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Raypak 1000 Boiler User Manual

1. Figure J 1 NATURAL DRAFT VERTICAL VENT WITHOUT ADD ON CONDENSING HEAT EXCHANGER Certified Recommended Minimum Maximum Venting Venting Vent Size Venting Length Catego Material Type B or ADB 1000 Type B or Type B or NOTE Rear venting is recommended to minimize interference with water piping Vent lengths are based on a lateral length of 2 feet Refer to the latest edition of the National Fuel Gas Code for further details ANSI Z223 1 or in Canada the latest edition of CAN CGA B149 1 and B149 2 31 e Natural Draft Vertical Venting System 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 negative draft must be within the range of 0 01 to 0 08 negative W C to insure proper operation The vent material must be in accordance with the above instructions for vent materials Vent material must be listed by a nationally recognized test agency The maximum and minimum venting length for Category I appliance shall be determined per the latest edition of the National Fuel Gas Code U S or B179 1 and 2 Installation Code Canada The diameter of vent flue pipe should be sized according to Part 11 of the latest edition of the National Fuel Gas Code U S and part 7 and appendix B of the CAN CGA B 149 1 and 2 installation code Canada The minimum flue pipe diameter for convention
2. 3 MIN 2 MIN E DIRECT VENT CAP A CONDENSATE Figure J 8 VERTICAL DIRECT VENTING WITH ADD ON SECONDARY CONDENSING HEAT EXCHANGER ADB 500 w CHX ADB 750 w CHX ADB 1000 w CHX Contact manufacturer for details Certified Venting Material UL17 38 Certified Venting Material e g AL 29 4C Stainless Steel PVC CPVC pool application only UL 17 38 Certified Venting Material e g AL 29 46 Stainless Steel PVC CPVC pool application only 17 38 Certified Venting Material e g AL 29 4C Stainless Steel PVC CPVC pool application only Maximum Vertical Venting Length 35 Subtract 10 feet per elbow Maximum three 3 elbows 35 Subtract 10 feet per elbow Maximum three 3 elbows 35 Subtract 10 feet per elbow Maximum three 3 elbows 46 Combustion Air Intake Pipe Material Galvanized Steel PVC ABS CPVC Galvanized Steel PVC ABS CPVC Galvanized Steel PVC ABS CPVC Air Inlet Size inches Maximum Air Intake Length feet 35 Subtract 10 feet per elbow Maximum three 3 elbows 35 Subtract 10 feet per elbow Maximum three 3 elbows 35 Subtract 10 feet per elbow Maximum three 3 elbows Vertical Direct Venting System With Add on Condensing Heat Exchanger Category IV Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combusti
3. x OPTIONAL Y FLUE VENT INSTALLATION Figure J 4 VERTICAL DIRECT VENTING WITHOUT ADD ON CONDENSING HEAT EXCHANGER Certified Recommended Minimum Maximum Combustion Air Air Maximum Air Venting Venting Vent Size Vertical Intake Pipe Inlet Size Intake Length Catego Material Inches Venting Height Material inches feet vanized PVC 45 ADB 500 7 5 25 ABS Subtract 10 feet per elbow CPVC Maximum three 3 elbows vanized Stee PVC 45 ADB 750 5 25 ABS Subtract 10 feet per elbow CPVC Maximum three 3 elbows vanized Stee PVC 45 ADB 1000 5 25 ABS Subtract 10 feet per elbow CPVC Maximum three 3 elbows Vent lengths are based on a lateral length of 2 feet Refer to the latest edition of National Fuel Gas Code for further details ANSI Z223 1 or in Canada the latest edition of CAN CGA B149 1 and B149 2 38 Vertical Direct Venting System Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue The negative draft must be within the range of 0 01 to 0 08 negative W C to insure proper operation The vent material must be in accor dance with the above instructions for vent materials Vent material must be listed by a nationally recognized test agency The maximum and minimum venting length for Category I appliance shall be de
4. AP ft w CHX 49 4 5 32 2 3 84 11 5 12 30 2 1 w CHX 73 10 0 49 5 2 36 3 5 110 22 1 12 F 2 24 Delta P Should include typical piping To From a single tank as well as bypass piping NOTE GPM flow rates limited by maximum acceptable velocity through heat exchanger tubes May be Table D 1 increased by 10 for closed heating systems Pressure drop would increase by 21 12 SECTION E HYDRONIC HEATING PIPING PUMP SELECTION In order to insure proper performance of your boiler system you must install a properly sized pump Raypak recommends using a 20 F Delta T as design Delta T Delta T is the temperature difference between the inlet and outlet water when the boiler is firing at full rate If a Delta T larger than 20 is necessary the bypass must be installed and adjusted to insure proper hydraulics through the boiler while still allowing minimum flow to satisfy the safety flow switch See Table D 1 for flow rate requirements PRESSURE DROP IN FEET OF HEAD FEEDWATER REGULATOR Raypak recommends that a feedwater regulator be installed and set at 12 PSIG minimum pressure at the highest point of 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 HEATING BOILERS All high points should be vented Purge valves and a bypass valve should be installed A boiler installed above radiation level must be provided with a low water
5. Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code NFGC ANSI Z223 1 latest edition National Electrical Code NEC ANSI NFPA 70 latest edition Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 when required For Canada only CAN CGA 8149 1 and 2 Installation Code and C S A C22 1 C E C Part 1 EQUIPMENT BASE The boiler should be mounted on a level structurally sound surface The boiler is approved for and can be installed 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 inches above the floor The boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliance 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 In addition the boiler shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc CLEARANCES TABLE 1 MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES INDOOR ALCOVE INSTALLATIONS Boiler Size Boiler Side 500 Floor See Note 1 Rear 1 Right 12 Water side Left 1
6. Areas causing contaminated combustion air dry cleaning laundry areas and establishments metal fabrication plants beauty shops refrigeration repair shops photo processing plants auto body shops plastic manufacturing plants furniture refinishing areas and establishments new building construction remodeling areas Check for areas and products as listed above before installing boiler If found remove products permanently OR provide outdoor combustion air 67 CALL d DESCRIPTION BURNER ASSEMBLY Burner Pilot Assembly IID 007105F 007106F 007107F Burner Pilot Assembly C 2 007110F 007111F 007112F Ignitor Spark Rod 007124F 007124F 007125F Plenum Assembly Complete 007131F 007132F 007133F Burner Block 007115F 007116F 007117F Burner Housing Refractory Block 007118F 007119F 007120F Baffle Gas Air Mixing 007126F 007127F 007128F Plenum End Panel 007136F 007137F 007138F High Tension Wire 007121F 007121F 007121F CONTROLS Auto Reset High Limit 007141F 007141F 007141F Flow Switch 007142F 007142F 007142F Manual Reset High Limit 007144F 007144F 007144F Printed Circuit Board Central Point Wiring 007146F 007146F 007146F Printed Circuit Boar
7. Valve Gas Manual A 1 007189F 007189F N A Valve Gas Manual A 1 1 4 N A N A 007190F Valve Gas Manual B 007195F 007195F 007195F Valve Pilot Gas Nat 007196F 007196F 007196F Valve Pilot Gas Pro 007197F 007197F 007197F Switch High Gas Pressure optional Not Shown 007188F 007188F 007188F 70 DESCRIPTION HEAT EXCHANGER Heat Exchange Assy Bronze Includes 18 S 007202F 007200F 007341F Inlet Outlet Header Bronze 007203F 007203F 007342F Return Header Bronze 007204F 007204F 007204F Tube Bundle Cupro Nickle 007206F 007207F 007208F Flue Baffle 007213F 007214F 007215F Heat Shield Baffle 2 pcs 007212F 007212F 007212F Studbolt HX 500 1000 006945F 006945F 006945F Header Gasket 20 PCS 007343F 007343F 007343F Well Bulb Sensor 1 2 x 3 5 16 007211F 007211F 007211F Drain Valve 006536F 006536F 006536F MISCELLANEOUS COMPONENTS Flow Swich Paddle 004079F 004079F 004079F In Line Fuse Holder Not Shown 007216F 007216F 007216F Guide PC Card 007143F 007143F 007143F Window Combustion Chamber 006947F 006947F 006947F T amp P Guage Direct Mount 007205F 007205F 007205F T amp P Guage 0 75 PSI Remote Mount 007344F 007344F 007344F T amp P Guage 0 200 PSI Remote Mount 007345F 007345F 007345F PRV 30 PSI 007217F 007218F 007219F PRV 45 PSI 007220F 007346F 007221F PRV 60 PSI 007222F 007222F 007222F PRV 75 PSI 007223F 007223F 007223F PRV 125 PSI 007224F 007224F 007224F PRV 150 PSI 007225F 007225F 007225F OPTIONS Not Shown Amplifier Flame Rec
8. or may cause other safety control damage or failure 2 2 Attach Manometers to Measure Pressures See Figure O 1 Attach 16 scale manometer to the first main gas shut off valve pressure tapping Location 1 Attach one 8 scale manometer to the outlet side of the second main gas shut off valve pressure tapping Location 2 Attach one 8 scale manometer to the outlet side of pilot gas valve pressure tapping Location 3 Attach one 8 manometer to T fitting air pressure switch and aluminum tubing Location 4 Turn Off Main Gas Valve Turn Off Pilot Gas Valve Reset Low Gas Pressure Cut off Switch 2 3 Bleed Air from Gas Line CAUTION Make sure there is no ignition source in the boiler room With power off slightly open union outside the cabinet to bleed air Close union when you smell gas Wait minimum 5 minutes to clear the gas out of the boiler room before continuing 59 24 Check the Gas Supply Pressure Location 1 Leave pilot gas valve and main gas shut off valve closed Slowly turn on main gas shut off valve Read the gas supply pressure from the manometer If pressure is gt 14 W C Turn off the valve e Check if the service regulator is installed and or adjust the service regulator 2 5 Install Monkey switch Location 5 The Monkey switch is a remote on off switch controlling the first gas valve Disconnect the purple black wire from the black wire on the ga
9. square inch per 4 000 BTUH of total input rating ofall equipment in the room when the opening is communicating directly with the outdoors or through vertical ducts The minimum free area required for horizontal ducts is one 1 square inch per 2 000 BTUH of total input rating to all the equipment in the room 4 Referto NFGC Part 5 for additional information Refer to Appendix A for additional information about combustion air quality Method 2 normally applied in cold climate regions 1 2 3 The mechanical equipment room must be provided with at least one permanent opening commencing within 12 inches of the top of the enclosure The opening must communicate directly or by ducts with outdoors The opening must have a minimum free area of 1 sq in per 3000 BTUH of the total input rating ofall equipment in the room or no less than the sum of the areas of all vent connectors in the confined space Refer to the latest version of NFGC part 5 for additional information WARNING Do not use one permanent opening method Method 2 if the equipment room is under negative pressure condition or the equipment is common vented with other gas fired appliances COMBUSTION AND VENTILATION AIR SUPPLY FOR CANADA INSTALLATION CAUTION All combustion air has to be drawn from the air outside the building the mechanical equipment room directly communicates with the outdoors Ventilation of the space occupied by the boiler shall be provide
10. 1 DT e SINGLE STAGE TANKSTAT Boiler must be electrically grounded in accordance with National Electrical Code ANSI NFPA No 70 and CSA C22 1 C E C Part 1 in Canada 2 STAGE TANKSTAT ENEE gt LEADS TH LEADS BOILER 1 BOILER 2 EE D WEE gt BREAK THE WIRE NUT AT THE BOILER TH CONNECTIONS AND ATTACH TO THE DUAL TANKSTAT PER ILLUSTRATION NOTES 1 Field installed ground to inside of junction box 2 If any of the original wire as supplied with the boiler must be replaced it must be replaced with 105 C wire or its equivalent 26 SECTION J VENTING CONNECTIONS GENERAL CAUTION Proper installation of flue exhaust venting is critical for the safe and efficient operation of the boiler For vent systems not shown in this section please contact your local authorized representative Definition of Appliance Categories Boilers are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent Note Category I A boiler which operates with a non positive vent static pressure and with a vent gas tempera ture that avoids excessive condensate production in the vent Category II A boiler which operates with a non positive vent static pressure and with a vent gas tempera ture that may cause excessive condensate production in the vent Category A boiler which operates with a positive vent pre
11. 12 W C and a maximum of 14 W C is required for propane gas The gas pressure regulator supplied is for low pressure service If upstream pressure exceeds 14 W C an intermediate gas pressure regulator of the lockup type must be installed NOTICE For fluctuating gas supply contact the factory When connecting additional gas utilization equipment to the gas piping system the existing piping must be checked to determine if it has adequate capacity 22 MAXIMUM EQUIVALENT PIPE LENGTH N NATURAL GAS 1000 BUT FT 60 SPECIFIC GRAVITY 0 5 W C PRESSURE DROP P PROPANE GAS 2500 BTU FT 1 53 SPECIFIC GRAVITY 0 6 W C PRESSURE DROP ss posso o ss es wo so 4 Wa ooo wa wa wa se ss os os o vo soo GAS PRESSURE REGULATOR The gas pressure regulator is nominally preset to the outlet values shown in the table below within 1 W C If an adjustment is needed turn the adjustment screw clockwise to increase pressure or counterclockwise to lower pressure REGULATOR PRESSURE SETTINGS See Tables O 2 and O 3 for Pressure Settings page 60 VENTING OF DIAPHRAGM GAS COMPONENTS Boilers have gas train components that have diaphragms in their construction that are supplied with a bleed line connec tion that must be connected to the outside atmosphere as required by NFGC or for Canada the B149 Installation Codes and applicable provisions of local codes Under NO
