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INSTALLATION AND OPERATING
Advanced
Design
Boiler
Models
751, 1001 &
1501 – Types H, WH & P
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property
damage, personal injury or loss of life. Refer to the user's information manual provided with this boiler.
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.
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.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3400.52E
INSTRUCTIONS
Effective: 02-22-07
L
W
Replaces: 04-01-03
P/N 241079 Rev. 6
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Related Manuals for Raypak 751
Summary of Contents for Raypak 751
- Page 1 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Refer to the user’s information manual provided with this boiler. 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.
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Page 3: Table Of Contents
CONTENTS WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply 11 Water Piping Hydronic Heating Gas Supply Connections Electrical Power Connections Venting Connections... -
Page 4: Warnings
WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. -
Page 5: Before Installation
If, after reviewing this manual, you still have questions which this manual does not answer, please contact the manufacturer 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 6: Component Locations
Component Locations Fig. 1: Component Locations... -
Page 7: General Safety
GENERAL SAFETY 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. -
Page 8: Installation
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 regula- tions 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. -
Page 9: Combustion And Ventilation Air
Fig. 2: Minimum Clearances from Combustible Surfaces Outdoor Installations Raypak Advanced Design Boilers are design certified by CSA for outdoor installation. Roof water drainage must be diverted away from boilers installed under overhangs. Min. Clearance from Heater Side Combustible Surfaces Rear 12”... - Page 10 Fig. 3: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- tance of 2 ft (61cm) from the centerline of the terminal...
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Page 11: Conventional Combustion Air Supply
(the mechanical equipment room directly communicates with the outdoors). 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... -
Page 12: Water Piping
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 fac- tory-tested and is rated for 160 PSI operating pressure. -
Page 13: Hydronic Heating
In order to ensure proper performance of your boiler system, you must install a properly sized pump. Raypak recommends using a 20°F ΔT as design ΔT. (ΔT is the temperature difference between the inlet and outlet water when the boiler is firing at full rate). If a ΔT larger than 20°F is necessary, the bypass must... - Page 14 Fig. 4: Single Boiler - Primary/Secondary Piping Fig. 5: Single Boiler - Primary/Secondary Piping with CHX...
- Page 15 Fig. 6: Dual Boiler Piping Fig. 7: Dual Boiler - Piping with CHX...
- Page 16 Fig. 8: Single Boiler - Low Temperature Application (Heat Pump) Primary/Secondary Piping DOMESTIC HOT WATER PIPING When designing the water piping system for domestic water applications, water hardness should be consid- ered. Table F indicates the suggested flow rates for ΔT=Temperature rise in °F...
- Page 17 Fig. 9: Single Boiler - Domestic Hot Water with One Storage Tank Fig. 10: Single Boiler - Domestic Hot Water with One Storage Tank and CHX...
- Page 18 Fig. 11: Single Boiler - Domestic Hot Water with One Storage Tank and CHX (2 pump system) Fig. 12: Single Boiler - Domestic Hot Water with One Storage Tank, One Pre-Heat Tank and CHX...
- Page 19 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 Fig. 13: Single Boiler - Pool Application Fig. 14: Single Boiler - Pool Application with CHX...
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Page 21: Gas Supply Connections
14 in. WC. The regulator should be placed a minimum distance of 10 times the pipe diam- eter 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... -
Page 22: Gas Supply Connection
1/2 PSIG. Relieve test pressure in the gas supply line before reconnect- ing the boiler and its manual shut off valve to the gas supply line. FAILURE TO FOLLOW THIS PROCE- DURE MAY DAMAGE THE GAS VALVES. Over pressurized gas valves are not covered by warranty. -
Page 23: Electrical Power Connections
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 VAC. The voltage is indicat- ed on the tie-in leads. Consult the wiring diagram shipped with the boiler in the instruction packet. The “TH”... - Page 24 The ADB is wired for 120 VAC. The voltage is indicat- ed 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 BREAK THE WIRE NUT AT THE BOILER "TH"...
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Page 25: 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. CAUTION: Stable vent pressure is critical to the safe and proper operation of the heater. - Page 26 Support of Vent Stack The weight of the vent stack or chimney must not rest on the boiler vent connection. Support must be provid- ed in compliance with applicable codes. The vent should also be supported to maintain proper clear- ances from combustible materials.
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Page 27: Venting Installation Tips
e) Terminate vent at least six (6) feet away from adja- cent walls. DO NOT terminate vent closer than five (5) feet below roof overhang. Canadian Installations Refer to the latest edition of CSA B149 Installation Code. A vent shall not terminate: a) Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings. - Page 28 Natural Draft Vertical Venting with- out Add-on Condensing Heat Exchanger (Category I) Fig. 21: Natural Draft Vertical Venting without Add-on Condensing Heat Exchanger (Category I) ADB-1501 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 fur- ther details (ANSI Z223.1), or in Canada, the latest edition of CSA B149.
