
pied by the heater(s) by an opening(s) for
ventilation air at the highest practical point com-
municating with the outdoors. The total
cross-sectional area shall be at least 1 in.2 of free
area per 20,000 BTUH (111 mm2 per kW) of total
input rating of all equipment in the room when the
opening is communicating directly with the out-
doors or through vertical duct(s). The total
cross-sectional area shall be at least 1 in.2 of free
area per 10,000 BTUH (222 mm2 per kW) of total
input rating of all equipment in the room when the
opening is communicating with the outdoors
through horizontal duct(s).
Indoor Units
The heater must be supplied with sufficient quantities
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.
3. In cold climates, and to mitigate potential freeze-
up, Raypak highly recommends the installation of
a motorized sealed damper to prevent the circula-
tion of cold air through the heater during the
non-operating hours.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty. (See
the Appendix.)
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
NOTE: It is recommended that the intake vent be
insulated to minimize sweating.
12
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three or four sheet metal screws (not supplied) equal- space shall be considered in making this determina-
ly distributed around the circumference of the duct. All tion. Each opening shall have a minimum free area of
ducting should be self-supported. The filter housing is 1 in.2 per 1,000 BTUH (2,225 mm2 per kW) of the total
not designed to support the air duct.
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.
CAUTION: Use TrueSeal combustion air if
damaging airborne contaminants are or will be
present in the heater area. See the Appendix
regarding air contamination.
TruSeal™ Combustion Air
All Air from Outdoors
In certain applications it may be necessary to utilize
the TruSeal option (sales order option D-21 or D-22)
and duct the combustion air directly to the blower.
Combustion air may be ducted directly to the heater by
using PVC, CPVC or sealed single-wall galvanized
ducting. The duct will attach directly to the air collar lo-
cated on the side of the heater, using three or four
sheet metal screws (not supplied) equally positioned
around the circumference of the duct. The screws and
duct connection point must be sealed with RTV (not
supplied). An in-line intake air filter kit (sales order
option D-17) must be installed in the combustion air
duct. TruSeal is generally used when damaging con-
taminants are present in the mechanical room.
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
are used, they shall be of the same cross-sectional
area as the net free area of the openings to which they
connect.
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.
TruSeal heater connection points are available as fol-
lows:
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.2 per
4,000 BTUH (550 mm2 per kW) of total input
rating of all equipment in the enclosure.
992B to 1802B
Left side – standard
Right side – optional
2002B to 2342B
Right side only
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.
b. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in.2 per 2,000
BTUH (1,100 mm2 per kW) of total input rat-
ing of all equipment in the enclosure.
Conventional Combustion Air
Supply
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:
U.S. Installations
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
a. 1 in.2 per 3,000 BTUH (740 mm2 per kW) of
the total input rating of all equipment located in
the enclosure, and
13
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b. Not less than the sum of the areas of all vent
connectors in the confined space.
of not less than 1 in.2 for each 30,000 BTUH mm2
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
ventilation air referred to in (1). This opening(s)
can be 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 18
in. (450 mm) from the floor, but not near piping.
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.
4. Refer to B149 Installation code for additional infor-
mation.
Water Piping
1. Ventilation of the space occupied by the heater
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).
NOTE: For 87%-efficiency boilers, see special
instructions on page 45.
General
The heater should be located so that any water leaks
will not cause damage to the adjacent area or struc-
tures.
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.2 per 7,000 BTUH (320 mm2 per kW) up
to and including 1 million BTUH, plus 1 in.2 per
14,000 BTUH (160 mm2 per 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).
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.
NOTE: Minimum pipe size for in/out connections is
1
2 ⁄
2
in. Verify proper flow rates and ΔT as instructed
in this manual.
Reversing Water Connections
Follow these instructions to change the water connec-
tions from the left-hand side (standard) to the
right-hand side.
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.
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.
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
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.
14
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5. Remove all plumbing fittings to the header. This
will include both inlet and outlet water pipe unions
and the pressure relief valve and drain piping.
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
the hydrostatic test before connecting gas piping or
electrical supply.
6. Remove limits, control bulbs and/or thermocou-
ples.
7. Remove the eight flange nuts and the in/out head-
er from the left-hand side.
8. Remove the eight flange nuts and the return head-
er from the right-hand side.
9. Reverse the headers to the new location.
Leaks must be repaired at once to prevent damage to
the heater. NEVER use petroleum-based stop-leak
compounds.
10. Install NEW red beveled O-rings flush against both
tube sheets with the bevel facing outward.
11. Push the header firmly against the O-rings. Install
and tighten the flange nuts onto the stud bolts until
finger tight.
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.
12. 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.
13. Re-route the capillary(s), wiring etc. to the new
location, adding thermal paste and shim to the
capillary well.
2. Make sure constant gauge pressure has been
maintained throughout test.
3. Check for leaks. Repair if found.
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.
Fig. 9: Torque Sequence
Relief Valve Piping
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.
15
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system, such as a three-way proportional valve or a
modulating two-way valve to control the bypass,
should be utilized.
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.
Cold Water Run
Cold water run differs from cold water start in that the
system water entering the heater remains below 105ºF
(41ºC) continuously. Typically, this is the case in swim-
ming pool heating and water source heat pump
applications as well as some others. If the system
water is kept in a 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.
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.
Temperature & Pressure Gauge
The temperature and pressure gauge is factory-
mounted in the in/out header.
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
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
Hydronic Heating
Pump Selection
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.
Min. Flow
P (ft)
1.3
Max Flow
P (ft)
13.1
20°F T
30°F T
40°F T
Model
No.
gpm
83
gpm
gpm
gpm
gpm
P (ft)
5.2
P (ft)
2.3
P (ft)
1.3
T
T
13
16
19
23
25
26
30
992B
55
71
42
53
64
76
84
87
98
42
53
64
76
84
87
98
40 132
40 132
40 132
40 132
40 132
40 132
40 132
1262B 106
1532B 129
9.6
4.3
2.4
2.4
14.8
15.7
N/A
N/A
N/A
N/A
86
7.1
4.0
4.0
16.5
1802B
2002B
2072B
2342B
N/A
N/A
N/A
N/A
101
112
116
132
10.7
13.8
14.8
21.4
6.0
6.0
18.3
7.9
7.9
19.0
8.5
8.5
19.0
12.1
12.1
21.4
Notes:
1. Basis for minimum flow is 40°F ΔT. Basis for maximum flow is 132 gpm.
2. Rear-mounted pumps may provide higher flow rates on smaller models than the system requirements
Table G: Heater Rates of Flow and Pressure Drops
16
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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.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
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.
*
*Maximum 4 times the pipe diameter or 12”, whichever is less.
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
17
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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
Pool Heating
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.
CAUTION: Power to the heater should be
interlocked with the main system pump to make sure
the heater does not fire without the main system
pump in operation. Improper flow control can
damage the heater. Uncontrolled flow (too high) or
restricted flow (too low) can seriously damage the
heater. Follow these instructions to make sure your
heater is properly installed.
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.
The Hi Delta pool heater is equipped with an external
pump and bypass arrangement as standard equip-
ment. This arrangement blends outlet water with the
inlet water to increase the inlet water temperature,
thereby reducing the likelihood of condensation form-
ing on the heat exchanger. The pump also serves to
Soft (0-4 grains per gallon) Medium (5-15 grains per gallon) Hard* (16-25 grains per gallon)
Model
No.
gpm
MTS SHL
gpm
MTS SHL
gpm
MTS SHL
T
P
2.7
4.4
7.1
T
P
5.2
T
P
992B 28 60
1262B 30 72
1532B 30 86
2
2
2
2
2
2
2
4.6 20
83
2
2
2
2
2
2
2
8.6
13 132 13.1
2
2
2
2
2
2
2
21.0
22.7
24.4
26.1
26.9
26.9
29.3
7.0 20 106
10.7 20 132
15.5 23 132
19.7 26 132
21.0 27 132
29.3 30 132
9.6
14.8 16 132 14.8
24.4 20 132 16.5
26.1 23 132 18.3
26.9 26 132 19.0
26.9 27 132 19.0
29.3 30 132 21.4
16.5
18.3
19.0
19.0
21.4
1802B 30 101 10.7
2002B 30 112 13.9
2072B 30 116 14.8
2342B 30 132 21.4
ΔT = Temperature rise, °F
ΔP = Pressure drop through heat exchanger, ft
1
SHL = System head loss, ft (based on heater and tank placed no more than 5 ft apart and equivalent length pipe/fittings of 2 ⁄
2”
tube = 25 ft)
gpm = Gallons per minute, flow rate
MTS = Minimum tubing size
*Must utilize optional cupro-nickel tubes. If over 25 grains per gallon, a water softener/treatment system must be utilized.
Caution: For scale free operation with "Hard Water" (16-25 grains per gallon of total hardness), the operating control must NOT be
set higher than 130 F. For higher than 130 F operation, a water softener/treatment system must be utilized.
Table H: Domestic Water Heater Flow Rate Requirements
18
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circulate water through the heater from the main sys-
tem piping.
slowly throttle Valve B closed to increase the inlet
water temperature to 105°F.
To complete the installation of the pool heater, the pool
thermostat needs to be installed in the main return wa-
ter line, upstream of the heater. This will ensure that
the heater will be energized at the right time. If the
main water line is too far away from the heater and the
capillary bulb will not reach it, locate the pool thermo-
stat adjacent to the main line and run wires back to the
heater.
Fig. 15: “H” Bypass Setting
*
Automatic Chlorinators and Chemical
Feeders
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 14: Single Pool Heater Application
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty.
Adjustment of the manual bypass valve is critical to
proper operation of the heater. The manual bypass
valve should be adjusted to achieve a minimum inlet
water temperature of 105°F and an outlet water tem-
perature below 140°F. When starting with a cold pool, All chemicals must be introduced and completely di-
make initial adjustments. Make final adjustments when luted into the pool or spa water before being circulated
pool water approaches desired temperature.
