Raypak HD401 User's Manual
Contents
1. Telephone 805 278 5300 Fax 800 872 9725 Web site www raypak com Project Name Date Division 23 52 33 13 1 2 Product Hi Delta SS copper finned tube hydronic boiler s 2 2 BOILERS A General 1 The boiler s shall be fired with gas at a rated input of BTU hr 2 The boiler s shall be CSA tested and certified with a minimum thermal efficiency of 84 percent 3 4 at full fire The boiler s shall be ASME inspected and stamped and National Board registered for 160 PSIG working pressure complete with a Manufacturer s Data Report The boiler s shall have a floor loading of 45 Ibs square foot or less B Heat Exchanger 1 The heat exchanger shall be of a single bank horizontal grid design with nine integral copper fin tubes each end of which is rolled into an ASME boiler quality steel tube sheet 2 The heat exchanger shall be sealed to 160 PSIG rated cast iron headers with high temperature silicone O ring gaskets 3 The low water volume heat exchanger shall be explosion proof on the water side and shall carry a twenty year warranty against thermal shock 4 The headers shall be secured to the tube sheet by stud bolts with flange nuts to permit inspection and maintenance without removal of external piping connections 5 The boiler s shall be capable of operating at inlet water temperatures as low as 105 F without condensation C Burners 1 The tubular burners shall have gas orifices punche2. Catalog No 2000 961 Effective 6 25 09 Replaces New Hi Delta SS TYPE H MODELS HD101 HD401 SUGGESTED SPECIFICATIONS DIVISION 23 52 33 13 FINNED WATER TUBE BOILERS PART 1 GENERAL 1 1 SUMMARY A Section includes gas fired copper finned tube hydronic heating boilers B Related Sections Specifier Note Use as needed 1 Building Services Piping Division 23 21 00 2 Breeching Chimneys and Stacks Venting Division 23 51 00 3 HVAC Instrumentation and Controls Division 23 09 00 4 Electrical Division 23 09 33 1 2 REFERENCES ANSI Z21 13 CSA 4 9 ASME Section IV 2006 UMC Section 1107 6 ANSI ASHRAE 15 1994 Section 8 13 6 National Fuel Gas Code ANSI Z223 1 NFPA 54 I B R NEC 1 3 SUBMITTALS A Product data sheet including dimensions rated capacities shipping weights accessories Qanmoom gt B Wiring diagram C Warranty information D Installation and operating instructions 14 QUALITY ASSURANCE A Regulatory Requirements 1 ANSI Z21 13 CSA 4 9 2 Local and national air quality regulations for low NOx lt 20 PPM NOx emissions boilers B Certifications 1 CSA 2 ASME H Stamp and National Board Listed 3 ISO 9001 1 5 WARRANTY A Limited one year warranty from date of installation B Limited twenty year thermal shock warranty C Limited ten year closed system heat exchanger warranty PART 2 PRODUCTS 2 1 MANUFACTURER A Raypak Inc 1 Contact 2151 Eastman Ave Oxnard CA 93030
3. anifold and blower air pressures C Submit copy of start up report to Architect and Engineer 3 3 TRAINING A Provide factory authorized service representative to train maintenance personnel on procedures and schedules related to start up shut down trouble shooting servicing and preventive maintenance B Schedule training at least seven days in advance END OF SECTION Project Name Date Division 23 52 33 13 4
4. d ports and slots be capable of quiet ignition and extinction without flashback at the orifice and be manufactured from corrosion resistant stainless steel with low expansion coefficient 2 The burners will be supplied with a fan assisted clean burning and highly efficient fuel air mixture D Pilot Control System 1 The boiler s shall be equipped with a 100 percent safety shutdown system 2 The ignition shall be Hot Surface Ignition type with full flame rectification by remote sensing separate from the ignition source with a three try for ignition sequence to ensure consistent operation 3 The igniter will be located away from the water inlet to protect the device from condensation during startup 4 Anexternal viewing port shall be provided permitting visual observation of burner operation E Gas Train 1 The boiler s shall have dual seated main gas valve s 2 Gas control trains shall have a redundant safety shut off feature main gas regulator and plugged pressure tapping to meet the requirements of ANSI Z21 13 CSA 4 9 F Boiler Control 1 The following safety controls shall be provided a High limit control b Flow switch C PSIG ASME pressure relief valve piped by the installer to an approved drain d Temperature and pressure gauge 2 The boiler s shall be equipped with an energy saving pump control relay Economaster mounted and wired which automatically shuts off the boiler pump at a set p
