Raypak SureRack Kit Service manual

E󰀨ective: 06-30-22
Replaces: 12-09-10
P/N 240792 Rev. 4
INSTALLATION INSTRUCTION
MANUAL
SureRack™
Kit
X-3 Restraint
Kit
FOR HI DELTA MODELS:
302-2342, 302A-2342A,
302B-2342B &
302C-2342C
AND DELTA LTD.
MODELS:
399-2339 & 399B-2339B

2
Revision 4 reects the following changes:
Added new part numbers to coversheet and "X-3 Restraint Bracket Kit". Added note: "The SureRack is designed to connect to the
lower unit to provide lateral bracing. Raypak cannot support using a SureRack as a platform to elevate an upper unit with no lower
unit". Added X-3 Restraint Bracket section.

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TABLE OF CONTENTS
1. X-1 KIT CONTENTS ................................................ 4
Anchoring Information ..............................................4
2. INSTALLATION........................................................ 7
3. X-2 ADD-ON LEG KIT ............................................. 9
4. X-3 RESTRAINT BRACKET KIT ......................... 10

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NOTE: The rack is to be assembled around the bottom
boiler rst. Do not pre-assemble. It is recommended
that the rack be installed rst prior to any plumbing,
electrical, venting, or gas hook-up.
NOTE: These instructions are intended for use by
qualied personnel specically trained and experienced
in the installation of this type of heating equipment and
related system components. Installation and service
personnel are required to be licensed in some states.
Persons not qualied shall not attempt to install this
equipment nor attempt repairs according to these
instructions.
NOTE: The SureRack is designed to connect to the
lower unit to provide lateral bracing. Raypak cannot
support using a SureRack as a platform to elevate an
upper unit with no lower unit.
1. X-1 KIT CONTENTS
Item* Description Qty
P/N for
Sizes
302**- 902**
399**- 899**
P/N for
Sizes
992**- 2342**
989**- 2339**
Location
1Leg assembly, front left and right rear 2 074520 074396 Corners
2Support beam 2 402161–402166 402145–402150 Top
3Leg assembly, front right and left rear 2 074521 074395 Top
4Washer, lock, 3/8
52 550136
Top
56 550136
5Screw, hex head, 3/8-16 UNC x 1.5
48 550266
Top Corners
52 550266
6Cross member
3 401680
Top
4 401680
7Spacer 24 550730 550730 Leg connections
8Bracket 12 401665 401665 Leg connections
9Upper restraint foot (X-3) 4 074522 067512 Leg connections
10 Screw, hex head, 3/8-16 UNC x 2.0 4 550267 550267 Leg connections
*Item numbers correspond to the numbers listed in Figure 1 on page 5.
Table A. KIT CONTENTS
**Indicates a letter is present after the model number throughout instruction set.

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Figure 1. SURERACK ASSEMBLY

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Model X-1 Kit No.
Item 1*
Leg Assembly
Item 3*
Leg Assembly
Item 2*
Support Beams
Item 6*
Cross Members
P/N Length
(in.) P/N Length (in.) P/N Length (in.) P/N Length (in.)
302 006906
074521 37.75 074520 37.75
402161 42.79
401680 29.8
399-402 006907 402162 49.79
499-502 006908 402163 56.79
649-652 006909 402164 67.29
749-752 006910 402165 74.29
899-902 006911 402166 84.79
989-992 011563
074396 45.95 074395 45.95
402145 64.12
402097 38.0
1259-1262 011564 402146 75.44
1529-1532 011565 402147 86.78
1799-1802 011566 402148 98.12
2069-2072 011567 402149 109.47
2339-2342 011568 402150 120.81
*Item numbers correspond to the numbers listed in Figure 1 on page 5.
Table B. PARTS LENGTHS FOR SURERACK ASSEMBLIES
Anchoring Information
For reference only. Recommended to match drill on job
site.
Use a minimum of two bolts ½” X 5”, A-307 Grade 5.2
or equivalent. Use Hilti® HY-150 adhesive to secure
expansion anchor.
Approved for all installations.
Refer to Figure 2 and Table C for more information.
Model
Anchoring Dimensions (in.)
A B C
302 34.29
22.71 3.5
399-402 41.29
499-502 48.29
649-652 58.79
749-752 65.79
899-902 76.29
989-992 55.62
30.81 3.5
1259-1262 66.94
1529-1532 78.28
1799-1802 89.62
1999-2002 100.97
2069-2072 100.97
2339-2342 112.31
Table C. ANCHORING DIMENSIONS

