INSTALLATION AND OPERATING INSTRUCTIONS Advanced Design Boiler Models 751, 1001 & 1501 – Types H, WH & P L W 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.
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 Water Piping Hydronic Heating Gas Supply Connections Electrical Power Connections Venting Connections Venting Installation Tips Venting Configurations Condensate Drain Controls WIRING
WARNINGS Pay Attention to These Terms DANGER: 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. CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
BEFORE INSTALLATION the left inside jacket of the heater. The model number will have the form H4-0751A ADB or similar depending on the heater size and configuration. The first character of the model number identifies application (H = Hydronic Heating System, W = Hot Water Supply System, P = Pool Application). The second character identifies the firing mode (4 = On-Off firing). The next four places identify the input of the heater in 1,000s of BTUH 0751 = 750,000 BTUH).
Component Locations Fig.
GENERAL SAFETY Time/Temperature Relationships in Scalds 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.
Equipment Base 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 regulations 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. The boiler should be mounted on a level, structurally sound surface.
Combustion and Ventilation 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 immediately surrounding the boiler, or via direct vent, where combustion air is drawn directly from outside. All installations must comply with the requirements of NFGC for U.S., CSA B149 for Canada, and all local codes.
Fig. 3: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 1 2 t TT * 2 U.S. Installations Canadian Installations 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 be opened 4 ft (1.
Conventional Combustion Air Supply through vertical ducts. The minimum free area required for horizontal ducts is one (1) square inch per 2,000 BTUH of total input rating to all the equipment in the room. U.S. Installations All Air from Inside the Building 4. Refer to NFGC, Part 5, for additional information. Refer to Appendix A for additional information about combustion air quality.
Relief Valve Piping 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 preferred straight down 18 inches from floor, but do not place near piping. This air supply opening requirement shall be in addition to the air opening for ventilation air required in (1).
Table D-1 40°F ΔP Should include typical piping To/From a single tank as well as bypass piping. Table E: Rate of Flow and Pressure Drop NOTE: gpm flow rates limited by maximum acceptable velocity through heat exchanger tubes. May be increased by 10% for closed heating systems. Pressure drop would increase by 21%.
Fig. 4: Single Boiler - Primary/Secondary Piping Fig.
Fig. 6: Dual Boiler Piping Fig.
Fig. 8: Single Boiler - Low Temperature Application (Heat Pump) Primary/Secondary Piping soft, medium and hard water. Hardness is specified as grains per gallon. DOMESTIC HOT WATER PIPING When designing the water piping system for domestic water applications, water hardness should be considered.
Fig. 9: Single Boiler - Domestic Hot Water with One Storage Tank Fig.
Fig. 11: Single Boiler - Domestic Hot Water with One Storage Tank and CHX (2 pump system) Fig.
POOL HEATING Automatic Chlorinators and Chemical Feeders 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 instructions to make sure your heater is properly installed.
Fig. 13: Single Boiler - Pool Application Fig.
Fig. 15: Double Boiler - Pool Application This based on average pool depth of 4’ 6” (4.5 ft) Table H: ADB Pool Sizing; Indoor or Outdoor GAS SUPPLY CONNECTIONS regulator must be installed to reduce to gas supply pressure to under 14 in. WC. The regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the boiler gas controls. All gas piping must be tested after installation in accordance with local codes.
Fig. 16: Connections Gas Supply Connection Gas Supply Pressure A minimum of 7 in. WC and a maximum of 10.5 in. WC upstream gas pressure is required under load and no load conditions for natural gas. A minimum of 12 in. WC and a maximum of 13 in. WC is required for propane gas. The gas pressure regulator supplied is for low pressure service. If upstream pressure exceeds 14 in. WC, an intermediate gas pressure regulator, of the dead lockup type, must be installed.
Gas Pressure Regulator Surge Protection The gas pressure regulator is nominally preset to the outlet values shown in Tables T and U, within +.1 in. WC. If an adjustment is needed, turn the adjustment screw clockwise to increase pressure or counterclockwise to lower pressure. Microprocessor-based and solid state controls are vulnerable to damage from voltage and amperage fluctuations in the power supply.
4. Provide an external surge suppressor capable of maintaining system integrity. BREAK THE WIRE NUT AT THE BOILER "TH" CONNECTIONS AND ATTACH TO THE SINGLE TANKSTAT PER ILLUSTRATION 5. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code. 6. Install boiler controls, thermostats, or building management systems in accordance with the applicable manufacturer’s instructions. 7. Conduit should not be used as the ground.
VENTING CONNECTIONS temperature that avoids excessive condensate production in the vent. Category II: A boiler which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent. 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.
Determination of Appliance Category for Venting Purposes and Venting Arrangements over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. Where local experience indicates that condensate is a problem with Category I and III appliances, this provision shall also apply.
e) Terminate vent at least six (6) feet away from adjacent walls. Follow items listed below to avoid personal injury or property damage. f) · Cut nonmetallic vent pipe with fine-toothed hacksaw (34 teeth per inch). · Do not use nonmetallic vent pipe or fittings that are cracked or damaged. · Do not use nonmetallic vent fittings if they are cut or altered. · Do not drill holes, or use screws or rivets, in nonmetallic vent pipe or fittings.
Natural Draft Vertical Venting without 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 further details (ANSI Z223.1), or in Canada, the latest edition of CSA B149.
Natural Draft Vertical Venting System Installation building openings must be consistent with the National Fuel Gas Code, or in Canada, the latest edition of the CSA B149 Installation Code for Gas Burning Appliances and Equipment. Gas vents supported only by flashing and extended above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads.
appliance not connected to the common vent system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate summer exhaust fan. Close fireplace dampers. When re-sizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the latest edition of the National Fuel Gas Code, ANSI Z223.
