Raypak 751 manual

INST ALLA TION AND OPERA TING INSTR UCTIONS CA T ALOG NO. 3400.52E Effective: 02-22-07 Replaces: 04-01-03 P/N 241079 Rev . 6 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 Y OUR SAFETY[...]

2[...]

WARNINGS 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 GENERAL SAFETY 7 T ime/T emperature Relationships in Scalds 7 INST ALLA TION 8 Installation Codes 8 Equipment Base 8 Clearances 8 Combustion and V entilation Air 9 Conventional Combustion Air Su[...]

4 D ANGER: Indicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored. CA UTION: Indicates the presence of hazards or un[...]

5 BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your ADB heater . Please review the General Safety information before installing the heater . Factory warranty does not apply to heaters that have been improperly installed or oper- ated. (Refer to the warranty at the back of this manual.)[...]

6 Component Locations Fig. 1: Component Locations[...]

7 GENERAL SAFETY 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 125°F . Safety and e[...]

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 . In addition, the boiler shall be instal[...]

9 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. Combustion and V entilation Air Indoor Units The boiler must be supplied with sufficient quantities of non-contaminated air to support proper combustion and eq[...]

10 U.S. Installations 1 Cana d i a n I nst a lla tions 2 A Clearance above grade , veranda, porch , deck, or balcony 1 ft ( 30 cm) 1 ft ( 30 cm) B Clearance to window or door that may b e opened 4 f t ( 1.2 m) be low o r to sid e of openin g; 1 foo t (30 c m) above op ening 3 ft (91 c m) C Clearance to permanen tly closed window ** D Ver tical clea[...]

11 Con v entional Combustion Air Supply U .S. Installations All Air from Inside the Building If all combustion air is drawn from the air inside the building (the mechanical equipment room does not receive air from outside): 1. The mechanical equipment room must be provid- ed with two permanent openings communicating directly with additional room(s)[...]

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 pre- ferred straight down 18 inches from floor , but do not place near piping. This air supply opening r[...]

HYDR ONIC HEA TING Pump Selection 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 dif ference between the inlet and outlet water when the boiler is firing at full rate). If a ΔT larger than 20°F is necessary , the bypas[...]

14 Fig. 4: Single Boiler - Primary/Secondary Piping Fig. 5: Single Boiler - Primary/Secondary Piping with CHX[...]

15 Fig. 6: Dual Boiler Piping Fig. 7: Dual Boiler - Piping with CHX[...]

16 Fig. 8: Single Boiler - Low T emperature Application (Heat Pump) Primary/Secondary Piping DOMESTIC HO T WA TER PIPING When designing the water piping system for domestic water applications, water hardness should be consid- ered. T able F indicates the suggested flow rates for T able F: Domestic W ater Heating Boiler Flow Rate Requirements ΔT=T [...]

17 Fig. 9: Single Boiler - Domestic Hot W ater with One Storage T ank Fig. 10: Single Boiler - Domestic Hot W ater with One Storage T ank and CHX[...]

18 Fig. 1 1: Single Boiler - Domestic Hot Water with One Storage T ank and CHX (2 pump system) Fig. 12: Single Boiler - Domestic Hot W ater with One Storage T ank, One Pre-Heat T ank and CHX[...]

19 POOL HEA TING 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. T o complete t[...]

20 Fig. 13: Single Boiler - Pool Application Fig. 14: Single Boiler - Pool Application with CHX[...]

21 Fig. 15: Double Boiler - Pool Application This based on average pool depth of 4’ 6” (4.5 ft) T able H: ADB Pool Sizing; Indoor or Outdoor GAS SUPPL Y CONNECTIONS Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve locat- ed outside the heater jacket. A pounds to inches regulator must be installe[...]

22 Fig. 16: Connections Gas Supply Connection 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 reconnect- ing the boiler and its manual shu[...]

23 Gas Pressur e R e gulator The gas pressure regulator is nominally preset to the outlet values shown in T ables T and U, within +.1 in. WC. If an adjustment is needed, turn the adjustment screw clockwise to increase pressure or counterclock- wise to lower pressure. V enting of Dia phra gm Gas Components Boilers have gas train components that have[...]

"TH" leads. Before starting the boiler , ensure that there is proper voltage to the boiler and pump. The boiler must be electrically grounded in accordance with National Electrical Code ANSI/NFP A No. 70 and CSA C22.1 C.E.C. Part 1 in Canada. Notes: 1. Field installed ground to inside of junction box. 2. If any of the original wire as sup[...]

25 VENTING CONNECTIONS General Definition of A ppliance Ca te gories Boilers are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Categor y I: A boiler which operates with a non-pos- itive vent static pressure and with a vent gas temperature that avoids excessive con[...]

26 Deter mination of A ppliance Categor y for V enting Pur poses and V enting Ar rangements Suppor t of V ent 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 ma[...]

27 e) T erminate vent at least six (6) feet away from adja- cent walls. f) 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 dwelli[...]

28 Natural Draft V er tical V enting with- out Add-on Condensing Heat Exc hanger (Categor y I) Fig. 21: Natural Draft V ertical V enting without Add-on Condensing Heat Exchanger (Category I) 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 edit[...]

29 Natural Draft V er tical 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 neg- ative draft must be within the range of 0.01 in. to 0.08 in. WC negative to ensure proper operation. The vent material must be in [...]

30 appliance not connected to the common vent sys- tem. T urn 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. Ad[...]