12. 3 elbows 35 Subtract 10 feet per elbow Maximum three 3 elbows Horizontal Thru wall Direct Venting System With Add on Condensing Heat Exchanger Category IV Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion prod ucts to the outdoors UL 17 38 Certified Venting Material e g AL29 4C MUST be used The vent must be installed to prevent the flue gas leakage Care must be taken during assembly to insure that all joints are sealed properly and are airtight For certain installations i e pool heat pump domestic hot water supply with pre heat tank PVC or CPVC may be used Contact manufacturer for details To prevent condensate accumulation in the vent it is required to install the horizontal portion of vent with a slight upward slope of not more than 1 4 per foot of horizontal run and an approved condensate trap must be installed per applicable codes UAV aA exe Pressurized common vent installations should be engineered UAV aera No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The Stainless Steel non restricted direct vent cap must be furnished by the boiler manufacturer in accordance with AGA CGA requirements 45 SECTION 1 8 Vertical Direct Venting Combustion Air With Add on Condensing Heat Exchanger Category IV INTAKE VENT
13. Top 0 Vent 1 Note 1 Do not install on carpeting VIEW ADB O 12 RIGHT SIDE OR REAR EXHAUST INSTALLATION 1 12 CONDENSING UNIT INSTALLATION RIGHT SIDE MOUNTING 750 1000 1 1 12 Water side 12 Water side 1 1 0 0 p 1 FRONT VIEW VERTICAL CLEARANCE ALL INSTALLATIONS TOP VIEW zl CONDENSING UNIT INSTALLATION REAR MOUNTING ALL CLEARANCES ARE CERTIFIED MINIMUMS AND SHOWN IN INCHES ADDITIONAL CLEARANCES ARE DESIRABLE FOR EASE OF SERVICE FOR VENTING SEE SECTION J Figure B 1 MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES AND FOR EASY SERVICING 8 Raypak Advanced Design Boilers are design certified by AGA CGA for outdoor installation Roof water drainage must be diverted away from boilers installed under overhangs TABLE 2 OUTDOOR INSTALLATION MINIMUM CLEARANCES Boiler Size Boiler Side 500 750 1000 Rear 6 6 6 Right 36 Water side 36 Water side 36 Water side Left 36 36 36 Top 0 0 0 Vent 1 15 1 WARNING Combustion air inlet blower air inlet should have 6 minimum clearance from any obstruction 1 walls or other appliances SECTION C COMBUSTION AND VENTILATION AIR COMBUSTION AND VENTILATION AIR Indoor Units The boiler must be supplied with sufficient quantities of non contaminated air to support proper combustion and equip ment ventilation Combustion air can
14. Turn off all electric power to the appliance if service is to be performed Remove upper front panel Turn off main manual gas valve and manual pilot gas valve Replace access panel If boiler fails to start check for Loose connections blown fuse or service switch off High temperature limit switch set below boiler water temperature Thermostat set below room temperature Gas not turned on at meter or boiler Incoming dynamic gas pressure less than 6 W C for Natural gas 10 W C for Propane 63 SECTION MAINTENANCE SUGGESTED MINIMUM MAINTENANCE SCHEDULE Regular service by a qualified service agency and maintenance must be performed to assure maximum boiler operating efficiency Maintenance as outlined below may be performed by the owner Yearly Beginning of each heating season Annual service call by qualified service agency Visually check top of vent for soot Call service person to clean Some sediment at bottom of vent is normal Visually inspect venting system for proper function deterioration or leakage Check that boiler area is free from combustible materials gasoline and other flammable vapors and liquids Check for and remove any obstruction to the flow of combustion or ventilation air to boiler Follow pre start up check in Section N Visually inspect burner flame Should see light blue flame with some orange at flame edge Check operation of safety devices Refer to manufacturer s
15. area unless previously approved by localauthority DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations Locate or guard vent to prevent condensate from damaging exterior finishes Use a 2 x 2 rust resistant sheet metal backing plate against brick or masonry surfaces DO NOT extend exposed vent pipe outside of building Condensate could freeze and block vent pipe Multiple direct vent installations require a four 4 foot clearance between the vent caps center to center U S Installations Refer to latest edition of the National Fuel Gas Code Vent termination requirements are as follows a b d D Vent must terminate at least four 4 feet below four 4 feet horizontally or one 1 foot above any door window or gravity air inlet to the building The vent must not be less than seven 7 feet above grade when located adjacent to public walkways Terminate vent at least three 3 feet above any forced air inlet located within ten 10 feet Vent must terminate at least four 4 feet horizontally and in no case above or below unless four 4 feet horizontal distance is maintained from electric meters gas meters regulators and relief equipment Terminate vent at least six 6 feet away from adjacent walls DO NOT terminate vent closer than five 5 feet below roof overhang Canada Installations Refer to the latest edition of CAN CGA B149 1 and B149 2 A ven
16. be supplied via conventional venting where combustion air is drawn from the area immediately surrounding the boiler or via direct vent where combustion air is drawn directly from outside All installa tions must comply with the requirements of NFGC for U S CAN CGA 149 1 and 2 for Canada and all local codes DIRECT COMBUSTION AIR If outside air is drawn through a vent pipe directly to the unit for combustion 1 Install combustion air direct vent in accordance with Section J of this manual 2 Provide for adequate ventillation of the space occupied by the boiler s by opening s for ventillation air at the highest practical point communicating with the outdoors The total cross sectional area shall be at least one 1 square inch of free area per 20 000 BTUH of total input rating of all equipment in the room when the opening is communicating directly with the outdoors or through vertical duct s The total cross sectional area shall be at least one 1 square inch of free area per 10 000 BTUH of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct s 3 Incold climates and to mitigate potential freeze up Raypak highly recommends the installation of a motorized sealed damper to prevent the circulation of cold air through the boiler during the non operating hours CONVENTIONAL COMBUSTION AIR SUPPLY FOR U S INSTALLATION ONLY All Air from Inside the Building If
17. circumstances shall bleed lines terminate in the gas utilization equip ment flue or exhaust system 23 SECTION I ELECTRICAL POWER CONNECTIONS Installations must follow these codes National Electrical Code and any other national state provincial or local codes or regulations having jurisdiction Safety wiring must be N E C Class 1 Boiler must be electrically grounded as required by N E C ANSI NFPA 70 latest edition In Canada C S A C22 1 C E C Part 1 The boiler is wired for 120 Volts The voltage is indicated on the tie in leads Consult the wiring diagram shipped with the boiler in the instruction packet The TH leads are connected to the remote tank control stat thermostat or elec tronic boiler control as applicable 24 Volts are supplied to this connection through the boiler transformer DO NOT attach line voltage to the TH leads Before starting the boiler check to insure proper voltage to the boiler and pump Install a separate disconnect means for each load Use appropriate sized wire as defined by NEC CSA and or local code All primary wiring should be 125 of minimum rating It is strongly recommended that all individually powered control modules and the boiler should be supplied from the same power source SURGE PROTECTION Microprocessor based and solid state controls are vulnerable to damage from voltage and amperage fluctuations in the power supply All sensitive control components should be protec
18. injury or loss of life 1 This appliance does have an intermittant pilot It is equipped with an ignition device which automatically lights the pilot Do Not try to light the pilot or burner by hand 2 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas 15 heavier than air and will settle on the floor 3 WHATTO DO IF YOU SMELL GAS 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 neighbor s telephone Follow the gas supplier s instructions Ifyou cannot reach your gas supplier call the fire department 4 Use only your hand to push in or turn the gas control knob Never use tools If the knob will not turn by hand do not try to repair it call a qualified service technician Forced or attempted repair may result in a fire or explosion 5 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 PRE START UP CHECK Verify boiler is filled with water 2 Check system piping for leaks If found repair immediately 3 Vent air from system Repeat steps 4 and 5 under Fill the System Air in system can interfere with water circulation and cause improper heat distribution SCh COMBUSTI
19. instructions Follow oil lubricating instructions on circulator Over oiling will damage circulator Water lubricated circulators do not need oiling 10 Visually inspect condensate drain piping for proper operation or deterioration 1f appropriate Check for plugged condensate trap Use cleanout plug to clear trap 11 To avoid potential of severe burn DO NOT REST HANDS ON OR GRASP PIPES Use a light touch return piping will heat up quickly 12 If mixing valve does not seem to be working the spring and thermostat may need to be replaced Call a qualified service technician 13 Check for piping leaks around circulators mixing valves relief valves and other fittings Repair if found DO NOT use petroleum based stop leak 19200 SIL OS ae Daily 1 Check that boiler area is free from combustible materials gasoline and other flammable vapors and liquids 2 Check for and remove any obstruction to the flow of combustion or ventilation air to boiler 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 2 Visually inspect burner flame 3 Visually inspect venting system for proper function deterioration or leakage 4 Check air vents for leakage 5 Check the hose fitting orifice on the blower Make certain that orifice is not blocked by grease dirt or any other debris If necessar
20. lation Code for Gas Burning Appliances and Equipment Gas vents supported only by flashing and extended above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads CAUTION Listed vent cap terminal must be used and sized adequately to evacuate the flue products from the boilers e Natural Draft Vertical Venting With Common Venting System Category I Appliance Only NOT To Be Utilized With Add on Condensing Heat Exchanger Manifolds that connect more than one boiler to a common 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 vent be less than the area of the largest boiler exhaust outlet 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 CAUTION Vent connectors for natural draft venting systems must be type vent or better 32 Common venting systems may be too large when an existing unit is removed At the time of removal of an existing appliance the following steps must be followed 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 a b d g Seal any unused opening in the common venting system Visual
21. products from the direct vent cap to be pulled into the combustion air intake installed above This type of installation can cause non warrantable problems with components and poor operation of the unit due to the recirculation of flue products Multiple direct vent caps should be installed in the same horizontal plane with a three 3 foot clearance from the side of one vent cap to the side of the adjacent vent cap s 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 DAAT Pressurized vent installations should be shared DATT No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants NOTICE If the boiler is vented directly out through the sidewall with no elbows and less than 6 feet of vent pipe a restricted direct vent cap supplied by Raypak should be utilized NOTICE In a catagory III installation a 9 8 inch vent adapter must be used on the ADB 1000 The Stainless Steel direct vent cap must be furnished by the boiler manufacturer in accordance with AGA CGA requirements 37 SECTION J 4 Vertical Direct Venting Combustion Air Category I 3 MIN NONRESTRICTED VENT CAP N INTAKE VENT E 2 MIN
