Raypak ADB 1001CHX Installation Manual

INSTALLATION AND OPERATING
INSTRUCTIONS
CATALOG 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 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.
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference.
Models 751, 1001 &
1501 – Types H, WH & P
Advanced Design Boiler
L
W
2
WARNINGS 4 BEFORE INSTALLATION 5
Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6
GENERAL SAFETY 7
Time/Temperature Relationships in Scalds 7
INSTALLATION 8
Installation Codes 8 Equipment Base 8 Clearances 8 Combustion and Ventilation Air 9 Conventional Combustion Air Supply 11 Water Piping 12 Hydronic Heating 13 Gas Supply Connections 21 Electrical Power Connections 23 Venting Connections 25 Venting Installation Tips 27 Venting Configurations 27 Condensate Drain 40 Controls 41
WIRING DIAGRAM 44 PRE START-UP 46
ADB Initial Start-Up 48
OPERATION 51
Lighting Instructions 51 To Turn Off Gas to Appliance 51
MAINTENANCE 51
Suggested Minimum Maintenance Schedule 51
CONNECTING THE CHX 52 APPENDIX 54
Inside Combustion Air Contamination 54
START-UP CHECKLIST 55 WARRANTY 56
CONTENTS
3
4
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.
NOTE:
Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.
DANGER: Make sure the gas on which the heater will operate is the same type as that specified on the heater 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 heater. Instead, shut off the gas supply at a location external to the heater.
WARNING: Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water.
WARNING: To minimize the possibility of improper operation, serious personal injury, fire, or damage to the heater:
Always keep the area around the heater free of combustible materials, gasoline, and other flammable liquids and vapors.
Heater should never be covered or have any blockage to the flow of fresh air to the heater.
WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
WARNING: Risk of electrical shock. More than one disconnect switch may be required to de-energize the equipment before servicing.
CAUTION: This heater requires forced water circulation when the burner is operating. See minimum and maximum flow rates. Severe damage will occur if the heater is operated without proper water flow circulation.
CAUTION: Operation of this heater in low temperature systems requires special piping to ensure correct operation.
CAUTION: If this heater is to be installed above radiation level, it must be provided with a low water cut-off device at the time of heater installation.
WARNINGS
Pay Attention to These Terms
5
BEFORE INSTALLATION
Raypak strongly recommends that this manual be re­viewed 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 oper­ated. (Refer to the warranty at the back of this manual.) Installation and service must be performed by a qualified installer, service agency or gas supplier. If, after reviewing this manual, you still have questions which this manual does not answer, please contact the manufacturer or your local Raypak representative.
Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.
Product Receipt
On receipt of your heater it is suggested that you visu­ally check for external damage to the shipping crate. If the crate is damaged, make a note to that effect on the Bill of Lading when signing for the shipment. Remove the heater from the shipping packaging. Report any damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that you receive the correct number of packages as indi­cated on the Bill of Lading.
Claims for shortages and damages must be filed with the carrier by consignee. Permission to return goods must be received from the factory prior to shipping. Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted. All returned goods are subject to a restocking charge.
When ordering parts, you must specify the model and serial number of the heater. When ordering under war­ranty conditions, you must also specify the date of installation.
Purchased parts are subject to replacement only under the manufacturer’s warranty. Debits for defec­tive replacement parts will not be accepted and will be replaced in kind only per Raypak’s standard war­ranties.
Model Identification
The model identification number and heater serial number are found on the heater rating plate located on
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). The remaining suffix identifies the control, ignition, and construction config­uration. The last three characters of the model number identifies the model type (ADB = Advanced Design Boiler).
Ratings and Certifications
Standards:
ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Hot Water Boilers
CAN 3.1 - latest edition, Industrial and Commercial Gas-Fired Package Boilers
ANSI Z21.10.3 · CSA 4.3 - latest edition, Gas Wa­ter Heaters
SCAQMD Rule 1146.2
All Raypak heaters are National Board Approved, and design-certified and tested by the Canadian Standards Association (CSA) for the U.S. and Canada. Each heater is constructed in accordance with Section IV of the American Society of Mechanical Engineers (ASME) Heater Pressure Vessel Code and bears the ASME stamp. The heater also complies with the latest edition of ASHRAE 90.1 Standard.