31 Horizontal Thr u-wall Dir ect V enting System (Categor y III) 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 through the wall to the out- doors. Adequate combustion and ventilation air must be s[...]

32 T able M: Horizontal Thru-wall Direct V enting without Add-on Secondary Condensing Heat Exchanger Horizontal Thr u-wall Dir ect V enting System (Categor y 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 e[...]

33 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, when installed in the same horizontal plane, should have three (3) foot clearance from the side of one vent cap to the side of the adjacent vent cap(s). Combustion air s[...]

34 V er tical Direct V enting System Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and uses the natu- ral 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 in. to -0.08 in. W[...]

35 T able O: V ertical V ent (CA TEGORY IV) with Add-on Condensing Heat Exchanger Model V enting Category Certified V enting Material V ent Size (inches) Maximum V ent Length (feet) ADB-751 w/CHX IV UL 1738 Certified V enting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 8 55 Subtract 10 ft per elbow , Max. 3 elbows ADB-1001 w/CHX IV UL 1738 Ce[...]

36 Model V enting Category Certified V enting Material V ent Size (inches) Maximum V ent Length (feet) ADB-751 w/CHX IV UL 1738 Certified V enting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 8 55 Subtract 10 ft per elbow , Max. 3 elbows ADB-1001 w/CHX IV UL 1738 Certified V enting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 10 55 Subtra[...]

37 Model V enting Category Certified V enting Material V ent Size (inches) Maximum V ent Length (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) ADB-751 w/CHX IV UL 1738 Certified V enting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 8 35 Subtract 10 ft per elbow , Max. 3 elbows Galvanized Steel [...]

38 Horizontal Thr u-wall Dir ect V enting System with Add-on Condensing Heat Ex changer (Ca te gor y 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 V enting Material (e.g. AL29-4C) MUST be used. The vent must be installed t[...]

39 Model V enting Category Certified V enting Material V ent Size (inches) Maximum V ent Length (feet) Combustion Air Intake Pipe Material Air Inlet Size (inches) Max. Air Intake Length (feet) ADB-751 w/CHX IV UL 1738 Certified V enting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 8 35 Subtract 10 ft per elbow , Max. 3 elbows Galvanized Steel [...]

40 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 pro- tected with a rust-resistant sheet metal plate. g) Multiple Outdoor V ent installations require a four (4) feet clearance between vent caps. The Stainless Steel non-restricted vent cap must be [...]

41 CONTR OLS Centr al P oint W iring (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 Diagnosti[...]

42 Fig. 30: CPW Board Pump T ur n-of f 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.[...]

43 U-2 Diagnostics Boar d The U-2 Diagnostics board is a solid-state electronic fault indicator that has been engineered to enhance safety , simplify troubleshooting and minimize equip- ment down time. The U-2 safety board is the central point for wiring, operations monitoring, and fault indi- cation for the boiler safeties. By having each safety r[...]

44 Figure L-2 WIRING DIAGRAM WIRING DIA GRAM[...]

45 Ignition Control Module The intermittent ignition device conserves energy by automatically extinguishing the pilot when the desired temperature is reached. When additional heat is need- ed, 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 [...]

46 Lo w Wa ter Cut Of f (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 Lo w Gas Pr essur e Switches — Manual R eset The low gas pres[...]

47 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-Star t-up Check 1. V erify boiler is filled with water . 2. Check system piping [...]

48 ADB INITIAL ST ART -UP T ools 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 • V olt meter • Amp probe • Elec. Dual reading thermometer with strap on sen- sors • 3/16” Al[...]

49 tion wire and proper grounding and wiring. T urn 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 . If the igniter is grounded out, it must be realigned. Re[...]

50 Main Bur ner Adjustment 1. T urn on the unit; about 45 seconds later , the pilot should light. If the pilot fails to light, repeat pilot adjustment. 2. Turn the top manual valve on, Location (2). The inner burner will fire. 3. Make sure that the supply gas manometer reads between 7 – 14 in. WC (dynamic pressure). 4. Check manifold pressure, Lo[...]

51 burners should reignite after pre-purge time delay . 8. T est limit control: While burner is operating, move indicator on high limit control below actual boiler water temperature. Burner should go off while blower circulator continues to operate. Raise set- ting on limit control above boiler water temperature and burner should reignite after pre[...]

52 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 . 6. Follow pre-start-up check in Section N. 7. Visually[...]

53 10. Connect the flue vent (Category IV venting, UL 1738 Certified V enting Material) to the 15° elbow of the CHX flue outlet. 1 1. Connect the PVC pipe (not supplied) for conden- sate water disposal (check with local authority regarding condensate disposal). 12. Replace the shroud. 13. Allow the silicone (RTV) to cure over-night. V ent Switch A[...]

54 APPENDIX Inside Combustion Air Contamination: 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. H[...]

55 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS ADB, HI-DELTA & M V B Thi s s ta rt-up checkl ist is to be complet ely f illed out by the servi ce technicia n sta r ti ng up t h e Raypak Boil er or Heat er for the f irs t ti me . All in fo rm ati on may b e us ed for wa rra n ty p ur pos es an d to en sur e tha t th e ins ta lla tio n is[...]

56 LIMITED P ARTS WARRANTY AD V ANCED 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 W arranty . L[...]

ww w .raypa k .c om Raypak, Inc., 2151 Eastman Avenue, 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 Litho in U. S. A.[...]