22. the pool thermostat adjacent to the main line and run wires back to the heater See Figure Gl a and Figure G2 b Adjustment of the bypass valve is critical to proper operation of the heater The bypass valve should be adjusted to achieve an inlet water temperature in the range of 90 F to 100 F and an outlet water temperature between 120 F and 130 When starting with a cold pool make initial adjustments Make final adjustments when pool water approaches desired temperature Refer to flow rate chart below HEATER FLOW MODEL 500 15 20 40 750 20 30 50 1000 25 35 70 Loop is secondary piping to heater from main system AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater Do not place chlorine tablets or bromine sticks in the skimmer High chemical concentrations will result when the pump is not running i e overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical backup into the heater when the pump is shut off NOTE High chemical concentrates from feeders chlorinators that are out of adjustment will cause very rapid corrosion to the heat exchanger in the heater Such damage is not covered under the warranty WINTERIZING YOUR HEATER When heaters installed outdoors in freezing climate areas are to be shut down for the winter please observe the f
23. 0 e g AL 29 4C Stainless Steel w CHX PVC CPVC pool Application Only UL 17 38 Certified Venting Material IV e g AL 29 4C Stainless Steel PVC CPVC pool Application Only ADB 750 wiCHX ADB 1000 wiCHX UL 17 38 Certified Venting Material e g AL 29 4C Stainless Steel PVC CPVC pool Application Only Contact Manufacturer for Details 40 Subtract 10 ft per elbow Maximum Three Elbows 55 Subtract 10 ft per elbow Maximum Three Elbows 55 Subtract 10 ft per elbow Maximum Three Elbows Vertical Vent Category IV with Add on Condensing Heat Exchanger Installation 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 vertically through the roof to the outdoors Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or in Canada the latest edition of CAN CGA B149 1 AND 2 Installation Code for Gas Burning Appliances and Equipment UL 17 38 Certified Venting Material e g AL29 4C MUST be used The vent must be installed to prevent the flue gas leakage Care must be taken during assembly to insure that all joints are sealed properly and are airtight For certain installations i e pool heat pump domestic hot water with pre heat tank PVC or CPVC may be used Contact Manufacturer for details To prevent the conde
24. 07 DEZ A E Gen JON A m OVAbZ gt lt Za 5313395 OL F Nil 7 NA Ce IOANNIS d Bd m 53031 5 NOA 9 Ka 109 23 1060 1 16 1 LVLSONH Q 195 1 o m Gish ION gt lt XV AN YA AN 9 P d TSN JON Ga H KE 25 a m Gen JON D HALA MB A LAW op B T ED 38 2 sa 018 Um S RUIS Eug Ge ANTM 2 7 MINS ac AR Wl WIRING DIAGRAM Figure L 2 uwol8 53 IGNITION CONTROL MODULE The intermittent ignition device conserves energy by automatically extinguishing the pilot when the desired temperature is reached When additional heat is needed the combustion air blower starts to purge all air from the combustion chamber for about 45 seconds On proof of air flow the air proving switch closes and the pilot reignites electrically eliminating the fuel costs of maintaining a constant pilot To assure safe operation the gas valve cannot open until the pilot relights and is verified The 100 pilot safety is an electronic device which closes the main gas valve within 8 10 of a second whenever the pilot flame is interrupted Pilot flame is automatically lit when the device is powered and pre purged Unit performs its own safety check a
25. Catalog No 3400 50 I Effective 12 01 00 Replaces 05 01 00 OPERATING AND INSTALLATION INSTRUCTIONS Models 500 750 1000 ADVANCED DESIGN BOILER FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity ofthis 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 dam age personal injury or loss of life Refer to the user s information manual provided with this boiler 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 boiler or kept in a safe place for future reference P N 240723 5 gt x Make sure the gas on which the boiler will operate is the same type as that specified on the boiler model and rating plate ING Should overheating occur or the gas supply valve fail to shut do not turn off or disconnect the electrical supply to the boiler Instead shut off
26. E AIR VENT PUMP UNION THERMOMETER OR MINIMUM THAT PIPING PERMITS SECTION F DOMESTIC HOT WATER PIPING When designing the water piping system for domestic water applications water hardness should be considered Table D 1 indicates the suggested flow rates for soft medium and hard water Hardness is specified as grains per gallon TABLE F 1 DOMESTIC WATER HEATING BOILER FLOW RATE REQUIREMENTS SOFT MEDIUM HARD 500 em S 750 D 42 63 11 1000 30 56 84 15 Delta Temperature rise in F GPM Gallons per minute See Table D 1 for Pressure Drop Figure F 1a SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK PRESSURE RELIEF VALVE Jr UNION DRAN VALVE EE CHECK VALVE BALL VALVE RECIRCULATION PUMP OR MINIMUM AIR SEPARATION THAT PIPING PERMITS EXPANSION TANK SYSTEM RETURN CITY WATER INLET Figure F 1b SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK AND CHX PRESSURE RELIEF VALVE AQ Jr vue check VALVE a BALL VALVE 4 PRESSURE REDUCING VALVE 86 AR VENT o CONDENSATE DRAIN AIR SEPARATION EXPANSION TANK OR MINIMUM THAT PIPING PERMITS CITY WATER INLET Figure F 1bb SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK AND CHX 2 pump system HOT WATER SUPPLY KEY PRESSURE RELIEF VALVE ae YF PUP SYSTEM RETURN RECIRCULATION UNI
27. F VALVE 3 GAS INLET SEDIMENT TRAP GAS REGULATOR 7 PRESSURE TAP LOCATION 2 V88 GAS VALVE NAT 2 PLCS BOILER JACKET Figure H 1 GAS SUPPLY CONNECTION The boiler and its manual shutoff valve must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1 2 PSIG 3 45 KPA The boiler must be isolated from the gas supply piping system by closing the manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG Relieve test pressure in the gas supply line before reconnecting the boiler 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 covered by warranty The boiler 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 CAUTION Do not use Teflon tape on gas line pipe thread A pipe compound rated for use with gas systems is recommended Apply sparingly only on male pipe ends CAUTION Support gas supply piping with hangers not by the boiler or its accessories Ensure the gas piping is protected from physical damage and freezing where required GAS SUPPLY PRESSURE minimum of 7 W C and a maximum of 14 W C upstream gas pressure is required under load and no load conditions for natural gas A minimum of
28. GA CGA requirements The outdoor vent terminal must be installed in a horizontal position to prevent recirculation of flue products The vent cap must be mounted directly on the vent pipe of the boiler OG In areas of high winds alleyways air handlers etc a downward 90 elbow must be mounted on the combustion air inlet to prevent any air flow fluctuation 48 SECTION K CONDENSATE DRAIN WARNING All condensation should be disposed of according to local county state and federal laws Refer to NFGC section 7 9 for additional information The Condensing Heat Exchanger CHX can generate up to one gallon per hour GPH of condensate for every 100 000 BTUH The maximum condensation rates for different size units are 5 GPH 7 5 GPH and 10 GPH for the ADB 500 750 and 1000 respectively CONDENSATE OUTLET CLEANOUT PLUG NOTE MUST ALWAYS BE BETWEEN AND 3 TO PREVENT FLUE GAS CONTAMINATION AND OR TRAPPED CONDENSATE IN CHX Figure 1 CONDENSATE TRAP ALIGNMENT 49 SECTION L CONTROLS WARNING Installation adjustment and service of boiler 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 boiler malfunction property damage personal injury or death WARNING Turn off the power to the boiler before installation adjustment or service of the Central Point Wiring board or an
29. ING 14 Figure E 2b SINGLE BOILER PRIMARY SECONDARY PIPING WITH CHX BOILER BYPASS PRESSURE RELIEF VALVE ADJUSTING VALVE 07 Pue ale UNION 2 DRAIN VALVE SYSTEM RETURN BALL VALVE PRESSURE REDUCING VALVE AIR VENT CITY WATER INLET NUERMCMETER OR MINIMUM THAT PIPING PERMITS TO SYSTEM AIR SEPARATION EXPANSION TANK Figure E 3a DUAL BOILER PRIMARY SECONDARY PIPING KEY E PRESSURE RELIEF VALVE E Pu Ar UNION SYSTEM RETURN DRAIN VALVE EE CHECK VALVE a BALL VALVE PRESSURE REDUCING VALVE AIR VENT THERMOMETER s OR MINIMUM THAT PIPING PERMITS CITY WATER INLET TO SYSTEM SEPARATION EXPANSION TANK 15 Figure E 3b DUAL BOILER PRIMARY SECONDARY PIPING WITH CHX BOILER BYPASS ADJUSTING VALVE TO SYSTEM AIR SEPARATION EXPANSION TANK Figure E 4a SINGLE BOILER LOW TEMPERATURE APPLICATION HEAT PUMP PRIMARY SECONDARY PIPING BOILER BYPASS ADJUSTING VALVE SYSTEM RETURN SYSTEM CITY WATER INLET AIR SEPARATION EXPANSION TANK SYSTEM RETURN CITY WATER INLET PRESSURE RELIEF VALVE Ar lt DRAIN VALVE AN CHECK VALVE BALL VALVE ee PRESSURE REDUCING VALVE THERMOMETER PUMP UNION AIR VENT OR MINIMUM THAT PIPING PERMITS PRESSURE RELIEF VALVE 7 E AF 27 DRAN VALVE LR CHECK VALVE PRESSURE REDUCING VALVE ot BALL VALV
30. ON AIR BLOWER INTAKE AIR PRESSURE TAP ADJUSTMENT LOCATION 4 KNOB eee PRESSURE TAP PRESSURE SWITCH LOCATION 3 MONKEY SWITCH PILOT AIR TUBE LOCATION 5 MANUAL GAS A VALVE PRESSURE TAP UT OFF MAIN m INJECTOR LOCATION 2 MIXING CHAMBER Flow SWTCH Tor PRV PRESSURE EQUALIZER TUBE TEMPERATURE SENSORS BURNER REFRAC ESCH IN OUT HEADER T amp P GAUGE HEAT EXCHANGER FLUE COLLECTOR COMBUSTION CHAMBER FLAME VIEWING FLAME VIEWING PLATE Blower fitting detail Figure O 1 COMPONENT AND PRESSURE TAP LOCATIONS 58 SECTION ADB INITIAL START UP 1 0 TOOLS NEEDED One8 0 8 16 scale manometer or larger Three 4 0 4 8 scale manometers or larger T fitting 7 16 and 1 2 open end wrenches Small and large flat head screwdrivers Volt meter Amp probe Elec Dual reading thermometer with strap on sensors 2 16 Allen wrench Remote switch with 12 minimum lead wires Monkey switch Combustion analyzer 2 0 PREPARATION FOR START UP WARNING DO NOT TURN ON GAS AT THIS TIME 2 1 Check Power Supply With volt meter at incoming power check voltage between Hot Common approx 120 VAC Hot Ground approx 120 VAC Common Ground lt 1 VAC If Common Ground is gt 1 VAC STOP Contact electrician to correct ground failure Warning Failure to do this may burn out 120V 24V transformer
31. ON Vertical Natural Draft Venting See Section J 1 Horizontal Thru Wall Venting See Section J 2 Vertical Venting See Section J 4 Horizontal Thru Wall Venting See Section J 3 Vertical Venting See Section J 5 Horizontal Thru Wall Venting See Section J 6 Vertical Venting See Section J 8 Horizontal Thru Wall Venting See Section J 7 APPLIANCE CATEGORY CERTIFIED VENTING MATERIALS or Equivalent Stainless Steel Gas Tight UL 17 38 Certified Venting Material UL 17 38 Certified Venting Material e g AL 29 4C Gas Tight UL 17 38 Certified Venting Material e g AL 29 4C Gas Tight UL 17 38 Certified Venting Material e g AL 29 4C Gas Tight COMBUSTION AIR INLET MATERIAL Galvanized Steel PVC ABS CPVC Galvanized Steel PVC ABS CPVC PVC or CPVC vent maybe used inconjunction with CHX special piping arrangement has to be made Contact manufacturer for details 103103210811 SurjuoA pue SurjuoA 00117011013130 102316 ACV ALEL Support of Vent Stack The weight of the vent stack or chimney must not rest on the boiler vent connection Support must be provided in compliance with applicable codes The vent should also be supported to maintain proper clearances from combustible materials Use insulated vent pipe spacers where the vent passes through combustible roofs and walls Vent Terminal Location NOTICE During winter mon
32. ON PUMP DRAN VALVE UNC CHECK VALVE it BALL VALVE PRESSURE REDUCING VALVE y AIR VENT CONDENSATE DRAIN THERMOMETER AIR SEPARATION EXPANSION TANK FLOW SWITCH OR MINIMUM CITY WATER INLET THAT PIPING PERMITS Figure F 1c SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK ONE PRE HEAT TANK AND CHX HOT WATER SUPPLY STORAGE TANK PRESSURE RELIEF VALVE SYSTEM RETURN CONDENSATE DRAIN CITY WATER INLET SECTION POOL HEATING 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 affect heater operation Follow these instructions to make sure your heater is properly installed The ADB unit is equipped with an external pump and bypass arrangement that blends outlet water with the inlet to increase the inlet water temperature thereby reducing the likelihood of condensation forming on the heat exchanger The pump also serves to circulate water through the heater form the main system piping To complete the installation of the pool heater the pool thermostat needs to be installed in the main return water line This will insure 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
33. See sections D for minimum and maximum flow rates Severe damage will occur if the boiler is operated without proper water flow circulation TABLE OF CONTENTS PAGE NO 10 12 13 17 19 22 24 27 49 50 56 57 59 62 63 64 66 67 68 SECTIONA BEFORE INSTALLING THE BOILER SECTIONB BOILER INSTALLATION SECTION COMBUSTION AND VENTILATION AIR SECTION D WATER PIPING GENERAL SECTIONE HYDRONIC HEATING PIPING SECTIONF DOMESTIC HOT WATER PIPING SECTIONG POOL HEATING SECTIONH GASSUPPLY CONNECTIONS SECTION I ELECTRICAL POWER CONNECTIONS SECTION J VENTING CONNECTIONS SECTION K CONDENSATE DRAIN SECTIONL CONTROLS SECTIONM GENERAL SAFETY PRECAUTIONS SECTIONN SECTION ADB INITIAL START UP MANUFACTURERS CERTIFIED PERSONNEL ONLY SECTION P POST START UP CHECK SECTION Q OPERATION SECTIONR MAINTENANCE SECTIONS CONNECTING CONDENSING HEAT EXCHANGER APPENDIX A COMBUSTION AIR CONTAMINATION ILLUSTRATED PARTS LIST Pay attention to these terms DANGER indicates the presence of immediate hazards which will cause severe personal 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 prod