Installations at Elevation
No de-rating is required for altitudes up to 7000 feet. Rated inputs, at sea level settings, are suitable for up to 5000 feet elevation. At altitudes between 5000 and 7000 feet, rated inputs are achieved with pressure set­tings adjustment. Consult the factory for installations at altitudes in excess of 7000 feet.
WARNING: Altering any RAYPAK pressure vessel by installing replacement heat-exchangers, tube bundle headers, or any other ASME part not manufactured and/or approved by RAYPAK will instantly void the ASME, and agency listings and any RAYPAK warranty on the vessel. Altering the ASME, agency ratings of the vessel also violates national, state, and local approval codes. The terms "boiler" and "heater" are used interchangeably in this manual.
6
Component Locations
Fig. 1: Component Locations
7
GENERAL SAFETY
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.
Safety and energy conservation are factors to be con­sidered when setting the water temperature on the thermostat. The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application.
Maximum water temperatures occur just after the boil­er’s burner has shut off. To determine the water temperature being delivered, turn on a hot water faucet and place a thermometer in the hot water stream.
NOTE: When this water heater is supplying general purpose hot water for use by individuals, a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information.
Time/Temperature Relationships in Scalds
The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.
Table A: Time to Produce Serious Burn
Water
Temp.
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About 1 second
Table courtesy of The Shriners Burn Institute
Time to Produce Serious
Burn
Water temperature over 125°F can cause instant severe burns or death from scalds.
Children, disabled, and elderly are at highest risk of being scalded.
See instruction manual before set­ting temperature at water heater.
Feel water before bathing or show­ering.
Temperature limiting valves are available, see manual.
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 installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replacement, etc.).
Clearances
Indoor Installations
8
Table B: Clearances – Indoor Installations
INSTALLATION
INSTALLATION
Installation Codes
Installations must follow these codes:
Local, state, provincial, and national codes, laws, regulations and ordinances
National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition (NFGC)
National Electrical Code, ANSI/NFPA 70 - latest edition (NEC)
Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, (CSD-1) when required
For Canada only: CAN/CSA B149 Installation Code and CSA C22.1 C.E.C. Part 1 (C22.1)
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.
To adjust the water temperature, insert a small straight screwdriver into slotted screw in hole in front of ther­mostat and turn wheel to desired setting.
CAUTION: Hotter water increases the risk of scalding! There is a hot water scald potential if the thermostat is set too high.
Auto Limit
*DO NOT install on carpeting.
CAUTION: The boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliance or to the structure. When such locations cannot be avoided, it is recommended that a suitable catch pan, adequately drained, be installed under the appliance. The pan must not restrict air flow.
Heater Side
Min. Clearance from
Combustible Surfaces
Floor *
Rear 12” (water side)
Right 1”
Left 1”
To p 0”
Vent 1”
Adjustment
Screw
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 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.
Direct Vent
If outside air is drawn through a vent pipe directly to the unit for combustion:
1. Install combustion air direct vent in accordance with the Venting section of this manual.
2. Provide for adequate ventilation of the space occupied by the boiler(s) by an opening(s) for ven­tilation air at the highest practical point communicating with the outdoors. The total cross sectional area shall be at least one (1) square inch of free area per 20,000 BTUH of total input rating of all equipment in the room when the opening is communicating directly with the outdoors or through vertical duct(s). The total cross sectional area shall be at least one (1) square inch of free area per 10,000 BTUH of total input rating of all equipment in the room when the opening is com­municating with the outdoors through horizontal duct(s).
3. In cold climates, and to mitigate potential freeze­up, Raypak highly recommends the installation of a motorized sealed damper to prevent the circula­tion of cold air through the boiler during the non-operating hours.
NOTE: In calculating free area, the required size of openings for combustion, ventilation, and dilution air shall be based on net free area of each opening. If the free area through a design of louver or grill is known, it shall be used in calculating the size opening required to provide the free area specified. For additional information, refer to the latest NFGC code requirements.