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer. High chemical concen-
The use of a bypass is required for proper operation in trations will result when the pump is not running (e.g.
a pool heating application. Use the following instruc- overnight).
tions to set the manual bypass:
Chlorinators must feed downstream of the heater and
open position, and have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off.
1
1. Set Valve A (the bypass) to ⁄
2
Valve B to fully open position.
2. Turn on pump.
NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will cause
3. Turn on heater and wait until heater goes to full
fire.
very rapid corrosion of the heat exchanger in the
heater. Such damage is not covered under the
warranty.
4. Adjust Valve A until the inlet water temperature is
105°F. NOTE: Opening the valve will increase the
temperature and closing the valve will decrease Winterizing Your Heater
the temperature.
Heaters installed outdoors in freezing climate areas
5. If this process does not raise the inlet water tem- should be shut down for the winter. To shut down
perature to 105°F and Valve A is fully open, then heater, turn off manual main gas valve and main gas
19
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shut-off. Close isolation valves and remove water pip- Total Dissolved Solids
ing from the in/out header on the heater. Drain the
heater and any piping of all water that may experience Total dissolved solids (TDS) is the measure of all min-
below-freezing temperatures.
erals and solids that are dissolved in the water. The
concentration of total dissolved solids is usually ex-
pressed in parts per million (ppm) as measured in a
water sample. Water with a high TDS concentration
will greatly accelerate lime and scale formation in the
hot water system. Most high TDS concentrations will
precipitate out of the water when heated. This can
generate a scale accumulation on the heat transfer
surface that will greatly reduce the service life of a
water heater. This scale accumulation can also
Pool/Spa Water Chemistry
NOTE: Chemical imbalance can cause severe
damage to your heater and associated equipment.
Water Hardness
Water hardness is mainly due to the presence of cal- impede adequate flow of water and may totally block
cium and magnesium salts dissolved in the water. The the water passages in the tubes of the heat exchang-
concentration of these salts is expressed in mg/l, ppm er. A heat exchanger that is damaged or blocked by
or grains per gallon, as a measure of relative hardness lime/scale accumulation must be replaced. Failure of a
of water. Grains per gallon is the common reference water heater due to lime scale build up on the heating
measurement used in the U.S. water heater industry. surface is non-warrantable. The manufacturer of the
Hardness expressed as mg/L or ppm may be divided water heater has no control of the water quality, espe-
by 17.1 to convert to grains per gallon. Water may be cially the TDS levels in your system. Total dissolved
classified as very soft, slightly hard, moderately hard solids in excess of 2,500 ppm will accelerate lime and
or hard based on its hardness number. The salts in scale formation in the heat exchanger. Heat exchang-
water will precipitate out when the water is heated and er failure due to total dissolved solids in excess of
will cause accelerated lime and scale accumulation on 2,500 ppm is a non-warrantable condition. Raypak
a heat transfer surface.
offers basic temperature guidelines for operation of a
potable water heater on normal to moderate levels of
Raypak water heaters can operate lime/scale-free hardness and solids but levels of hardness and total
using potable water with a hardness not exceeding 25 dissolved solids beyond normal limits for operation will
grains per gallon. Proper operation is achieved by set- require special setup and operation.
ting the temperature rise/water flow per the guidelines
in the installation instructions. If the hardness of the
NOTE: Failure of a heat exchanger due to lime
water exceeds the maximum level of 25 grains per gal-
scale build-up on the heating surface, low pH or
lon special measures must be taken to adjust flow and
other chemical imbalance is non-warrantable.
temperature rise. Water should be softened to a hard-
ness level no lower than 5 grains per gallon. Water
softened as low as 0 to 1 grain per gallon may be
Gas Supply
under-saturated with respect to calcium carbonate
resulting in water that is aggressive and corrosive.
DANGER: Make sure the gas on which the heater
will operate is the same type as specified on the
heater’s rating plate.
pH of Water
pH is a measure of relative acidity, neutrality or alka-
linity. Dissolved minerals and gases affect water’s pH.
The pH scale ranges from 0 to 14. Water with a pH of
7.0 is considered neutral. Water with a pH lower than
7 is considered acidic. Water with a pH higher than 7
is considered alkaline. A neutral pH (around 7) is desir-
able for most potable water applications. Corrosion
damage and water heater failures resulting from water
pH levels of lower than 6 or higher than 8 are non-war-
rantable. The ideal pH range for water used in a
storage tank or a copper water heater system is 7.2 to
7.8.
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
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.
20
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Gas Supply Connection
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.
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).
Reversing Gas Supply Connection
Reversing the standard fuel connection from the left-
hand to the right-hand side is a simple field operation.
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.
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.
Fig. 16: Gas Supply Connection
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.
2”
2-1/2”
3”
4”
Model
No.
N
P
N
P
N
P
--
--
--
--
--
--
N
--
--
--
--
--
--
P
--
--
--
--
--
--
--
992B
1262B
1532B
1802B
2002B
2072B
2342B
120 300 300
--
--
75
50
40
30
30
20
180 170 325 560
120 125 250 400
100 100 225 340
80
80
55
75
75
55
175 260
175 260
135 160 400 600
3
Natural gas – 1,000 BTU per ft , .60 specific gravity at 0.5 in. WC pressure drop
3
Propane gas – 2,500 BTU per ft , 1.53 specific gravity at 0.6 in. WC pressure drop
Table I: Maximum Equivalent Pipe Length
21
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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.
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.
10. Replace the left and right front panels on the
heater.
•
•
Safety wiring must be NEC Class 1.
Heater must be electrically grounded as required
by the NEC.
Gas Supply Pressure
•
In Canada, CSA C22. 1 C.E.C. Part 1.
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
pressure regulator, of the lockup type, must be
installed.
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.
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.
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.
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.
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
It is strongly recommended that all individually-pow-
ered control modules and the heater should be
supplied from the same power source.
NOTE: Field-supplied isolation relays should be
installed when field-connected controllers are
mounted more than 50 equivalent feet (18 Ga) from
heater.
Check the Power Source
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.)
Fig. 17: Gas Valves
22
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NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.
prior to working with any electrical connections or
components.
3. Observe proper wire colors while making electri-
cal connections. Many electronic controls are
polarity sensitive. Components damaged by
improper electrical installation are not covered by
warranty.
4. Provide overload protection and a disconnect
means for equipment serviceability as required by
local and state code.
BLACK
CIRCUIT
BREAKER
WHITE
GREEN
5. Install heater controls, thermostats, or building
management systems in accordance with the
applicable manufacturers’ instructions.
GROUND
A
B
C
6. Conduit should not be used as the earth ground.
Fig. 18: Wiring Connections
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.
Check the power source:
AC = 108 VAC Minimum, 132 VAC MAX
AB = 108 VAC Minimum, 132 VAC MAX
BC = <1 VAC Maximum
Field Wiring Connection
Fig. 19: Multi-meter
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.
To field-connect a stage controller, remove factory-
installed jumpers and wire stage controller as shown in
Fig. 21-24.
Making the Electrical Connections
Fig. 20: Wiring Location
Refer to Fig. 18-26.
1. Verify that circuit breaker is properly sized by
referring to heater rating plate. A dedicated circuit
breaker should be provided.
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause im-
proper and dangerous operation. Verify proper
operation after servicing.
2. Turn off all power to the heater. Verify that power
has been turned off by testing with a multi-meter
23
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DANGER: SHOCK HAZARD
Make sure electrical power to the heater is discon-
nected to avoid potential serious injury or damage to
components.
Fig. 21: On-Off Wiring Connections
Fig. 23: 3-Stage Wiring Connections
Fig. 24: 4-Stage Wiring Connection
Installer action is required to electrically enable your
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
for temperature control connections. This will be done
based on the controller option selected with your
heater order.
1. For Pool and Closed-Loop Water-Source Heat
Pump applications, your heater should be config-
Fig. 22: 2-Stage Wiring Connections
24
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SINGLE
STAGE
TANKSTAT
ured 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 1532B, you will jumper stages
two, three and four. Then your heater will either be
on at full fire, or it will be off.
STAGE 1
CONNECTION
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.
ATTACH STAGE 1 CONNECTIONS
ON HEATER TO THE SINGLE STAGE
TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.
Fig. 26: Single-Stage Tankstat
Venting
NOTE: For 87%-efficiency boilers, see special
instructions on page 43.
CAUTION: Proper installation of flue venting is criti-
cal for the safe and efficient operation of the heater.
3. For single-stage controller connections, attach the
stage 1 connections on heater 1 to the tankstat per
Fig. 26.
General
Heater must be electrically grounded in accordance
with the NEC, and CSA C22.1 C.E.C. Part 1 in
Canada.
Flue Exhaust Tee
2-STAGE
TANKSTAT
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.
STAGE 2 CONNECTION OR
STAGE 1 CONNECTION
STAGE 1
CONNECTION
Model
Diameter
Order Number
OF HEATER 2
992B
10”
12”
011841
011842
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.
1262B, 1532B
1802B, 2002B,
2072B
14”
16”
011843
011844
2342B
Fig. 25: 2-Stage Tankstat
Table J: Flue Exhaust Tee Kits
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.
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.
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.
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.
25
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Category II – A heater which operates with a non-pos- Use insulated vent pipe spacers where the vent pass-
itive vent static pressure and with a vent gas
temperature that may cause excessive condensate
production in the vent.
es through combustible roofs and walls.
NOTE: During winter months check the vent cap
and make sure no blockage occurs from build-up of
snow or ice.
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.
Vent Terminal Location
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.
1. Condensate can freeze on the vent cap. Frozen
condensate on the vent cap can result in a blocked
flue condition.
2. Give special attention to the location of the vent
termination to avoid possibility of property dam-
age or personal injury.
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.
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.
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.
CAUTION: When condensate traps are installed,
condensate must be routed to an appropriate
container for neutralization before disposal, as
required by local codes.
