Instruction/ maintenance manual of the product 1001 Raypak
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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.
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 .
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 SEC.
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.
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.
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.
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.
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.
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.
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 .
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.
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).
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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).
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.
• 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.
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.
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) .
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.
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.
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.
• 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.
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.
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.
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 EXC.
• 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.
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.
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.
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.
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.
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.
• 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 n.
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.
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.
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.
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 .
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-.
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 .
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.
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.
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 .
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 .
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 .
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.
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.
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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 (T op)…………….
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.
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.
An important point after buying a device Raypak 1001 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Raypak 1001 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Raypak 1001 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Raypak 1001 you will learn all the available features of the product, as well as information on its operation. The information that you get Raypak 1001 will certainly help you make a decision on the purchase.
If you already are a holder of Raypak 1001, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Raypak 1001.
However, one of the most important roles played by the user manual is to help in solving problems with Raypak 1001. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Raypak 1001 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