5. eriod after boiler shut down adjustable for two settings of five or ten minutes to avoid standby losses associated with constant pump operation G Firing Mode 1 For models HD101 HD401 provide two stage fire control of the gas input to the boiler on off fire optional H Boiler Diagnostics Project Name Date Division 23 52 33 13 2 1 Provide internal LED displaying the following boiler status faults a Steady on Internal control failure b One flash Air flow fault c Two flashes Erroneous flame signal d Three flashes Ignition lockout Combustion Chamber The lightweight high temperature multi piece interlocking ceramic fiber combustion chamber liner shall be sealed to reduce standby radiation losses reducing jacket losses and increasing unit efficiency J Venting 1 When routed vertically the boiler s flue material and size shall be in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA54 latest edition Category 2 When routed horizontally the boiler s flue material and size shall meet or exceed the requirements as specified for Category III in the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition 3 The boiler s shall be TruSeal direct vent ready The boiler s shall meet safety standards for direct vent equipment as noted by the 2006 UMC Section 1107 6 ASHRAE 15 1994 Section 8 13 6 and ANSI Z21 13 CSA 4 9 K Cabinet 1 The corrosion resistant ga
6. ge of the dial shall be 105 F to 120 F The PID Logic shall be capable of limiting system overshoot to a maximum of 10 F on initial start up or call for heat The cold water run system shall be shipped loose for field installation The cold water run pump shall have the following diagnostic LED s a Power b Heat Request c Reduced Out d Out 2 3 SOURCE QUALITY CONTROL A The boiler s shall be completely assembled wired and fire tested prior to shipment from the factory B The boiler s shall be furnished with the sales order ASME Manufacturer s Data Report inspection sheet wiring diagram rating plate and Installation and Operating Manual Project Name Date Division 23 52 33 13 3 PART 3 EXECUTION 3 1 INSTALLATION A Must comply with Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition National Electrical Code ANSI NFPA 70 latest edition Canada only CAN CSA B149 Installation Code and CSA C22 1 CEC Part Manufacturer s installation instructions including required service clearances and venting guidelines akwNnN gt B Manufacturer s representative to verify proper and complete installation 3 2 START UP A Shall be performed by Raypak factory trained personnel B Test during operation and adjust if necessary 1 Safeties 2 Operating Controls 3 Static and full load gas supply pressures 4 Gas m
7. lvanized steel jackets shall be finished with a baked on epoxy powder coat which is suitable for outdoor installation applied prior to assembly for complete coverage and shall incorporate louvers in the outer panels to divert air past heated surfaces 2 The boiler s if located on a combustible floor shall not require a separate combustible floor base 3 Combustion air intake shall be on the left side of the cabinet L Operating Controls 1 The boiler s shall feature an optional controller Specifier Note The remaining items in this section are options Delete those that are not being specified M Boiler Pump Refer to Equipment Schedule N Cold Water Run System 1 The boiler s shall be configured with a cold water run automatic proportional bypass system that ensures the boiler will experience inlet temperatures in excess of 105 F in less than 7 minutes to avoid damaging condensation The unit will automatically shut down if the inlet temperature is not achieved within the 7 minute time frame The cold water run system shall be configured with a variable speed pump that is controlled by a system matched PID control that injects the correct amount of cold water directly into the boiler loop to maintain a minimum inlet temperature The PID controller temperature sensor shall be located in the inlet header of the boiler The control shall have a temperature setting dial located on the face of the board The temperature ran
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