Raypak B-195 User's Manual
Contents
1. Improper ground Loose wiring Remote sensor Insufficient gas pressure Supply water temperature too low Dishwasher times not set properly Operating limit set too low 17 3d 3e 3f 4a 4b Ac Ad 5a 5b 5c Excessive negative pressure exerted by the exhaust system on the vent will prevent N O combustion air vent Switch from closing Provide means to relieve pressure and close the N O Switch If combustion air vent switch will not close replace switch Disconnect igniter leads from ignition module Make sure 24V is present across ignition terminals on the igni tion module during the ignition cycle If not replace ignition module Check resistance reading across igniter leads If circuit is open or reading is greater than 30 ohms replace the igniter A new igniter will measure between 1 to 6 ohms at room tem perature During the ignition cycle 24V should be presentatthe MV1 and GND termi nals for about 5 seconds If no 24V is measured replace the ignition mod ule If 24V is present replace the gas valve Check ground connections inside control box Check all connections and wire nuts Check wire connection to remote sen sor Check gas pressure at outlet of valve under load pressure should be 3 5 in W C for Natural gas 10 5 in W C for Propane gas Ensure supply water temperature is at least 140 F Ensure dishwasher operates correctly Check rinse cycl2. Or if an inclined manometer is available pressure measured at the combustion air switch pressure tap can be set at 0 35 W C for natural gas and 0 60 W C for propane by means of the adjustment screw Pressure at this level will result in the proper COz levels mentioned above Again the factory setting will be adequate for most field conditions and adjustment will not normally be required CAUTION A dusty kitchen environment combined with greasy laden air will clog the combustion air blower wheel and cause premature failure of the heater Combustion air must not be contaminated by corrosive chemical fumes which can severely damage the heater Measures must be taken to prevent the entry of corrosive chemical fumes to the combustion and ventilation air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and paint removers Other harmful elements may come from bleaches air fresheners or mastics Vapors from these types of products can form corrosive acid compounds when burned in a gas flame The resulting acid condensate can damage or substantially reduce the life of the heater It may be necessary to provide outside air directly to the heater in order to avoid this problem An adequate supply of air for proper combustion and ventilation must be provided in accordance with Sec 5 3 of the National Fu
3. CODE REQUIREMENTS Installation must be in accordance with local codes or in the absence of local codes with the latest edition of the National Fuel Gas Code ANSI Z223 1 the National Electrical Code ANSI NFPA 70 For Canada CAN CGA B149 1 and 2 and CSA C22 2 No 1 LEG INSTALLATION Four 4 legs are supplied loose within the carton for installation at the site This will provide the required six inch clearance off the floor To install the legs raise one end of the heater just high enough to allow the legs to be screwed into the two corners of that end Make sure each leg is tightened securely by hand Lower the heater gently to minimize any undue strain on the two 2 legs Gently raise the other end and repeat the same procedure for the other two 2 legs Rotate the lower section of each leg as necessary to level the heater in place Booster water heater should not be located in an area where water leakage will result in damage to the area adjacent to it or to lower floors of the structure Where such areas cannot be avoided it is recommended that a suitable catch pan adequately drained be installed under this heater Do not install directly on carpeting CLEARANCE REQUIREMENTS Floor Top Left Right Front Back Vent Side Side gt o 6 e J Alcove e 1 Approved for installation on combustible flooring A front clearance of at least 24 is recommended for adequate service of burner tray and controls COMBUST
4. DO NOT attempt to light the burner by hand B Before operating smell all around the heater area for gas Be sure to smell next to the floor because some gases are heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric 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 f you cannot reach your gas supplier call the fire department C Useonly your hand to push in move or turn the gas control knob or lever Never use tools If the knob or lever will not push in move or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this heater if any part has been under water Immediately call a qualified service techni cian to inspect the heater and to replace any part of the control system and gas control which has been underwater HOT SURFACE IGNITION MODELS WITH ROBERTSHAW GAS VALVE 1 STOP Read the safety information 2 Turn off all electrical power to the appliance 3 Remove front door and control box cover 13 4 This appliance is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Push in and move gas control lever counter clockwise to OFF position 6 Wait f