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.
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.
6. Un-insulated single-wall metal vent pipe shall not
be used outdoors in cold climates for venting gas-
fired equipment.
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.
Support of Vent Stack
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.
Combustion
Air Supply
Exhaust
Configuration
Heater Venting
Category
Certified
Materials
Combustion Air
Inlet Material
Vertical Natural
Draft Venting
I
“B” Vent
From Inside Building
(Non-Direct Venting)
Horizontal Through-
the-Wall Venting
Stainless Steel
(Gas Tight)
III
I
Vertical Natural
Draft Venting
Galvanized Steel
PVC
“B” Vent
From Outside Building
(Direct Venting)
ABS
CPVC
Horizontal Through-
the-Wall Venting
Stainless Steel
(Gas Tight)
III
Table K: Venting Category Requirements
26
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8. Locate and guard vent termination to prevent acci- Canadian Installations
dental contact by people or pets.
Refer to latest edition of B149 Installation code.
A vent shall not terminate:
9. DO NOT terminate vent in window well, stairwell,
alcove, courtyard or other recessed area.
10. DO NOT terminate above any door, window, or 1. Directly above a paved sidewalk or driveway
gravity air intake. Condensate can freeze, causing
ice formations.
which is located between two single-family dwell-
ings and serves both dwellings.
11. Locate or guard vent to prevent condensate from 2. Less than 7 ft (2.13 m) above a paved sidewalk or
damaging exterior finishes. Use a rust-resistant
sheet metal backing plate against brick or mason-
ry surfaces.
paved driveway located on public property.
3. Within 6 ft (1.8 m) of a mechanical air supply inlet
to any building.
12. DO NOT extend exposed vent pipe outside of
building. Condensate could freeze and block vent 4. Above a meter/regulator assembly within 3 ft (915
pipe.
mm) horizontally of the vertical centre-line of the
regulator.
U.S. Installations
5. Within 6 ft (1.8 m) of any gas service regulator
vent outlet.
Refer to the latest edition of the National Fuel Gas
Code.
6. Less than 1 ft (305 mm) above grade level.
Vent termination requirements are as follows:
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.
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.
2. The vent must not be less than 7 ft above grade 8. Underneath a verandah, porch or deck, unless the
when located adjacent to public walkways.
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).
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.
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).
5. Terminate vent at least 6 ft away from adjacent
walls.
1. Disconnect all electrical power from the heater (if
applicable).
6. DO NOT terminate vent closer than 5 ft below roof
overhang.
2. Disconnect or isolate the main gas pipe from the
heater (if applicable).
7. The vent terminal requires a 12 in. vent terminal
clearance from the wall.
3. Remove the screws, gasket and dustcover from
the rear of the heater.
8. Terminate vent at least 1 ft above grade, including
normal snow line.
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.
9. Multiple direct vent installations require a 4 ft
clearance between the ends of vent caps located
on the same horizontal plane.
27
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5. Remove the screws, retaining ring and rain gasket The maximum and minimum venting length for Cate-
from top of heater.
gory I appliances shall be determined per the NFGC
(U.S.) or B149 (Canada).
6. Remove the screws, flue collar and gasket from
the run side of the tee located in the flue box on The diameter of vent flue pipe should be sized accord-
top of the heater.
ing to the NFGC (U.S.) and B149 (Canada). The
minimum flue pipe diameter for conventional negative
7. Reverse the components and reattach in the new draft venting using double-wall Type B vent is: 10 in.
location.
for Model 992B; 12 in. for Models 1262B and 1532B;
14 in. for Models 2002B and 2072B; and 16 in. for
8. Make sure that the stainless steel cover, now lo- 2342B.
cated on the run side of the tee, is sealed to avoid
any flue gas spillage.
NOTE: A vent adapter (field-supplied) must be used
to connect Type B vent to the unit.
CAUTION: The silicone vent gaskets must be prop-
erly reinstalled to prevent flue gas leakage. Replace
any torn or worn vent gaskets.
Venting Installation Tips
Support piping:
•
•
•
horizontal runs - at least every 5 ft
vertical runs - use braces
under or near elbows
WARNING: Examine the venting system at least
once a year. Check all joints and vent pipe
connections for tightness, corrosion or deterioration.
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)
Fig. 27: 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 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.
28
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Termination
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.
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.
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.
1. Seal any unused opening in the common venting
system.
CAUTION: A listed vent cap terminal, adequately
sized, must be used to evacuate the flue products
from the heaters.
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.
Common Venting System
Manifolds that connect more than one heater to a com-
mon chimney must be sized to handle the combined
load. Consult available guides for proper sizing of the
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.
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
Vertical Venting
Height*
Air Inlet
Max. Length**
Certified
Model Venting
Material
Combustion Air
Intake Pipe
Material
Vent Size
Min.
Max.
10”
12”
992B
10”
12”
75’
100’
1262B
Galvanized Steel,
PVC,
1532B
Category I
(Type B
Equivalent)
1802B
2002B
2072B
2342B
5’
25’
ABS,
CPVC
14”
16”
40’
75’
* 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 K: Category I Vertical Venting
29
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speed. Do not operate summer exhaust fan. Close The total length of the horizontal through-the-wall flue
fireplace dampers.
system should not exceed 70 equivalent ft in length. If
horizontal run exceeds 70 equivalent ft, an appropri-
4. Place in operation the appliances being inspected. ately sized extractor must be used. Each elbow used
Follow the manufacturer’s instructions for lighting is equal to 10 ft of straight pipe. This will allow installa-
each appliance. Adjust thermostat so appliance tion in one of the four following arrangements:
will operate continuously.
•
•
•
•
70’ of straight flue pipe
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.
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
6. After it has been determined that each appliance the venting system.
remaining connected to the common venting sys-
tem properly vents when tested as outlined above, The vent must be installed to prevent flue gas leakage.
return doors, windows, exhaust fans, fireplace Care must be taken during assembly to ensure that all
dampers and other gas burning appliances to their joints are sealed properly and are airtight. The vent
previous conditions of use.
must be installed to prevent the potential accumulation
of condensate in the vent pipes. It is required that:
7. Any improper operation of the common venting
system should be corrected so that the installation 1. The vent must be installed with a slight downward
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-
slope of not more than 1/4 inch per foot of hori-
zontal run to the vent terminal.
sized to approach the minimum size as 2. The vent must be insulated through the length of
determined using the appropriate tables in the
NFGC (U.S.) or B149 (Canada).
the horizontal run.
For installations in extremely cold climate, it is re-
quired that:
Horizontal Through-the-Wall Venting
(Category III)
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.
*
2. The vent must be insulated through the length of
the horizontal run.
Termination
The flue direct vent cap MUST be mounted on the ex-
terior of the building. The direct vent cap cannot be
installed in a well or below grade. The direct vent cap
must be installed at least 1 ft above ground level and
above normal snow levels. The Raypak-approved
stainless steel flue direct vent cap must be used (sales
order option D-15).
*Requires optional vent tee.
Fig. 28: Horizontal Through-the-Wall Venting
(Category III)
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).
WARNING: No substitutions of flue pipe or vent
cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants.
30
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Combustion
Air
Intake Pipe
Material
Air Inlet
Max. Length*
Certified
Venting Vent Size Equivalent
Material
Maximum
Model
No.
Vent Length*
10”
12”
992B
1262B
1532B
1802B
2002B
2072B
2342B
10”
12”
70’
Room Air
75’
100’
Galvanized
Steel,
40’
Ducted
Combustion
Air
Category III
PVC,
ABS,
CPVC
14”
16”
40’
75’
* Subtract 10 ft per elbow. Max. 3 elbows.
Maximum combustion air duct length terminated at 100 equivalent ft.
Table L: Category III Horizontal and Direct Venting
The total length of the through-the-wall flue cannot
exceed 40 equivalent ft in length for the flue outlet.
Each elbow used is equal to 10 ft of straight pipe. This
will allow installation in one of the three following
arrangements:
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.
•
•
•
40’ of straight flue pipe
30’ of straight flue pipe and one elbow
20’ of straight flue pipe and two elbows.
Direct Vent - Horizontal Through-
the-Wall
The total length of air supply pipe cannot exceed the
distances listed in Table L. Each elbow used is equal
to 10 ft of straight pipe. This will allow installation in
any arrangement that does not exceed the lengths
shown in Table L.
The flue direct vent cap is not considered in the over-
all length of the venting system.
Care must be taken during assembly that all joints are
sealed properly and are airtight.
The vent must be installed to prevent the potential ac-
cumulation of condensate in the vent pipes. It is
required that:
1. The vent must be installed with a slight downward
slope of not more than 1/4 inch per foot of hori-
zontal run to the vent terminal.
Note: When vertical height exceeds 25 ft,
consult factory prior to installation.
Fig. 29: Direct Vent - Horizontal Through-the-Wall
2. The vent must be insulated through the length of
the horizontal run.
Installation
These installations utilize the heater-mounted blower
to draw combustion air from outdoors and vent com-
bustion products to the outdoors.
31
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For installations in extremely cold climate, it is re-
quired that:
Direct Vent - Vertical
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.
2. The intake vent must be insulated through the
length of the horizontal run.
Termination
The flue direct vent cap MUST be mounted on the ex-
terior of the building. The direct vent cap cannot be
installed in a well or below grade. The direct vent cap
must be installed at least 1 ft above ground level and
above normal snow levels.
Note: When vertical height exceeds 25 ft, consult
factory prior to installation.
Fig. 30: Direct Vent - Vertical
The direct vent cap MUST NOT be installed with any
combustion air inlet directly above a direct vent cap.
This vertical spacing would allow the flue products
from the direct vent cap to be pulled into the combus-
tion air intake installed above.
Installation
These installations utilize the heater-mounted blower
to draw combustion air from outdoors and force the
heated flue products through the vent pipe under posi-
tive pressure. The vent material must be in
accordance with the above instructions for vent mate-
rials. Vent material must be listed by a nationally
recognized test agency.