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Page 29: Condensing Heat Exchanger
CSA B149 Installation Code (Canada). The flue pipe diameter for conventional negative draft venting using double-wall B type vent is 8” for the ADB 751, 10” for the 1001, and 12” for the ADB 1501. NOTE: Vent Adapter will have to be used to connect B vent to the unit. - Page 30 appliance not connected to the common vent sys- tem. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will oper- ate at maximum speed. Do not operate summer exhaust fan. Close fireplace dampers. d) Place in operation the appliances being inspected. Follow the manufacturers instructions for lighting each appliance.
- Page 31 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. WARNING: No substitutions of flue pipe or vent cap material are allowed.
- Page 32 Table M: Horizontal Thru-wall Direct Venting without Add-on Horizontal Thru-wall Direct Venting System (Category III) Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combus- tion 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.
- Page 33 Such substitutions would jeopardize the safety and health of inhabitants. The Stainless Steel direct vent cap must be fur- nished by the boiler manufacturer in accordance with its listing. ADB-1501 *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 CSA B149 Installation Code.
- Page 34 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 sup- ported for the design and weight of the material employed to maintain clearances and to prevent phys- ical damage or separation of joints.
- Page 35 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 edi- tion of CSA B149 Installation Code for Gas Burning Appliances and Equipment.
- Page 36 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 edi- tion of CSA B149 Installation Code for Gas Burning Appliances and Equipment.
- Page 37 Steel PVC*, CPVC* *Contact the manufacturer for details. **If the boiler is direct vented, a 6 to 8 in. adapter must be installed at the blower inlet. Table Q: Horizontal Thru-wall Direct Venting with Add-on Condensing Heat Exchanger (Category IV)
- Page 38 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 combus- tion products to the outdoors. UL 1738 Certified Venting Material (e.g. AL29-4C) MUST be used.
- Page 39 AL29-4C Stainless Steel PVC*, CPVC* *Contact the manufacturer for details. **If the boiler is direct vented, a 6 to 8 in. adapter must be installed at the blower inlet. Vertical Direct Venting System With Add-on Condensing Heat Exchanger (Category IV) Installation...
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Page 40: Condensate Drain
1 (one) gallon per hour (gph) of condensate for every 100,000 BTUH. The maximum condensation rate for the ADB 751 is 7.5 gph, the ADB 1001 is 10 gph, and the ADB 1501 is 15 gph. Fig. 29: Condensate Trap Alignment... -
Page 41: Controls
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 any boiler controls. Failure to... - Page 42 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 43 Once a fault has been detected, the U-2 board will illu- minate 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 board will display the priority fault based on the safety hierarchy as labeled on the U-2 board.
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Page 44: Wiring Diagram
WIRING DIAGRAM Figure L-2 WIRING DIAGRAM... -
Page 45: Flow Switch
Fig. 32: High Limit — Manual Reset Flow Switch Dual-purpose control shuts off boiler in case of pump failure or low water condition. Mounted and wired in series with the main gas valve. Check with the manu- facturer for proper paddle size. Utilize correct paddle size for proper operation. -
Page 46: Pre Start-Up
The low gas pressure switch automatically shuts down the boiler if gas supply drops below the factory setting of 6 in. WC for Natural gas, and 10 in. WC for Propane gas. - Page 47 Pre-Start-up Check 1. 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.”...
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Page 48: Adb Initial Start-Up
• Close union when you smell gas. • Wait minimum 5 minutes to clear the gas out of the boiler room before continuing. Check the Gas Supply Pressure, Location (1) • Leave pilot gas valve and first manual gas valve closed;... - Page 49 tion wire and proper grounding and wiring. Turn power back on. Repeat Step 3. If there 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.
- Page 50 5. Followed start-up procedure for proper start-up? 6. Is burner flame visible? 7. 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 con-...
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Page 51: Operation
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 52: Connecting The Chx
3. Visually inspect venting system for proper func- tion, deterioration or leakage. 4. Check that boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids. 5. Check for and remove any obstruction to the flow of combustion or ventilation air to boiler. - Page 53 13. Allow the silicone (RTV) to cure over-night. Vent Switch Adjustment: In order to ensure 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.
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Page 54: Appendix
• 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... -
Page 55: Start-Up Checklist
RAYPAK PRODUCTS ADB, HI-DELTA & MV B This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. -
Page 56: Warranty
8. Chemical, particulate matter or other airborne contamination of combustion air or use of chemical additives to water. PARTS REPLACEMENT: Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty. - Page 57 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 Litho in U. S. A.