Raypak ADB 1001CHX Installation Manual

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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.

WHAT TO DO IF YOU SMELL GAS:

• 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

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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

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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

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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.

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Component Locations

Fig. 1: Component Locations

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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.

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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

Table B: Clearances – Indoor Installations

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

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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.

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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,

deck, or balcony

Clearance to window or door that may be

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

Canadian Installations

3 ft (91 cm)

C Clearance to permanently closed window **

Vertical clearance to ventilated soffit located above the terminal within a horizontal dis-

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-

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

other appliance

K Clearance to mechanical air supply inlet

Clearance above paved sidewalk or paved

driveway located on public property

Clearance under veranda, porch, deck or

balcony

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code

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)

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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).

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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.

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.

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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.

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

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Fig. 4: Single Boiler - Primary/Secondary Piping

Fig. 5: Single Boiler - Primary/Secondary Piping with CHX

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Fig. 6: Dual Boiler Piping

Fig. 7: Dual Boiler - Piping with CHX

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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.

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Fig. 9: Single Boiler - Domestic Hot Water with One Storage Tank

Fig. 10: Single Boiler - Domestic Hot Water with One Storage Tank and CHX

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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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POOL HEATING

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.

To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return water line. This will ensure that the heater will be energized at the right time. If the main water line is too far away from the heater and the capillary bulb will not reach it, locate the pool thermostat adjacent to the main line and run wires back to the heater. See Figure 13 and 14.

Adjustment of the bypass valve is critical to proper operation of the heater. The bypass valve should be adjusted to achieve a minimum inlet water temperature of 105°F and an outlet water temperature of 125°F. When starting with a cold pool, make initial adjustments. Make final adjustments when pool water approaches desired temperature. Refer to Table G for flow rates.

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.

Table G: Flow Rates

*Loop is secondary piping to heater from main system

CAUTION: ADB bypass piping should be copper and/or CPVC. PVC piping should NOT be used.

Automatic Chlorinators and Chemical Feeders

All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place chlorine tablets or bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (i.e. overnight).

Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the heater when the pump is shut off.

Winterizing Your Heater

When heaters installed outdoors in freezing climate areas are to be shut down for the winter, please observe the following procedure:

1. Turn off manual main gas and main gas shut off. Remove the drain plug or open the drain valves located on the bottom header.

Pool and Spa Water Chemistry

NOTE: High chemical concentrates from feeders

and chlorinators that are out of adjustment will cause very rapid corrosion to the heat exchanger in the heater. Such damage is not covered under the warranty.

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 (max TDS at 3000 ppm). If the pH drops below 7.2, the heater will be severely damaged.

NOTE: Heat exchanger damage resulting from chemical imbalance is not covered under the warranty.

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Fig. 13: Single Boiler - Pool Application

Fig. 14: Single Boiler - Pool Application with CHX

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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

Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve located outside the heater jacket. A pounds to inches

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. The boiler and its gas connection must be leak-tested before placing it in operation.

DANGER: Make sure the gas on which the boiler will operate is the same type as specified on the boiler model and rating plate.

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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 reconnecting the boiler and its manual shut off valve to the gas supply line. FAILURE TO FOLLOW THIS PROCE- DURE MAY DAMAGE THE GAS VALVES. Over pressurized gas valves are not covered by warranty. The boiler and its gas connections shall be leak tested before placing the appliance in operation. Use soapy water for leak test: DO NOT use open flame.

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.

When connecting additional gas utilization equipment to the gas piping system, the existing piping must be checked to determine if it has adequate capacity.

CAUTION: The boiler and its manual shutoff valve must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 PSIG (3.45 kPa).

CAUTION: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with Propane gas systems is recommended. Apply sparingly only on male pipe ends, leaving the 2 end threads bare.

CAUTION: Support gas supply piping with hangers, not by the boiler or its accessories. Ensure the gas piping is protected from physical damage and freezing where required.

Model

1-1/2”

NPT

2” NPT

2-1/2”

NPT

3” NPT

751 65 200 N/A N/A

1001 35 125 200 N/A

1501 15 60 125 225

NOTE: The supply gas pressure must not fluctuate by more than +/- 1.0 in. WC. For fluctuating gas supply contact the factory.

Maximum equivalent pipe length. Natural gas 100 BTU/FT

.60 specific gravity @.5 in. WC pressure

drop.

Table I: Gas Pipe Sizing

Page 23

Gas Pressure Regulator

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.

Venting of Diaphragm Gas Components

Boilers have gas train components that have diaphragms in their construction that are supplied with a bleed line connection that must be connected to the outside atmosphere as required by NFGC or (for Canada) the B149 Installation code and applicable provisions of local codes. Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system.

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.E.C. ANSI/NFPA 70-latest edition.

· In Canada, C.S.A. C22. 1 C.E.C. Part 1.

The boiler is wired for 120 VAC. The voltage is indicated on the tie-in leads. Consult the wiring diagram shipped with the boiler in the instruction packet. The “TH” leads are connected to the remote tank control stat, thermostat, or electronic boiler control as applicable. 24 Volts are supplied to this connection through the boiler transformer. DO NOT attach line voltage to the “TH” leads. Before starting the boiler check to insure proper voltage to the boiler and pump.

Install a separate disconnect means for each load. Use appropriate-sized wire as defined by NEC, CSA and/or local code. All primary wiring should be 125% of minimum rating.

It is strongly recommended that all individually-powered control modules and the boiler should be supplied from the same power source.

Surge Protection

Microprocessor-based and solid state controls are vulnerable to damage from voltage and amperage fluctuations in the power supply. All sensitive control components should be protected by a suitable commercial-grade surge protection device.

If any of the original wire as supplied with the boiler must be replaced, it must be replaced with 105°C wire or its equivalent.

Check the Power Source

Using a volt-ohm meter (VOM), check the following voltages at the circuit breaker panel prior to connecting any equipment: Make sure proper polarity is followed and house ground is proven.

AC = 108 Volts AC Minimum, 132 Volts MAX AB = 108 Volts AC Minimum, 132 Volts MAX BC = Must be less than 1.0 Volts AC

Making the Electrical Connections

Refer to Fig. 18 and the wiring diagram.

1. Verify circuit breaker is properly sized by referring to boiler rating plate. Adedicated motor duty circuit breaker should be provided.

2. Turn off all power to the boiler. Verify that power has been turned off by testing with a volt-ohm meter prior to working with any electrical connections or components.

3. Observe proper wire colors while making electrical connections. Many electronic controls are polarity sensitive. Components damaged by improper electrical installation are not covered by warranty.