This type of installation can cause non-warrantable
problems with components and poor operation of the
heater due to the recirculation of flue products. Multi-
ple direct vent caps should be installed in the same
horizontal plane with a 4 ft clearance from the side of
one vent cap to the side of the adjacent vent cap(s).
The connection from the appliance flue to the stack
must be as direct as possible and should be the same
size or larger than the vent outlet.
Combustion air supplied from outdoors must be free of
particulate and chemical contaminants. To avoid a
blocked flue condition, keep the vent cap clear of
snow, ice, leaves, debris, etc.
See Table K for Category I venting guidelines.
It is recommended that in colder climates, the intake
vent be insulated.
WARNING: No substitutions of flue pipe or vent
cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants.
Termination
The flue terminal should be vertical and should termi-
nate outside the building at least 2 ft above the highest
point of the roof 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 horizontal 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 openings must be consis-
tent with the NFGC (U.S.) or B149 (Canada).
The stainless steel flue direct vent cap must be fur-
nished by the heater manufacturer in accordance with
its listing (sales order option D-15).
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 carefully the vent manufacturer’s installation
instructions.
32
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Flues supported only by flashing and extended above
the roof more than 5 ft should be securely guyed or
braced to withstand snow and wind loads.
NOTE: Condensate can freeze on the vent cap.
Frozen condensate on the vent cap can result in a
blocked flue condition.
The air inlet opening MUST be installed 1 ft above the
roof line or above normal snow levels that might ob-
struct combustion air flow. This dimension is critical to
the correct operation of the heater and venting system
and reduces the chance of blockage from snow. The
vent cap must have a minimum 3 ft vertical clearance
from the air inlet opening.
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).
Freeze Protection
Outdoor Installation
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.
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.
Controls
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:
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.
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).
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.
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.
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.
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.
CAUTION: Risk of electric shock: More than one
disconnect switch may be required to de-energize
the equipment before servicing.
4. Install above grade level and above normal snow
levels.
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.
33
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12. Power is applied to terminal P1-1 of the Universal
Diagnostics Board. 24 VAC power is then applied
in series to all typically closed safeties wired into
the heater. All safeties are verified to ensure that it
is safe to operate the heater. The safety compo-
nents wired into the diagnostic board are: low
water cut-off (optional), blocked vent switch, man-
ual vent temp switch (optional), manual reset high
limit, low gas pressure switch, high gas pressure
switch (optional), and auto-reset high limit (option-
al).
Fig. 31: Status LED Indicator Decal
13. If any of the safeties do not close, a signal is sent
to the Universal Diagnostics Board to indicate a
safety fault.
Heater Sequence of Operation
Models 992B-1262B
14. Power is applied to terminal TP-1 of the
Economaster II pump delay to energize the circuit
board.
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. Once all safeties are closed and verified, a 24 VAC
signal is output from the Auto High Limit to J5 pin
3 of the CPW board of the heater.
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.
16. 24 VAC power is now sent to the coil of relay K-1.
17. Relay K-1 (N.C.) will now be energized, and opens
the N.C. contacts to disable the alarm (optional)
and turns off the red LED safety shutdown light on
the front status board.
3. 120 VAC is waiting at the N.O. contacts of the
Economaster II pump delay.
4. Terminals L1 and F1 of the ignition module are
powered with 120VAC.
18. The common terminal of the Auto High Limit will
now send a 24 VAC signal to pin 1 of the “panel
switch”.
5. 120 VAC power is also applied to the control
power connector on the circuit board.
19. The “panel 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. 120 VAC power is waiting at the N.O. contacts of
K-3 relay to energize the heater blower.
7. The 120/24 VAC transformer outputs 24 VAC.
20. After the standby switch is placed into the “ON”
position, a 24 VAC signal is sent to the
“enable/disable” connection (normally jumpered).
8. 24 VAC is sent to pin L1 of the low water cut-off
(optional) and the red power light is energized.
9. 24 VAC is applied to the blue power light located
on the status display board.
21. 24 VAC switched power is applied to the S24V ter-
minal on the ignition module.
10. 24 VAC is also applied to the red LED safety shut-
down light on the status display board until the
safeties have been proven.
22. 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.
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 a safety or limit circuit stays ener-
gized for more than 5 seconds.
23. When a CFH occurs, a 24 VAC signal is sent to the
CFH light on the status panel located on the lower
left front of the control compartment.
34
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External Lights
Color
Light
Indication
Power
Blue
Main power is on
Thermostat is closed
Call For Heat
Yellow
One or more safeties is inopera-
tive
Safety
Red
Ignition
Flow
Red
Ignition module is inoperative
Flow is present
Blower 1 is on
Blower 2 is on
Blower 3 is on
Stage 1 is on
Green
Green
Green
Green
Green
Green
Green
Green
Blower 1
Blower 2
Blower 3
Stage 1
Stage 2
Stage 3
Stage 4
Stage 2 is on
Stage 3 is on
Stage 4 is on
Table M: Status LED Indicators
24. Power is also sent from pin 2 of the stage 1 con- 33. The 120 VAC signal continues to the coil of the
nection to pin P1-3 of the universal diagnostic
board.
blower relay K-3 (N.O.).
34. The 120 VAC signal continues to the 120 VAC
safety terminals located at J13 on the circuit
board.
25. Power is now sent to terminal TP4 of the
Economaster II to energize the relay and close the
contacts.
35. When the coil on relay K-3 is powered, the N.O.
relay contacts close and energize the blowers
from the J8 connections on the CPW board.
26. Power is waiting at the common terminal of the
flow switch waiting for closure and sufficient water
flow.
36. After proper air pressure is received in the air
plenum, the air pressure switches will close.
27. The heater pump is energized upon relay closure
of the Economaster II.
37. If there is insufficient air pressure and the air pres-
sure switches do not close, a 24 VAC signal is sent
to the Universal Diagnostics Board to indicate the
fault.
28. Upon sufficient flow from the heater pump, the
flow switch contacts will close.
29. If there is insufficient flow and the flow switch does
not close, a 24 VAC signal is sent to the Universal 38. A 24 VAC signal is now sent to the blower LED on
Diagnostics Board to indicate the fault.
the status board.
30. The flow light is energized; located on the front 39. Power is applied to the optional equipment inter-
status panel. lock connection (normally jumpered).
31. A 24 VAC signal is also sent to the “TH” terminal 40. The 24 VAC signal is then sent to the 24 VAC safe-
located on the ignition module. ty connector.
32. Once the 24 VAC “TH” signal is received at the 41. 24 VAC is now sent to the pressure switch (P.S.)
ignition module, the internal contacts between F1
and F2 close sending a 120 VAC signal to the 120
terminal on the ignition module.
VAC pilot duty terminals, located at J14 on the cir- 42. Once the pressure switch signal is received at the
cuit board.
ignition module, the heater performs a 15-second
pre-purge, and then the hot surface igniter is ener-
35
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gized by a 120 VAC signal from S-1 on the ignition 54. After closure of the stage 3 contacts, power is
module for approximately 30 seconds. (The hot
surface igniter must draw greater than 3.1 amps
applied to TD-2.
while being energized or ignition lockout will occur 55. After a 5 second countdown TD-2 contacts close.
after three tries.)
56. Gas valve 3 then receives 24 VAC and is ener-
43. Once the ignition module determines that the hot
surface igniter has heated up and operating prop-
gized.
erly, a 24 VAC signal is output from pin GV on the 57. The stage 3 LED on the status display board is
module. now illuminated (end of sequence for 992B).
44. 24 VAC signal is received at gas valve 1 thus ener- 58. Power is applied to pin 7 of the stage 4 connec-
gizing it. tions on the CPW board.
45. The stage 1 LED on the status display board is 59. After closure of the stage 4 contacts, power is
now illuminated. applied to TD-3 (1262B only).
46. The coil of relay K-2 is now energized with the 60. After a 5-second countdown TD-3 contacts close.
N.O. contacts closing downstream of the stage 2
and stage 3 connections.
61. Gas valve 4 (solenoid valve located in the front air
plenum) then receives 24 VAC and is energized.
47. The gas coming through the burners should ignite
from the heat of the hot surface igniter and the 62. The stage 4 LED on the status display board is
flame should carry over from one burner to the
other burners of stage 1. The remote sensor is
now illuminated.
now trying to sense the flame. If the flame is not 63. The heater is now operating at full fire.
sensed within 4 seconds, the ignition module will
shut down gas valve 1 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.
Models 1532B – 1802B
1. The black (hot) wire lead goes directly to the main
power switch. This black toggle switch is located
at the middle front of the control compartment.
2. When the main power switch is placed in the “ON”
position, 120 VAC is applied to the 120 VAC termi-
nal block on the circuit board and the 120/24 VAC
transformer is powered.
48. If the ignition module locks out, a signal will be
sent to the Universal Diagnostics Board to indicate
an ignition fault.
3. 120 VAC is waiting at the N.O. contacts of the
Economaster II pump delay.
49. When power is sent to gas valve 1 it is also sent to
time delay relay 1 (TD-1) which starts a 5-second
countdown.
4. Terminals L1 and F1 of the ignition module are
powered with 120VAC.
50. After the 5-second countdown from TD-1, 24 VAC
is waiting at pin 3 of the stage 2 connections on
the CPW board.
5. 120 VAC power is also applied to the control
power connector on the circuit board.
51. After closure of the stage 2 contacts Gas valve 2
is energized.
6. 120 VAC power is waiting at the N.O. contacts of
K-3 relay to energize the heater blowers.
52. The stage 2 LED on the status display board is
now illuminated.
7. The 120/24 VAC transformer outputs 24 VAC.
8. 24 VAC is sent to pin L1 of the low water cut-off
(optional) and the red power light is energized.