5. FEET Gas Propane 79 180 Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve lo cated outside the jacket A manual shut off valve is provided loose and must be installed at the site The heater and its gas connection shall be leak tested before placing the heater in operation The heater and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 5 kPa The heater must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 5 kPa Dissipate test pressure from the gas supply line before re connecting the heater and its manual shut off cock to the gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVER PRESSURED GAS VALVES ARE NOT COV ERED BY THE 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 open flame NOTE DO NOT use teflon tape on gas line pipe threads A flexible sealant suitable for use with Natural and Propane gases is recommended MANUAL VALVE IHS HH GAS
6. Pressure Switch N O 651288 007377F Gas Valve Nat 006541F Gas Valve Pro 601170 Gas Valve Manual Shut Off Not Shown 006543F Heat Exchanger Complete 005705F Inlet Outlet Header 005766F Return Header 004982F Tube Bundle 005706F Heat Exchanger Tube 005707F Baffle Kit 005708F Carriage Bolt Kit 004248F Stud Bolt Kit 007911F Header Gasket 005083B CONTROL BOX Control Box Complete Includes 1 C 1 P 005709F Wiring Box 005725F Transformer 24 120 50 VA 006533F On Off Switch 006531F 005710F Air Pressure Switch Tubing 005712F Pump 004990F Pump Cartridge 951116F Pump Flange Gasket 005191F Drain Valve 501520 Temperature amp Pressure Relief Valve 501753 Pressure Regulator Not Shown 006539F Temperature Gauge if equipped 601157 Storage Tank 5 Gallon 005713F Gas Flex Hose 005714F Wire Harness 005715F Inspection Window 005193F Silicone Rubber Sealant 100z 005755F Blower Manifold Seal 005711F Deliming Kit 052871F For Altitudes Above 2000 Feet Above Sea Level Consult Factory 20 our PARTNO oS DESCRIPTION PART NO PILOT Ignition Control Module 005703F Hot Surface Ignitor 005329F Remote Sensor 601501 SHEETMET Jacket Top mm Steel 005717F Flue Collector 005720F Combustion Box 005721F Combustion Box Front Panel Kit 005722F Combustion Box Rear Panel 005767F Combustion Box Top Panel 005727F Access Panel 005723F Control Panel With Gauge Hole Stainless Steel 005718F Control Panel Without Gauge Hole Stain
7. Section related to burner removal BURNER INSPECTION VISUAL 1 Shut off electrical power and gas supply to the heater 2 Disconnect wiring to hot surface ignitor and sensor Remove screws on burner access panel Remove refractory block Visaully inspect burner tray panel Reverse above procedure to reinstall checking burner tray and seal to prevent leakage Oak o ADJUSTMENTS REPLACEMENTS OF COMPONENTS CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components 1 Gas Valve Replacement a Shut off electrical power and gas supply to the heater b Remove gas piping to gas valve inlet c Remove front panel and leftside access panel d Disconnect flex hose gas line e Disconnect wiring connections to gas valve f Remove 2 screws holding gas valve g Reverse above procedure to reinstall 2 Hot Surface Ignitor Replacement Shut off electrical power and gas supply to the heater Disconnect wiring leads to the igniter by pulling apart plastic connector plugs Remove bracket holding ignitor cylinder Reverse above procedure to reinstall CAUTION Silicon carbide ignitor is fragile and brittle Exercise extreme care in handling the assembly to avo
8. VALVE EIL TS LEFT SIDE JACKET PANEL SEDIMENT TRAP Fig 8984 GAS PRESSURE SPECIFICATIONS Inches W C S Manifold The maximum inlet gas pressure must not exceed the value shown above The minimum gas pressure shown is for the purposes of input adjustment The gas valve is provided with a pressure tap to measure the gas pressure downstream which is also the manifold pressure WATER PIPING The inlet and outlet water connections are 3 4 in NPT A water pressure regulator is shipped loose with the heater Install as needed between the booster heater and dishwasher lines Adjust setting to maintain 20 PSI at the dishwasher Install a suitable water hammer arrester be tween the booster heater and dishwasher as shown on page 10 typical piping A drain valve is provided in the tank for draining water during servicing The temperature and pressure relief valve is easily accessible through the front A nipple is provided shipped loose with the heater for installation in the T amp P relief valve A drain line must be connected to the nipple and run to a safe place of disposal WARNING Failure to do so can cause water damage or burns due to scalding if the relief valve should open Drain line must be as short as possible pitch downward from the relief valve and have the same size as the valve discharge connection through out its entire length Refer to tag attached to T amp P relief valve The temperature a