Fig. 17: Check Power Source

Page 24

"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/NFPA 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 supplied with the boiler must be replaced, it must be replaced with 105°C wire or its equivalent.

4. Provide an external surge suppressor capable of maintaining system integrity.

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. There must be a solid wired ground.

Electrical Connections — Domestic Hot Water

The ADB is wired for 120 VAC. The voltage is indicated on the tie-in leads. Consult the wiring diagram shipped with the boiler in the instruction packet. The "TH" leads are for the remote tank control through the boiler transformer. DO NOT attach line voltage to the

NOTE: A grounding electrode conductor shall be used to connect the equipment grounding conductors, the equipment enclosures, and the grounded service conductor to the grounding electrode.

Fig. 18: Field Wiring Connections

CAUTION: When servicing controls, label all wires prior to disconnection. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

DANGER — SHOCK HAZARD — Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components.

Fig. 19: Single Stage Tankstat

Fig. 20: 2-Stage Tankstat

BREAK THE WIRE NUT AT THE

BOILER "TH" CONNECTIONS AND

ATTACH TO THE SINGLE TANKSTAT

PER ILLUSTRATION

BREAK THE WIRE NUT AT THE

BOILER "TH" CONNECTIONS AND

ATTACH TO THE DUAL TANKSTAT

PER ILLUSTRATION

Page 25

VENTING CONNECTIONS

General

Definition of Appliance Categories

Boilers are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent.

Category I: A boiler which operates with a non-positive vent static pressure and with a vent gas

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.

Category III: A boiler which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category IV: A boiler which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

See Table J for vent category requirements for the Advanced Design Boiler.

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.

CAUTION: Stable vent pressure is critical to the safe and proper operation of the heater. A combination of barometric dampers, balancing dampers, extractors, or draft inducers may be required to stabilize the vent pressure.

NOTE: For additional information on appliance categorization, see appropriate ANSI Z21 Standard and the latest edition Standard of National Fuel Gas Code or in Canada, the latest edition of CSA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of local building codes.

Table J: ADB Category Determination for Venting Purpose and Venting Arrangement

NOTE: PVC or CPVC vent may be used in conjunction with CHX, special piping arrangement has to be made. Contact manufacturer for details.

A D B

E N

I N G

R R A N G E M E N

Tight

Page 26

Determination of Appliance Category for Venting Purposes and Venting Arrangements

Support of Vent Stack

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.

Use insulated vent pipe spacers where the vent passes through combustible roofs and walls.

Vent Terminal Location

Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury.

a) Gases may form a white vapor plume in winter.

The plume could obstruct a window view if the termination is installed in close proximity to windows.

b) Prevailing winds could cause freezing of conden-

sate and water/ice buildup on building, plants or roof.

c) The bottom of the vent terminal and the air intake

shall be located at least 12 inches above grade, including normal snow line.

d) Un-insulated single-wall metal vent pipe shall not

be used outdoors on cold climates for venting gas utilization equipment.

e) Through-the-wall vents for Category II and IV

appliances and non-categorized condensing appliances shall not terminate over public walkways or

WARNING: Contact the manufacturer of the vent material if there is any question about the appliance categorization and suitability of a vent material for application on a Category III or IV vent system. Using improper venting materials can result in personal injury, death or property damage.

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.

f) Locate and guard vent termination to prevent acci-

dental contact by people and pets.

g) DO NOT terminate vent in window well, stairwell,

alcove, courtyard or other recessed area, unless previously approved by local authority.

h) DO NOT terminate above any door, window, or

gravity air intake. Condensate can freeze causing ice formations.

i) Locate or guard vent to prevent condensate from

damaging exterior finishes. Use a 2' x 2' rust resistant sheet metal backing plate against brick or masonry surfaces.

j) DO NOT extend exposed vent pipe outside of

building. Condensate could freeze and block vent pipe.

k) Multiple direct vent caps, when installed in the

same horizontal plane, should have a three (3) foot clearance from the side of one vent cap to the side of the adjacent vent cap(s).

U.S. Installations

Refer to latest edition of the National Fuel Gas Code.

Vent termination requirements are as follows:

a) Vent must terminate at least four (4) feet below,

four (4) feet horizontally, or one (1) foot above any door, window or gravity air inlet to the building.

b) The vent must not be less than seven (7) feet

above grade when located adjacent to public walkways.

c) Terminate vent at least three (3) feet above any

forced air inlet located within ten (10) feet.

d) Vent must terminate at least four (4) feet horizon-

tally, and in no case above or below unless four (4) feet horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment.

NOTE: During winter months check the vent cap and make sure no blockage occurs from build up of snow. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.

Page 27

e) Terminate 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 dwellings and serves both dwellings.

b) Less than 7 ft. (2.13m) above a paved sidewalk or

paved driveway located on public property.

c) Within 6 ft. (1.8m) of a mechanical air supply inlet

to any building.

d) Above a meter/regulator assembly within 3 ft.

(900mm) horizontally of the vertical center-line of the regulator.

e) Within 6 ft. (1.8m) if any gas service regulator vent

outlet.

f) Less than 1 ft. (300mm) above grade level.

g) Within 3 ft (1m) of a window or door which can be

opened in any building, any non-mechanical air supply inlet to any building to the combustion air inlet of any other appliance.

h) Underneath a verandah, porch or deck, unless:

(i) the verandah, porch or deck is fully open on a

minimum of two sides beneath the floor, and

(ii) the distance between the top of the vent termi-

nation and the underside of the verandah, porch or deck is greater than 1 ft (30cm).

Venting Installation Tips

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).

· 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.

To make metallic vent joints:

· Do not install seams of vent pipe on bottom of runs.

· Completely seal all joints and seams with silicone sealant.

Venting Configurations

The following is a detailed explanation of each venting system WITHOUT and WITH add-on condensing heat exchanger (CHX), its installation requirements, the components used, and part numbers for each.

For boilers connected to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the latest edition of National Fuel Gas Code, or in Canada, the latest edition of CSA B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of local building codes.

NOTE: For direct vent installations where the air is piped in from outside, the protective screen on the combustion air blower may be relocated to the air inlet termination elbow to act as an inlet screen.

NOTE: The words "Flue Exhaust", "Flue" and "Exhaust Vent" are used interchangeably.

WARNING: Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness, corrosion or deterioration.

Page 28

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)

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.

Table K: Natural Draft Vertical Vent without Add-on Condensing Heat Exchanger

ADB-1501

Page 29

Natural Draft Vertical Venting 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 0.01 in. to 0.08 in. WC negative to ensure proper operation. The vent material must be in accordance with the above instructions for vent materials. Vent material must be listed by a nationally recognized test agency.