53. Power is applied to pin 5 of the stage 3 connec-
tions on the CPW board.
36
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9. 24 VAC is applied to the blue power light located 21. 24 VAC switched power is applied to the S24V ter-
on the status display board. minal on ignition modules 1 and 2.
10. 24 VAC is also applied to the red LED safety shut- 22. When the “enable/disable” contacts are closed,
down light on the front status board until the
safeties have been proven.
the 24 VAC signal travels to pin 1 of the stage 1
connection and waits for a CFH.
11. 24 VAC is applied to the alarm circuit (optional). If 23. When a CFH occurs, a 24 VAC signal is sent to the
the E-5 sales option (Alarm) is included a 5-sec-
ond time delay relay will not allow the alarm to
sound unless a safety or limit circuit stays ener-
gized for more than 5 seconds.
CFH light on the status panel located on the lower
left front of the control compartment.
24. Power is also sent from pin 2 of the stage 1 con-
nection to pin P1-3 of the universal diagnostic
board.
12. Power is applied to terminal P1-1 of the Universal
Diagnostics Board. 24 VAC power is then applied
in series to all typically closed safeties wired into 25. Power is now sent to terminal TP4 of the
the heater. All safeties are verified to ensure that it
is safe to operate the heater.
The safety components wired into the diagnostic
Economaster II to energize the relay and close the
contacts.
board are: low water cut-off (optional), blocked 26. Power is waiting at the common terminal of the
vent switch, manual vent temp switch (optional),
manual reset high limit, low gas pressure switch,
high gas pressure switches (optional), and auto-
reset high limit (optional).
flow switch waiting for closure and sufficient water
flow.
27. The heater pump is energized upon relay closure
of the Economaster II.
13. If any of the safeties do not close, a signal is sent
to the Universal Diagnostics Board to indicate a 28. Upon sufficient flow from the heater pump, the
safety fault.
flow switch contacts will close.
14. Power is applied to terminal TP-1 of the 29. If there is insufficient flow and the flow switch does
Economaster II pump delay to energize the circuit
board.
not close, a 24 VAC signal is sent to the Universal
Diagnostics Board to indicate the fault.
15. Once all safeties are closed and verified, a 24 VAC 30. The flow light is energized; located on the front
signal is output from the Auto High Limit to J5 pin
3 of the CPW board of the heater.
status panel.
31. A 24 VAC signal is also sent to the “TH” terminal
located on ignition module one.
16. 24 VAC power is now sent to the coil of relay K-1.
17. Relay K-1 (N.C.) will now be energized, and opens 32. Once the 24 VAC “TH” signal is received at ignition
the N.C. contacts to disable the alarm (optional)
and turns off the red LED safety shutdown light on
the front status board.
module one, the internal contacts between F1 and
F2 close sending a 120 VAC signal to the 120 VAC
pilot duty terminals, located at J14 on the circuit
board.
18. The common terminal of the Auto High Limit will
now send a 24 VAC signal to pin 1 of the “panel 33. The 120 VAC signal continues to the coil of the
switch”.
blower relay K-4 (N.O.).
19. The “panel switch” (rocker switch) located at the 34. The 120 VAC signal continues to the 120 VAC
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.
safety terminals located at J13 on the circuit
board.
35. When the coil on relay K-4 is powered, the N.O.
relay contacts close and energize the blowers
from the J8 connections on the CPW board.
20. After the standby switch is placed into the “ON”
position, a 24 VAC signal is sent to the
“enable/disable” connection (normally jumpered).
37
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36. After proper air pressure is received in the air 48. If ignition module one locks out, a signal will be
plenum, the air pressure switches will close.
sent to the Universal Diagnostics Board and to the
status display board to indicate an ignition fault.
37. If there is insufficient air pressure and the air pres-
sure switch does not close, a 24 VAC signal is sent 49. When power is sent to gas valve 1 it is also sent to
to the Universal Diagnostics Board to indicate the
fault.
time delay relay 1 (TD-1) which starts a 5-second
countdown.
38. A 24 VAC signal is now sent to the blower LED’s 50. After the 5-second countdown from TD-1, 24 VAC
on the status board.
is waiting at pin 3 of the stage 2 connections on
the CPW board.
39. Power is applied to the optional equipment inter-
lock connection (normally jumpered).
51. After closure of the stage 2 contacts Gas valve 2
is energized.
40. The 24 VAC signal is then sent to the 24 VAC safe-
ty connector.
52. The stage 2 LED on the status display board is
now illuminated.
41. 24 VAC is now sent to the pressure switch (P.S.)
terminal on the ignition modules.
53. Power is applied to pin 5 of the stage 3 connec-
tions on the CPW board.
42. Once the pressure switch signal is received at
ignition module one, the heater performs a 15 sec- 54. The temperature controller closes the stage 3 con-
ond pre-purge, then hot surface igniter one is
energized by a 120 VAC signal from S-1 on igni-
tacts at J3 on the CPW board.
tion module one for approximately 30 seconds. 55. Power is applied to the “TH” terminal of ignition
(The hot surface igniter must draw greater than
3.1 amps while being energized or ignition lockout
will occur after three tries.)
module 2.
56. Once the “TH” signal is received at ignition module
2, the heater performs a 15 second pre-purge,
then hot surface igniter 2 is energized by a 120
VAC signal from S-1 on ignition module 2 for
approximately 30 seconds. (The hot surface ignit-
er must draw greater than 3.1 amps while being
energized or ignition lockout will occur after three
tries.)
43. Once ignition module one determines that hot sur-
face igniter one has heated up and operating
properly, a 24 VAC signal is output from pin GV on
module one.
44. 24 VAC signal is received at gas valve 1 thus ener-
gizing it.
57. Once ignition module 2 determines that hot sur-
face igniter two is operating properly, a 24 VAC
signal is sent to energize gas valve 3.
45. The stage 1 LED on the status display board is
now illuminated.
46. The coil of relay K-2 is now energized with the 58. The stage 3 LED on the status display board is
N.O. contacts closing downstream of the stage 2
and upstream of the stage 3 connections.
now illuminated.
59. The gas coming through the stage 3 burners
should ignite from the heat of hot surface igniter
two and the flame should carry over from one
burner to the other burners of stage 3. Remote
flame sensor two is now trying to sense the flame.
If the flame is not sensed within 4 seconds, the
ignition module will shut down gas valve 3 and
retry the hot surface igniter. During ignition retry
the heater must perform a 15-second pre-purge
and approximately a 30-second igniter warm-up
before opening gas valve 3 again. The standard
ignition module will attempt ignition a maximum of
three times prior to ignition lockout.
47. The gas coming through the burners should ignite
from the heat of hot surface igniter one and the
flame should carry over from one burner to the
other burners of stage 1. Remote flame sensor
one is now trying to sense the flame. If the flame
is not sensed within 4 seconds, the ignition mod-
ule will shut down gas valve 1 and retry hot
surface igniter one. During ignition retry the heater
must perform a 15-second pre-purge and approx-
imately a 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.
38
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60. If ignition module two locks out, a signal will be 11. 24 VAC is applied to the alarm circuit (optional). If
sent to the Universal Diagnostics Board and to the
status display board to indicate an ignition fault.
the E-5 sales option (Alarm) is included a 5 sec-
ond time delay relay will not allow the alarm to
sound unless a safety or limit circuit stays ener-
gized for more than 5 seconds.
61. The coil of relay K-5 (N.O.) is now energized with
the (K-5) contacts closing downstream of the
stage 4 connections.
12. Power is applied to terminal P1-1 of the Universal
Diagnostics Board. 24 VAC power is then applied
in series to all typically closed safeties wired into
the heater. All safeties are verified to ensure that it
62. Power is now applied to time delay relay 3 and the
contacts of TD-3 close after 5 seconds.
is
safe
to
operate
the
heater.
63. The stage 4 controller contacts close.
64. Power is applied to gas valve 4.
The safety components wired into the diagnostic
board are: low water cut-off (optional), blocked
vent switch, manual vent temp switch (optional),
manual reset high limit, low gas pressure switch,
high gas pressure switches (optional), and auto-
reset high limit (optional).
65. The stage 4 LED on the status display board is
now illuminated.
66. The heater is operating at full fire.
13. If any of the safeties do not close, a signal is sent
to the Universal Diagnostics Board to indicate a
safety fault.
Models 2002B – 2342B
14. Power is applied to terminal TP-1 of the
Economaster II pump delay to energize the circuit
board.
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. Once all safeties are closed and verified, a 24 VAC
signal is output from the Auto High Limit to J5 pin
3 of the CPW board of the heater.
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.
16. 24 VAC power is now sent to the coil of relay K-1.
3. 120 VAC is waiting at the N.O. contacts of the
Economaster II pump delay.
17. Relay K-1 (N.C.) will now be energized, and opens
the N.C. contacts to disable the alarm (optional)
and turns off the red LED safety shutdown light on
the front status board.
4. Terminals L1 and F1 of the ignition module are
powered with 120VAC.
18. The common terminal of the Auto High Limit will
now send a 24 VAC signal to pin 1 of the “panel
switch”.
5. 120 VAC power is also applied to the control
power connector on the circuit board.
6. 120 VAC power is waiting at the N.O. contacts of
K-3 relay to energize the heater blower.
19. The “panel 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.
7. The 120/24 VAC transformer outputs 24 VAC.
8. 24 VAC is sent to pin L1 of the low water cut-off
(optional) and the red power light is energized.
20. After the standby switch is placed into the “ON”
position, a 24 VAC signal is sent to the
“enable/disable” connection (normally jumpered).
9. 24 VAC is applied to the blue power light located
on the status display board.
21. 24 VAC switched power is applied to the S24V ter-
minal on ignition modules 1 and 2.
10. 24 VAC is also applied to the red LED safety shut-
down light on the front status board until the
safeties have been proven.
22. 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.
