Table of Contents
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OPERATING AND
INSTALLATION
INSTRUCTIONS
Models 500,750,1000
A
DVANCED
D
ESIGN
B
OILER
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity
of this or any other appliance. To do so may result in an explosion or fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property 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.
Catalog No.: 3400.50-I
Effective:
12-01-00
Replaces:
05-01-00
®
P/N 240723
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Table of Contents
Related Manuals for Raypak 1000
Summary of Contents for Raypak 1000
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Page 1: Installation Instructions
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. - Page 2 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.
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Page 3: Table Of Contents
(MANUFACTURERS CERTIFIED PERSONNEL ONLY) SECTION P: SECTION Q: SECTION R: SECTION S: APPENDIX A: COMBUSTION AIR CONTAMINATION ILLUSTRATED PARTS LIST BEFORE INSTALLING THE BOILER BOILER INSTALLATION COMBUSTION AND VENTILATION AIR WATER PIPING - GENERAL HYDRONIC HEATING PIPING DOMESTIC HOT WATER PIPING POOL HEATING... - Page 4 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.
- Page 5 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.
- Page 6 Figure A-1 ADVANCED DESIGN BOILER COMPONENT LOCATIONS...
- Page 7 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.
- Page 8 12” (Water side) Left 1” 0” Vent 1” Note 1. Do not install on carpeting. Figure B-1 MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES AND FOR EASY SERVICING 1000 1" 1" 12" (Water side) 12" (Water side) 1” 1” 0” 0” 1”...
- Page 9 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 Rear 6" Right 36” (Water side) Left 36"...
- Page 10 In cold 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.
- Page 11 1. Ventilation of the space occupied by the boiler shall be provided 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).
- Page 12 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 require 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.
- Page 13 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 Delta Delta Delta using a 20°F T as design T. ( T is the temperature difference between the inlet and outlet water when the Delta boiler is firing at full rate).
- Page 14 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.
- Page 15 Figure E-2b SINGLE BOILER - PRIMARY/SECONDARY PIPING WITH CHX Figure E-3a DUAL-BOILER PRIMARY/SECONDARY PIPING...
- Page 16 Figure E-3b DUAL BOILER -PRIMARY/SECONDARY PIPING WITH CHX Figure E-4a SINGLE BOILER - LOW TEMPERATURE APPLICATION (HEAT PUMP) PRIMARY/SECONDARY PIPING...
- Page 17 T = Temperature rise in °F Figure F-1a SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK Figure F-1b SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK AND CHX TABLE F-1 DOMESTIC WATER HEATING BOILER FLOW RATE REQUIREMENTS GPM = Gallons per minute...
- Page 18 Figure F-1bb SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK AND CHX (2 pump system) Figure F-1c SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK, ONE PRE-HEAT TANK AND CHX...
- Page 19 SECTION G: POOL HEATING CAUTION: 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.
- Page 20 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 G-1a SINGLE BOILER - POOL APPLICATION Figure G-2b SINGLE BOILER - POOL APPLICATION WITH CHX...
- Page 21 Figure G-3a DOUBLE BOILER - POOL APPLICATION...
- Page 22 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.
- Page 23 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 24 All sensitive control components should be protected 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.
- Page 25 Verify circuit breaker is properly sized by referring to boiler rating plate. A dedicated motor duty circuit breaker should be provided. 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.
- Page 26 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. BREAK THE WIRE NUT AT THE BOILER "TH"...
- Page 27 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.
- Page 28 NOTE: PVC or CPVC vent maybe used inconjunction with CHX, special piping arrangement has to be made. Contact manufacturer for details.
- Page 29 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.
- Page 30 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). ·...
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Page 31: Section A
SECTION J-1 Natural Draft Vertical Venting Without Add-on Condensing Heat Exchanger (Category I) Figure J-1 NATURAL DRAFT VERTICAL VENT WITHOUT ADD-ON CONDENSING HEAT EXCHANGER* 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. - Page 32 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.
- Page 33 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.
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Page 34: Section B
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. - Page 35 WARNING: Pressurized common vent installations should be engineered. In a catagory III installation, a 9-8 inch vent adapter must be used on the ADB 1000. NOTICE: The Stainless Steel direct vent cap must be furnished by the boiler manufacturer in accordance with AGA/...