The maximum and minimum venting length for Category I appliance shall be determined per the latest edition of the National Fuel Gas Code (U.S.) or B149 Installation Code (Canada).

The diameter of vent flue pipe should be sized according to Part 11 of the latest edition of the National Fuel Gas Code (U.S.) and part 7 and appendix B of the CSA B149 Installation Code (Canada). The flue pipe diameter for conventional negative draft venting using double-wall B type vent is 8” for the ADB 751, 10” for the 1001, and 12” for the ADB 1501.

The connection from the appliance vent to the stack must be as direct as possible and shall be the same diameter as, or larger than the vent outlet. The vent must be installed to prevent accumulation of condensate and, where necessary, have means provided for drainage of condensate. The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot from the boiler to the vent terminal. The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints.

Natural Draft Vertical Vent Termination

The vent terminal should be vertical and should terminate outside the building at least two (2) feet above the highest point of the roof that is within 10 feet. The vent cap should have a minimum clearance of four (4) feet horizontally from and in no case above or below (unless a four (4) foot horizontal distance is maintained) electric meters, gas meters, regulators and relief equipment.

The distance of the vent terminal from adjacent public walkways, adjacent buildings, open windows and

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.

Natural Draft Vertical Venting with Common Venting System, Category I Appliance Only (NOT to be Utilized with Add-on Condensing Heat Exchanger)

Manifolds that connect more than one boiler to a common chimney must be sized to handle the combined load. Consult available guides for proper sizing of the manifold and the chimney. At no time should the area of the vent be less than the area of the largest boiler exhaust outlet.

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.

a) Seal any unused opening in the common venting

system.

b) Visually inspect the venting system for proper size

and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other unsafe condition.

c) Insofar as is practical, close all building doors and

windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any

NOTE: Vent Adapter will have to be used to connect B vent to the unit.

CAUTION: Listed vent cap terminal must be used and sized adequately to evacuate the flue products from the boilers.

WARNING: Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure.

CAUTION: Vent connectors for natural draft venting systems must be type “B” vent or better.

Page 30

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.

d) Place in operation the appliances being inspected.

Follow the manufacturers instructions for lighting each appliance. Adjust thermostat so appliance will operate continuously.

e) Test for natural draft (negative pressure) 12"

above the outlet elbow after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe, toilet paper trick.

f) After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances to their previous conditions of use.

g) Any improper operation of the common venting

system should be corrected so that the installation conforms with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CSA B149 Installation Code for Gas Burning Appliances and Equipment.

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 Z223.1, in Canada, Appendix B of the latest edition of the Installation Code for Gas Burning Appliances and Equipment.

Fig. 22: Horizontal Thru-Wall Venting without Add-on

Condensing Heat Exchanger (Category III)

Table L: Horizontal Thru-wall Venting without Add-on

Condensing Heat Exchanger (Category III)

ADB-1501

Page 31

Horizontal Thru-wall Direct Venting System (Category 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 outdoors. Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or, in Canada, the latest edition of CSA B149 Installation Code for Gas Burning Appliances and Equipment.

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:

· 65′ of straight flue pipe.

· 55′ of straight flue pipe and one elbow.

· 45′ of straight flue pipe and two elbows.

· 35′ of straight pipe and three elbows.

The direct vent cap is not considered in the overall length of the venting system. The vent must be installed to prevent the flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight.

The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is recommended that:

a) The vent be installed with a slight downward slope

of not more than 1/4" per foot of horizontal run to the vent terminal.

b) The vent be insulated through the length of the

horizontal run.

For appliances installed in extreme cold climate, it is recommended that:

a) The vent be installed with a slight upward slope of

not more than 1/4" per foot of horizontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes.

b) The vent be insulated through the length of the

horizontal run.

Horizontal Thru-wall Direct Vent Termination

The direct vent cap MUST be mounted on the exterior of the building. The direct vent cap cannot be installed in a well or below grade. The direct vent cap must be installed at least one (1) foot above ground level and above normal snow levels. The Raypak supplied direct vent cap must be used.

The Stainless Steel direct vent cap must be furnished by the boiler manufacturer in accordance with its listing.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

WARNING: For common vent installations, contact the factory.

Fig. 23: Horizontal Thru-Wall Direct

Venting/Combustion Air

(Category III)

Page 32

Table M: Horizontal Thru-wall Direct Venting without Add-on

Secondary Condensing Heat Exchanger

Horizontal Thru-wall Direct Venting 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. Each elbow used is equal to ten (10) feet of straight pipe. This will allow installation in one of the three following combinations:

· 45′ of straight flue pipe.

· 35′ of straight flue pipe and one elbow.

· 25′ of straight flue pipe and two elbows.

The total length air supply pipe cannot exceed fortyfive (45) feet in length for the combustion air inlet. Each elbow used is equal to ten (10) feet of straight pipe. This will allow installation in one of the three following combinations:

· 45′ of straight combustion air pipe

· 35′ of straight combustion air pipe and one elbow.

· 25′ of straight combustion air pipe and two elbows.

The direct vent cap is not considered in the overall length of the venting system.

Care must be taken during assembly that all joints are sealed properly and are airtight.

The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is recommended that:

a) The vent be installed with a slight downward slope

of not more than 1/4" per foot of horizontal run to the vent terminal.

b) The vent be insulated through the length of the

horizontal run.

For appliances installed in extreme cold climate, it is recommended that:

a) The vent be installed with a slight upward slope of

not more than 1/4" per foot of horizontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes.

b) The vent be insulated through the length of the

horizontal run.

Horizontal Thru-wall Direct Vent Termination

Multiple direct vent caps MUST NOT be installed with one combustion air inlet directly above a direct vent cap. This vertical spacing would allow the flue products from the direct vent cap to be pulled into the combustion air intake installed above.

ÁDB-1501

Page 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 supplied from outdoors must be free of particulate and chemical contaminants. To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.

The Stainless Steel direct vent cap must be furnished by the boiler manufacturer in accordance with its listing.

WARNING: For common vent installations call factory.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Fig. 24: Vertical Direct Venting/Combustion Air

(Category I)

*Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of National Fuel Gas Code for further details (ANSI Z223.1) or in Canada, the latest edition of CSA B149 Installation Code.

Table N: Vertical Direct Venting without Add-on Condensing Heat Exchanger

ADB-1501

Page 34

Vertical Direct Venting 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. The negative draft must be within the range of -0.01 in. to -0.08 in. WC to ensure proper operation.

The vent material must be in accordance with the above instructions for vent materials. Vent material must be listed by a nationally recognized test agency.