39
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23. When a CFH occurs, a 24 VAC signal is sent to the 38. A 24 VAC signal is now sent to the blower LED’s
CFH light on the status panel located on the lower
left front of the control compartment.
on the status board.
39. Power is applied to the optional equipment inter-
lock connection (normally jumpered).
24. Power is also sent from pin 2 of the stage 1 con-
nection to pin P1-3 of the universal diagnostic
board.
40. The 24 VAC signal is then sent to the 24 VAC safe-
ty connector.
25. Power is now sent to terminal TP4 of the
Economaster II to energize the relay and close the 41. 24 VAC is now sent to the pressure switch (P.S.)
contacts.
terminal on the ignition modules.
26. Power is waiting at the common terminal of the 42. Once the pressure switch signal is received at
flow switch waiting for closure and sufficient water
flow.
ignition module one, the heater performs a 15-sec-
ond pre-purge, then hot surface igniter one is
energized by a 120 VAC signal from S-1 on igni-
tion module one for approximately 30 seconds.
(The hot surface igniter must draw greater than
3.1 amps while being energized or ignition lockout
will occur after three tries.)
27. The heater pump is energized upon relay closure
of the Economaster II.
28. Upon sufficient flow from the heater pump, the
flow switch contacts will close.
43. Once ignition module one determines that hot sur-
face igniter one has heated up and operating
properly, a 24 VAC signal is output from pin GV on
module one.
29. If there is insufficient flow and the flow switch does
not close, a 24 VAC signal is sent to the Universal
Diagnostics Board to indicate the fault.
30. The flow light is energized; located on the front 44. 24 VAC signal is received at gas valve 1 thus ener-
status panel. gizing it.
31. A 24 VAC signal is also sent to the “TH” terminal 45. The stage 1 LED on the status display board is
located on ignition module one. now illuminated.
32. Once the 24 VAC “TH” signal is received at ignition 46. The coil of relay K-2 is now energized with the
module one, the internal contacts between F1 and
F2 close sending a 120 VAC signal to the 120 VAC
pilot duty terminals, located at J14 on the circuit
board.
N.O. contacts closing downstream of the stage 2
and upstream of the stage 3 connections.
47. The gas coming through the burners should ignite
from the heat of hot surface igniter one and the
flame should carry over from one burner to the
other burners of stage 1. Remote flame sensor
one is now trying to sense the flame. If the flame
is not sensed within 4 seconds, the ignition mod-
ule will shut down gas valve 1 and retry hot
surface igniter one. During ignition retry the heater
must perform a 15-second pre-purge and approx-
imately a 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.
33. The 120 VAC signal continues to the coil of the
blower relay K-4 (N.O.).
34. The 120 VAC signal continues to the 120 VAC
safety terminals located at J13 on the circuit
board.
35. When the coil on relay K-4 is powered, the N.O.
relay contacts close and energize the blowers
from the J8 connections on the CPW board.
36. After proper air pressure is received in the air
plenum, the air pressure switches will close.
48. If ignition module one locks out, a signal will be
sent to the Universal Diagnostics Board and to the
status display board to indicate an ignition fault.
37. If there is insufficient air pressure and the air pres-
sure switch does not close, a 24 VAC signal is sent
to the Universal Diagnostics Board to indicate the
fault.
40
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49. When power is sent to gas valve 1 it is also sent to 63. The coil of relay K-5 (N.O.) is now energized with
time delay relay 1 (TD-1) which starts a 5-second
countdown.
the (K-5) contacts closing downstream of the
stage 4 connections.
50. After the 5-second countdown from TD-1 and the 64. Remote flame sensor 2 is trying to rectify flame.
internal contacts close, time delay relay 2 (TD-2 )
receives 24 VAC.
65. Power is now applied to time delay relay 3 and the
contacts of TD-3 located upstream of the stage 4
connection close after 5 seconds.
51. Gas valve 1a is energized allowing the remainder
of stage 1 to fire.
66. The stage 4 controller contacts close.
52. After the 5-second countdown from TD-2 the inter-
nal contacts close allowing 24 VAC to sit at pin 3 67. Power is applied to gas valve 4.
of the stage 2 connection on the CPW board.
68. The stage 4 LED on the status display board is
now illuminated.
53. After closure of the stage 2 contacts Gas valve 2
is energized.
69. The heater is now operating at full fire.
54. The stage 2 LED on the status display board is
now illuminated.
55. The temperature controller closes the stage 3 con-
tacts at J3 on the CPW board.
56. Power is applied to pin 5 of the stage 3 connec-
tions on the CPW board.
57. Power is applied to the “TH” terminal of ignition
module 2.
58. Once the “TH” signal is received at ignition module
2, the heater will perform a 15-second pre-purge,
and then hot surface igniter 2 is energized by a
120 VAC signal from S-1 on ignition module 2 for
approximately 30 seconds. (The hot surface ignit-
er must draw greater than 3.1 amps while being
energized or ignition lockout will occur after three
tries.)
59. If ignition module two locks out, a signal will be
sent to the Universal Diagnostics Board and to the
status display board to indicate an ignition fault.
60. 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 GV on the
module.
61. 24 VAC signal is received at gas valve 3 thus ener-
gizing it.
62. The stage 3 LED on the status display board is
now illuminated.
41
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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. Turning off the power to the
heater WILL NOT reset the ignition module.
Ignition Module
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-
High Limit (Manual Reset)
Fig. 32: Ignition Module
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
Fig. 33: High Limit (Manual Reset)
heater performs its own safety check and opens the The heater is equipped with a manual reset high limit
main valve only after the igniter is proven to be capa- temperature device. Push the reset button and adjust
ble of ignition.
the setting to 40 - 50°F above desired operating tem-
perature.
The standard ignition module will attempt to light three
times before locking out. To reset it, turn off power to Flow Switch
the heater, wait 30 seconds and re-apply power.
Code
On
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
Ignition lockout
Fig. 34: Flow Switch
Low igniter current
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 24 VAC, check control
supply voltage
Internal fault;
Replace module
Operating Control
Table N: Ignition Module Diagnostic LED Codes
The heater may be equipped with different types of
operating controls. Consult the individual control data
42
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sheets supplied with your heater paperwork. See the
gas pressure switch automatically shuts down the
General Safety Section for safety precautions con- heater if gas manifold pressure rises above the recom-
cerning domestic hot water applications.
mended setting of 5.0 in. WC for natural gas, and 11.5
in. WC for propane gas.
Fig. 35: 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. 37: High/Low Gas Pressure Switch
Fig. 38: Fan-Proving Switch
Fig. 36: Low Water Cut-Off
High and Low Gas Pressure Switches
The low gas pressure switch (standard) connection
mounts upstream of the gas valve to ensure that suffi-
cient gas pressure is present for proper regulator
performance. The low gas pressure switch automati-
cally shuts down the heater if gas supply drops below
the factory setting of 5.0 in. WC for natural gas, and
10.0 in. WC for propane gas.
The high gas pressure switch (optional) connection
mounts down-stream of the stage-1 gas valve. If the
gas pressure regulator fails, the high gas pressure
switch automatically shuts down the burner. The high
Fig. 39: Blocked Vent Switch
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Pump Time Delay
There are two versions of the Pump Time Delay. The
first is the Economaster II. It is an electronic device
that allows the operator to set a variable time (3 to 10
minutes) for the pump to run after the boiler shuts off.
See Fig. 40 (A) . The time is factory-set at 7 minutes
and it can be re-adjusted in the field.
The second version is a fully enclosed solid state TDR
with a white jumper that selects one of two time
delays. See Fig. 40 (B). If the jumper is on pins 6 and
7 (default) the delay time is 5 minutes. If the jumper is
not on pins 6 and 7, the time delay is 10 minutes.
In a conventional system, when the Aquastat is satis-
fied, the main gas valve closes, but the pump
continues operating. With either time delay relay the
boiler pump is programmed to continue running for an
optimum period of time in order to absorb the residual
heat from the combustion chamber and use it in the
system. The pump then shuts off until the next call for
heat is received from the Aquastat.
Fig. 41: UDB Diagnostic Board
UDB Fault History
To view the fault codes in the UDB history file:
1. Press the UP or DOWN buttons on the membrane
switch for 2 seconds to access the fault history.
2. Press either button to scroll through the recorded
faults in history.
3. The most recent fault recorded will be the first fault
displayed (the last 16 faults are stored in the his-
tory, on a rolling basis). There is no time or date
stamp associated with these faults.
(A)
(B)
4. When the history of faults has been exhausted,
pushing the UP or DOWN buttons again will roll
the fault history over and it will start again.
5. To exit the fault history, wait for 10 seconds and
the board will automatically exit the history mode.
To clear the fault history, press and hold both the UP
and DOWN buttons for 5 seconds while the power is
on.
NOTE: Once the history has been cleared, it cannot
be recovered.
Fig. 40: Economaster Time Delay Relays (TDR)
Diagnostic information is provided any time a fault is
recorded. This information is intended to assist in
locating the problem with the heater, but is not exhaus-
tive.
UDB Diagnostic Board
This heater is equipped with a diagnostic board which
will indicate faults as they occur. Refer to the following
section for instructions on accessing, reviewing and
clearing these faults.
If multiple fault conditions occur at the same time, only
the fault that caused the heater to shut down will be
recorded in the history.
44
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ends that a thermometer be placed into the boiler inlet
piping next to the in/out header to facilitate tempera-
ture adjustment. Inlet water temperatures below 120ºF
(49ºC) can excessively cool the products of combus-
tion, resulting in condensation on the heat exchanger.
87%-Efficiency Boilers –
Special Instructions
NOTE: The constructions of the 84%- (standard)
and 87%-efficiency (optional) boilers are very similar,
and they are installed to the same requirements,
except as noted in this section.
Venting
CAUTION: Proper installation of flue venting is criti-
cal for the safe and efficient operation of the boiler.