9. exclusion or 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 VARY FROM STATE TO STATE The sole remedy against Raypak with respect to defective parts shall be as provided in this Warranty Itis agreed that Raypak shall have no liability whether under this Warranty or in contract tort or otherwise for any special consequential or incidental damages RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 23 Certified Quality System www raypak com Raypak Inc 2151 Eastman Avenue Westlake Village CA 93030 805 278 5300 FAX 800 872 9725 Raypak Canada Limited 2805 Slough St Mississauga Ontario Canada L4T 1G2 416 677 7999 FAX 416 677 8036 Litho in U S A
10. may cause problems such as above planters patios or over public walk ways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment The gas booster heater may be vented 3 ways 1 Through the sidewall or the ceiling as discussed previously Into the exhaust system See illustration on page 6 Vent pipe must not penetrate filter When the unit is vented into the exhaust system an electrical inter lock must be provided to allow the flow of gas to the booster heater burner ONLY when the exhaust system is energized Free vented into a room or space where other gas fired equipment is installed provided that one or more of the other installed equipment is furnished with a venting system or other approved means for removing the vent gases so the aggregate input of the remaining unvented equipment including the booster heater does not exceed 20 BTU per hour per cubic foot of volume The volume of a room or space directly connected by a doorway archway or other opening of comparable size that cannot be closed may be included in the calculations Refer to the National Fuel Gas Code ANSI Z223 1 NFPA 54 GAS PIPING The gas inlet pipe size is 1 2 NPT to the gas valve Provide an adequate size gas supply line The line should not be smaller than 1 2 NPT according to the chart below MAXIMUM EQUIVALENT PIPE LENGTH
11. CATALOG NO 3300 511 Effective 01 01 03 Replaces 01 01 01 OPERATING AND INSTALLATION INSTRUCTIONS Model B 195 GAS FIRED AUTOMATIC INSTANTANEOUS BOOSTER WATER HEATER FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance To do so may result in an explosion or fire WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Refer to this manual Installation and service must be performed by a qualified installer service agency or the gas supplier FOR YOUR SAFETY 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 This manual should be maintained in legible condition and kept adjacent to the heater or kept in a safe place for future reference Product Discontinued December 2003 P N 240707 CONTENTS PAGE DESCRIPTION 3 1 RECEIVING EQUIPMENT 3 2 GENERAL SPECIFICATIONS AND DIMENSIONS 4 3 INSTALLATION PROCEDURES 4 Code Requirements 4 Combustion Ventilation Air 5 Venting 8 Gas Piping 8 Water Piping 11 Electrical Wiring 12 4 START UP AND OPERATION 12 Co
12. ION AIR BLOWER T amp P RELIEF VALVE MANUAL RESET LIMIT IGNITOR FLAME OBSERVATION PORT VENT OUTLET WATER INLET WATER SENSOR AUTO RESET LIMIT WATER OUTLET ACCESS PANEL TEMPERATURE GAUGE PROBE PUMP CIRCULATOR IGNITION MODULE SPST Relay OPERATING LIMIT CONTROL DRAIN VALVE Fig 91571 COMPONENT LOCATION SEQUENCE OF OPERATION The booster heater is designed to maintain a tempera ture of 180 deg F 82 2 Deg C of 490 GPH water required for the rinse cycle of a commercial dish washer An inlet temperature of 140 Deg F 60 Deg C will produce optimum results Provided the necessary power water gas and vent connections are completed the unit is started by the activation of the on off switch located on the left side panel The blower motor and the circulator pump will also start Providing the operating and safety controls includ ing the vent switch is closed the ignition module will energize the ignitor The hot surface ignitor then heats up and is proven to be capable of ignition The gas valve is then energized The burner will be lit and the remote sensor will sense the flame Ifthe burner flame is not sensed within four seconds the gas valve will shut off The ignition module will try for a total of three cycles to prove ignition If after third cycle ignition is not proven the module will go into lockout and a Red LED will start blinking To recycle the burner momentarily turn the powe
13. ION VENTILATION AIR B195 COMBUSTION AIR ADJUSTMENT This model is equipped with an air adjustment screw on the combustion air blower inlet For natural gas the opening is factory set at about 2 12 diagonal dimension for propane gas the opening is 1 875 diagonal dimension which should be the proper setting for most installations However field conditions including unusual gas characteristics may create a need for adjustment to achieve optimum performance When the combustion air setting is proper there will be some lifting of the flames on some areas of the burner tile under cold start conditions After about five minutes of operation the flames should settle down and blue tips should become visible on some areas and orange glow on other sections of the burner tile Lifting of flames beyond five minutes would indicate too much combustion air The adjustment screw should be turned clockwise to reduce the combustion air supply until the lifting settles down If the blue tips disappear and the entire burner surface becomes radiant white it indicates that there is not enough combustion air and the adjustment screw should be turned counterclockwise to increase the combustion air opening until the blue tips and orange glow become visible again The optimum excess air will result in CO2 levels between 8 and 8 5 for natural gas and 9 2 to 9 796 for propane If a flue gas analyzing equipment is available the opening can be adjusted to achieve this CO level