The maximum and minimum venting length for Category I appliance shall be determined per the latest edition of the National Fuel Gas Code (U.S.) and CSA B149 Installation Code (Canada).

The diameter of vent flue pipe should be sized according to part 11 of the latest edition of the National Fuel Gas Code (U.S.) and part 7 and Appendix B of CSA B149 Installation Code (Canada). The flue pipe diam

eter for conventional negative draft venting using double-wall B type vent is 12” for the ADB 1501.

The connection from the appliance vent to the stack must be as direct as possible and should be the same as or larger than the vent outlet. The vent must be installed to prevent accumulation of condensate and, where necessary, have means provided for drainage of condensate. The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot from the boiler to the vent terminal.

The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints.

Vertical Direct Vent Termination

The vent terminal should be vertical and should terminate outside the building at least two (2) feet above the highest point of the roof within 10 feet. The vent cap should have a minimum clearance of four (4) feet horizontally from and in no case above or below (unless a four (4) foot horizontal distance is maintained) electric meters, gas meters, regulators and relief equipment.

The distance of the vent terminal from adjacent public walkways, adjacent buildings, open windows and building openings must be consistent with the National Fuel Gas Code, or in Canada, the latest edition of 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.

The vertical direct vent cap is designed for roof top mounting only. The air inlet opening MUST be installed one (1) foot above the roof line or above normal snow levels that might obstruct combustion air flow. This dimension is critical to the correct operation of the boiler and venting system and reduces the chance of blockage from snow. The vent cap must have a minimum 3 foot vertical clearance above the air inlet opening.

Fig. 25: Vertical Venting with Add-on Condensing Heat

Exchanger (Category IV) Domestic Water

Page 35

Table O: Vertical Vent (CATEGORY IV) with Add-on Condensing Heat Exchanger

Model Venting Category

Certified Venting

Material

Vent Size (inches)

Maximum Vent

Length (feet)

ADB-751 w/CHX IV

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

ADB-1001 w/CHX IV

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

ADB-1501 w/CHX IV

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

Vertical Vent (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. Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or, in Canada, the latest edition of CSA B149 Installation Code for Gas Burning Appliances and Equipment.

UL 1738 Certified Venting Material (e.g. AL29-4C) MUST be used. The vent must be installed to prevent the flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight.

For certain installations, i.e. pool, heat-pump domestic hot water with pre-heat tank, PVC or CPVC may be used. Contact the manufacturer for details.

To prevent the condensation 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.

The Stainless Steel non-restricted direct vent cap must be furnished by the boiler manufacturer in accordance with its listing.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Fig. 26: Horizontal Thru-wall Venting with Add-on Condensing Heat Exchanger (CHX)

*Contact the manufacturer for details.

Page 36

Model Venting Category

Certified Venting

Material

Vent Size (inches)

Maximum Vent

Length (feet)

ADB-751 w/CHX IV

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

ADB-1001 w/CHX IV

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

ADB-1501 w/CHX IV

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

*Contact the manufacturer for details.

Table P: Horizontal Thru-wall Venting with Add-on Condensing Heat Exchanger

Horizontal Thru-wall Venting 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. Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or, in Canada, the latest edition of CSA B149 Installation Code for Gas Burning Appliances and Equipment.

UL 1738 Certified Venting Material (e.g. AL29-4C) MUST be used. The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight.

For certain installations, i.e. pool, heat pump, domestic hot water supply with pre-heat tank, PVC or CPVC may be used. Contact manufacturer for details.

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, so the condensation in the vent pipe drains back to the boiler.

The Stainless Steel non-restrictive direct vent cap must be furnished by the boiler manufacturer in accordance with its listing.

WARNING: For common vent installations contact factory.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Page 37

Model

Venting

Category

Certified Venting

Material

Vent Size

(inches)

Maximum Vent

Length (feet)

Combustion Air

Intake Pipe

Material

Air Inlet

Size

(inches)

Max. Air

Intake Length

(feet)

ADB-751

w/CHX

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

Subtract 10 ft per

elbow, Max. 3

elbows

Galvanized

Steel

PVC, ABS

CPVC

Subtract 10 ft

per elbow,

Max. 3 elbows

ADB-1001

w/CHX

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

Subtract 10 ft per

elbow, Max. 3

elbows

Galvanized

Steel

PVC, ABS

CPVC

Subtract 10 ft

per elbow,

Max. 3 elbows

ADB-1501

w/CHX

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

Subtract 10 ft per

elbow, Max. 3

elbows

Galvanized

Steel

PVC, ABS

CPVC

8**

Subtract 10 ft

per elbow,

Max. 3 elbows

*Contact the manufacturer for details. **If the boiler is direct vented, a 6 to 8 in. adapter must be installed at the blower inlet.

Table R: Vertical Direct Venting with Add-on

Secondary Condensing Heat Exchanger

Vertical Direct Venting 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 products to the outdoors.

For certain installations, i.e. pool, heat-pump, domestic hot water supply with pre-heat tank, PVC or CPVC may be used. Contact manufacturer for details.

The Stainless Steel non-restricted direct vent cap must be furnished by the boiler manufacturer in accordance with its listing.

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 CSA requirements. It must be installed directly on the boiler in a horizontal position. Notching of the vent cap mounting flange may be necessary to clear outlet piping on some models.

Care must be taken when locating the outdoor unit because the flue gases discharged from the vent cap can condense as they leave the cap. Improper location can result in damage to adjacent structures or building finish. For maximum efficiency and safety, the following precautions must be observed:

a) Outdoor models must be installed outdoors and

must use the non-restricted direct vent cap supplied by the manufacturer.

b) Periodically check venting system. The boiler’s

venting areas must never be obstructed in any way and minimum clearances must be observed to prevent restriction of combustion and ventilation air. Keep area clear and free of combustible and flammable materials.

c) Do not locate adjacent to any window, door walk-

way, or gravity air intake. The vent should be located four (4) feet horizontally from such areas.

d) Install above grade level and above normal snow

levels.

WARNING: For common vent installations, contact the factory.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Page 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 Vent installations require a four

(4) feet clearance between vent caps.

The Stainless Steel non-restricted vent cap must be furnished by the boiler manufacturer in accordance with its listing.

The outdoor vent terminal must be installed in a horizontal position to prevent recirculation of flue products. The vent cap must be mounted directly on the vent pipe of the boiler.

NOTE: Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.

CONDENSATE DRAIN

The Condensing Heat Exchanger (CHX) can generate up to 1 (one) gallon per hour (gph) of condensate for every 100,000 BTUH. The maximum condensation rate for the ADB 751 is 7.5 gph, the ADB 1001 is 10 gph, and the ADB 1501 is 15 gph.