34. TTINGS IN BETWEEN BOILER BYPASS ADJUSTING VALVE 2 POOL STAT WITH 2POLE RELAY TO TURN POWER OFF TO EACH POOL HEATER ADB POOL SIZING Indoor or Outdoor FROM POOL SEE NOTE 2 DESIRED TEMPERATURE RISE POOL AREA IN SQUARE FEET HEATER MODEL MBTUH OUT P500 420 1795 1436 1197 1026 P500 CHX 490 2094 1675 1396 1197 P750 630 2692 2154 1795 1538 P750 CHX 735 3141 2513 2094 1795 P1000 839 6 3572 2857 2381 2041 P1000 CHX 979 5 4167 3334 2778 2381 This is based on average pool depth of 4 6 4 5 FT 21 FILTER alr DRAIN VALVE Ie CHECK VALVE 44 SECTION GAS SUPPLY CONNECTIONS MANGER Make sure the gas on which the boiler will operate is the same type as specified on the boiler model and rating plate Gas piping must have a sediment trap ahead of the boiler gas controls and a manual shut off valve located outside the heater jacket A pounds to inches regulator must be installed to reduce to gas supply pressure to under 14 W C The regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the boiler gas controls All gas piping must be tested after installation in accordance with local codes The boiler and its gas connection must be leak tested before placing it in operation PILOT GAS VALVE REGULATOR ADJ SCREW GAS LINE TO PILOT MANUAL PILOT GAS VALVE PRESSURE TAP LOCATION 3 GAS PRESSURE LOW SWITCH NAT MANUAL GAS A VALVE MANUAL SHUT OF
35. al negative draft venting using double wall B type vent is 7 for ADB 500 8 for the ADB 750 and 9 for the ADB 1000 NOTICE Vent Adapter will have to be used to connect B vent to the unit The connection from the appliance vent to the stack must be as direct as possible and shall be the same diameter as or larger than the vent outlet The vent must be installed to prevent accumulation of condensate and where necessary have means provided for drainage of condensate The horizontal breaching of a vent must have an upward slope of not less than 1 4 inch per linear foot from the boiler 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 clearances and to prevent physical damage or separation of joints e Natural Draft Vertical Vent Termination The vent terminal should be vertical and should terminate outside the building at least two 2 feet above the highest point of the roof that is within 10 feet The vent cap should have a minimum clearance of four 4 feet horizontally from and in no case above or below unless a four 4 foot 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 consistent with the National Fuel Gas Code or in Canada the latest edition of CAN CGA B149 Instal
36. all combustion air is drawn from the air inside the building the mechanical equipment room does not receive air from outside 1 mechanical equipment room must be provided with two permanent openings communicating directly with additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space An unconfined space is defined as a space whose volume is more than 50 cubic feet per 1 000 BTUH of the aggregate input rating of all appliances installed in that space 2 Each opening must have a minimum free area of one 1 square inch per 1 000 BTUH of the total input rating of all gas utilization equipment in the mechanical equipment room 3 One opening must commence within twelve 12 inches of the top and one opening must commence within twelve 12 inches of the bottom of the room 4 Refer to NFGC Part 5 for additional information Air from Outdoors If all combustion air is drawn from the air outside the building the mechanical equipment room directly communicates with the outdoors either of the following two methods can be used Method 1 1 The mechanical equipment room must be provided with two permanent openings one commencing within twelve 12 inches of the top and one commencing within twelve 12 inches of the bottom of the room 2 The openings must communicate directly or by ducts with the outdoors 3 Eachopening must have a minimum free area of one 1
37. ar Panel 007294F 007295F 007296F Jacket Rear Panel Connection Option 007299F 007300F 007301F Base Assembly 007304F 007304F 007305F Leg Bracket 4 pcs per boiler 007306F 007306F 007306F Base Reflector Panel 007307F 007307F 007307F Flue Exhaust Flange Assembly 006948F 006949F 006946F Flue Exhaust Cover 007310F 007311F 007312F Control Box Assy 007145F 007145F 007145F Bracket Pressure Switch MTG 007161F 007161F 007161F Valve Pilot Mounting Bracket Not shown 007198F 007198F 007198F Intake Air Cover Panel 007315F 007315F 007315F CHX Condensing Heat Exchanger Not Shown HEAT EXCHANGER Heat Exchange Assy Bronze 007618F 007619F 007620F Inlet Header Bronze 007621F 007621F 007622F Outlet Header Bronze 007623F 007623F 007624F Tube Bundle Cupro Nickle 007625F 007626F 007627F Studbolt HX 500 1000 007628F 007628F 007628F Header Gasket 800001B 800001B 800001B Condensing Drain 007629F 007629F 007630F SHEETMETAL Internal Chamber 007631F 007632F 007633F Base Assy 007634F 007634F 007635F Cover Panel Front 007636F 007637F 007638F Cover Panel Rear 007639F 007640F 007641F Cover Panel Left Side 007642F 007643F 007644F Cover Panel Right Side 007645F 007646F 007647F Header Top Cover 007648F 007648F 007648F 72 START UP SETTINGS TODAY S DATE PRESSURE SETTINGS Blower burner W C PIU eed d ota hu W C Main Burner W C Blower burner on W C Supply Gas
38. ate trap must be installed per applicable codes b The vent be insulated through the length of the horizontal run Horizontal Thru wall Direct Vent Termination The direct vent cap MUST be mounted on the exterior 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 one 1 foot above ground level and above normal snow levels The Raypak supplied direct vent cap must be used NOTICE If the boiler is vented directly out through the sidewall with no elbows and less than 6 feet of vent pipe a restricted direct vent cap supplied by Raypak should be utilized DATT No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants DATT Pressurized common vent installations should be engineered NOTICE In a catagory III installation 9 8 inch vent adapter must be used on the ADB 1000 The Stainless Steel direct vent cap must be furnished by the boiler manufacturer in accordance with AGA CGA requirements 35 SECTION 7 3 Figure J 3 Horizontal Thru Wall Direct Venting Combustion Air Category INSULATED EXHAUST VENTING 9 MIN DIRECT VENT CAP 3 MIN een VENT 6 MIN HORIZONTAL THRU WALL DIRECT VENTING WITHOUT ADD ON SECONDARY CONDENSING HEAT EXCHANGER Certified Venting Material Venting Category 8 50 Stainless Stee
39. ater temperature insert a small straight screwdriver into slotted screw in hole in front of thermostat and turn wheel to desired setting Adjustment Screw ez elt Hotter water Increases the risk of SCALDING A There is a Hot Water SC AT D Potential if the tank thermostat is set too high NOTE When this hot water boiler is supplying general purpose hot water requirements for use by individuals a thermo statically 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 56 SECTION PRE START UP FILL THE SYSTEM Close manual and automatic air vents and drain cock Fill to correct system pressure Correct pressure will vary with each application Open automatic air vent two turns Slowly feed water to boiler Starting on the lowest floor open air vents one at a time until water squirts out Close vent Repeat with remaining vents Close manual water feed valve when correct boiler pressure is reached Re c INSPECT VENTING SYSTEM 1 Check all vent pipe connections and flue pipe material 2 Ensure vent terminations are installed per code and are clear of all debris or blockage FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property dam age personal
40. board will display the priority fault based on the safety hierarchy as labeled on the U 2 board Once the first fault is cleared the second fault lamp will illuminate until cleared WARNING Only qualified persons shall attempt to repair the boiler Improper adjustment service or mainte nance may damage the equipment create a hazard resulting in asphyxiation explosion fire electric shock personal injury or property damage and will void the warranty 52 0009007 NYHL 000006 SLNdNI 337108 L 9 501 ONIMIM 39V1d3M Z NMOHS SV STOMINOO 30 gees NO S3IM3S NI Old D D 4 RR HOLIMS V 025 SI 02 101 N3HA v M DE 200 29 O D 5 uud 31 0 N ama 18 ya 3unssaud M wNouao P wins O ON ON O wun 1 SOUSONDVII 06 Were 20 dOL OL EZ Mn HOLMS NOH DER 1 xot 30N30035 SOUSONOVIC ower 7 ANIGd TENIS 13838 LGN OL DN 8 Ee Sa Mas n Ag canddns NLY 77 a 335 Dean 104 TIVO OvAvZ 5 e aano e m Q D 3ABQ 76 LHe HI fa inm ana ILON 335 aud NOLLINOI 78 4 L A NOISNAL AL SAIKI 6
41. cause severe burns D A N G E R instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available see note below Maximum water temperatures occur just after the boiler 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 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 Temperature Time to Produce Serious Burn Temperature Time to Produce Serious Burn 120 F More than 5 minutes 140 F Less than 5 seconds 125 F 1 1 2 to 2 minutes 145 F Less than 3 seconds 130 F About 30 seconds 150 F About 1 1 2 seconds 135 F About 10 seconds 155 F About 1 second Table courtesy of The Shriners Burn Institute TIME TEMPERATURE RELATIONSHIPS IN SCALDS The temperature of the water in the hot water boiler can be regulated by setting the temperature dial on front of the thermostat To comply with safety regulations the thermostat was set at its lowest setting before the hot water boiler was shipped from the factory The illustration below shows the thermostat and how to adjust the water temperature To adjust the w
42. cutoff device The boiler when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water heating boiler 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 boiler water during the cooling cycle It is highly recommended that the piping be insulated AIR SEPARATION EXPANSION TANK All boilers should be equipped with a properly sized expansion tank with an air separation fitting as shown in the following diagrams THREE WAY VALVES Valves designed to blend water temperatures or reduce water circulation through the boiler should not be used Raypak heaters are high recovery low mass heaters not subject to thermal shock Raypak offers a full line of electric sequencers that produce direct reset of boiler water temperature Refer to the Controls Section in our Complete Catalog PRESSURE RELIEF VALVE f Fu ule UNION 7 DRAIN VALVE SYSTEM RETURN a CHECK VALVE BALL VALVE PRESSURE REDUCING VALVE AIR VENT THERMOMETER TO SYSTEM CITY WATER INLET OR MINIMUM AIR SEPARATION THAT PIPING PERMITS EXPANSION TANK Figure E 2a SINGLE BOILER PRIMARY SECONDARY PIP
43. d U2 007147F 007147F 007147F Remote Aquastat Storage tank Tankstat 007148F 007148F 007148F Switch Pressure Vent Normally Closed 007158F 007158F 007158F Switch Pressure Air Normally Open 007163F 007163F 007163F Control Box Cover 007149F 007149F 007149F Thermostat Manual Reset 006035F 006035F 006035F CONTROL BOX Control Box Complete 007150F 007150F 007150F Transformer 120 24 50 VA 006533F 006533F 006533F Terminal Block 8 space 007152F 007152F 007152F Relay DPDT 24 VAC 007153F 007153F 007153F Connector Wire Bonding 14 6 007155F 007155F 007155F Ignition Control IID 007156F 007156F 007156F Switch Rocker SPST 16A 006872F 006872F 006872F FAN Blower Combustion Air 007159F 007159F 007159F Air Shutter Assembly 006942F 006943F 006944F Cap Intake Vent 007162F 007162F 007162F GAS TRAIN Auto On Off Valve V 88 004093F 004093F 004094F Bleed Line Assembly 007166F 007166F 007166F Vent Line Assembly 007167F 007167F 007167F Manifold Gas Injector Nat 007168F 007169F 007170F Manifold Gas Injector Pro 007173F 007174F 007175F Orifice Pilot Air 007178F 007178F 007178F Orifice Pilot Pro 007180F 007180F 007180F Orifice Pilot Nat 007181F 007181F 007181F Regulator Gas 1 Nat 007182F 007183F N A Regulator Gas 1 1 4 Nat N A N A 007184F Regulator Gas 1 Pro 007185F 007185F N A Regulator Gas 1 1 4 Pro N A N A 007186F Switch Low Gas Pressure 007187F 007187F 007187F
44. d by an opening s for ventilation air at the highest practical point communicating with outdoors The total cross sectional area of such an opening s shall be at least 10 of the area required in 2 and 3 but in no case shall the cross sectional area be less than 10 square inches 6500 square mm When air supply is provided by natural air flow from the outdoors for natural draft partial fan assisted fan assisted or power draft assisted burners there shall be a permanent air supply opening s having a cross section area of not less than 1 sq in per 7000 BTUH 310 sq mm per kW up to and including 1 million BTUH plus 1 sq in per 14000 BTUH 155 sq mm per kW in excess of 1 million BTUH This opening s shall be either located at or ducted to a point neither more than 18 inches 450 mm nor less than 6 inches 150 mm above the floor level The duct can also Goose Neck through the roof The duct is preferred straight down 18 from floor but do not place near piping This air supply opening requirement shall be in addition to the air opening for ventilation air required in 1 When air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator draft hood 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 supply opening s having a total cross sectional area of not less than 1 sq in for