14. amperage If pump does not draw 0 67 0 78 amps re move and inspect impeller Replace cartridge or entire pump as needed Clean and inspect blower wheel Check operation Replace blower if needed If Red LED on circuit board is ON check for a loose sensor connection or defective sensor Sensor resis tance readings 60 F 45 500x 2300 ohms 80 F 28 000 1300 ohms If Yellow LED is ON water tempera ture is above set point When either Red or Yellow LED is ON heater will be shut down Check 24V power at OUT and COMM terminals If no 24V is present when Red or Yellow LED is not ON replace control board Excessive vent length or resistance or blocked vent will open the air vent switch Remove blockage If switch stays open replace air vent switch Depress the Manual Reset High Limit switch Ensure Operating Limit setting is 185 F or less Perform Pump Check Procedure High Limit trips may be due to a damaged pump Perform Operating Limit Check Procedure If High Limit will not reset replace High Limit 4 Unit energized pump and blower running Ignitor is glowing Burners will not stay lighted Unit does not produce suffcient hot water 3e 3f 4a 4b 4C 4d 5a 5b 5c Continuation TROUBLE SHOOTING GUIDE 3d Excessive vent exhaust or defective air vent switch Ignition module or igniter may be defective Gas valve or the ignition module may be defective
15. e positively sealed Follow carefully the vent manufacturers installation instructions WARNING Provide a screen or barrier to prevent personal injury in areas where personnel contact with vent pipe can occur but DO NOT INSULATE the vent pipe nor use means that will restrict thermal expansion or movement of the vent VENTING THROUGH TYPICAL EXHAUST SYSTEM VENT HOOD VENT PIPE DISHWASHER DISH TABLE OR CONVEYER VENT PIPE SHOULD NOT PENETRATE FILTER MUST BE 2 3 ABOVE SKIRT BOTTOM Applies only to exhaust hood over cooking equipment TYPICAL THRU THE WALL VENTING THRU THE WALL TERMINATION TEE x FITTING OR THIMBLE OUTSIDE WALL COMBUSTIBLE SIDEWALL e TERMINATION 2 DP COMBUSTIBLE WALL kk TERMINATION TEE n EH THRU THE WALL FITTING OR THIMBLE SUPPLIED BY OTHERS E DISH TABLE VENT PIPE OR COUNTER NON COMBUSTIBLE SIDEWALL TERMINATION SEALANT COVER PLATE NON COMBUSTIBLE WALL x SUPPLIED BY VENT MANUFACTURER MAINTAIN 1 MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS TO THE VENT Fig 8975 3 All horizontal runs of the vent pipe shall have a minimum rise of 1 4 per foot of length and should be supported at maximum intervals of 5 feet for Canada 3 feet and at each point where an elbow is used For horizontal venting the total length of 4 inch diameter pipe shall not exceed 30 feet with up to two 90
16. e time and inspect spray nozzles for correct pressure setting or damage Adjust operating limit to minimum tem perature that provides 180 F rinse Do not set above 185 F Verify booster operates correctly if not recheck all procedures listed above 6 REPLACEMENT PARTS LIST NOTE To supply the correct part it is important that you state the model number serial number and type of gas when applicable Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag completely filled in with the heater Serial Number Model Number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty the part will be returned in kind or equivalent substitution freight collect Credit will not be issued RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 18 9 M 19 CALL OUT DESCRIPTION PART NO BURNER TRAY Burner Tray Complete Nat 005704F Burner Tray Complete Pro 006761F Burner Orifice Nat N Sea Level 351204 Burner Orifice Pro 19 Sea Level 351416 CONTROLS Operating Limit 005197F Probe Sensor 006532F Manual Reset High Limit 008093F Auto Reset High Limit 601270 Combustion Air Vent
17. ed warranty conditions you must also specify date of installation Raypak recommends that this manual be reviewed thoroughly before installing your Raypak Heater If there are any questions which this manual does not answer please contact your local Raypak Representative 2 GENERAL SPECIFICATIONS The Raypak Booster Heater is design certified and tested under the requirements of the American National Standard ANSI Z 21 10 3 and the Canadian National Standard CAN 1 4 3 M85 and bears the National Sanitation Foundation NSF seal The Raypak Booster Heater is an instantaneous tube type free standing unit intended for use as a supplier of 180 Deg F dishwasher rinse water Inlet water temperature to the heater of 140 deg F is required for optimum operation of the heater Water enters the heat exchanger from the heater inlet water connection The water then is circulated through two passes of copper finned tubes through a stainless steel tank and to the dishwasher Water is also re circulated through a bypass system that assures the availability of the proper temperature water at the heater outlet SPECIFICATIONS AND DIMENSIONS Input GPH Delivery at Indicated Temperature Rise Model MBH 40 F 50 F 100 F 120 F 140 F 140 INLET WATER 3 4 FPT ELECTRICAL INLET 28 GAS INLET 1 2 FPT 4 FLUE EXHAUST 180 SUPPLY WATER 3 4 MPT Fig 9165 3 INSTALLATION PROCEDURES