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.

WARNING: All condensation should be disposed of according to local, county, state, and federal laws. Refer to NFGC, section 7.9, for additional information.

Fig. 29: Condensate Trap Alignment

Page 41

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.

The CPW Board

The Central Point Wiring (CPW) board serves as the central tie point for connecting all other control components in the boiler. The CPW board provides boiler operating status and fault indication using eight LEDs which function as described in Table S.

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-purge. The location of each user adjustable timing is shown in Figure 30.

WARNING: 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 result in control damage, boiler malfunction, property damage, personal injury, or death.

WARNING: Turn off the power to the boiler before installation, adjustment or service of the Central Point Wiring board or any boiler controls. Failure to do so may result in board damage, boiler malfunction, property damage, personal injury, or death.

CAUTION: This appliance has provisions to be connected to more than one (1) supply source. To reduce the risk of electric shock, disconnect all such connections before servicing.

CAUTION: Risk of electric shock. More than one (1) disconnect switch may be required to deenergize the equipment before servicing.

Table S: CPW Board LED Indicators

Light noitacidnIroloC

Power CDV 42neerG is applied to the system

Pump Green Boiler Pump is energized. Pilot Yellow Power applied to the Pilot Gas Valve. (PV signal on.) Main Gas rewoPne Call for Heat rehTneerG mostat is closed. Call for heat present. Service Red (Flashing) One or more of the safeties are open. Refer to U-2 Board Blower Green Blower is energized.

erG applied to Main Gas Valve. (MV signal on.)

.delbasid si draoB .draob eht no tnerruc daolrevOdeRrorrE metsyS

Page 42

Fig. 30: CPW Board

Pump Turn-off 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 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.

By properly setting the pump turn-off delay, the boiler pump will continue running for a limited period of time in order to extract any residual heat from the combustion chamber. The pump will then shut off to conserve energy until the next call for heat.

The pump-off time delay should be set to the minimum time required to extract all residual heat from the heat exchanger. If temperature as monitored at the boiler outlet increases more than 5°F after the pump turns off following a firing cycle, the pump-off time delay should be extended by thirty seconds. Increase or decrease time delay as appropriate until outlet temperature does not spike more than 5°F after pump shut-off following a prolonged firing cycle (> 5min.)

Blower Fan Pre-purge

The CPW board has a built-in pre-purge delay which operates the blower fan for a user-adjustable time period prior to pilot trial for ignition. The pre-purge period ensures that the combustion chamber is clear of all excess combustible gases prior to commencing the pilot ignition cycle. The pre-purge delay is factory set for 45 seconds and it can be adjusted in the field from 45 seconds to 120 seconds. To optimize boiler response time on call-for-heat, set the pre-purge delay to the minimum allowed by local, state or national code.

Blower Fan Post-purge

The CPW board has a built-in post-purge delay to exhaust residual combustion products after the main gas valve closes. The post-purge timing is factory set at 3 minutes and is not field-adjustable.

Freeze Protection Feature

The CPW board is programmed to turn-off 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 not reactivated within a pre-set time for any reason, the CPW board will turn off the blower to prevent blowing cold air continuously and freezing the heat exchanger. The blower drives will open and the system will lock in the off state.

To restart the system, primary power or the thermostat signal must be turned off and back on. The pre-set freeze protection feature time is approximately 5 minutes.

CAUTION: The boiler requires forced water circulation when the burner is operating and the pump must be interlocked with the boiler. See the Water Piping section for minimum and maximum water flow rates and pump selection.

NOTE: Pump will come on when power is first applied to the boiler.

Page 43

U-2 Diagnostics Board

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. The U-2 safety board is the central point for wiring, operations monitoring, and fault indication for the boiler safeties. By having each safety report directly to the U-2 board, each safety function can be individually monitored.

The U-2 adds complete diagnostics features that aid in the rapid diagnosis of irregularities in boiler operation. A single U-2 Diagnostics Board can monitor a maximum of eight safeties at one time. If, due to code requirements, more than eight safety devices must be monitored, two or more boards will be used to provided extended diagnostics capabilities. Advanced Design Boilers equipped with the standard safety suite will utilize the configuration shown in Table T.

The U-2 safety board has a series of red LED lights to indicate a fault occurring at a monitored safety. An

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.)

Once a fault has been detected, the U-2 board will illuminate the corresponding LED lamp, will shut-down the boiler, and will light the flashing red LED “Service” lamp on the CPW board. If more than one fault is detected, the U-2 board will display the priority fault based on the safety hierarchy as labeled on the U-2 board. Once the first fault is cleared, the second fault lamp will illuminate until cleared.

WARNING: Only qualified persons shall attempt to repair the boiler. Improper adjustment, service or maintenance may damage the equipment, create a hazard resulting in asphyxiation, explosion, fire, electric shock, personal injury or property damage, and will void the warranty.

Table T: U-2 Diagnostic Board LEDs

Light noitacidnIroloC

System Enabled Yellow U-2 Diagnostics safety board is functional. Manual High Limit Red Water temperature is over the manual high limit setting. Auto High Limit Red Water temperature is over the auto high limit setting.

Low Water Cut-off (option) Red Insufficient water volume for boiler operation. High/Low Gas Pressure Red Gas supply pressure is below or above the allowed minimum gas supply

pressure to ensure safe operation.

Burner High Limit Red Mixer or PVC vent pipe, if installed, is over heated.

.wol oot si etar wolf retaWdeRhctiwS wolF

Blower/Ignition Lockout Red Blower failure, not enough combustion air or the equipment has an ignition

lock-out condition.

Blocked Vent Red The vent pressure switch has detected a blocked vent.

Page 44

WIRING DIAGRAM

Figure L-2 WIRING DIAGRAM

Page 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 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.

To ensure safe operation, the gas valve cannot open until the pilot relights and is verified. The 100% pilot safety is an electronic device which closes the main gas valve within 8/10 of a second whenever the pilot flame is interrupted. Pilot flame is automatically lit when the device is powered and pre-purged. Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit.

High Limit — Manual Reset

This appliance is equipped with a manual reset, high limit, safety device. Push the reset button and adjust the setting to 40°F above the desired operating temperature.

Flow Switch

Dual-purpose control shuts off boiler in case of pump failure or low water condition. Mounted and wired in series with the main gas valve. Check with the manufacturer for proper paddle size. Utilize correct paddle size for proper operation.

High Limit — Auto Reset

This appliance is equipped with an automatic, high limit, safety device. Set the auto high limit to 30°F above the desired operating temperature.