Water Piping
An 87%-efficiency boiler requires a minimum inlet
water temperature of 120ºF (49ºC) to prevent exces-
sive condensation in the combustion chamber. An
87%-efficiency boiler operated with an inlet tempera-
ture of less than 120ºF (49ºC) must have a manual
bypass or an approved low-temperature operation
system to prevent problems with condensation. A man-
ual bypass, shown in Fig. 15, must be piped into the
system at the time of installation. This piping is like a
primary/secondary boiler installation with a bypass in
the secondary boiler piping. Raypak strongly recomm-
Appliance Categories
See Table P for appliance category requirements for
the 87%-efficiency Hi Delta.
NOTE: For additional information on appliance
categorization, see appropriate code NFGC (U.S.)
and B149 (Canada), or applicable local building
codes.
20°F T
30°F T
40°F T
Min. Flow
P (ft)
Max Flow
P (ft)
Model
No.
gpm P (ft) gpm
P (ft) gpm
P (ft) gpm
T
gpm
T
992BE
1262BE
1532BE
1802BE
2002BE
2072BE
2342BE
86
5.6
10.3
16.5
N/A
N/A
N/A
N/A
57
2.5
4.6
43
1.4
2.6
4.3
6.5
8.5
9.1
12.9
43
55
1.4
2.6
4.3
6.5
8.5
9.1
12.9
40 132
40 132
40 132
40 132
40 132
40 132
40 132
13.1
14.8
16.5
18.3
19.0
19.0
21.4
13
17
20
24
26
27
31
110
132
N/A
N/A
N/A
N/A
73
89
55
67
7.6
67
104
116
120
N/A
11.5
14.8
15.8
N/A
78
78
87
87
90
90
102
102
Note: Basis for minimum flow is 40°F ΔT. Basis for maximum flow is 132 gpm.
Table O: Heater Rate of Flow and Pressure Drop
Combustion
Air Supply
Exhaust
Configuration
Heater Venting
Category
Certified
Materials
Combustion Air
Inlet Material
Vertical Natural Draft
Venting
II
IV
II
AL29-4C
Stainless Steel
(Gas Tight)
From Inside Building
(Non-Direct Venting)
Horizontal Through-
the-Wall Venting
Vertical Natural Draft
Venting
Galvanized Steel
PVC
AL29-4C
Stainless Steel
(Gas Tight)
From Outside Building
(Direct Venting)
ABS
CPVC
Horizontal Through-
the-Wall Venting
IV
Table P: Category Determination for Venting Purpose and Venting Arrangement
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11. Locate or guard vent to prevent condensate from
damaging exterior finishes. Install a rust-resistant
sheet metal backing plate against brick or mason-
ry surfaces.
WARNING: Contact the vent material manufacturer
if there are any questions about the appliance
category or suitability of a vent material for Category
II, III or IV applications. Using improper venting
materials can result in personal injury, death or
property damage.
12. DO NOT extend exposed vent pipe outside of
building. Condensate could freeze and block vent
pipe.
Vent Terminal Location
Condensate Management
NOTE: During winter months check the vent cap
and make sure no blockage occurs from build-up of
snow or ice.
Condensate must be routed from the condensate trap
to an appropriate container for neutralization before
disposal, as required by local codes.
1. Condensate can freeze on the vent cap. Frozen
condensate on the vent cap can result in a blocked
flue condition.
Vertical Venting (Category II)
2. Give special attention to the location of the vent
termination to avoid possibility of property dam-
age or personal injury.
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.
4. Prevailing winds, in combination with below-freez-
ing temperatures, can cause freezing of
condensate and water/ice build-up on building,
plants or roof.
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.
6. Un-insulated single-wall metal vent pipe shall NOT
be used outdoors in cold climates for venting gas
utilization equipment.
7. Through-the-wall vents for Category II and IV
appliances shall not terminate over public walk-
ways or areas where condensate or vapor could
create a nuisance or hazard, or be detrimental to
the operation of regulators, relief valves or other
equipment.
Note: When vertical height exceeds 25 ft,
consult factory prior to installation.
*Requires optional vent tee.
Fig. 42: Vertical Venting (Category II)
CAUTION: A properly sized listed vent cap
terminal must be used to evacuate the flue products
from the boilers.
8. Locate and guard vent termination to prevent acci-
dental contact by people or pets.
Common Venting System
9. DO NOT terminate vent in window well, stairwell,
alcove, courtyard or other recessed area, unless
previously approved by local authority.
Manifolds that connect more than one boiler to a com-
mon chimney must be engineered to handle the
combined load. Consult available guides for proper
sizing of the manifold and the chimney. At no time
should the area of the vent be less than the area of the
largest boiler exhaust outlet.
10. DO NOT terminate above any door, window, or
gravity air intake. Condensate can freeze, causing
ice formations.
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pressure reading must be between -0.01 and -0.1 in.
WC as measured 12 in. from the appliance flue outlet.
Each elbow used is equal to 10 ft of straight pipe. This
will allow installation in one of the four following com-
binations:
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.
Horizontal Through-the-Wall Venting
(Category IV)
•
•
•
•
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.
The vent must be installed to prevent flue gas leakage.
Care must be taken during assembly to ensure that all
joints are sealed properly and are airtight. The vent
must be installed to prevent the potential accumulation
of condensate in the vent pipes. It is recommended
that:
*Requires optional vent tee.
Fig. 43: Horizontal Through-the-Wall Venting
(Category IV)
1. The vent must be installed with a slight upward
slope of not more than 1/4 in per foot of horizontal
run to the vent terminal.
Installation
2. The vent must be insulated through the length of
the horizontal run.
These installations utilize the boiler-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 mechanical room in accordance
with the NFGC (U.S.) and B149 (Canada).
Common Venting System
Common venting of Category IV systems is not al-
lowed.
WARNING: No substitutions of flue pipe or vent
cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants.
The total length of the horizontal through-the-wall ex-
haust vent system should not exceed 70 ft in length. If
horizontal run exceeds 70 ft, an appropriately sized
extractor must be used. To maintain proper operation,
Air Inlet
Max. Length*
Certified
Venting
Material
Maximum
Equivalent
Vent Length*
Combustion Air
Intake Pipe
Material
Model
Vent Size
10”
12”
992BE
1262BE
1532BE
1802BE
2002BE
2072BE
2342BE
10”
12”
70’
Room Air
75’
100’
Galvanized Steel,
PVC,
Category II
or IV
40’
Ducted
Combustion
Air
ABS,
CPVC
14”
16”
40’
75’
* Subtract 10 ft per elbow. Max. 3 elbows.
Maximum combustion air duct length terminated at 100 equivalent ft.
Table Q: Category II and IV Venting
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The stainless steel direct vent cap must be furnished
by the boiler manufacturer in accordance with its list-
ing (sales order option D-15).
The flue exhaust direct vent cap is not considered in
the overall length of the venting system.
Care must be taken during assembly that all joints are
sealed properly and are airtight.
Use only double-wall vent pipe and the special gas
vent pipes listed for use with category II or IV gas burn-
ing boilers, such as the stainless steel Saf-T vent by
Heat Fab Inc. (800-772-0739), Protech Systems 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.
The vent must be installed to prevent the potential ac-
cumulation of condensate in the vent pipes. It is
recommended that:
1. The vent must be installed with a slight downward
slope of not more than 1/4 inch per foot of hori-
zontal run to the vent terminal.
Direct Vent - Horizontal Through-
the-Wall
2. The vent must be insulated through the length of
the horizontal run.
For installations in extremely cold climate, it is rec-
ommended 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.
2. The intake vent must be insulated through the
length of the horizontal run.
Common Venting System
Fig. 44: Direct Vent - Horizontal Through-the-Wall
Common venting of Category IV systems is not al-
lowed.
Installation
These installations utilize the boiler-mounted blower to
draw combustion air from outdoors and vent combus-
tion products to the outdoors.
WARNING: No substitutions of flue pipe or vent
cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants.
The total length of the direct vent through-the-wall
exhaust vent cannot exceed 40 ft in length for the flue
outlet. Each elbow used is equal to 10 ft of straight
pipe. This will allow installation in one of the three fol-
lowing combinations:
The stainless steel flue exhaust direct vent cap must
be furnished by the boiler manufacturer in accordance
with its listing (sales order option D-15).
Use only double-wall vent pipe and the special gas
vent pipes listed for use with category II or IV gas burn-
ing boilers, such as the stainless steel Saf-T vent by
Heat Fab Inc. (800-772-0739), Protech Systems 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.
•
•
•
40’ of straight flue pipe
30’ of straight flue pipe and one elbow
20’ of straight flue pipe and two elbows
The total length air supply duct cannot exceed the dis-
tances listed. Each elbow used is equal to 10 ft of
straight pipe. This will allow installation in one of the
three following combinations:
•
•
•
40’ of straight combustion air pipe
30’ of straight combustion air pipe and one elbow
20’ of straight combustion air pipe and two elbows
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Direct Vent - Vertical
Note: When vertical height exceeds 25 ft, consult
factory prior to installation.
*Requires optional vent tee if vented horizontally out back of heater.
Fig. 45: Direct Vent - Vertical
Vertical Venting
Height*
Air Inlet
Max. Length**
Certified
Venting Vent Size
Material
Combustion Air
Intake Pipe
Material
Model
Min.
Max.
10”
12”
992BE
1262BE
1532BE
1802BE
2002BE
2072BE
2342BE
10”
12”
75’
100’
Galvanized Steel,
PVC,
Category II
or IV
5’
25’
ABS,
CPVC
14”
40’
75’
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 R: Category II or IV Vertical Venting
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Wiring Diagram—Models 992B–1262B
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Wiring Diagram—Models 1532B–2342B
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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 .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 Hi
Delta 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
pres-sure.
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 Hi Delta heaters, depending on their size, have
two to five burner sections. Each burner section is sup-
plied gas by gas valves incorporated into a single
valve body. A maximum of three burner sections may
be controlled by a single hot surface ignition system.