Fig. 2: Minimum Clearances from Combustible
Surfaces
Heater Side
Min. Clearance from
Combustible Surfaces
Rear 12” (water side)
Right 36”
Left 36”
To p 0”
Vent 1”
Table C: Clearances – Outdoor Installations
WARNING: Combustion air inlet (blower air inlet) should have 6" minimum clearance from any obstruction, i.e. walls or other appliances.
CAUTION: Remove the screen off the blower inlet and install a screen (1/2"-3/4" mesh) on the inlet elbow.
10
U.S. Installations
Fig. 3: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table D: Vent/Air Inlet Termination Clearances
Clearance above grade, veranda, porch,
A
deck, or balcony
Clearance to window or door that may be
B
opened
4 ft (1.2m) below or to side
of opening; 1 foot (30 cm)
1 ft (30 cm) 1 ft (30 cm)
above opening
1
Canadian Installations
3 ft (91 cm)
2
C Clearance to permanently closed window **
Vertical clearance to ventilated soffit located above the terminal within a horizontal dis-
D
tance of 2 ft (61cm) from the centerline of the
5 ft (1.5m) *
terminal
E Clearance to unventilated soffit **
F Clearance to outside corner **
G Clearance to inside corner 6 ft (1.83m) *
Clearance to each side of center line ex-
H
tended above meter/regulator assembly
*
3 ft (91 cm) within a height
15 ft above the me-
ter/regulator assembly
I Clearance to service regulator vent outlet * 6 ft (1.83m)
Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any
J
other appliance
K Clearance to mechanical air supply inlet
Clearance above paved sidewalk or paved
L
driveway located on public property
Clearance under veranda, porch, deck or
M
balcony
1
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
2
In accordance with the current CAN/CG A-B149 Installation C odes
t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that s erves
both dwellings
TT Permitted only if veranda, porch, deck, or balc ony is fully open on a minimum of two sides beneath the floor and top of terminal and
underside of ver anda, porch, deck or balcony is greater than 1 ft (30cm)
* Clearances in accordance with local installation codes and the requirements of the gas supplier
4 ft (1.2m) below or to side
of opening; 1 ft (30 cm)
above opening
3 ft (91 cm) above if within
10 ft (3m) horizontally
7 ft (2.13m) 7 ft (2.13m) t
* 12 in. (30 cm) TT
3 ft (91 cm)
6 ft (1.83m)
11
Conventional 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 provid­ed with two permanent openings communicating directly with additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. (An uncon­fined space is defined as a space whose volume is more than 50 cubic feet per 1,000 BTUH of the aggregate input rating of all appliances installed in that space.)
2. Each opening must have a minimum free area of one (1) square inch per 1,000 BTUH of the total input rating of all gas utilization equipment in the mechanical equipment room.
3. One opening must commence within twelve (12) inches of the top, and one opening must com­mence within twelve (12) inches of the bottom of the room.
4. Refer to NFGC, Part 5, for additional information.
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. The mechanical equipment room must be provid­ed with two permanent openings, one commencing within (twelve) 12 inches of the top, and one commencing within twelve (12) inches of the bottom of the room.
2. The openings must communicate directly, or by ducts, with the outdoors.
3. Each opening must have a minimum free area of one (1) square inch per 4,000 BTUH of total input rating of all equipment in the room when the open­ing is communicating directly with the outdoors or
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.
4. Refer to NFGC, Part 5, for additional information. Refer to Appendix A for additional information about combustion air quality.
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 version of NFGC, part 5 for additional information.
1. Ventilation of the space occupied by the boiler shall be provided by an opening(s) for ventilation air at the highest practical point communicating with outdoors. The total cross-sectional area of such an opening(s) shall be at least 10% of the area required in (2) and (3), but in no case shall the cross-sectional area be less than 10 square inches (6500 square mm).
2. When air supply is provided by natural air flow from the outdoors for natural draft, partial fan assisted, fan-assisted or power draft-assisted burners, there shall be a permanent air supply opening(s) having a cross section area of not less than 1 sq. in. per 7000 BTUH (310 sq. mm per kW) up to and including 1 million BTUH, plus 1 sq. in. per 14000 BTUH (155 sq. mm per kW) in excess
WARNING: Do not use one permanent opening method (Method 2) if the equipment room is under negative pressure condition or the equipment is common vented with other gas-fired appliances.