Fig. 31: Ignition Module

Fig. 32: High Limit — Manual Reset

NOTE: Flow switch will not operate if flow is less than 20 gpm.

Fig. 33: Flow Switch

Fig. 34: Auto Reset — High Limit

Page 46

Low Water 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.

High and Low Gas Pressure Switches — Manual Reset

The low gas pressure switch mounts upstream of the gas pressure regulator to ensure that sufficient gas pressure is present for proper regulator performance. The low gas pressure switch automatically shuts down the boiler if gas supply drops below the factory setting of 6 in. WC for Natural gas, and 10 in. WC for Propane gas.

The high gas pressure switch (optional) mounts downstream of the gas pressure regulator. If the gas pressure regulator fails, the high gas pressure switch automatically shuts down the burner.

Fig. 35: Low Water Cut Off

Fig. 36: Gas Pressure Switch

PRE-START-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.

5. Starting on the lowest floor, open air vents one at a time until water squirts out. Close vent.

6. Repeat with remaining vents.

7. Close manual water feed valve when correct boiler pressure is reached.

Inspect Venting System:

1. Check all vent pipe connections and flue pipe material.

2. Ensure vent terminations are installed per code and are clear of all debris or blockage.

For Your Safety — Read Before Lighting

1. This appliance has an intermittent pilot. It is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot or burner by hand.

2. BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

3. WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any telephone in your building.

• Immediately call your gas supplier from a

neighbor's telephone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the

fire department.

4. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not turn by hand, do not try to repair it, call a qualified service technician. Forced or attempted repair may

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Page 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-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.” Air in system can interfere with water circulation and cause improper heat distribution.

Fig. 37: Component and Pressure Tap locations

Fig. 38: Blower “T” Fitting Detail

Page 48

ADB INITIAL START-UP

Tools 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

• Volt meter

• Amp probe

• Elec. Dual reading thermometer with strap on sensors

• 3/16” Allen wrench

• Combustion analyzer

Preparation for Start-up

Check Power Supply

With voltmeter at incoming power check voltage between:

Hot - Common (»120 VAC) Hot – Ground (»120 VAC) Common - Ground (< 1 VAC)

If Common - Ground is > 1 VAC - STOP: Contact electrician to correct ground failure.

Attach Manometers to Measure Pressures (See Fig. 37)

• Attach 16" scale manometer to the first gas shutoff valve pressure tapping, Location (1)

• Attach one 8" scale manometer to each manual gas valve pressure tapping, Locations (2) and (3).

• Attach one 8" scale manometer to the outlet side of pilot gas valve pressure tapping, Location (4).

• Attach one 8" manometer to “T” fitting, air pressure switch, and aluminum tubing, Location (5).

Turn Off The 1 1/2” Manual Gas Valve; Turn Off Pilot Gas Valve; Reset Low Gas Pressure Cut-off Switch;

Bleed Air from Gas Line

• With power off, slightly open union outside the cabinet to bleed air.

• Close union when you smell gas.

• Wait minimum 5 minutes to clear the gas out of the boiler room before continuing.

Check the Gas Supply Pressure, Location (1)

• Leave pilot gas valve and first manual gas valve closed;

• Slowly turn on main gas shut-off valve (outside the unit);

• Read the gas supply pressure from the manometer (Location 1);

• If pressure is > 14" W.C., Turn off the valve;

• Check if the service regulator is installed and/or adjust the service regulator.

START-UP

Blower Adjustment

1. Main gas shut-off valve is still closed;

2. Turn power on;

3. Check blower manometer reading, Location (5). Compare your reading to the “Pre-Fire” values shown in tables T and U. If not, adjust the air shutter on the blower to attain the correct value;

4. Turn power off.

Pilot Adjustment

1. Turn on the gas shut-off valve, the main gas manual valve, and the pilot manual valve;

2. Turn off the manual gas valves at Locations (2) and (3);

3. Turn power on, after 40-45 seconds, ignition control will energize and send spark to ignition, observe through view port for spark;

4. If you do not see spark, turn off power, check igni-

CAUTION: Verify that the vent system and combustion air supply have been approved.

WARNING: DO NOT TURN ON GAS AT THIS TIME.

WARNING: Failure to do this may burn out 120V24V transformer, or may cause other safety control damage or failure.

CAUTION: Make sure there is no ignition source in the boiler room.

NOTE: Reference the start-up pressures settings located on the side of the control box.

Page 49

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. Confirm it is centered and reinstall burner head;

6. If you have spark, turn off unit;

7. Turn on power. Unit will pre-purge 40-45 seconds and move onto ignition trial. You will hear a click

from pilot gas valve (you will not hear the sparking);

8. The pilot may not light at first trial; leave the unit running until you have pilot. If you still do not see pilot over 90 seconds; turn off the unit; repeat steps 6-8;

9. Check pilot manifold pressure, Location (4). Compare the reading to the value listed in the tables;

10. Check pilot flame; 8 distinct circular blue flames around the center of the pilot;

11. Replace the cap for pilot manifold adjustment screw; do not over-tighten.

Note: For different gas control options, call the factory for proper pressure settings.

Table U: Pressure Settings and Emission Guidelines (True Readings) for NAT. GAS

Table V: Pressure Settings and Emission Guidelines (True Readings) for LP GAS

Page 50

Main Burner Adjustment

1. Turn 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, Location (2); this should read to within ± 0.1 in. WC of the values shown in tables U and V.

5. If adjustment is required, remove screw cap off the top gas pressure regulator, and adjust regulator.

6. Slowly turn the bottom manual valve on, Location (3). The outer burner will fire.

7. Make sure that the supply gas manometer reads between 7 – 14 in. WC (dynamic pressure).

8. Check manifold pressure, Location (3); this should read to within ± 0.1 in. WC of the values shown in tables U and V.

9. If adjustment is required, remove screw cap off the bottom gas pressure regulator, and adjust regulator.

10. The blower pressure should increase about 3/10 in. (0.3 in.) WC equaling the “Firing” value in tables U and V.

11. Lock the blower shutter by tightening the shutter nut while holding the black knob fixed.

12. Allow minimum 5 minutes of run time; then attach flue analyzer, check emission and compare the CO2 reading to that of table U and V.

13. If CO2 is high, reduce bottom manifold gas pressure.

14. If CO2 is low, increase the bottom manifold gas pressure.

15. All pressure readings especially manifold pressures should be within ±0.1 in. of listed values.

16. Replace the screw caps back on the gas regulators.

Your ADB is tuned in!

Safety Inspection

· Check thermostat and high limit settings.