45. each 30 000 BTUH 70 sq mm per kW of total rated input of the burner s and the location ofthe opening s shall not interfere with the intended purpose of the opening s for ventilation air referred to 1 This opening s can be ducted to a point neither more than 18 inches 450 mm nor less than 6 inches 150 mm above the floor level The duct can also Goose Neck through the roof The duct is preferred to be straight down 18 from floor but do not place near piping Refer to the latest version of CAN CGA B149 1 and B149 2 for additional information SECTION D WATER PIPING GENERAL The boiler should be located so that any water leaks will not cause damage to the adjacent area or structures All units should be plumbed in accordance with the appropriate diagram from Section E F or G or per a suitable engineered piping arrangement This boiler requires forced water circulation when the burner is operating See Table D 1 for minimum and maximum flow rates and water pump selection The pump must be interlocked with the boiler to prevent boiler operation without water circulation See Figure L 2 Wiring Diagram and Figure L 1 RELIEF VALVE PIPING WARNING Pressure relief valve discharge piping must be piped near the floor close to a floor drain to eliminate the potential of severe burns Do not pipe to any area where freezing could occur Refer to local codes HYDROSTATIC TEST Unlike many other types of boilers Raypak boilers do not re
46. gh the wall to the outdoors Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or in Canada the latest edition of CAN CGA B149 1 and 2 Installation Code for Gas Burning Appliances and Equipment 34 The total length of the thru wall exhaust vent system cannot exceed sixty five 65 feet in length for the flue outlet Each elbow used is equal to ten 10 feet of straight pipe This will allow installation in one of the four following combinations 65 of straight flue pipe 55 of straight flue pipe and one elbow 45 of straight flue pipe and two elbows 35 of straight pipe and three elbows The direct vent cap is not considered in the overall length of the venting system The vent must be installed to prevent the flue gas leakage Care must be taken during assembly to insure 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 a The vent be installed with a slight downward slope of not more than 1 4 per foot of horizontal run to the vent terminal b The vent be insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that a The vent be installed with a slight upward slope of not more than 1 4 per foot of horizontal run to the vent terminal In this case an approved condens
47. he to join the ADB flue outlet to the CHX flue inlet 8 Connect the CHX water as specified in the piping diagram Check for water leak 9 Secure the flue connection from step 7 above with the stainless steel screws supplied 10 Connect the flue vent Category IV venting UL 17 38 Certified Venting Material to the 15 elbow of the CHX flue outlet 11 Connect the PVC pipe not supplied for condensate water disposal check with local authority regarding conden sate disposal 12 Replace the shroud VENT SWITCH ADJUSTMENT In order to insure proper operation of the ADB boiler with a CHX attached to it the vent switch must be adjusted to proper setting The vent switch is located on the J box just outside the ignition module Use the following steps Turn power off disconnect the electrical wiring and the rubber hose Remove the switch it has a black plastic orifice at the hose connection On the backside remove the purple seal from atop the adjusting screw Turn the plastic hex screw 1 turn clockwise Seal with silicone Reinstall in reverse order CHX Rate of Flow and Pressure Drop Model 500__ _ _ 0 5 0 6 0 9 Model 110 750 LZ 046 Model 1000 11116177 Figure 8 1 Connecting Add On Condensing Heat Exchanger to ADB 66 APPENDIX A INSIDE COMBUSTION AIR CONTAMINATION All boilers experience some condensation during start up The condensate from flue gas is slightly acid
48. ic In most cases the pH level is not harmful to vents or drains When combustion air is contaminated by vapors from products in areas listed below the acidic levels in the condensate increase Higher acidic levels attack many materials including stainless steel commonly used in high efficiency systems The boiler can use special corrosion resistant nonmetallic vent material You may however choose to use outside com bustion air for one or more of these reasons installation is in an area containing contaminants listed below which will induce acidic condensation you want to reduce infiltration into your building through openings around windows and doors you using AL29 4C stainless steel vent pipe which is more corrosion resistant than standard metallic vent pipe In extremely contaminated area 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 e anti static fabric softeners used in clothes dryers chloride type bleaches detergents and cleaning solvents found in household laundry rooms adhesives used to fasten building products and other similar products
49. ilding management systems in accordance with the applicable manufacturer s instructions 7 Conduit should not be used as the ground There must be a solid wired ground 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 120V Hot Black 120V Common White Ground Green Pump Wiring 120V TH Leads 24V To tank stat on domestic hot water Systems or building management System on space heating applications Figure I 2 FIELD WIRING CONNECTION 25 ELECTRICAL CONNECTIONS DOMESTIC HOT WATER 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 The boiler is normally wired for 120 volts The voltage is indicated on the tie in leads Consult the wiring diagram shipped with the boiler in the instruction packet The TH leads are for the remote tank control through the boiler transformer DO NOT attach line voltage to the TH leads Before starting boiler check to insure proper voltage to boiler and pump BREAK THE WIRE NUT AT THE BOILER TH CONNECTIONS AND ATTACH TO THE SINGLE TANKSTAT PER ILLUSTRATION TH LEADS BOILER
50. is not field adjustable 51 Freeze Protection Feature The CPW board is programmed to turn off the blower in case there is a lock out condition If there is a call for heat signal and the pilot valve signal is removed and not reactivated within a pre set time for any reason the CPW board will turn off the blower to prevent blowing cold air continuously and freezing the heat exchanger The blower drives will open and the system will lock in the off state To restart the system primary power or the thermostat signal must be turned off and back on The pre set freeze protection feature time 1s approximately 5 minutes U 2 Diagnostics Board The U 2 Diagnostics board is a solid state electronic fault indicator that has been engineered to enhance safety simplify troubleshooting and minimize equipment down time The U 2 safety board is the central point for wiring operations monitoring and fault indication for the boiler safeties By having each safety report directly to the U 2 board each safety function can be individually monitored The U 2 adds complete diagnostics features that aid in the rapid diagno sis of irregularities in boiler operation A single U 2 Diagnostics Board can monitor a maximum of eight safeties at one time If due to code requirements more than eight safety devices must be monitored two or more boards will be used to provided extended diagnostics capabilities Advanced Design Boilers equipped with the standard safety su
51. ite will utilize the configuration shown in Table L 2 Table L 2 U 2 Diagnostic Board LEDs Light Color Indication System Enabled Yellow U 2 Diagnostics safety board is functional Manual High Limit Red Water temperature 1s over the manual high limit setting Auto High Limit Red Water temperature is over the auto high limit setting Flow Switch Red Water flow rate is too low Low Water Cut off option Red Insufficient water volume for boiler operation High Low Gas Pressure Red Gas supply pressure is below or above the allowed minimum gas supply pressure to ensure safe operation Burner High Limit Red Mixer or PVC vent pipe if installed is over heated Blower Ignition Lockout Red Blower failure not enough combustion air or the equipment has an ignition lock out condition Blocked Vent Red The vent pressure switch has detected a blocked vent The U 2 safety board has a series of red LED lights to indicate a fault occurring at a monitored safety An additional light indicates that the diagnostics board is energized and is currently monitoring for safety faults In order to prevent spurious alarm conditions the U 2 board monitors safeties only during the actual firing cycle Once a fault has been detected the U 2 board will illuminate the corresponding LED lamp will shut down the boiler and will light the flashing red LED Service lamp on the CPW board If more than one fault is detected the U 2
52. l gas tight Stainless Steel gas tight Maximum Venting Length feet Vent Size inches Subtract 10 ft per elbow Maximum Three Elbows 45 Subtract 10 ft per elbow Maximum Three Elbows Galvanized Steel PVC ABS CPVC Galvanized Steel PVC ABS CPVC Maximum Air Intake Length Combustion Air Air Inlet Size Intake Pipe Material inches feet 45 Subtract 10 ft per elbow Maximum Three Elbows 45 Subtract 10 ft per elbow Maximum Three Elbows Stainless Steel gas tight See notice next page 45 Subtract 10 ft per elbow Maximum Three Elbows 36 Galvanized Steel PVC ABS CPVC 45 Subtract 10 ft per elbow Maximum Three Elbows Horizontal Thru wall Direct Venting System Category Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors The total length of the thru wall exhaust vent cannot exceed forty five 45 feet in length for the flue outlet Each elbow used is equal to ten 10 feet of straight pipe This will allow installation in one of the three following combinations 45 of straight flue pipe 35 of straight flue pipe and one elbow 25 of straight flue pipe and two elbows The total length air supply pipe cannot exceed forty five 45 feet in length for the combustion air inlet Each elbow used is equal to ten 10 feet of straight pipe This will allow installa
53. l Thru Wall Direct Venting Combustion Air With Add On Condensing Heat Exchanger Category IV 9 MIN INSULATED EXHAUST DIRECT VENT VENTING CAP 2 2 3 MIN ELBOW 7 NCINTAKE VENT 7 6 MIN TRAP 7 ps CONDENSATE Figure J 7 HORIZONTAL THRU WALL DIRECT VENTING WITH ADD ON CONDENSING HEAT EXCHANGER Go Catego Combustion Air Air Maximum Air Intake Pipe Inlet Size Intake Length Material inches feet Certified Recommended Venting Vent Size Material Inches Maximum Vertical Venting Length UL17 38 Certified Venting Galvanized Steel ADB 500 w CHX ADB 750 w CHX ADB 1000 w CHX Contact Manufacturer for details Material e g AL 29 4C Stainless Steel PVC CPVC pool application only UL 17 38 Certified Venting Material e g AL 29 46 Stainless Steel PVC CPVC pool application only 17 38 Certified Venting Material e g AL 29 46 Stainless Steel PVC CPVC pool application only 35 Subtract 10 feet per elbow Maximum three 3 elbows 35 Subtract 10 feet per elbow Maximum three 3 elbows 35 Subtract 10 feet per elbow Maximum three 3 elbows 44 PVC ABS CPVC Galvanized Steel PVC ABS CPVC Galvanized Steel PVC ABS CPVC 35 Subtract 10 feet per elbow Maximum three 3 elbows 35 Subtract 10 feet per elbow Maximum three
54. ly inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appli ances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common vent system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate summer exhaust fan Close fireplace dampers Place in operation the appliances being inspected Follow the manufacturers instructions for lighting each appli ance Adjust thermostat so appliance will operate continuously Test for natural draft negative pressure 12 above the outlet elbow after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe toilet paper trick After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use Any improper operation of the common venting system should be corrected so that the installation conforms with the latest edition of the National Fuel Gas Code ANSI 7223 1 in Canada the lates
55. nce of four 4 feet horizontally from and in no case above or below unless a four 4 foot 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 consistent with the National Fuel Gas Code or in Canada the latest edition of CAN CGA B149 1 and 2 Installation Code for Gas Burning Appliances and Equipment Gas vents supported only by flashing and extended above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads The vertical direct vent cap is designed for roof top mounting only The air inlet opening MUST be installed one 1 foot above the roof line or above normal snow levels that might obstruct combustion air flow This dimension is critical to the correct operation of the boiler and venting system and reduces the chance of blockage from snow The vent cap must have aminimum 3 foot vertical clearance above the air inlet opening 39 SECTION J 5 Vertical Venting With Add On Condensing Heat Exchanger Category IV Domestic Water NONRESTRICTED 10 OR LESS 1 VENT PIPE Figure J 5 VERTICAL VENT CATEGORY IV WITH ADD ON CONDENSING HEAT EXCHANGER Maximum Venting Certified Vent Size Venting Length Category Venting Material inches feet 55 UL 17 38 Certified Venting Material ADB 50