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Page 36: Section C
SECTION J-3 Figure J-3 HORIZONTAL THRU-WALL DIRECT VENTING WITHOUT ADD-ON SECONDARY CONDENSING HEAT EXCHANGER *See notice next page. Horizontal Thru-Wall Direct Venting/Combustion Air (Category III) - Page 37 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.
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Page 38: Section D
SECTION J-4 Vertical Direct Venting/Combustion Air (Category I) Figure J-4 VERTICAL DIRECT VENTING WITHOUT ADD-ON CONDENSING HEAT EXCHANGER *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. - Page 39 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.
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Page 40: Section E
SECTION J-5 Vertical Venting With Add-On Condensing Heat Exchanger (Category IV) Domestic Water Figure J-5 VERTICAL VENT (CATEGORY IV) WITH ADD-ON CONDENSING HEAT EXCHANGER *Contact Manufacturer for Details... - Page 41 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.
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Page 42: Section F
SECTION J-6 Horizontal Thru-wall Venting With Add-on Condensing Heat Exchanger (CHX) Figure J-6 HORIZONTAL THRU-WALL VENTING WITH ADD-ON CONDENSING HEAT EXCHANGER *Contact Manufacturer for Details. ** See notice next page. - Page 43 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.
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Page 44: Section G
SECTION J-7 Horizontal Thru-Wall Direct Venting/Combustion Air With Add-On Condensing Heat Exchanger (Category IV) Figure J-7 HORIZONTAL THRU-WALL DIRECT VENTING WITH ADD-ON CONDENSING HEAT EXCHANGER *Contact Manufacturer for details. - Page 45 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.
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Page 46: Section H
SECTION J-8 Vertical Direct Venting/Combustion Air With Add-on Condensing Heat Exchanger (Category IV) Figure J-8 VERTICAL DIRECT VENTING WITH ADD-ON SECONDARY CONDENSING HEAT EXCHANGER *Contact manufacturer for details... - Page 47 • 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 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 flue gas leakage.
- Page 48 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 some models. See Section B for correct clearances.
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Page 49: Section K
The Condensing Heat Exchanger (CHX) can generate up to 1 (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. Figure K-1... -
Page 50: Section L
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... - Page 51 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.
- Page 52 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.
- Page 53 Figure L-2 WIRING DIAGRAM...
- Page 54 MANUAL RESET HIGH LIMIT 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.
- Page 55 The low gas pressure switch automatically shuts down the boiler if gas supply drops below the factory setting of 6" W.C. for Natural gas, and 10" W.C. for propane gas.
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Page 56: Section M
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. -
Page 57: Section N
5. Starting on the lowest floor, open air vents one at a time until water squirts out. Close vent. 6. Repeat with remaining vents. 7. Close manual water feed valve when correct boiler pressure is reached. INSPECT VENTING SYSTEM: 1. Check all vent pipe connections and flue pipe material. - Page 58 Blower "T" fitting detail. Figure O-1 COMPONENT AND PRESSURE TAP LOCATIONS...
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Page 59: Section O
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. approx 120 VAC) approx 120 VAC) - Page 60 2.4 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 > 14" W.C.; Turn off the valve; •...
- Page 61 • 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.
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Page 62: Section P
• 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.) -
Page 63: Section Q
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? •... -
Page 64: Section R
SECTION R: 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. - Page 65 If you 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. If you find rust deposits in vent elbow - check for high water flowrate or low inlet water temperatures. Clean boiler as above.
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Page 66: Section S
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: •... - Page 67 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: •...
- Page 73 TODAY'S DATE: __________________________________________________ PRESSURE SETTINGS: Blower (burner off)……………… Pilot……………………………… Main Burner……………………… Blower (burner on) ……………… Supply Gas (static) ……………… Supply Gas (dynamic) …………… Power Supply……...………. EMISSION : (Analyzer readings) ……………………………… CO……………………………… Excess Air………………………… ______ % ………………………………… ______ % NOx……………………………… Flue Temperature………………… amb.
- Page 74 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX: (800) 872-9725 Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 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.