18. el Gas Code ANSI Z223 1 or applicable provisions of the local building codes Do not obstruct the flow of combustion and ventilation air to the heater VENTING The vent pipe must be the same size or larger than the 4 diameter outlet on the heater The standard vent outlet is on the right side but this can be changed to the left side by reversing the orientation of the flue collector box This can be done easily in the field Remove the top casing cover to gain access to the flue collector box Remove the screws along the sides of the flue collector Disconnect the vent switch tubing from the fitting and remove the fitting from the flue collector box Lift the box and turn around the other direction Remove the stainless steel plug button and install the fitting in its place then install the plug button where the fitting was removed Reconnect the vent switch tubing to the fitting Replace and secure the flue collector box with the screws previously removed The maximum flue gas temperature at the heater outlet is less than 400 degrees F Use only the special gas vents listed for use with Category III gas burning heaters such as the stainless steel Saf T Vent manufactured by Heat Fab Inc 800 772 0739 or the StaR 34 stainless steel gas vents manufactured by Flex L International Inc 800 561 1980 of the FasNSeal stainless steel gas vents manufactured by ProTech Systems Inc 800 766 3473 A special adapter may be required Pipe joints must b
19. elbows and 1 termination vent For each additional elbow reduce the total pipe length by 10 feet The minimum length in either case is 2 feet with two elbows ending in a termination vent For vertical venting the lengths described above should be fol lowed with a termination vent at the top The minimum length is 5 feet with up to two elbows and a termination vent For sidewall venting locate the heater as close as possible to the wall being used The maximum and minimum wall thickness is determined by the wall thimble available from the vent manufacturer Refer to the vent manufacturer installation instructions Additional requirements when venting through a sidewall 1 The vent terminal shall be located at least three feet above any forced air inlet located within ten feet or at least four feet below four feet horizontally from or one foot above any door window or gravity air inlet into any building It shall also have a minimum horizontal clearance of four feet from electric meters gas meters regulator and relief equipment 2 The vent terminal shall be located not less than seven feet above grade when it is adjacent to public walkways 3 The bottom of the vent terminal shall be located at least twelve inches above grade or ground or normally expected snow accumulation level The snow level may be higher on walls exposed to prevailing winds 4 Avoid areas where local experience indicates that condensate drippage
20. hin sight of the heater Remove the control box cover and make the power supply connection in the field wiring compartment The pump and blower supplied with the heater are pre wired and operate with the heater control system NOTE If it is necessary to replace any of the original wiring it must be replaced with 105 C rated wire or its equivalent 10 LADDER DIAGRAM COMB AIR BLOWER WATER BK W w 120 V w TRANSFORMER SENSOR X HOT SURFACE IGNITION MODULE CONTROL REMOTE SENSOR BL HIGH LIMIT HIGH LIMIT GAS VALVE COMBUSTION VENT AIR FLOW REMOTE WATER TEMP SENSOR SWITCH N O JuNcroNBox BL Y co JI HOT SURFACE IGNITOR TRANSFORMER 21V 120V POWER SWITCH ON OFF CONTROL 24V TEMPERATURE HOT SURFACE CONTROL IGNITION SYSTEM COMBUSTION AIR BLOWER BK E KEY mwa 120V 120V FIELD 24V 24V WIRED O WIRENUT m CONNECTOR BK W BLACK WHITE STRIPE DANGER SHOCK HAZARD BLUE Turn off electrical power to boost heater before servicing any SEEN component in the heater to prevent equipment damage or ORANGE fel RED personal injury VIOLET NOTE IF it is necessary to replace any of the original wiring it WAITE must be replaced with 105 C rated wire or its equivalent 11 4 START UP AND OPERATION REMOTE SENSOR COMBUSTION AIR VENT PRESSURE SWITCH ON OFF SWITCH ELECTRICAL CONNECTION TRANSFORMER GAS CONNECTION P GAS VALVE COMBUST