56. nd opens the main valve only after the pilot is proven to be lit HIGH LIMIT MANUAL RESET This appliance is equipped with a manual reset high limit safety device Push the reset button and adjust the setting to 40 F above the desired operating temperature FLOW SWITCH Dual purpose control shuts off boiler in case of pump failure or low water condi tion Mounted and wired in series with the main gas valve Check with Manufac turer for proper paddle size Utilize correct paddle size for proper operation NOTICE Flow switch will not operate if flow is less than 20 GPM HIGH LIMIT AUTO RESET This appliance is equipped with an automatic high limit safety device Set the auto high limit to 30 F above the desired operating temperature 54 IGNITION MODULE MANUAL RESET HIGH LIMIT AUTO RESET HIGH LIMIT 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 3 second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets LOW WATER CUT OFF HIGH AND LOW GAS PRESSURE SWITCHES MANUAL RESET The low gas pressure switch mounts upstream of the gas pressure regulator to ensure that sufficient gas pressure is present for proper regulator performance The low gas pressure switch automatically shuts down the boiler if gas supply drop
57. not hear the sparking 7 The pilot may not light at first trial leave the unit running until you have pilot If you still do not see pilot over 90 seconds turn off the unit repeat step 6 8 Check pilot manifold pressure Location 3 Compare the reading to the values listed in tables O 2 and O 3 9 Check pilot flame 8 distinct circular blue flames around the center of the pilot 10 Replace the cap for pilot manifold adjustment screw NP TABLE O 2 PRESSURE SETTINGS FOR NAT GAS TABLE O 3 PRESSURE SETTINGS FOR PROPANE Blower Main Pilot Firing Pre Fire 3 9 11 4 9 8 9 4 9 3 10 4 9 8 ADB500 CHX 4 1 ADB750 ADB750 CHX 4 4 4 ADB1000 ADB1000 CHX UJ a 3 8 42 Note For different gas control options call factory for proper pressure settings ie IRI etc 60 3 3 Main Burner Adjustment 1 Turn unit off 2 Check to make sure that the pressure equalizer tube is securely connected between the blower and gas pressure regulator 3 Turn on the unit about 45 seconds later the pilot should light If the pilot fails to light repeat step 3 2 for pilot adjustment 4 Turn Monkey switch on The main burner will fire 5 blower pressure should increase about 2 10 0 2 W C equaling the value in tables O 2 or O 3 6 Make sure that the supply gas manometer reads between 7 14 W C dynamic pressure 7 Check manifold pressure Location 2 this
58. nsation accumulation in the vent it is required to install the horizontal portion of vent with a slight upward slope of not more than 1 4 per foot of horizontal run and an approved condensate trap must be installed per applicable codes UZ Va Ase No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The Stainless Steel non restricted direct vent cap must be furnished by the boiler manufacturer in accordance with AGA CGA requirements 41 SECTION 1 6 Figure 1 6 HORIZONTAL THRU WALL VENTING WITH ADD ON Horizontal Thru wall Venting With Add on Condensing Heat Exchanger CHX CONDENSING HEAT EXCHANGER ADB 500 w CHX ADB 750 w CHX ADB 1000 w CHX UL 17 38 Certified Venting Material e g AL 29 4C Stainless Steel PVC CPVC pool Application Only UL 17 38 Certified Venting Material e g AL 29 4C Stainless Steel PVC CPVC pool Application Only UL 17 38 Certified Venting Material e g AL 29 4C Stainless Steel PVC CPVC pool Application Only Contact Manufacturer for Details See notice next page 42 VENT CAP CONDENSATE Subtract 10 ft per elbow Maximum Three Elbows Subtract 10 ft per elbow Maximum Three Elbows Subtract 10 ft per elbow Maximum Three Elbows Horizontal Thru wall Venting System Category IV Installation This installation utilize the boiler mounted blower to vent the combusti
59. ollowing step by step procedure 1 Turn off manual main gas and main gas shut off Remove the drain plug or open the drain cock located the bottom header SPA WATER CHEMISTRY NOTE Chemical imbalance can cause severe damage to your heater and associated equipment Maintain your water pH between 7 4 and 7 8 and total alkalinity between 100 and 150 p p m If the mineral content and dissolved solids in the water become too high scale forms inside the heat exchanger tubes reducing heater efficiency and also damaging the heater If the pH drops below 7 2 the heater will be severely damaged NOTE Heat exchanger damage resulting from chemical imbalance is not covered under the warranty Figure 1 SINGLE BOILER POOL APPLICATION PRESSURE RELIEF VALVE 0 Pue UNION d DRAN VALVE BOILER BYPASS ADJUSTING VALVE FROM POOL CHECK VALVE FILTER wre PRESSURE s REDUCING VALVE Vis BALL VALVE P AIR VENT TO POOL f THERMOMETER OR MINIMUM THAT PIPING PERMITS Figure G 2b SINGLE BOILER POOL APPLICATION WITH CHX PRESSURE RELIEF VALVE E Pune A UNION BOILER BYPASS ADJUSTING VALVE L VALE FROM POOL AN Ece VALE FILTER PRESSURE 24 REDUCING VALVE aet BALL VALVE AIR VENT TO POOL f THERMOMETER OR MINIMUM THAT PIPING PERMITS 20 Figure G 3a DOUBLE BOILER POOL APPLICATION TO POOL NOTES 1 MINIMUM STRAIGHT RUN OF PIPE WITH NO FI
60. on prod ucts to the outdoors UL 17 38 Certified Venting Material e g AL29 4C MUST be used The vent must be installed to prevent flue gas leakage Care must be taken during assembly to insure that all joints are sealed properly and are airtight For certain installations i e pool heat pump domestic hot water supply with pre heat tank PVC or CPVC may be used Contact manufacturer for details To prevent the condensation accumulation in the vent it is required to install the horizontal portion of vent with a slight upward slope of not more than 1 4 per foot of horizontal run and an approved condensate trap must be installed per applicable codes UZ ere Pressurized common vent installations should be engineered DST No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The Stainless Steel non restricted direct vent cap must be furnished by the boiler manufacturer in accordance with AGA CGA requirements 47 Outdoor Installation with Add On Condensing Heat Exchanger Outdoor models are self venting when installed with the factory supplied non restricted direct vent cap and require no additional vent piping This special vent cap is provided with the boiler in accordance with AGA CGA requirements It must be installed directly on the boiler in a horizontal position Notching of the vent cap mounting flange may be neces sary to clear outlet piping on
61. on products to the outdoors Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the outdoors Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or in Canada the latest edition of CAN CGA B149 1 and 2 Installation Code for Gas Burning Appliances and Equipment UL 17 38 Certified Venting Material e g AL29 4C MUST be used The vent must be installed to prevent flue gas leakage Care must be taken during assembly to insure that all joints are sealed properly and are airtight For certain installations i e pool heat pump domestic hot water supply with pre heat tank PVC or CPVC may be used Contact manufacturer for details To prevent condensate accumulation in the vent it is required to install the horizontal portion of vent with a slight upward slope of not more than 1 4 per foot of horizontal run and an approved condensate trap must be installed per applicable codes so the condensation in the vent pipe drains back to the boiler UAV ere Pressurized common vent installations should be engineered UZ Va ese No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The Stainless Steel non restrictive direct vent cap must be furnished by the boiler manufacturer in accor dance with AGA CGA requirements 43 SECTION J 7 Horizonta
62. pane gas High gas pressure switch optional at 1 W C above manifold pressure Insert ignition control lockout tests as safety check Follow Up Safety checks must be recorded as performed Turn unit on After main burner ignition Check Manometer for proper reading Cycle unit several times and recheck readings Re analyze with unit running record or print results Turn unit off remove all Manometers and replace blower switch hose replace all gas pressure caps and plugs Remove monkey switch Check for gas leaks one more time Check around unit for debris and remove combustible and flammable products i e paper gasoline etc 61 SECTION POST START UP CHECK Check off steps as completed Boiler and heat distribution units or storage tank filled with water Automatic air vent if used open two full turns during venting procedure Air purged from system Air purged from gas piping Piping checked for leaks Followed start up procedure for proper start up Is burner flame visible Test safety controls If boiler is equipped with a low water cutoff or additional safety controls test for operation as outlined by manufacturer Burner should be operating and should go off when controls are tested When safety devices are restored burners should reignite after pre purge time delay 8 Test limit control While burner is operating move indicator on high limit control below actual boiler water temperature Burner sho
63. quire hydrostatic testing prior to being placed in operation The heat exchanger has already been factory tested and is rated for 150 PSI operating pressure However Raypak does recommend hydrostatically testing the piping connections to the boiler and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based antifreeze Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply Leaks must be repaired at once to prevent damage to the boiler NEVER use petroleum based stop leak compounds 1 Connect fill water supply Fill boiler with water be sure bleed valve is open When water flows from bleed valve shut off water Close bleed valve Carefully fill the rest of the system being sure to eliminate any entrapped air by using high point vents Close feed valve TEST AT standard operating pressure for at least 24 hours 2 Make sure constant gauge pressure has been maintained throughout test 3 Check for leaks Repair if found LOW TEMPERATURE SYSTEM Boiler requires minimum inlet temperature of 105 F Consult sections E F or G for piping details For Pool temperature requirements See Section G TEMPERATURE amp PRESSURE GAUGE The temperature and pressure gauge 1s factory mounted in the inlet outlet header BOILER RATE OF FLOW AND PRESSURE DROP MIN FLOW MODEL f AP AP t AP f
64. ral guidelines for flue gas analysis for the ADB boilers Emissions will vary with different applications hydronic water heater or pool venting including direct vent ambient conditions T P and humidity and the condition of the boiler Emissions Gas Range 8 8 9 5 CO 50 150 ppm 10 25 ppm 4 0 5 0 2 62 SECTION OPERATION OPERATING INSTRUCTIONS Lighting Instructions RYN SE aun STOP Read the safety information first Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do Not try to light the burner by hand Remove upper front panel Turn on main manual gas valve and pilot manual gas valve Wait five 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 information If you do not smell gas go to next step Turn on all electric power to the appliance Set thermostat to desired setting The appliance will operate The pilot burner will light after the pre purge time delay 45 seconds Then the pilot will light the main burner If the appliance will not operate follow the instruction To Turn Off Gas To Appliance and contact a qualified service technician Replace upper front panel TO TURN OFF GAS TO APPLIANCE E aS Set the thermostat to lowest setting
65. s below the factory setting of 6 W C for Natural gas and 10 W C for propane gas The high gas pressure switch optional mounts down stream of the gas pressure regulator If the gas pressure regulator fails the high gas pressure switch automatically shuts down the burner GAS PRESSURE SWITCH Pressure Control Device A uniquely designed pressure control device is used for ADB to ensure the proper operation of the unit even if there is a slight change of blower pressure 8 6 The rubber hose has to be securely connected between the blower and regulator during the time the unit is running not block the hose fitting orifice on the blower Regular inspection is required PLENUM GAS VALVE REGULATOR Figure L 7 PRESSURE CONTROL DEVICE ACU TRACK 55 SECTION GENERAL SAFETY PRECAUTIONS To meet commercial water use needs an external operating control for this hot water boiler is adjustable up to 210 F However water temperatures over 125 F can cause instant severe burns or death from scalds The preferred starting point for setting the control for supplying general purpose hot water is 125 F Safety and energy conservation are factors to be considered 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 consistent with the application Water temperature over 125 F can
66. s valve Install remote switch in between using wire nuts 3 0 START UP 3 1 Blower Adjustment 1 Turn the Monkey switch off 2 Turn power on 3 Check blower manometer reading Location 4 Compare your reading to the values shown in tables O 2 for natural gas and O 3 for propane for the appropriate size unit The reading should be about 2 10 0 2 lower If not adjust the air shutter on the blower to attain the correct value 4 Turn power off 32 Pilot Adjustment Turn on the gas shut off valve Turn Monkey switch off This will allow pilot to light but not main burner 3 Turn power on after 40 45 seconds ignition control will energize and send spark to ignition observe through view port for spark 4 If you do not see spark turn off power check ignition wire and proper grounding and wiring Turn power back on Repeat Step 1 Ifthere is still no spark after several attempts the igniter may be misaligned 5 Check to see if igniter is grounded out by pulling the spark wire and doing a continuity check between the igniter and burner If the igniter is grounded out it must be realigned Remove the burner Loosen the igniter nut locate the igniter in the center of the burner head and tighten igniter nut Confirm it is centered and reinstall burner head 5 Ifyou have spark turn off unit 6 Turnon power Unit will pre purge 40 45 seconds and to ignition trial You will hear a click from pilot gas valve you will