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Figure 2. SURERACK ANCHORING INFORMATION
NOTE: The rack is to be assembled around the bottom
boiler rst. Do not pre-assemble. It is recommended
that the rack be installed rst prior to any plumbing,
electrical, venting, or gas hook-up.
Figure 3. ASSEMBLE RACK AROUND BOTTOM
BOILER
INSTALLATION
READ COMPLETELY BEFORE ASSEMBLING RACK.
1. Identify the heater model number. This information
is on the rating plate located on the lower right front
panel. Confirm correct item lengths for the unit to be
installed. Refer to Table B.
2. Once the unit is located in its permanent position,
remove the left and right access panels from the front
and rear of the boiler as shown in Figure 4.
Figure 4. FRONT VIEW
3. Reverse the exhaust vent panels to the alternate
locations at rear of the heater on the bottom unit. See
Figure 5. Refer to the heater I&O manual for detailed
instructions (P/N: 241663 or 241664). These manuals
can be found in the document library at www.raypak.
com.
ALTERNATE FLUE
CONNECTION
FLUE EXHAUST
COMBUSTION AIR
FILTER (INLET)
Figure 5. REAR VIEW
4. Remove the 8 plastic plugs from the lower boiler
corners and 8 from the boiler midsections.

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5. Place one leg (items 1 & 3) at each corner of the
boiler as shown in Figure 1 & Figure 6. The legs are
NOT interchangeable.
VIEW OF BOTTOM RIGHT FOOT
THESE CORNERS WILL ALWAYS
FACE OUTWARDS
Figure 6. RACK LEG
6. Place one "L" shaped spacer angle (item 8) inside of
the boiler at each corner as shown in Figure 7.
SPACE MOUNTED
INSIDE LEG AND UNIT
BRACKET-BOTTOM
VIEW UNDER UNIT
BOTTOM OF FOOT
Figure 7. LEG INSTALLATION (1)
7. Insert one 1-1/2" (item 5) bolt and washer (item 4)
through the slot on leg.
8. Immediately install the spacer (item 7) between the
inside of the leg and the boiler. See Figure 7 & Figure
8.
9. Continue to push the bolt through the hole in the
heater. See Figure 7.
SPACER
BRACKET
MID-LEG ARRANGEMENT
Figure 8. LEG INSTALLATION (2)
10. Start threading the bolt into the spacer angle.
11. Do not tighten at this step. Leave spacer angle and
bolt loosely threaded.
12. On the same leg, move up to the mid section of
heater and repeat steps 7 through 11. See Figure 8.
13. Repeat steps 6 to 11 on the remaining corners at the
bottom and midsection of the other three legs. See
Figure 7. (16 total).
14. Tighten all the leg bolts after all the attaching bolts
are in place.
15. If it is required that the legs be bolted to the floor,
follow these steps:
a. Move the boiler into its final installation location.
b. Mark the hole locations.
c. Move the unit out of the way so that the holes can
be drilled. Insert anchors into the holes.
d. Once anchors have been put in place, move the
unit back over the holes.
e. Bolt the legs to the anchors in the floor.
16. Lay the 2 support beams (item 2) across the top of
the legs with the cutout facing down and outward.
See Figure 9.
CROSS MEMBER
SUPPORT BEAM
LEG
CUT-OUT FACES
OUTWARD
Figure 9. CROSS BEAM ASSEMBLY
17. Set one restraint foot assembly (item 9) on each
corner of the top of the leg, with the flat side facing
outward. See Figure 10.
18. Insert 1½" bolt (item 5) with washers (item 4) (top &
bottom) in all four holes through all three layers of
metal. Hand tighten.
19. Repeat this process on the remaining 3 corners.
20. Lay the cross members (item 6) across the top of the
rack from the front to back See Figure 9.
NOTE: Models 302–902/399-899 will have three cross
members. Models 992–2342/989-2339 will have four
cross members.