21. id damage 3 Ignition Module Replacement a Shut off electrical power to the heater b Remove control cover screws and open con trol compartment Disconnect wiring connections to module Remove screws 2 holding module Reverse above procedure to reinstall 4 Transformer Replacement a Shut off electrical power to the heater b Remove control cover screws and open con trol compartment Disconnect wiring connections from transformer leads Remove screws 2 holding transformer Reverse above procedure to reinstall 14 10 Limit Control Module a Shut off electrical power to the heater b Remove control cover screws and open con trol compartment c Disconnect wiring connections to the board d Carefully pull out the control board from the nylon pin supports e Reverse above procedure to reinstall Sensor Probe Replacement a Shut off electrical power to the heater b Shut off water supply to the heater and open drain valve to remove water to the sensor probe level c Remove front panel and control box cover Disconnect wire leads from temperature con trol module Remove sensor probe from the header Use 7 16 wrench Reverse above procedure to reinstall Manual Reset High Limit Control Replacement a Shut off electrical power and water supply to the heater Remove front panel and open drain valve to remove water to the limit control level in the tank Disconnect wiring connections to li
22. ignition system will go into a lock out mode To resume service the heater will need to be reset by momentarily turning the ON OFF switch to the OFF position and then to the ON position Water Shock Absorber by others Union 2 PLCS by others 140 F Inlet Ball Valve 2 PLCS by others 180 F To Dishwasher Pressure Reducing Valve Install As Close To Dishwasher As Possible Suggested Pressure Gauge by others Fig 9153 TYPICAL PIPING Water Shock Absorber by others Pressure Circulator Reducing Valve 2 GPM Recommended by others 7T 180 F To Dishwasher Check Valve 140 F inlet Install As Close To Dishwasher Ball Valve 2 PLCS As Possible by others Union 2 PLCS Suggested Pressure Gauge by others by others Fig 9154 TYPICAL PIPING FOR RECIRCULATION SYSTEM WHEN BOOSTER HEATER IS GREATER THAN 10 FEET FROM DISHWASHER ELECTRICAL The electrical power supply requirement for the heater is 120 volts 60 Hz 5 0 amps or less Field wiring connections and electrical grounding must comply with the local codes or in the absence of local codes with the latest edition of the National Electrical Code ANSI NFPA 70 NOTE Polarity must be observed for the heater to operate properly Consult wiring diagram Provide a separate fused circuit from the main electrical panel to the heater and a disconnecting means wit
23. ive 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to next step 7 Move gas control lever clockwise to ON position IN OFF GAS INLET Fig 8934 1 Replace control box cover and front door Turn on all electric power to the appliance 0 If the appliance will not operate Follow the instructions To Turn Off Gas To Heater and call your service technician or gas supplier 0 0 TO TURN OFF GAS TO HEATER 1 Turnoffall the electric power to the heater if service is to be performed 2 Remove front door and control box cover 3 Push in and move gas control lever counter clockwise lt to OFF CAUTION Should overheating occur or the gas sup ply fails to shut off DO NOT turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance Failure to observe this precaution may aggravate the over heated condition resulting in possible damage to the heater and injury to the user SECTION 4 TESTING THE IGNITION SAFETY SHUT OFF The ignition system safety shut off must be tested by conducting the following method of tests With the system power off manually shut off the gas supply Turn power back on observe the igniter start to heat up and glow bright orange After about four 4 seconds the gas valve is energized then de energ
24. izes after the third try the module goes into a safety lockout a few sec onds later Igniter will stop glowing and the Red LED on the module will start blinking Manually reopen the gas supply No gas should be flowing into the main burners End of test To reset the system momentarily shut off power switch then turn it back on again Igniter will start to heat up and normal heating cycle will occur as described in the sequence of operation on page 12 MAINTENANCE INSTRUCTIONS 1 The water pump motor and the combustion air blower motor are permanently lubricated and re quires no other maintenance 2 Venting system for this heater may be equipped with high temperature plastic material rated for operation at 480 F maximum Check for signs of deformation in the plastic vent pipes which will be an indication of excessive temperature and abnor mal conditions in the venting system Refer to the instructions supplied by the vent pipe manufac turer 3 The burner is made of ceramic material and oper ates in the infrared mode When the burner is operating properly very little blue flame will be visible due to the incandescent brightness of the ceramic material This can be observed through the glass observation port hole 4 Depending on the condition of the kitchen environ ment the burner and blower wheel may require to be cleaned of lint or grease laden dust Inspect the burner box every six months Refer to the Servic ing