67. sent Service Red Flashing One or more of the safeties are open Refer to U 2 Board Blower Green Blower is energized 50 In addition to monitoring and displaying boiler status the CPW board controls the timing of various operating functions including boiler pump turn off delay blower fan pre purge and blower fan post purge The location of each user adjustable timing is shown in Figure L 1 601338 Q S N P N D1 D8 D12 016 015 022 09 013 MV PV BLOWER ON SERMCE CALL FOR HEAT PUMP ON OVERLOAD POWER PUMP RELAY e D E ue ES a EE PREPURGE PUMP DELAY Figure L 1 CPW Board Pump Turn off Delay The CPW board has a built in pump driver with pump turn off delay which allows the operator to set how long the pump will run after the boiler shuts off The delay is factory set for 7 minutes but can be field adjusted from 3 minutes to 10 minutes The pump relay can directly power a pump of up to 12 0 amps draw or 1 0 Hp capacity Pumps with larger amp draws should be energized through a pump contactor that is controlled by the CPW board By properly setting the pump turn off delay the boiler pump will continue running for a limited period of time in order to extract any residual heat from the combustion chamber The pump will then shut off to conserve energy until the next call for heat The pump off time delay should be set
68. should read to within 0 1 W C of the values shown in tables O 2 or O3 8 Ifadjustment is required turn off the Monkey switch 9 Remove screw cap off the gas pressure regulator adjust regulator replace the screw cap then turn the Monkey switch on Repeat steps 4 9 until the proper gas pressure and or CO are achieved 10 Allow minimum 5 minutes of run time then attach flue analyzer CO reading should be within 8 8 and 9 5 11 If CO is higher than 9 5 reduce manifold gas pressure 12 IfCO is lower than 8 8 increase the manifold gas pressure 13 When adjusting blower pressure for excess air keep all pressure readings especially manifold pressure within 0 1 of listed values Your ADB is tuned in 34 Safety Inspection Check all thermostats and high limit settings Attach thermometers to IN OUT piping and take the temperature measurement see Table D 1and F 1 for correct flow balance During the following safety checks leave manometers and analyzer hooked up check and record If other gas fired equipment in the room and on same gas main check all 4 pressures on ADB with them running Remember supply gas should always be 7 14 when boiler is firing Check stats for ON OFF operation Check Hi Limits for ON OFF operation While in operation to check inspect flow switch operation Check the low gas pressure switches low gas pressure switch are factory set at 6 W C for natural gas an 10 for pro
69. some models See Section B for correct clearances Care must be taken when locating the outdoor unit 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 effi ciency and safety the following precautions must be observed a Outdoor models must be installed outdoors and must use the non restricted direct vent cap supplied by the manufacturer b Periodically check venting system The boiler 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 c Donot locate adjacent to any window door walkway or gravity air intake The vent should be located four 4 feet horizontally from such areas d Install above grade level and above normal snow levels e A venting system shall terminate at least 3 feet above any forced air inlet located within 10 feet f Adjacent brick or masonry surfaces must be protected with a rust resistant sheet metal plate g Multiple Outdoor Vent installations require a four 4 feet clearance between vent caps Oe Condensate can freeze on the vent cap Frozen condensate on the vent cap result in a blocked flue condition The Stainless Steel non restricted vent cap must be furnished by the boiler manufacturer in accordance with A
70. ssure and with a vent gas temperature that avoids excessive condensate production in the vent Category IV A boiler which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent See Table J 1 for vent category requirements for the Advanced Design Boiler For additional information on appliance categorization see appropriate ANSI Z21 Standard and the latest edition Standard of National Fuel Gas Code or in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of local building codes Determination of Appliance Category for Venting Purposes and Venting Arrangements WARNING Contact the manufacturer of the vent material if there is any question about the appliance categori zation 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 2 87 DOS V E N T G A R R A N G E M E N T s NOTE HEAT EXCHANGER OPTIONS Without ADD ON CONDENSING HEAT EXCHANGER CHX With ADD ON CONDENSING HEAT EXCHANGER CHX COMBUSTION AIR SUPPLY From Inside Building Non Direct Venting From Outside Building Direct Venting From Inside Building Non Direct Venting From Outside Building Direct Venting EXHAUST CONFIGURATI
71. static W C Supply Gas dynamic W C Power Supply Volts EMISSION Analyzer readings Lise A _____ ot eo ke dais o INO c E _ PPM Flue Temperature SE amb Temperature 73 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 FAX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada LAT 1G2 905 677 7999 FAX 905 677 8036 Raypak Australia Pty Ltd 7 Geddes Street Mulgrave Victoria Australia 3170 613 9560 4944 FAX 613 9560 4974 8 98 Litho in U S A
72. t drill holes or use screws or rivets in nonmetallic vent pipe or fittings To make metallic vent joints Do not install seams of vent pipe on bottom of runs 100 Seal all joints and seams with silicone sealant NOTICE For direct vent installations where the air is piped in from outside the protective screen on the combustion air blower may be relocated to the air inlet termination elbow to act as an inlet screen WARNING Examine the venting system at least once a year Check all joints and vent pipe connections for tightness corrosion or deterioration NOTE The words Flue Exhaust Flue and Exhaust Vent are used interchangeably VENTING CONFIGURATIONS The following is a detailed explanation of each venting system WITHOUT and WITH add on condensing heat exchanger CHX its installation requirements the components used and part numbers for each For boilers connected to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equip ment of the latest edition of National Fuel Gas Code or in Canada the latest edition of CAN CGA B149 1 and 2 Instal lation Code for Gas Burning Appliances and Equipment or applicable provisions of local building codes 30 SECTION J 1 Natural Draft Vertical Venting Without Add on Condensing Heat Exchanger Category I 10 OR LESS E NONRESTRICTED VENT CAP 2 MIN W
73. t edition of CAN CGA B 149 1 and 2 Installation Code for Gas Burning Appliances and Equipment When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as deter mined using the appropriate tables in Appendix G in the latest edition of the National Fuel Gas Code ANSI 7223 1 in Canada Appendix B of the latest edition of the Installation Code for Gas Burning Appliances and Equipment 33 SECTION J 2 Horizontal Thru Wall Venting Without Add on Condensing Heat Exchanger Category 1 INSULATED 1 MIN EXHAUST VENTING 2 N OPTIONAL FLUE VENT INSTALLATION Figure J 2 HORIZONTAL THRU WALL VENTING WITHOUT ADD ON CONDENSING HEAT EXCHANGER CATEGORY Venting Certified Vent Size Maximum Category Venting Material inches Venting Length Feet ADB 500 SR Subtract e per elbow Gas Tight Maximum 3 elbows Stainless Steel 65 ADB 750 Gas Tight Subtract 10ft per elbow g Maximum 3 elbows Stainless Steel 9 ADB 1000 Subtract 108 per elbow Gas Tight Maximum 3 elbows See notice next page Horizontal Thru wall Direct Venting System Category IIT Installation 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 throu
74. t shall not terminate b d f g h Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwell ings Less than 7 ft 2 13m above a paved sidewalk or paved driveway located on public property Within 6 ft 1 8m ofa mechanical air supply inlet to any building Above a meter regulator assembly within 3 ft 900mm horizontally of the vertical center line of the regulator Within 6 ft 1 8m ifany gas service regulator vent outlet Less than 1 ft 300mm above grade level Within 3 ft 1m of a window or door which can be opened in any building any non mechanical air supply inlet to any building to the combustion air inlet of any other appliance Underneath a verandah porch or deck unless i the verandah porch or deck is fully open on a minimum of two sides beneath the floor and ii the distance between the top of the vent termination and the underside of the verandah porch or deck is greater than 1 ft 30cm 29 Venting Installation Tips Support piping horizontal runs at least every five 5 feet vertical runs use braces under or near elbows Follow items listed below to avoid personal injury or property damage Cut nonmetallic vent pipe with fine toothed hacksaw 34 teeth per inch Do not use nonmetallic vent pipe or fittings that are cracked or damaged Do not use nonmetallic vent fittings if they are cut or altered Do no
75. ted by a suitable commercial grade surge protection device If any of the original wire as supplied with the boiler must be replaced it must be replaced with 105 C wire or its equivalent CHECK THE POWER SOURCE Using a volt ohm meter VOM check the following voltages at the circuit breaker panel prior to connecting any equipment Make sure proper polarity is followed and house ground is proven nnn n LI VOLT OHM METER Fig 9237 FIGUREI 1 AC 108 Volts AC Minimum 132 Volts MAX CHECK POWER SOURCE 108 Volts AC Minimum 132 Volts MAX BC Must be less than 1 0 Volts AC 24 MAKING THE ELECTRICAL CONNECTIONS Refer to Fig I 2 Wiring Connection and Fig L 2 Wiring Diagram 1 Verify circuit breaker is properly sized by referring to boiler rating plate A dedicated motor duty circuit breaker should be provided 2 Turn off all power to the boiler Verify that power has been turned off by testing with a volt ohm meter prior to working with any electrical connections or components 3 Observe proper wire colors while making electrical connections Many electronic controls are polarity sensitive Components damaged by improper electrical installation are not covered by warranty 4 Provide an external surge suppressor capable of maintaining system integrity 5 Provide overload protection and a disconnect means for equipment serviceability as required by local and state code 6 Install boiler controls thermostats or bu
76. termined per the latest edition of the National Fuel Gas Code U S and CAN CGA B149 1 and 2 Installation Code Canada The diameter of vent flue pipe should be sized according to part 11 ofthe latest edition of the National Fuel Gas Code U S and part 7 and Appendix B of CAN CGA B149 1 and 2 installation code Canada The minimum flue pipe diameter for conventional negative draft venting using double wall B type vent is 7 for ADB 500 8 for the ADB 750 and 9 for ADB 1000 NOTICE Vent Adapter may have to be used to connect B vent to the unit For ADB 500 a 6 diameter to 7 diameter adapter is needed The connection from the appliance vent to the stack must be as direct as possible and should be the same as or larger than the vent outlet The vent must be installed to prevent accumulation of condensate and where necessary have means provided for drainage of condensate The horizontal breaching of a vent must have an upward slope of not less than 1 4 inch per linear foot from the boiler 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 clearances and to prevent physical damage or separation of joints e Vertical Direct Vent Termination The vent terminal should be vertical and should terminate outside the building at least two 2 feet above the highest point of the roof within 10 feet The vent cap should have a minimum cleara
77. the gas supply at a location external to the appliance WARNING Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water WARNING To minimize the possibility of improper operation serious personal injury fire or damage to the boiler never violate the following safety rules 1 Always keep the area around the boiler free of combustible materials gasoline and other flammable liquids and vapors 2 Never cover the boiler lean anything against it store trash or debris near it stand on it or in any way block the flow of fresh air to the boiler ARNING More than one 1 supply source This appliance has provisions to be connected to more than one 1 supply source To reduce the risk of electrical shock disconnect all such connections before servicing ARNING Risk of electrical shock More than one 1 disconnect switch may be required to de energize the equipment before servicing CAUTION Operation of this boiler on low temperature systems requires special piping to insure correct operation Consult Sections E F or G for piping details CAUTION If this boiler is to be installed above radiation level it must be provided with a low water cutoff device at the time of boiler installation CAUTION This boiler requires forced water circulation when the burner is operating