· Attach thermometers to IN/OUT piping and take

temperature measurement, see Table E and G for correct flow balance.

· During the following safety checks leave manometers, and analyzer hooked up, check and record.

· If other gas fired equipment in the room and on same gas main, check gas pressures on ADB with them running.

Remember, supply gas should always be between 7 in. and 14 in. WC.

· Check thermostat control for ON/OFF operation;

· Check safety Hi Limits for ON/OFF operation;

· While in operation inspect flow switch;

· Check the low gas pressure switch, it is factory set at 6 in. WC for natural gas;

· High gas pressure switch (optional) at 1 in. WC above manifold pressure;

· Insert ignition control lockout test as safety check

Follow-up

• Safety checks must be recorded as performed;

• Turn unit on;

• After main burner ignition. Check Manometers for proper readings;

• Verify that the blower shutter is locked;

• Cycle unit several times and recheck readings;

• Re-analyze with unit running record or print results;

• Turn unit off, remove all Manometers and replace blower switch hose, replace all gas pressure caps and plugs;

• Check for gas leak one more time;

• Check around unit for debris and remove combustible and flammable products, i.e. paper, gasoline etc.

POST START-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. Followed start-up procedure for proper start-up?

6. Is burner flame visible?

7. Test safety controls: If boiler is equipped with a low water cutoff or additional safety controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when controls are tested. When safety devices are restored,

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.

Page 51

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.

• Turn power on; after about 45 seconds of pre-

purge, the pilot comes on. The pilot (and therefore the burner) should fail to light. The standard lockout time is 90 seconds; then the pilot light goes off and the boiler goes into post-purge. (If the lockout module is attached to boiler, a lockout light comes on.)

• Turn the power off; open the pilot manual

valve; (reset the lockout module if applicable).

• Wait 30 seconds, then turn power on. The

burner should ignite after pre-purge time delay.

10. To restart system, follow the lighting instructions.

11. High limit control set to design temperature requirements of system? For multiple zones: flow adjusted as required in each zone?

12. Boiler cycled with thermostat? Raise to highest setting and verify boiler goes through normal startup cycle. Reduce to lowest setting and verify boiler goes off.

13. Observed several operating cycles for proper operation?

14. Set room thermostat or tankstat to desired temperature?

15. Reviewed all instructions shipped with this boiler with owner or maintenance personnel, returned to envelope and given to owner or placed in pocket inside front panel on boiler?

OPERATION

Operating 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. DO NOT try to light the burner by hand.

5. Remove upper front panel.

6. Turn on main manual gas valve and pilot manual gas valve.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, especially near the floor. If you then smell gas. STOP! Follow the steps in the safety information. If you do not smell gas, go to next step.

8. Turn on all electric power to the appliance.

9. Set thermostat to desired setting. The appliance will operate. The pilot burner will light after the prepurge time delay (45 seconds). Then the pilot will light the main burner.

10. If the appliance will not operate, follow the instruction "To Turn Off Gas to Appliance", and contact a qualified service technician.

11. Replace upper front panel.

To Turn Off Gas to Appliance

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove upper front panel.

4. Turn off main manual gas valve and manual pilot gas valve.

5. Replace access panel.

If boiler fails to start, check for:

• Loose connections, blown fuse or service

switch off?

• High temperature limit switch set below boiler

water temperature?

• Thermostat set below room temperature?

• Gas not turned on at meter or boiler?

• Incoming dynamic gas pressure less than 6 in.

WC for Natural gas, 10 in. WC for Propane?

MAINTENANCE

Suggested Minimum Maintenance Schedule:

Regular service by a qualified service agency and maintenance must be performed to ensure maximum boiler operating efficiency.

Maintenance as outlined below may be performed by the owner.

Yearly (Beginning of each heating season):

1. Annual service call by qualified service agency.

2. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal.

Page 52

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. Follow oil-lubricating instructions on circulator. Over-oiling will damage circulator. Water-lubricated circulators do not need oiling.

10. Visually inspect condensate drain piping for proper operation or deterioration (if appropriate). Check for plugged condensate trap. Use clean-out plug to clear trap.

11. To avoid potential of severe burn, DO NOT REST HANDS ON OR GRASP PIPES. Use a light touch

- return piping will heat up quickly.

12. If mixing valve does not seem to be working, the spring and thermostat may need to be replaced. Call a qualified service technician.

13. Check for piping leaks around circulators, mixing valves, relief valves and other fittings. Repair, if found. DO NOT use petroleum based stop leak.

Daily:

1. Check that boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids.

2. Check for and remove any obstruction to the flow of combustion or ventilation air to boiler.

Monthly:

1. Check for piping leaks around circulators, mixing valves, relief valves, and other fittings. If found, repair at once. DO NOT use petroleum-based stop leak compounds.

2. Visually inspect burner flame.

3. Visually inspect venting system for proper function, deterioration or leakage.

4. Check air vents for leakage.

5. Check the hose fitting/orifice on the blower. Make certain that orifice is not blocked by grease, dirt or any other debris. If necessary, use a thin wire to clean up the orifice.

Periodically:

1. Check relief valve. Refer to manufacturer’s instructions on valve.

2. Test low water cutoff, if used. Refer to manufacturer’s instructions.

3. Visually inspect condensate drain hose for proper operation or deterioration (if appropriate). Check for plugged condensate trap. Use cleanout plug to clear trap.

4. Clean screen in vent termination and air intake.

Cleaning Boiler Heating Surfaces:

The following service procedures must be performed ONLY 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. Also check burner, replace if damaged.

2. If you find rust deposits in vent elbow - check for high water flow rate or low inlet water temperatures. Clean boiler as above.

CONNECTING THE CONDENSING HEAT EXCHANGER (CHX)

Refer to Fig. 39 for the following steps:

1. Remove the shroud.

2. Remove the top cover.

3. Secure the 15° elbows (supplied) as shown one on each side of the CHX, using the stainless steel screws (supplied).

4. Seal the connection with high temperature RTV (supplied).

5. Replace the top cover.

6. Level the CHX with the ADB by adjusting the leveling screws at the base.

7. Place a line of RTV on the crimped end of the flue outlet from the ADB and slide the CHX to join the ADB flue outlet to the CHX flue inlet.

8. Connect the CHX water as specified in the piping diagram. Check for water leak.

9. Secure the flue connection from step 7 above with the stainless steel screws (supplied).

NOTE: Connect the vent before connecting the water piping. Install unions on water inlet and outlet of CHX for ease of maintenance. The CHX requires cleaning as often as once a year.

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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. The vent switch is located on the J-box, just outside the ignition module. Use the following steps:

• Turn power off; disconnect the electrical wiring and the rubber hose.