Canadian Installations
CAUTION: All combustion air has to be drawn from
the air outside the building (the mechanical equipment room directly communicates with the outdoors).
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).
3. When air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator, draft hood or similar flue gas dilu­tion device installed in the same space, in addition to the opening for ventilation air required in (1), there shall be a permanent air supply opening(s) having a total cross-sectional area of not less than 1 sq. in. for each 30,000 BTUH (70 sq. mm per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere with the intended purpose of the opening(s) for ventila­tion air referred to (1). This opening(s) can be 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 to be straight down 18 inches from floor, but do not place near piping.
4. Refer to the latest version of CSA B149 for addi­tional information.
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 the following sections or per a suitable engineered piping arrangement.
12
Relief Valve Piping
Hydrostatic Test
Unlike many other types of boilers, Raypak boilers do not require hydrostatic testing prior to being placed in operation. The heat exchanger has already been fac­tory-tested and is rated for 160 PSI operating pressure. However, Raypak does recommend hydro­statically testing the piping connections to the boiler and the rest of the system prior to operation. This is particularly true for hydronic systems using expensive glycol-based antifreeze. Raypak recommends con­ducting the hydrostatic test before connecting gas piping or electrical supply.
Leaks must be repaired at once to prevent damage to the boiler. NEVER use petroleum-based stop-leak compounds.
1. Connect fill water supply. Fill boiler with water (be sure bleed valve is open). When water flows from bleed valve, shut off water. Close bleed valve. Carefully fill the rest of the system, being sure to eliminate any entrapped air by using high point vents. Close feed valve. TEST AT standard oper­ating pressure for at least 24 hours.
2. Make sure constant gauge pressure has been maintained throughout test.
3. Check for leaks. Repair if found.
Low Temperature System
Boiler requires minimum inlet temperature of 105°F. Consult the following sections for piping details. (For Pool temperature requirements, See the Pool Heating Section).
Temperature & Pressure Gauge
The temperature and pressure gauge is factory­mounted in the inlet/outlet header.
WARNING: Pressure relief valve discharge piping must be piped near the floor close to a floor drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur. Refer to local codes.
CAUTION: This boiler requires forced water circulation when the burner is operating. See Table E for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the boiler to prevent boiler operation without water circulation.
HYDRONIC HEATING
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 difference between the inlet and outlet water when the boiler is firing at full rate). If a ΔT larger than 20°F is necessary, the bypass must be installed and adjusted to ensure proper hydraulics through the boiler while still allowing minimum flow to satisfy the safety flow switch. See Table E for flow rate requirements.
Pressure Drop in Feet of Head Feedwater Regulator
Raypak recommends that a feedwater regulator be in­stalled and set at 12 psi minimum pressure at the highest point of the 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 device. The boiler, when used in connec­tion with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler.
13
The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air, must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle. It is highly recom­mended that the piping be insulated.
Air-Separation/Expansion Tank
All boilers should be equipped with a properly sized expansion tank with an air separation fitting as shown in the following diagrams.
Three-Way Valves
Valves designed to blend water temperatures or reduce water circulation through the boiler should not be used. Raypak heaters are high recovery low mass heaters not subject to thermal shock. Raypak offers a full line of electric sequencers that produce direct reset of boiler water temperature. Refer to the Controls Section in our Complete Catalog.
Table D-1
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%.
40°F
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 Temperature Application (Heat Pump) Primary/Secondary Piping
DOMESTIC HOT WATER PIPING
When designing the water piping system for domestic water applications, water hardness should be consid­ered. Table F indicates the suggested flow rates for
Table F: Domestic Water Heating Boiler Flow Rate Requirements
ΔT=Temperature rise in °F GPM=Gallons per minute See Table D for Pressure Drop
soft, medium and hard water. Hardness is specified as grains per gallon.
17
Fig. 9: Single Boiler - Domestic Hot Water with One Storage Tank
Fig. 10: Single Boiler - Domestic Hot Water with One Storage Tank and CHX
18
Fig. 11: Single Boiler - Domestic Hot Water with One Storage Tank and CHX (2 pump system)
Fig. 12: Single Boiler - Domestic Hot Water with One Storage Tank, One Pre-Heat Tank and CHX
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