Horizontal Thru-wall Direct Venting System (Category III) Installation Horizontal Thru-wall Direct Vent Termination 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 outdoors.
ÁDB-1501 Table M: Horizontal Thru-wall Direct Venting without Add-on Secondary Condensing Heat Exchanger Horizontal Thru-wall Direct Venting System (Category III) Installation The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is recommended that: These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors.
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 supplied from outdoors must be free of particulate and chemical contaminants.
Vertical Direct Venting System Installation and Equipment. Gas vents supported only by flashing and extended above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads. 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 in. to -0.08 in.
Model Venting Category Certified Venting Material Vent Size (inches) Maximum Vent Length (feet) IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 8 55 Subtract 10 ft per elbow, Max. 3 elbows IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 10 55 Subtract 10 ft per elbow, Max. 3 elbows IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 12 55 Subtract 10 ft per elbow, Max.
Model Venting Category Certified Venting Material Vent Size (inches) Maximum Vent Length (feet) IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 8 55 Subtract 10 ft per elbow, Max. 3 elbows IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 10 55 Subtract 10 ft per elbow, Max. 3 elbows IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* 12 55 Subtract 10 ft per elbow, Max.
Fig. 27: Horizontal Thru-Wall Direct Venting/Combustion Air with Add-on Condensing Heat Exchanger (Category IV) Model ADB-751 w/CHX ADB-1001 w/CHX ADB-1501 w/CHX Venting Category Certified Venting Material IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* IV UL 1738 Certified Venting Material e.g.
Horizontal Thru-wall Direct Venting System with Add-on Condensing Heat Exchanger (Category IV) Installation To prevent condensate accumulation in the vent, it is required to install the horizontal portion of vent with a slight upward slope of not more than 1/4" per foot of horizontal run and an approved condensate trap must be installed per applicable codes. These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors.
Model ADB-751 w/CHX ADB-1001 w/CHX ADB-1501 w/CHX Venting Category Certified Venting Material IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* IV UL 1738 Certified Venting Material e.g. AL29-4C Stainless Steel PVC*, CPVC* Vent Size (inches) Maximum Vent Length (feet) Combustion Air Intake Pipe Material 8 35 Subtract 10 ft per elbow, Max.
e) A venting system shall terminate at least 3 feet above any forced air inlet located within 10 feet. f) NOTE: In areas of high winds (alleyways, air handlers, etc.), a downward 90° - elbow must be mounted on the combustion air inlet to prevent any air flow fluctuation. Adjacent brick or masonry surfaces must be protected with a rust-resistant sheet metal plate. g) Multiple Outdoor Vent installations require a four (4) feet clearance between vent caps.
CONTROLS Central Point Wiring (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 Diagnostic Boards.
Fig. 30: CPW Board Pump Turn-off Delay Blower Fan Pre-purge 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 fieldadjusted from 3 minutes to 10 minutes. The pump relay can directly power a pump of up to 12.0 amps draw or 3/4 hp capacity. Pumps with larger amp draws should be energized through a pump contactor that is controlled by the CPW board.
U-2 Diagnostics Board additional light indicates that the diagnostics board is energized and is currently monitoring for safety faults. (In order to prevent spurious alarm conditions, the U-2 board monitors safeties only during the actual firing cycle.) The U-2 Diagnostics board is a solid-state electronic fault indicator that has been engineered to enhance safety, simplify troubleshooting and minimize equipment down time.
WIRING DIAGRAM Figure L-2 WIRING DIAGRAM 44
Ignition Control Module Flow Switch 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 pilot reignites electrically, eliminating the fuel costs of maintaining a constant pilot.
Low Water Cut Off (Optional) PRE-START-UP 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. 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.
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-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.
ADB INITIAL START-UP Turn Off The 1 1/2” Manual Gas Valve; Turn Off Pilot Gas Valve; Reset Low Gas Pressure Cut-off Switch; CAUTION: Verify that the vent system and combustion air supply have been approved. Bleed Air from Gas Line CAUTION: Make sure there is no ignition source in the boiler room.
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. If the igniter is grounded out, it must be realigned. Remove the burner. Loosen the igniter nut, locate the igniter in the center of the burner head and tighten igniter nut.
NOTE: Emissions will vary with different applications (hydronic, water heater, or pool), venting (including direct vent), ambient conditions (T, P, and humidity), and the condition of the boiler. · · NOTE: For high altitude (above 5000 ft), call the factory for proper pressure settings. Remember, supply gas should always be between 7 in. and 14 in. WC. Main Burner Adjustment · · · · 1. Turn on the unit; about 45 seconds later, the pilot should light.
burners should reignite after pre-purge time delay. 8. Test 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 setting on limit control above boiler water temperature and burner should reignite after prepurge time delay. 9. Test ignition system safety device: • Turn power off. • Close the pilot manual valve.
3. Visually inspect venting system for proper function, 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 inspect burner flame. Should see light blue flame, with some orange at flame edge. 8. Check operation of safety devices. Refer to manufacturer’s instructions. 9.
10. Connect the flue vent (Category IV venting, UL 1738 Certified Venting Material) to the 15° elbow of the CHX flue outlet. 11. Connect the PVC pipe (not supplied) for condensate water disposal (check with local authority regarding condensate disposal). 12. Replace the shroud. 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.
APPENDIX • • • Inside Combustion Air Contamination: Check for areas and products as listed above before installing boiler. If found: All boilers experience some condensation during startup. 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.
START-UP CHECKLIST FOR FAN-ASSISTED 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. Additionally this form will be used to record all equipment operation functions and required settings.
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 charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner's responsibility.
www.raypak.com 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.
