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Catalog No.: 3400.50-I
Effective: 12-01-00
Replaces: 05-01-00
OPERATING AND
INSTALLATION
INSTRUCTIONS
Models 500,750,1000
ADVANCED
DESIGN
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. To do so may result in an explosion or fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property dam-
age, personal injury or loss of life. Refer t
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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. WARNING: 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. WARNING: Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any
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TABLE OF CONTENTS PAGE NO. 4 SECTION A: BEFORE INSTALLING THE BOILER 7 SECTION B: BOILER INSTALLATION 10 SECTION C: COMBUSTION AND VENTILATION AIR 12 SECTION D: WATER PIPING - GENERAL 13 SECTION E: HYDRONIC HEATING PIPING 17 SECTION F: DOMESTIC HOT WATER PIPING 19 SECTION G: POOL HEATING 22 SECTION H: GAS SUPPLY CONNECTIONS 24 SECTION I: ELECTRICAL POWER CONNECTIONS 27 SECTION J: VENTING CONNECTIONS 49 SECTION K: CONDENSATE DRAIN 50 SECTION L: CONTROLS 56 SECTION M: GENERAL SAFETY PRECAUTION
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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. NOTICE indicates special instruc
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MODEL IDENTIFICATION 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 Heating System, W = Hot Water Supply System, P = Pool Application). The second character identifies the firing mode (4 = On-Off firing). The next four pl
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Figure A-1 ADVANCED DESIGN BOILER COMPONENT LOCATIONS 6
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SECTION B: BOILER INSTALLATION INSTALLATION 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/NFPA 70 - latest edition. · Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required. · For Canada only: CAN/CGA B149.1 and .2 Installation Code and C.S.A. C22. 1 C.E.C. Part 1. EQ
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CLEARANCES TABLE 1 MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES (INDOOR ALCOVE INSTALLATIONS) Boiler Size Boiler Side 500 750 1000 Floor See Note 1. Rear 1 1" 1" Right 12 (Water side) 12" (Water side) 12" (Water side) Left 1 1 1 Top 0 0 0 Vent 1 1 1 Note 1. Do not install on carpeting. Figure B-1 MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES AND FOR EASY SERVICING 8
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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. TABLE 2 OUTDOOR INSTALLATION MINIMUM CLEARANCES Boiler Size Boiler Side 500 750 1000 Rear 6" 6" 6" Right 36 (Water side) 36" (Water side) 36" (Water side) Left 36" 36" 36" Top 0" 0" 0" Vent 1" 1" 1" WARNING: Combustion air inlet (blower air inlet) should have 6" minimum clearance from any obstruction, i.e. walls or
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SECTION C: COMBUSTION AND VENTILATION AIR COMBUSTION AND VENTILATION AIR (Indoor Units) The boiler must be supplied with sufficient 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 surrounding the boiler, or via direct vent, where combustion air is drawn directly from outside. All installa- tions must comply with the requirements of NFGC fo
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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 input rating of all equipment in the room, or no less than the sum of the areas of all vent connectors in the confined space. . Refer to the latest ver
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SECTION D: WATER 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 requires forced water circulation when the burner is operating. See Table D-1 for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the boiler to p
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SECTION E: HYDRONIC HEATING 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 than 20°F is necessary, the bypass must be installed and adjusted to insure proper hydraulics through the boiler while still allowing minimum flow to satisf
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PRESSURE DROP IN FEET OF HEAD FEEDWATER REGULATOR 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 local codes. PIPING - HEATING BOILERS All high points should be vented. Purge valves and a bypass valve should be installed. A boiler installed above radiation level must be provided with a low water cutoff devi
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Figure E-2b SINGLE BOILER - PRIMARY/SECONDARY PIPING WITH CHX Figure E-3a DUAL-BOILER PRIMARY/SECONDARY PIPING 15
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Figure E-3b DUAL BOILER -PRIMARY/SECONDARY PIPING WITH CHX Figure E-4a SINGLE BOILER - LOW TEMPERATURE APPLICATION (HEAT PUMP) PRIMARY/SECONDARY PIPING 16
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SECTION F: DOMESTIC HOT WATER PIPING When designing the water piping system for domestic water applications, water hardness should be considered. Table D- 1 indicates the suggested flow rates for soft, medium and hard water. Hardness is specified as grains per gallon. TABLE F-1 DOMESTIC WA TER HEA TING BOILER FLOW RA TE REQUIREMENTS Delta T = Temperature rise in °F GPM = Gallons per minute See Table D-1 for Pressure Drop Figure F-1a SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK Figure
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Figure F-1bb SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK AND CHX (2 pump system) Figure F-1c SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK, ONE PRE-HEAT TANK AND CHX 18
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SECTION G: POOL HEATING 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. The ADB unit is equipped with an external pump and bypass arrangement that blends outlet water with
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SPA WATER 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 efficiency and also damaging the heater. If the pH drops below 7.2, the heater will be severely damaged. NOTE: Heat exchanger damage resulting from chemical imba