25. less Steel 006360F Door Stainless Steel 005719F Blower Mounting Panel 005728F Gas Valve Mounting Wrenching Bracket 005726F 006217F 21 LIMITED PARTS WARRANTY COMMERCIAL BOOSTER HEATER SCOPE Raypak Inc Raypak warrants to the owner that all parts of this booster heater excluding controls and pump will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth inthis Warranty The Warranty is effective from date of original booster heater installation and satisfactory proof of the original installation date such as installer invoice is required THIS WARRANTY WILL BE VOID IF THE HEATER IS NOT INSTALLED IN ACCORDANCE WITH LOCAL CODES AND ORDINANCES OR IF THE HEATER RATING PLATE IS ALTERED OR REMOVED OR IF THE HEATER IS MOVED FROM ITS ORIGINAL PLACE OF INSTALLATION HEAT EXCHANGER WARRANTY Five 5 Years This includes only the copper and bronze waterways Twenty 20 Years against Thermal Shock excluded however if caused by booster heater operating at large changes exceeding 150 F between the water temperature at intake and booster heater temperature or operating at booster heater temperatures exceeding 200 F TOTAL FIVE YEAR STAINLESS STEEL TANK WARRANTY First Year Raypak will replace the tank if it fails under normal use and service 2nd thru 5th Year Raypak will replace the tank if it fails under normal use and service provided that the owner m
26. mit control Remove limit control from the tank Use 1 hex wrench being careful not to break plastic body Reverse above procedure to reinstall b Auto Reset High Limit Replacement a Shut off electrical power and water supply to the heater Remove front panel and open drain valve to remove water to the limit control level in the header c Disconnect wiring connections to limit control d Remove limit control e Reverse above steps to reinstall b Air Vent Switch Replacement a Shut off electrical power to the heater b Remove front panel c Remove wiring connections to switch d Remove screws 2 holding the switch e Reverse above procedure to reinstall Remote Sensor Replacement a Shut off electrical power amp gas supply to the heater b Remove front panel c Disconneect wiring lead from sensor d Remove the screws 2 e Reverse above procedure to reinstall 15 11 12 13 Combustion Air Blower Replacement a Shut off electrical power to heater b Remove front panel and access cover on left side of heater Remove screws 3 on blower housing mount ing panel Drop down blower assembly from discharge connection Open field wiring box and disconnect blower wiring f Reverse above steps to reinstall blower Pump Circulator Replacement a Shut off electrical power to the heater b Shut off water supply and open drain valve to remove water in the piping at the pump le
27. mponent Location 12 Sequence of Operation 12 START UP Procedures 16 5 SERVICING UNIT 16 Trouble Shooting Guide Maintenance 18 6 PARTS 19 Illustrated Parts 20 Parts List 23 WARRANTY These instructions are provided to assure the proper installation operation and maintenance of the Raypak Booster Heater Should questions arise regarding the specification installation operation or servicing of the unit contact the local distributor or contact the Raypak factory CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1 RECEIVING EQUIPMENT On receipt of your equipment it is suggested that you visually check for external damage to the carton If the carton is damaged it is suggested that a note be made on the Bill of Lading when signing for equipment Remove the heater from the carton and if itis damaged report the damage to the carrier immediately Be sure that you receive the number of packages indicated on the Bill of Lading Claims for shortages and damages must be filed with the carrier by consignee Purchased parts are subject to replacement only under the manufacturer s limited warranty Debits for defective replacement parts will not be accepted and defective parts will be replaced in kind only per our standard warranties When ordering parts you must specify Model and Serial Number of heater When ordering under limit
28. nd pressure relief valve should be manually operated at least once a yearto insure that the valve mechanism is still functional Repair or alteration of valve in any way is prohibited by National Safety Standards and or local codes If the relief valve discharges occasionally or peri odically this may be due to thermal expansion in a closed water supply system Contact the water sup plier or the local plumbing inspector on how to correct this situation DO NOT plug the relief valve or install a shut off valve in the discharge drain line The heater is equipped with a circulator to provide the minimum water flow in the heater and maintain a uniform water temperature in the tank Depending on heater distance from the dishwasher it may be neces sary to run empty rack s to purge supply of line lower than the required 180 F water temperature For this reason it is best to locate heater as close as possible to the dishwasher CAUTION In severe cold weather freezing air can be drawn through the vent pipes to the heat exchanger during overnight shut down period If there is no water circulation or heat in the water freezing can occur which will damage the heat exchanger To avoid freezing damage constant water circulation should be maintained by keeping the booster heater energized so that the circulator pump will run Closing the manual gas shut off valve will prevent unnecessary heating of the water NOTE Under this condition the
