Raypak 500 manual

Catalog No.: 3 4 0 0 .50-I Effective: 12-01-00 Replaces: 05-01-00 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. T o do so may result in an explosion or fire. W ARNING: Improper installation, adjustment, alteration, service or maintena[...]

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 SECTI[...]

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

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. · S tandard 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 500 750 1000 Floor See Note 1. Rear 1 ” 1" 1" Right 12” (W ater side) 12" (W ater side) 12" (W ater side) Left 1 ” 1 ” 1 ” To p 0 ” 0 ” 0 ” V e n t 1” 1” 1” Note 1. Do not install on c[...]

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 500 750 1000 Rear 6 " 6 " 6 " Right 36” (W ater side) 36" (W ater side) 36"[...]

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

Method 2 (normally applied in cold climate regions): 1 . The mechanical equipment room must be provided with at least one permanent opening, commencing within 12 inches of the top of the enclosure. 2. The opening must communicate directly or by ducts with outdoors. 3 . The opening must have a minimum free area of 1 sq. in per 3000 BTUH of the total[...]

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 equires for ced water cir culation 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 difference between the inlet and outlet water when the boiler is firing at full rate). If a Delta T larger [...]

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 of f valve as required by l[...]

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

16 Figure E-3b DUAL BOILER -PRIMAR Y/SECONDARY PIPING WITH CHX Figure E-4a SINGLE BOILER - LOW TEMPERA TURE APPLICA TION (HEA T PUMP) PRIMAR Y/SECONDAR Y 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 ST ORAGE T ANK AND CHX (2 pump system) Figure F-1c SINGLE BOILER DOMESTIC HOT W A TER WITH ONE ST ORAGE 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[...]

SP A W A TER CHEMISTR Y 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[...]

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 TO R 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. REGULA TOR PRESSURE SETTINGS: See T ables O-2 and O-3 for Pressure Settings. (p[...]

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 off all power to the boiler . V erify that power has been turned off by testing with a volt-o[...]

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

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. Definition of Appliance Categories Boilers are divided into four categories based on the pres[...]

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 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 ar[...]

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 e rtical 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 acc[...]

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) *See notice next page. • Horizontal Thru-wall Direct V enting System (Categor y III) Installation These installations utilize the boiler-mounted blo[...]

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 Direct V enting/Combustion Air (Category III) Figure J-3 HORIZONT AL THRU-W ALL DIRECT VENTING WITHOUT ADD-ON SECONDARY CONDENSING HEA T EXCHANGER *See notice next page. 36[...]

• Horizontal Thru-wall Direct 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 equa[...]

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 ertical 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 *Contact Manufacturer for Details 40[...]

• V ertical V ent (Categor y 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 [...]

SECTION J-6 Horizontal Thru-wall V enting W ith Add-on Condensing Heat Exchanger (CHX) Figure J-6 HORIZONT AL THRU-W ALL VENTING WITH ADD-ON CONDENSING HEA T EXCHANGER 42 *Contact Manufacturer for Details. ** See notice next page.[...]

• 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 Direct 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 *Contact Manufacturer for details.[...]

• Horizontal Thru-wall 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 pr[...]

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

47 • V e rtical Dir ect 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 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[...]

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 accor ding 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 rates for d[...]

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

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-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 h[...]

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. S tarting on the lowest floor, open air vents one at a time until water squirts out. Cl[...]

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

SECTION O: ADB INITIAL ST AR T -UP 1 . 0 TOOLS NEEDED • One 8-0-8 , 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 • V olt meter • Amp probe • Elec. Dual reading thermometer with strap on sensors ?[...]

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.; T urn of f the valve; • Check if the service regulator is installed and/or adjust the service regul[...]

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 . T urn 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 [...]

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 pur ged 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. Remove[...]

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 procedur es 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) 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 R TV (supplied). 5. Replace the to[...]

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[...]

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

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 S treet, Mulgrave, V ictoria, Australia 3170 (613) 9560 4944 F AX: (613) 9560-4974 8/98 Litho in U. S. A. ww[...]