Raypak B-195 User manual

CATALOG NO.: 3300.51I
Effective: 01-01-03
Replaces: 01-01-01
Model B-195
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.
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.
This manual should be maintained in legible
condition and kept adjacent to the heater or kept
in a safe place for future reference.
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.
OPERATING AND
INSTALLATION
INSTRUCTIONS
GAS FIRED AUTOMATIC
INSTANTANEOUS
BOOSTER WATER
HEATER
P/N 240707
NSF
®
Product Discontinued December 2003

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 - Component 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.
2
CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to
the State of California to cause cancer, birth defects or other reproductive harm.

3
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 it is 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 limited
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 60°F 70°F 80°F 100°F 120°F 140°F
B-195 195 490 392 327 280 245 196 163 140
Fig #9165

3. INSTALLATION PROCEDURES.
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
* 0" 6" 6" Alcove 6" 1"
*Approved for installation on combustible flooring.
A front clearance of at least 24" is recommended for adequate service of burner-tray and controls.
COMBUSTION/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 CO2levels between 8 and 8.5% for natural gas and 9.2 to 9.7% for
propane. If a flue gas analyzing equipment is available, the opening can be adjusted to achieve this CO2level.
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 CO2levels 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.
4

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 Fuel 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 be 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.
5

6
Fig. #8975.3
Applies only to exhaust hood over cooking equipment.

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° 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 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.
2. 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.
3. 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.
7

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 (FEET)
Pipe Size
Gas 1/2" 3/4" 1"
Natural 5 30 100
Propane 70 180
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.
Fig. # 8984
GAS PRESSURE SPECIFICATIONS
Inches W.C.
Gas Min Max Manifold
Natural 4.5 10.5 3.5
Propane 11.0 14.0 10.0
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.
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.
8

9
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 & 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 & P relief valve.
The temperature and pressure relief valve should
be manually operated at least once a year to 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
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.

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 within 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