• Remove the switch (it has a black plastic orifice at the hose connection).

• On the backside, remove the (purple) seal from atop the adjusting screw.

• Turn the plastic hex screw 1-1/2 turn clockwise.

• Seal with silicone.

• Reinstall in reverse order.

Table W: CHX Rate of Flow and Pressure Drop

Fig. 39: Connecting Add-on Condensing Heat Exchanger to ADB

Page 54

APPENDIX

Inside Combustion Air Contamination:

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. Higher acidic levels attack many materials, including stainless steel commonly used in high efficiency systems.

The ADB can use special corrosion-resistant nonmetallic vent material. You may, however, choose to use outside combustion air for one or more of these reasons:

• installation is in an area containing contaminants listed below which will induce acidic condensation.

• you want to reduce infiltration into your building through openings around windows and doors.

• you are using AL29-4C stainless steel vent pipe, which is more corrosion-resistant than standard metallic vent pipe. In extremely contaminated area, this may also experience deterioration.

Products causing contaminated combustion air:

• spray cans containing chloro/fluorocarbons

• permanent wave solutions

• chlorinated waxes/cleaners

• chlorine-based swimming pool chemicals

• calcium chloride used for thawing

• sodium chloride used for water softening

• refrigerant leaks

• paint or varnish removers

• hydrochloric acid/muriatic acid

• cements and glues

• anti-static fabric softeners used in clothes dryers

• chloride-type bleaches, detergents, and cleaning

solvents found in household laundry rooms

• adhesives used to fasten building products

• ... and other similar products

Areas causing contaminated combustion air:

• dry cleaning/laundry areas and establishments

• metal fabrication plants

• beauty shops

• refrigeration repair shops

• photo processing plants

• auto body shops

• plastic manufacturing plants

• furniture refinishing areas and establishments

• new building construction

• remodeling areas

Check for areas and products as listed above before installing boiler. If found:

• remove products permanently, OR

• provide outdoor combustion air

Page 55

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.

GAS SUPPLY DATA CLEARANCES

Regulator Model & Size _________ / ______CFH Front Clearance _______________In. Gas Line Size (in room) ________________In. NPT Right Side Clearance _______________In. Length of Gas Line ________________Eq Ft Left Side Clearance _______________In. Low Gas Pressure Setting ________________In. WC Rear Clearance _______________In. High Gas Pressure Setting ________________In. WC Overhead Clearance _______________In. Gas Shut-Off Valve Type ________________ ( Ball, Lube cock)

Sediment Trap ________________Y/N Voltage Supply (VAC) No Load______ Load_____ Port _______Std______Full Voltage -24 VAC _______________VAC Voltage Com to Ground _______________VAC

VISUAL INSPECTION OF COMPONENTS

Verify inspection was done and condition of components are in good working order with a “yes” Wiring Harness _________________ Y/N Operating Control Setting _______________deg F Burner/s (flame) _________________ Y/N Refractory (visual) _________________ Y/N Sketch plumbing on reverse side Remote flame sense _________________ Y/N

Covers in place for outdoor _________________ Y/N Flow Rate in GPM or Delta T _______________If Avail

VENTING

Vent Size: _____________ Stack Height:_______ Low Water Cutoff _______________Test Category: _________ sketch vent on reverse side *** Vent Material: __________________ Plumbing Size _______________ Vent Termination Type: __________________ Pump Size: _________ Combustion Air Openings: Low __________ in2 Impeller trim____________ Pump Model___________ Ventilation air High __________ in2 Louvers __________________ Screens________________

Pump Economaster setting _______________Minutes

EMISSIONS SETTINGS AND TEST INFORMATION

(AT FULL FIRE)

Blower Pressure Setting _________________In. WC See manual or card tag Supply Gas Pressure Verify stable pressure static & Pilot Gas Pressure _________________In. WC See manual or card tag Manifold Gas Pressure _________________In. WC See manual or card tag

The following measurements must be obtained with a Combustion Analyzer. NOX _________________PPM Less than 20 PPM (If required by Certifying Agency) Free Oxygen _________________% See manual CO _________________PPM Less than 150 PPM CO2 _________________% See manual

Model Number: ______________________________ Serial Number: _______________________________ *** Note: draw venting with details, such as extractors, barometric dampers, blast dampers or draft inducers

_________________In. WC dynamic condition

ELECTRICAL

Hot Surface Igniter Auto High Limit Setting Manual Reset High Limit Setting

_______________Ohms _______________deg F _______________deg F

WATER SUPPLY

Measure flow rate at full fire

Number of Tanks and Size Qty____ _______Gallons

(boiler) Pump HP: ______

Nominal Factory Recommended Settings

See manual or card tag

Site Altitude Above Sea Level __________________Ft.

Job Name _______________________________________________________________________________________

Address _________________________________________________________________________________________

Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; Roof______; Below Grade______

Mechanical Contractor / Installer _______________________________________________________________________

Date and Time of Start-up _____________Print Name and Signature of Start-up Technician_________________________

Information must be faxed to: (805) 278-5471 in order to ensure warranty consideration Attn: Service Manager

Page 56

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.

HEA

T EXCHANGER W

ARRANTY

° Ten (10) Years from date of boiler installation. This includes only cupro-nickel with bronze or cast iron waterways. ° T

wenty (20) Years from date of boiler installation against "Thermal Shock" (excluded, however, if caused by boiler operation at large changes exceeding 150°F between the water temperature at intake and boiler temperature, or operating at boiler temperatures exceeding 230°F).

UFF HEAD BODY BURNER WARRANTY

° T

en (10) Y

ears from date of boiler installation.

ANY O

THER PART MANUFA

CTURED BY RAYPAK:

One (1) Year warranty from date of boiler installation, or eighteen (18) months from date of factory shipment based on Raypak's records, whichever comes first. SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE VOID IF THE BOILER RATING PLATE IS ALTERED OR REMOVED.

ADDITION

WARRANTY EXCLUSIONS:

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the boiler in accordance with our printed instructions provided;

2. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding boiler design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the boiler system;

7. Failing to eliminate air from, or replenish water in, the connected water system;

8. Chemical, particulate matter or other airborne contamination of combustion air or use of chemical additives to water.

TS REPLACEMENT:

Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer.

O MAKE

WARRANTY CLAIM:

Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be received from Raypak before replacement of any part.

CLUSIVE WARRANTY - LIMITATION OF LIABILITY:

This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak's behalf. THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK'S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not apply to you.

This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the date of manufacture plus thirty (30) days.

Page 57

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.

Raypak ADB 1001CHX Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual