Raypak 1001 manual

Catalog No.: 3400.52D Effective: 04-01-03 Replaces: 02-15-03 FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materi- als in the vicinity of this or any other appliance. T o do so may result in an explosion or fire. W ARNING: Improper installation, adjustment, alteration, service or maintenance[...]

DANGER: Make sure the gas on which the boiler will operate is the same type as that specified on the boiler model and rating plate. W ARNING: 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 the gas supply at a location external to the appliance. W A[...]

3 T ABLE OF CONTENTS P AGE NO. 4 SECTION A: BEFORE INST ALLING THE BOILER 7 SECTION B: BOILER INST ALLA TION 10 SECTION C: COMBUSTION AND VENTILA TION AIR 12 SECTION D: W A TER PIPING - GENERAL 13 SECTION E: HYDRONIC HEA TING PIPING 17 SECTION F: DOMESTIC HOT W A TER PIPING 19 SECTION G: POOL HEA TING 22 SECTION H: GAS SUPPL Y CONNECTIONS 24 SECTIO[...]

Pay attention to these terms: DANGER indicates the pr esence of immediate hazar ds which will cause sever e personal injur y , death or substantial pr operty damage if ignor ed. W ARNING indicates the presence of hazar ds or unsafe practices which could cause severe personal injury , death or substantial pr operty damage if ignor ed. CAUTION indica[...]

MODEL IDENTIFICA TION 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 H[...]

6 Figure A-1 ADV ANCED DESIGN BOILER COMPONENT LOCA TIONS[...]

SECTION B: BOILER INST ALLA TION INST ALLA TION CODES Installations must follow these codes: · 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/NFP A 70 - latest edition. · Standard for Controls and Safety Devices [...]

8 CLEARANCES T ABLE 1 MINIMUM CLEARANCES FROM COMBUSTIBLE SURF ACES (INDOOR ALCOVE INST ALLA TIONS) Boiler Size Boiler Side 751, 1001, 1501 Floor See Note 1. Rear 1” Right 12” (W ater side) Left 1” To p 0” V ent 1” Note 1. Do not install on carpeting. Figure B-1 MINIMUM CLEARANCES FROM COMBUSTIBLE SURF ACES AND FOR EASY SER VICING[...]

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. T ABLE 2 OUTDOOR INST ALLA TION MINIMUM CLEARANCES Boiler Size Boiler Side 751, 1001, 1501 Rear 6 " Right 36” (W ater side) Left 36" To p 0 " V ent 1" W AR[...]

SECTION C: COMBUSTION AND VENTILA TION AIR COMBUSTION AND VENTILA TION AIR (Indoor Units) The boiler must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation. Combustion air can be supplied via conventional venting, where combustion air is drawn from the area immedi- ately surroundin[...]

All 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 t[...]

SECTION D: W A TER 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. CAUTION: This boiler r equir es for ced water circulation wh[...]

13 SECTION E: HYDRONIC HEA TING 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 dif ference between the inlet and outlet water when the boiler is firing at full rate). If a Delta T lar ge[...]

Figure E-2a SINGLE BOILER - PRIMARY/SECONDARY PIPING 14 PRESSURE DROP IN FEET OF HEAD FEEDW A TER REGULA TOR 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 l[...]

Figure E-2b SINGLE BOILER - PRIMARY/SECONDARY PIPING WITH CHX 15 Figure E-3a DUAL-BOILER PIPING[...]

16 Figure E-3b DUAL BOILER - PIPING WITH CHX Figure E-4a SINGLE BOILER - LOW TEMPERA TURE APPLICA TION (HEA T PUMP) PRIMAR Y/SECONDARY PIPING[...]

SECTION F: DOMESTIC HOT W A TER PIPING When designing the water piping system for domestic water applications, water hardness should be considered. T able D- 1 indicates the suggested flow rates for soft, medium and hard water . Hardness is specified as grains per gallon. T ABLE F-1 DOMESTIC W A TER HEA TING BOILER FLOW RA TE REQUIREMENTS Delta T =[...]

18 Figure F-1bb SINGLE BOILER DOMESTIC HOT W A TER WITH ONE STORAGE T ANK AND CHX (2 pump system) Figure F-1c SINGLE BOILER DOMESTIC HOT W A TER WITH ONE STORAGE T ANK, ONE PRE-HEA T T ANK AND CHX[...]

19 SECTION G: POOL HEA TING 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. Follow these instruct[...]

POOL AND SP A W A TER 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 ef[...]

Figure G-3a DOUBLE BOILER - POOL APPLICA TION 21[...]

22 SECTION H: GAS SUPPL Y CONNECTIONS DANGER: 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 r[...]

23 GAS PRESSURE REGULA TOR The gas pressure regulator is nominally preset to the outlet values shown in table O-2 and O-3, within +. 1" W .C. If an adjustment is needed, turn the adjustment screw clockwise to increase pressure or counterclockwise to lower pressure. VENTING OF DIAPHRAGM GAS COMPONENTS Boilers have gas train components that have[...]

24 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/NFP A 70-latest edition. · In Canada, [...]

25 MAKING THE ELECTRICAL CONNECTIONS Refer to Fig. I-2 W iring Connection, and Fig. L-2 W iring Diagram. 1 . V erify circuit breaker is properly sized by referring to boiler rating plate. A dedicated motor duty circuit breaker should be provided. 2 . T urn of f all power to the boiler . V erify that power has been turned off by testing with a volt-[...]

26 ELECTRICAL CONNECTIONS - DOMESTIC HOT W A TER CAUTION: Label all wires prior to disconnection when ser vicing contr ols. W iring errors can cause impr oper and danger ous operation. V erify pr oper operation after servicing. DANGER - SHOCK HAZARD Make sur e electrical power to the heater is disconnected to avoid potential serious injury or damag[...]

27 SECTION J: VENTING CONNECTIONS GENERAL CAUTION: Pr oper 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: S table vent pr essur e is critical to the safe and pr oper operation of the heater [...]

T able J-1 ADB Category Determination for V enting Purpose and V enting Arrangement 28 NOTE: PVC or CPVC vent maybe used inconjunction with CHX, special piping arrangement has to be made. Contact manufacturer for details. A D B V E N T I N G A R R A N G E M E N T S[...]

29 Support of V ent S tack 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 [...]

V enting Installation T ips 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 a[...]

31 SECTION J-1 Natural Draft V ertical V enting Without Add-on Condensing Heat Exchanger (Category I) Figure J-1 NA TURAL DRAFT VER TICAL VENT WITHOUT ADD-ON CONDENSING HEA T EXCHANGER* NOTE: *Rear venting is recommended to minimize interference with water piping **V ent lengths are based on a lateral length of 2 feet. Refer to the latest edition o[...]

• Natural Draft V ertical V enting 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 acco[...]

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)[...]

SECTION J-2 Horizontal Thru-W all V enting Without Add-on Condensing Heat Exchanger (Category III) Figure J-2 HORIZONT AL THRU-W ALL VENTING WITHOUT ADD-ON CONDENSING HEA T EXCHANGER (CA TEGOR Y III) • Horizontal Thru-wall Dir ect V enting System (Category III) Installation These installations utilize the boiler-mounted blower to vent the combust[...]

35 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' o[...]

SECTION J-3 Horizontal Thru-W all Dir ect V enting/Combustion Air (Category III) Figure J-3 HORIZONT AL THRU-W ALL DIRECT VENTING WITHOUT ADD-ON SECONDAR Y CONDENSING HEA T EXCHANGER 36[...]

• Horizontal Thru-wall Dir ect V enting System (Category III) 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 use d is equ[...]

SECTION J-4 V ertical Direct V enting/Combustion Air (Category I) Figure J-4 VER TICAL DIRECT VENTING WITHOUT ADD-ON CONDENSING HEA T EXCHANGER *V ent 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. [...]

• V ertical Direct V enting 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[...]

SECTION J-5 V er tical V enting With Add-On Condensing Heat Exchanger (Category IV ) Domestic W ater Figure J-5 VER TICAL VENT (CA TEGOR Y IV) WITH ADD-ON CONDENSING HEA T EXCHANGER 40[...]

• V ertical V ent (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 b[...]

SECTION J-6 Horizontal Thru-wall V enting With Add-on Condensing Heat Exchanger (CHX) Figure J-6 HORIZONT AL THRU-W ALL VENTING WITH ADD-ON CONDENSING HEA T EXCHANGER 42[...]

• Horizontal Thru-wall V enting System (Category IV) Installation This installation 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 through the wall to the outdoors. Adequate combustion and ventilation air must be supplied to the[...]

SECTION J-7 Horizontal Thru-W all Dir ect V enting/Combustion Air W ith Add-On Condensing Heat Exchanger (Category IV) Figure J-7 HORIZONT AL THRU-W ALL DIRECT VENTING WITH ADD-ON CONDENSING HEA T EXCHANGER 44[...]

• Horizontal Thru-wall Direct V enting System W ith Add-on Condensing Heat Exchanger (Category IV) Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors. UL 17-38 Certified V enting Material (e.g. AL29-4C) MUST be used. The vent must be installed to pre[...]

SECTION J-8 V ertical Direct V enting/Combustion Air W ith Add-on Condensing Heat Exchanger (Category IV) Figure J-8 VER TICAL DIRECT VENTING WITH ADD-ON SECONDAR Y CONDENSING HEA T EXCHANGER 46[...]

47 • V ertical Direct V enting 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 V enting Material (e.g. AL29-4C) MUST be used. The vent must be installed to prevent fl[...]

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 horizon[...]

49 SECTION K CONDENSA TE DRAIN W ARNING: 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 1 (one) gallon per hour (GPH) of condensate for every 100,000 BTUH. The maximum condensation rate for the[...]

50 SECTION L CONTROLS W ARNING: Installation, adjustment and service of boiler controls including timing of various operating functions must be performed by a qualified installer or service agency . Failure to do so may r esult in contr ol damage, boiler malfunction, pr operty damage, personal injury , or death. W ARNING: T urn off the power to the[...]

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-pur ge. The location of each user - adjustable timing is shown in Figure L-1. Figure L-1 CPW Board • Pump Turn-off Delay The CPW board has a buil[...]

• Freeze Protection Feature The CPW board is programmed to turn-of f 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 [...]

53 Figure L-2 WIRING DIAGRAM[...]

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 p[...]

LOW W A TER CUT OFF (OPTIONAL) The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 3 second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. HIGH AND LOW GAS PRESSURE SWITCHES - MANUAL RESET The low gas pressure switc[...]

SECTION M: GENERAL SAFETY PRECAUTIONS T o 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 [...]

57 SECTION N: PRE-ST AR T -UP FILL THE SYSTEM: 1 . Close manual and automatic air vents and drain cock. 2 . Fill to correct system pressure. Correct pressure will vary with each application. 3 . Open automatic air vent two turns. 4 . Slowly feed water to boiler . 5 . Starting on the lowest floor , open air vents one at a time until water squirts ou[...]

58 Figure O-1 COMPONENT AND PRESSURE T AP LOCA TIONS Blower "T" fitting detail.[...]

SECTION O: ADB INITIAL ST AR T -UP 59 CAUTION: V erify that the vent system and combustion air supply have been approved. 1.0 TOOLS NEEDED • One 8-0-8 , 16” scale manometer (or larger) • Four 4-0-4, 8” scale manometers (or larger) • “T” fitting • 7/16” and 1/2" open end wrenches • Small and large flat-head screwdrivers • [...]

60 Note:For differ ent gas contr ol options, call factory for pr oper pr essur e settings (ie; IRI, etc) 2.4 Check the Gas Supply Pressure, Location (1) • Leave pilot gas valve and first manual gas valve closed; • Slowly turn on main gas shut-off valve (outside the unit); • Read the gas supply pressure from the manometer (Location 1); • If [...]

61 T ABLE O-3: Pressur e Settings and Emission Guidelines (T rue Readings) for LP GAS Note: For different gas control options, call the factory for proper pressure settings (i.e. IRI, etc) NOTICE: Emissions will vary with different applications (hydronic, water heater , or pool), venting (including direct vent), ambient conditions (T , P , and humi[...]

SECTION P: POST ST AR T -UP CHECK Check off steps as completed: 1. Boiler and heat distribution units or storage tank filled with water? 2. Automatic air vent, if used, open two full turns during venting procedure? 3. Air purged from system? 4. Air purged from gas piping? Piping checked for leaks? 5. Followed start-up procedure for proper start-up?[...]

SECTION Q: OPERA TION OPERA TING INSTRUCTIONS Lighting Instructions 1. STOP! Read the safety information first. 2. Set the thermostat to the lowest setting. 3 . Turn off all electric power to the appliance. 4 . This appliance is equipped with an ignition device which automatically lights the burner . Do Not try to light the burner by hand. 5 . Remo[...]

SECTION R: MAINTENANCE SUGGESTED MINIMUM MAINTENANCE SCHEDULE: Regular service by a qualified service agency and maintenance must be performed to assure maximum boiler operating ef ficiency . Maintenance as outlined below may be performed by the owner . Y early (Beginning of each heating season): 1 . Annual service call by qualified service agency [...]

CLEANING BOILER HEA TING SURF ACES: The following service procedures must be performed ONL Y by a qualified service agency . Boiler owner should not attempt these procedures. 1 . 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 . Als[...]

66 SECTION S: CONNECTING CONDENSING HEA T EXCHANGER (CHX) Figure S-1 Connecting Add-On Condensing Heat Exchanger to ADB Refer to Figure S-1 for the following steps: NOTICE: Connect the vent before connecting the water piping. Install unions on water inlet and outlet of CHX for ease of maintenance. The CHX require cleaning as often a s once the year[...]

67 APPENDIX A INSIDE COMBUSTION AIR CONT AMINA TION: All boilers experience some condensation during start-up. The condensate from flue gas is slightly acidic. 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[...]

68[...]

69[...]

70[...]

71[...]

72[...]

[...]

ST AR T -UP SETTINGS TODA Y'S DA TE: __________________________________________________ PRESSURE SETTINGS: Blower (burner off)……………… ______ "W .C. Pilot……………………………… ______ "W .C. Main Burner (T op)……………. ______ "W .C. Main Burner (Bottom)………… ______ "W .C. Blower (burner[...]

LIMITED PARTS WARRANTY ADVANCED DESIGN BOILER™ SCOPE: Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor cha[...]

Raypak, Inc. , 2151 Eastman A venue, Oxnard, CA 93030 (805) 278-5300 F AX: (800) 872-9725 Raypak Canada L TD , 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 F AX: (905) 677-8036 Raypak Australia Pty . Ltd , 7 Geddes Street, Mulgrave, V ictoria, Australia 3170 (613) 9560 4944 F AX: (613) 9560-4974 8/98 Litho in U. S. A. www[...]