The middle of the three burner sections is ignited
directly with a hot surface ignition system.
Refer to Fig. 46. 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.
54
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1. Manually close the downstream leak test valve.
This completes leak testing for a single Hi Delta mani-
fold 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. 46: Leak Test
55
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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.
56
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TROUBLESHOOTING
Does the power switch
provide power to the
Check the switch
and/or line voltage
control panel?
NO
Step 1
Replace ignition module
Is there a Call For
Heat?
YES
YES
Unit is in standby mode.
Check all safety limit
devices and voltage from
the transformer to J10 on
CPW board.
NO
Reattach.
Step 2
Step 3
Step 4
Is Disable jumper intact? (J1)
YES
NO
NO
Is there 120VAC at J8
Connector on the CPW board?
NO
Does F2 on ignition module
have 120VAC?
NO
Do the combustion air
blowers come on?
YES
YES
YES
Is 24VAC at present at TH (J3 & J12 on CPW
board and orange wire on ignition module)?
NO
YES
Check flow switch, all
connectors on CPW board
and controller.
Are the blower lights
illuminated?
NO
Is air pressure switch(s) and
J2 of CPW board (N.O.)
powered?
Check the fan relay. Is there
120VAC at K3 relay?
YES
YES
NO
YES
NO
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?
NO
NO
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 greater than
3.1 Amps.
Is air switch
bouncing?
YES
Is the flame
sensor signal to
the ignition
NO
NO
Replace HSI
YES
module greater
than 1 uA DC?
Step 6
Step 7
Readjust to 3.5” W.C.
gas.
Is the unit running?
Are the gas valve
settings correct?
NO
NO
YES
YES
NO
Is the unit running?
NO
Is static and dynamic inlet
manifold gas pressure correct?
Is downdraft present?
Replace gas valve
YES
YES
NO
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
57
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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 Hi Delta 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 53.)
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).
58
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6. Perform leakage test on gas valves. (See Fig. 46.)
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 51.)
2. Check drip leg and gas strainers.
3. Test high and low gas pressure interlocks (if
equipped). (See “Safety Inspection” on page 52.)
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 52.)
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
51.)
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 52.)
2. Test high limit and operating temperature. (See
“Post Start-Up Check,” page 53.)
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.
59
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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:
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:
•
•
remove products permanently, OR
install TruSeal direct vent
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
similar products
•
•
Areas where contaminated combustion air commonly
exists:
•
•
•
•
•
•
•
dry cleaning/laundry areas
metal fabrication plants
beauty shops
refrigeration repair shops
photo processing plants
auto body shops
plastic manufacturing plants
60
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LIMITED PARTS WARRANTY
HI DELTA – TYPES H AND WH
MODELS 992B–2342B
SCOPE
Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free
from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor
charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the
owner’s responsibility.
HEAT EXCHANGER WARRANTY
Domestic Hot Water
Five (5) years from date of heater installation. Includes copper heat exchanger with bronze and cast iron waterways.
Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways.
Space Heating (Closed Loop System)
Ten (10) years from date of heater installation. Includes both cupro-nickel and copper heat exchanger with bronze or cast iron water-
ways.
Thermal Shock Warranty
Twenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large
changes exceeding 150°F between the water temperature at intake and heater temperature, or operating at heater temperatures exceed-
ing 230°F).
ANY OTHER PART MANUFACTURED BY RAYPAK
One (1) year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records,
whichever comes first.
SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE
VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.
ADDITIONAL WARRANTY EXCLUSIONS
This warranty does not cover failures or malfunctions resulting from:
1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;
2. Abuse, alteration, accident, fire, flood and the like;
3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;
4. High velocity flow exceeding heater design rates;
5. Failure of connected systems devices, such as pump or controller;
6. Use of non-factory authorized accessories or other components in conjunction with the heater system;
7. Failing to eliminate air from, or replenish water in, the connected water system;
8. Chemical contamination of combustion air or use of chemical additives to water.
PARTS REPLACEMENT
Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested,
with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for
only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak
will apply any such warranty as may be provided to it by the parts manufacturer.
TO MAKE WARRANTY CLAIM
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the prob-
lem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service
Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be
received from Raypak before replacement of any part.
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY
This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST
RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK
SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE,
FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states
do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above
limitation or exclusion may not apply to you.
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that
you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective
date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manufacture plus
thirty (30) days.
Original Owner
Mailing Address
Model Number
Serial Number
Date of Installation
Installation Site
Contractor/Installer
City
State
Zip Code
Daytime Telephone Number
RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com
61
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LIMITED PARTS WARRANTY
HI DELTA – TYPE P
MODELS 992B–2342B
SCOPE
Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free
from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor
charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the
owner’s responsibility.
HEAT EXCHANGER WARRANTY
Five (5) years from date of heater installation. Includes cupo-nickel heat exchanger with bronze and cast iron waterways.
Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways.
Thermal Shock Warranty
Twenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large
changes exceeding 150°F between the water temperature at intake and heater temperature, or operating at heater temperatures exceed-
ing 230°F).
ANY OTHER PART MANUFACTURED BY RAYPAK
One (1) Year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records,
whichever comes first.
SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE
VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.
ADDITIONAL WARRANTY EXCLUSIONS
This warranty does not cover failures or malfunctions resulting from:
1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;
2. Abuse, alteration, accident, fire, flood and the like;
3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;
4. High velocity flow exceeding heater design rates;
5. Failure of connected systems devices, such as pump or controller;
6. Use of non-factory authorized accessories or other components in conjunction with the heater system;
7. Chemical contamination of combustion air or use of chemical additives to water.
8. Misuse or neglect, including but not limited to freeze-ups, operating the heater with cabinet door off, having flow restrictions or obstruc-
tions between the heater outlet and pool/spa or not maintaining proper chemical balance (pH level must be between 7.2 and 7.8 and
total alkalinity between 100 and 150 PPM. Total Dissolved Solids (TDS) must be no greater than 2500 PPM).
PARTS REPLACEMENT
Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested,
with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for
only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak
will apply any such warranty as may be provided to it by the parts manufacturer.
TO MAKE WARRANTY CLAIM
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the prob-
lem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service
Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be
received from Raypak before replacement of any part.
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY
This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST
RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK
SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE,
FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states
do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above
limitation or exclusion may not apply to you.
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that
you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective
date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manufacture plus
thirty (30) days.
Original Owner
Mailing Address
Model Number
Serial Number
Date of Installation
Installation Site
Contractor/Installer
City
State
Zip Code
Daytime Telephone Number
RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com
62
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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.
Additionally this form will be used to record all equipment operation functions and required settings.
GAS SUPPLY DATA
Regulator Model & Size
Gas Line Size (in room)
Length of Gas Line
Low Gas Pressure Setting
High Gas Pressure Setting
Gas Shut-Off Valve Type
( Ball, Lube cock)
CLEARANCES
Front Clearance
Right Side Clearance
Left Side Clearance
Rear Clearance
_________ / ______CFH
________________In. NPT
________________Eq Ft
________________In. WC
________________In. WC
________________
_______________In.
_______________In.
_______________In.
_______________In.
_______________In.
Overhead Clearance
ELECTRICAL
Sediment Trap
Port
________________Y/N
_______Std______Full
Voltage Supply (VAC)
Voltage -24 VAC
Voltage Com to Ground
Hot Surface Igniter
Auto High Limit Setting
Manual Reset High Limit Setting
Operating Control Setting
No Load______ Load_____
_______________VAC
_______________VAC
_______________Ohms
_______________deg F
_______________deg F
_______________deg F
VISUAL INSPECTION OF COMPONENTS
Verify inspection was done and condition of components are in
good working order with a “yes”
Wiring Harness
Burner/s (flame)
Refractory (visual)
Remote flame sense
Covers in place for outdoor
_________________ Y/N
_________________ Y/N
_________________ Y/N
_________________ Y/N
_________________ Y/N
Sketch plumbing on reverse side
WATER SUPPLY
Flow Rate in GPM or Delta T
Measure flow rate at full fire
Pump Economaster setting
Low Water Cutoff
_______________If Avail
_______________Minutes
_______________Test
Qty____ _______Gallons
_______________
Pump HP: ______
Pump Model___________
Screens________________
VENTING
Vent Size: _____________
Category: _________
Vent Material:
Vent Termination Type:
Combustion Air Openings:
Ventilation air
Stack Height:_______
sketch vent on reverse side *** Number of Tanks and Size
__________________
__________________
Low __________ in2
High __________ in2
Plumbing Size
Pump Size: _________(boiler)
Impeller trim____________
Louvers __________________
EMISSIONS SETTINGS AND TEST INFORMATION
(AT FULL FIRE)
Nominal Factory Recommended Settings
Blower Pressure Setting
Supply Gas Pressure
_________________In. WC
_________________In. WC
See manual or card tag
See manual or card tag
Verify stable pressure static & dynamic condition
Pilot Gas Pressure
Manifold Gas Pressure
_________________In. WC
_________________In. WC
See manual or card tag
See manual or card tag
The following measurements must be obtained with a Combustion Analyzer.
NOX
Free Oxygen
CO
_________________PPM
_________________%
_________________PPM
_________________%
Less than 20 PPM (If required by Certifying Agency)
See manual
Less than 150 PPM
See manual
CO2
Model Number: ______________________________
*** Note: draw venting with details, such as extractors,
barometric dampers, blast dampers or draft inducers
Serial Number: _______________________________
Site Altitude Above Sea Level __________________Ft.
Job Name _______________________________________________________________________________________
Address _________________________________________________________________________________________
Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; Roof______; Below Grade______
Mechanical Contractor / Installer _______________________________________________________________________
Date and Time of Start-up _____________Print Name and Signature of Start-up Technician_________________________
Information must be faxed to: (805) 278-5471 in order to ensure warranty consideration Attn: Service Manager
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Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468
Litho in U.S.A.
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