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21. Insert 1½" bolts (item 5) with washers (item 4) (top &
bottom) into the cross members. Hand tighten. See
Figure 10.
22. Insert 1½" bolts (item 5) with washers (item 4) (top
& bottom) into the cross members (item 6) and hand
tighten. See Figure 10.
23. Carefully install second unit on top of SureRack.
24. Attach restraint feet (item 9) to each corner of upper
unit. See Figure 10.
FLAT SIDE OF
RESTRAINT FOOT
FACES OUTWARD
UPPER FOOT RESTRAINT
INSTALL 38-16 X 2” SCREW AT
THIS LOCATION ONLY, ONE ON
EACH CORNER OF THE BOILER
Figure 10. RESTRAINT FOOT
NOTE: Each corner will have: 1 – 1-1/2" bolt AND ALSO
1 – 2" bolt (See Figure 10 detail).
25. Fully tighten all the nuts and bolts on the restraint feet
on the support beams and on the cross members.
Also re-tighten the bolts on the bottom of the rack
assembly.
Figure 11. COMPLETED ASSEMBLY
X-2 ADD-ON LEG KIT
NOTE: The X-2 Add-On Leg Kit should be used if it
is necessary to meet requirements for above-grade
installations.
1. Detach the two 1-1/2” leg bolts.
2. Remove one anchor bolt and one restraint foot bolt
(1/2 X 5”).
3. Attach the leg. See Figure 12.
4. Insert two 2” bolts in the side and tighten.
5. Attach one 2” bolt on the top and bottom and tighten.
6. Repeat the steps above for the remaining 3 legs.
ABOVE GRADE INSTALLATION
ADD ON KIT.
302-902/399-899: 007046
992-2342/989-2339: 007053
REMOVE THE TWO (2) 3/8-16 X
1-1/2 LEG BOLTS, THEN INSTALL
THE 2” LONG LEG BOLTS
Figure 12. INSTALLING THE X-2 LEGS

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X-3 RESTRAINT BRACKET KIT
NOTE: The X-3 Restraint Bracket Kit can be used stand-
alone to securely anchor a single Hi Delta or Delta
LTD appliance to structure. Anchor size and quantity
determination is site specic, by others
Item Description Qty
P/N for Sizes
302-902
399-899
(008136)
P/N for Sizes
992-2342
989-2339
(008147)
Location
4 Washer, Lock, 3/8" 8 550136
Restraint Bracket
Connections
7 Spacer 8 550730
8 Bracket 4 401665
9 Restraint Bracket 4 074522 067512
10 Screw, Hex Head, 3/8"-16 UNC x 2.0" 8 550267
ASSEMBLY
1. Place one foot at each corner of the boiler.
2. Place one “L” shaped mounting bracket under the
boiler at each corner as shown in Figure 13.
3. Insert one 2” bolt and washer through the hole on
restraint bracket, making sure to place a spacer
between the restraint bracket and the boiler cabinet.
4. Start to thread bolt into mounting bracket as shown in
Figure 13, tighten evenly.
5. Repeat the previous procedure on all four corners of
the boiler as shown in Figure 13.
6. Once all 4 feet have been installed you can mark the
floor for drilling anchor holes.
7. Two bolts per foot are recommended for anchoring.
8. The mounting brackets must be installed as shown
in Figure 13.

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UPPER FOOT RESTRAINT
INSTALL THE 3/8-16 X 2” SCREW
AT THIS LOCATION ONLY, ONE
ON EACH CORNER OF THE
BOILER
FLAT SIDE OF RESTRAINT
FOOT FACES FORWARD
Figure 13. X-3 RESTRAINT FOOT DETAILS
Refer to Table C and Figure 2 in this
instruction for anchoring information.

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NOTES
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] www.raypak.com