29. nstructions 2 Abuse alteration accident fire flood and the like 3 Sediment or lime buildup freezing or other conditions causing inadequate water circulation 4 High velocity flow exceeding booster 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 booster heaters 7 Failure to eliminate air from or replenish water in the connected water system 8 Chemical contamination of combustion air or owner s use of chemical additives to water TO MAKE A WARRANTY CLAIM Promptly notify the selling dealer supplying model and serial numbers and description of the problem The dealer must then notify it s Raypak distributor for instructions regarding the claim If the dealer is not available contact SERVICE MANAGER at the address listed below In all cases proper authorization must first be received from Raypak before any part is replaced Any replaced part must be made available to Raypak in exchange for replacement 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 ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED Some States do not allow limitations on how long an implied warranty lasts or for the
30. r switch to the off position and then to the on position When the water temperature exceeds the setting of the operating controller the burner will shut 12 off until the next call for heat The operating limit control is factory set at 185 F Combustion air blower and the circulator pump will cycle On Off with the operating limit controller START UP PROCEDURES SECTION 1 FILLING THE SYSTEM Fill the heater system with water purging all air It is recommended that the system be flushed before putting heater into operation This can be done by opening the drain valve located under the stainless steel tank SECTION 2 CHECKING CIRCULATOR PUMP Before lighting the heater make sure the circulator is operating properly With the gas valve in the off position activate the power switch The circulator should start immediately Allow the circulator to pump the water through the system NOTE The circulator motor does not require lubrica tion SECTION 3 LIGHTING THE HEATER Safety lighting and other performance criteria were met for the burner assembly and control assembly when the heater was tested for design certification under the ANSI Z21 10 3 Standard WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This heater DOES NOT have a pilot Itis equipped with a hot surface ignition device which automati cally lights the burner
31. ust pay Raypak a portion of the published list price in effect at the time notice of the failure is given REPLACEMENT PRICE REPLACEMENT PRICE YEAR OF CLAIM PERCENT OF LIST PRICE YEAR OF CLAIM PERCENT OF LIST PRICE 2 20 4 60 3 40 5 80 ANY OTHER PART MANUFACTURED BY RAYPAK One 1 Year Warranty or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part Verification of the in warranty failure will be made through inspection by a local recognized and certified service agency or the local Raypak representative at Raypak s option The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on the controls and the pump but Raypak will apply any such warranties as may be provided to it by the part s manufacturer LABOR CHARGES Labor charges to replace any failed part during the first 90 days of this Warranty will be paid by Raypak Service must be performed by a recognized and certified service agency during normal working hours All other costs are excluded from this warranty and are the owners responsibility ADDITIONAL WARRANTY EXCLUSIONS This Warranty does not cover failures or malfunctions resulting from 1 Failure to properly install operate or maintain the booster heater in accordance with our printed i
32. vel c Remove front panel and access panel on right side of cabinet d Disconnect wiring and conduit connections to motor e Remove plumbing connections to pump as sembly f Reverse above procedure to reinstall Temperature and Pressure Relief Valve Replacement a Shut off electrical power to the heater b Shut off water supply and open drain valve to remove water in the tank to the relief valve level Remove front panel Disconnect plumbing connections to the T amp P relief valve Reverse above procedure to reinstall c q f 5 SERVICING UNIT TROUBLE SHOOTING GUIDE PROBLEM 1 On Off switch energized Unit does not operate 2 Pump Blower NOT running 3 Unit energized pump and blower running but burner is NOT on POSSIBLE CAUSE 1a 1b 2a 2b 26 3a 3b 3c No power to heater Defective transformer Loose wire s Defective pump Defective blower Limit control operating limit or sensor may be defective Blocked vent or defective air vent switch Trippedor defective manual reset limit 16 SUGGESTED SOLUTION 2a 2b 2c 3a 3b 3c Cycle the Power Switch off then on Check circuit breaker and electrical disconnect Check for reversed polarity and im proper ground Check dishwasher vent interlock if applicable Check secondary voltage If no 24 volts replace transformer Check wiring connection s Check pump
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