78. thorized Returned Goods Receipt number will not be accepted All returned goods are subject to a stocking charge When ordering parts you must specify the Model and Serial Number of the boiler When ordering under warranty condi tions you must also specify the date of installation Purchased parts are subject to replacement only under the manufacturer s warranty Debits for defective replacement parts will not be accepted and will be replaced in kind only per Raypak s standard warranties MODEL IDENTIFICATION The model identification number and boiler serial number are found on the boiler data plate located on the left inside jacket of the boiler The model number will have the form H4 0500A ADB or similar depending on the boiler size and configuration The first character of the model number identifies application H Hydronic Heating System W Hot Water Supply System P Pool Application The second character identifies the firing mode 4 On Off firing The next four places identify the input of the boiler in 1 000s of BTUH 0500 500 000 BTUH The remaining suffix identifies the control ignition and construction configuration The last three characters of the model number identifies the model type ADB Advanced Design Boiler RATINGS AND CERTIFICATION All Raypak boilers are National Board Approved design certified and tested under the applicable American National Standard CSA Standard for USA and Canada Each boiler is cons
79. ths check the vent cap and make sure no blockage occurs from build up of snow Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury a b d f g h i 0 k Gases may form a white vapor plume in winter The plume could obstruct a window view if the termination is installed in close proximity to windows Prevailing winds could cause freezing of condensate and water ice buildup on building plants or roof The bottom of the vent terminal and the air intake shall be located at least 12 inches above grade including normal snow line Un insulated single wall metal vent pipe shall not be used outdoors on cold climates for venting gas utilization equipment Through the wall vents for Category II and IV appliances and non categorized condensing appliances shall not terminate over public walkways 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 Where local experience indicates that condensate is a problem with Category I and III appliances this provision shall also apply Locate and guard vent termination to prevent accidental contact by people and pets DO NOT terminate vent in window well stairwell alcove courtyard or other recessed
80. tification C 2 007358F 007358F 007358F Control Burner Flame Safeguard C 2 Ignition 007359F 007359F 007359F Detector UV Flame C 2 007360F 007360F 007360F Generator Spark C 2 007361F 007361F 007361F Panel Contol Mounting 007362F 007362F 007362F Remote Sensor for Low Water Cut Off 007228F 007228F 007228F Low Water Cut Off PC Board 007157F 007157F 007157F PUMPS 2 2 2 1 2 Pump Circulating Bronze Soft Water 007226F 007226F 007227F Pump Circulating Bronze Medium Water 007226F 007347F 007348F Pump Circulating Bronze Hard Water 007349F 007350F 007351F Pump Circulating Cl Soft Water 007232F 007232F 007233F Pump 2 Medium Water 007232F 007353F 007354F 007355F 007356F 007357F Blanket Return Header Refracto 007241F 007241F 007241F 71 DESCRIPTION 007242F 007242F 007243F Flue Collector Front No opening 007244F 007245F 007246F Flue Collector Rear opening 007249F 007250F 007251F Support Channel 007254F 007254F 007255F Control Box Cover 007256F 007256F 007256F Return Header Cover 007257F 007257F 007257F Door Lower 007258F 007259F 007260F Jacket Upper Front Panel 007263F 007263F 007264F Access Panel Flue Lower 007267F 007268F 007269F Access Panel Flue Upper 007272F 007273F 007274F Access Panel Flue 1 Pc blank solid 007277F 007277F 007278F Jacket Side Right Panel 007281F 007282F 007283F Jacket Side Right Panel Connection Option 007284F 007285F 007286F Jacket Side Left Panel 007289F 007290F 007291F Jacket Re
81. tion in one of the three following combinations 45 of straight combustion air pipe 35 of straight combustion air pipe and one elbow 25 of straight combustion air pipe and two elbows The 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 The vent must be installed to prevent the potential accumulation of condensate in the vent pipes It is recommended that a The vent be installed with a slight downward slope of not more than 1 4 per foot of horizontal run to the vent terminal b The vent be insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that a The vent be installed with a slight upward slope of not more than 1 4 per foot of horizontal run to the vent terminal In this case an approved condensate trap must be installed per applicable codes b The vent be insulated through the length of the horizontal run Horizontal Thru wall Direct Vent Termination The direct vent cap MUST be mounted on the exterior 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 one 1 foot above ground level and above normal snow levels Multiple direct vent caps MUST NOT be installed with one combustion air inlet directly above a direct vent cap This vertical spacing would allow the flue
82. to the minimum time required to extract all residual heat from the heat exchanger If temperature as monitored at the boiler outlet increases more than 5 F after the pump turns off following a firing cycle the pump off time delay should be extended by thirty seconds Increase or decrease time delay as appropriate until outlet temperature does not spike more than 5 F after pump shut off following a prolonged firing cycle gt 5min CAUTION The boiler requires forced water circulation when the burner is operating and the pump must be interlocked with the boiler See Section D for minimum water maximum flow rates and pump selection NOTICE Pump will come on when power is first applied to the boiler Blower Fan Pre purge The CPW board has a built in pre purge delay which operates the blower fan for a user adjustable time period prior to pilot trial for ignition The pre purge period ensures that the combustion chamber is clear of all excess combustible gases prior to commencing the pilot ignition cycle The pre purge delay is factory set for 45 seconds and it can be adjusted in the field from 45 seconds to 120 seconds To optimize boiler response time on call for heat set the pre purge delay to the minimum allowed by local state or national code Blower Fan Post purge The CPW board has a built in post purge delay to exhaust residual combustion products after the main gas valve closes The post purge timing is factory set at 3 minutes and
83. tructed in accordance with Section IV of the American Society of Mechanical Engineers ASME Boiler Pressure Vessel Code and bears the ASME stamp This boiler complies with the latest edition of ASHRAE 90 1 Standard Altering any RAYPAK pressure vessel by installing replacement heat exchangers tube bundle headers or any other ASME part not manufactured and or approved by RAYPAK will instantly void the ASME and agency listings and any RAYPAK warranty on the vessel Altering the ASME agency ratings of the vessel also violates national state and local approval codes The terms boiler and heater are used interchangeably in this manual No derate is required for altitudes up to 7000 feet Rated inputs at sea level settings are suitable for up to 5000 feet elevation At altitudes between 5000 and 7000 feet rated inputs are achieved with pressure settings adjustment Consult the factory for installations at altitudes in excess of 7000 feet FLUE CONNECTION BLOWER iz Ww d WATER INLET OPERATIONS CENTER CONTROL ENCLOSURE 22 H BURNER GAS TRAIN COD fe PRESSURE SWITCHES 1 e FLUE CONNECTION OPTIONAL LOCATION HEAT EXCHANGER BURNER FLAME BASE BURNER FLAME Figure A 1 ADVANCED DESIGN BOILER COMPONENT LOCATIONS SECTION BOILER INSTALLATION INSTALLATION CODES Installations must follow these codes
84. uct or property damage if ignored NOTICE indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards SECTION A BEFORE INSTALLING THE BOILER Raypak strongly recommends that this manual be reviewed thoroughly before installing your Raypak boiler Factory warranty does not apply to boilers that have been improperly installed or operated 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 factory or your local Raypak representative Thank you for purchasing a Raypak product We hope you will be satisfied with the high quality and durability of our equipment PRODUCT RECEIPT On receipt of your product it is suggested that you visually 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 boiler from the shipping packaging Report any damage to the carrier immediately On occasion some items will be shipped loose Be sure that you receive the correct number of packages as indicated 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 au
85. uld go off while blower circulator continues to operate Raise setting on limit control above boiler water temperature and burner should reignite after pre purge time delay 9 Test ignition system safety device Turn power off Close the pilot manual valve Turn power on after about 45 seconds of pre purge the pilot comes on The pilot and therefore the burner should fail to light The standard lockout time is 90 seconds then the pilot light goes off and the boiler goes into post purge If the lockout module is attached to boiler a lockout light comes on Turn the power off open the pilot manual valve reset the lockout module if applicable Wait 30 seconds then turn power on The burner should ignite after pre purge time delay 10 To restart system follow lighting instructions in Section 11 High limit control set to design temperature requirements of system For multiple zones flow adjusted as required in each zone 12 Boiler cycled with thermostat Raise to highest setting and verify boiler goes through normal start up cycle Reduce to lowest setting and verify boiler goes off 13 Observed several operating cycles for proper operation 14 Setroom thermostat or tankstat to desired temperature 15 Reviewed all instructions shipped with this boiler with owner or maintenance personnel returned to envelope and given to owner or placed in pocket inside front panel on boiler EMISSIONS GUIDELINES Gene
86. y use a thin wire to clean up the orifice Periodically 1 Check relief valve Refer to manufacturer s instructions on valve Test low water cutoff if used Refer to manufacturer s instructions 3 Visually inspect condensate drain hose for proper operation or deterioration if appropriate Check for plugged condensate trap Use cleanout plug to clear trap 4 Cleanscreen in vent termination and air intake 64 CLEANING BOILER HEATING SURFACES The following service procedures must be performed ONLY by a qualified service agency Boiler owner should not attempt these procedures 1 Ifyou find soot in top of vent elbow some sediment in bottom of vent is normal remove vent attachment to the ADB and clean flue exhaust baffle inside the boiler Also check burner replace if damaged 2 Ifyou find rust deposits in vent elbow check for high water flowrate or low inlet water temperatures Clean boiler as above 65 SECTION S CONNECTING CONDENSING HEAT EXCHANGER CHX Refer to Figure S 1 for the following steps 1 Remove the shroud 2 Remove the top cover 3 Secure the 15 elbows supplied as shown one on each side of the CHX using the stainless steel screws sup plied 4 Seal the connection with high temperature RTV supplied 5 Replace the top cover 6 Level the CHX with the ADB by adjusting the leveling screws at the base 7 Place a line of on the crimped end of the flue outlet from the ADB and slide t
87. y boiler controls Failure to do so may result in board damage boiler malfunction property damage personal injury or death CAUTION This appliance has provisions to be connected to more than one 1 supply source To reduce the risk of electric shock disconnect all such connections before servicing CAUTION Risk of electric shock More than one 1 disconnect switch may be required to de energize the equipment before servicing CENTRAL POINT WIRING CPW Central Point Wiring is an advanced control Integration technique that provides complete boiler diagnostic capability and greatly simplifies troubleshooting At the heart of CPW is the Operations Status Center which is comprised of two different circuit boards the CPW board and one or more U 2 Diagnostic Boards THE CPW BOARD The Central Point Wiring CPW board serves as the central tie point for connecting all other control components in the boiler The CPW board provides boiler operating status and fault indication using eight LEDs which function as described in Table L 1 Table L 1 CPW Board LED Indicators Light Color Indication Power Green 24 VDC is applied to the system System Error Red Overload current on the board Board is disabled Pump Green Boiler Pump is energized Pilot Yellow Power applied to the Pilot Gas Valve PV signal on Main Gas Green Power applied to Main Gas Valve MV signal on Call for Heat Green Thermostat is closed Call for heat pre

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