Raypak H7-108A Installation Manual

INSTALLATION & OPERATING

CUS

INSTRUCTIONS

Models 88AR–398A

Type H

AVERTISSEMENT: Assurez-vous de bien suivre

WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

les instructions données dans cette notice pour réduire au minimum le risqué d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.

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.

Ne pas entreposer ni utilizer d’essence ou ni d’autres vapeurs ou liquids inflammables à proimité de cet appareil ou de tout autre appareil.

CE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAS:

Ne pas tenter d’allumer d’appareil. • Ne touchez á aucun interrupteur; ne pas vous• server des téléphones se trouvant dans la bâtiment. Appelez immédiatement votre fournisseur de• gaz depuis un voisin. Suivre les instructions du fournisseur. Si vous ne pouvez rejoinder le fournisseur,• appelez le service es incendies.

L’installation et l’entretien doivent être assurés par un installeur qualifié ou par le fournisseur de gaz.

Catalog No. 1000.66B Effective: 06-01-16 Replaces: 12-08-15 P/N 241556 Rev. 3

Rev. 3 reflects the following: Changes to: Minor changes to pages 8, 17, 22, 29, 37, 38, 39, 40, 52, 55, 58, 59, 66 and 67. Updated Wiring Diagram

on page 47.

Additions: Information under Condensate Management on page 37. Deletions: Information under Ignition Control Functions on page 39.

CONTENTS

WARNINGS 4

Pay Attention to These Terms 4

BEFORE INSTALLATION 5

Product Receipt 5 Model Identification 6 Ratings and Certifications 6 Installations at Elevation 6 Component Locations 7 General Information 7

BOILER DIMENSIONS 8

Time/Temperature Relationships in Scalds 9

INSTALLATION 9

Installation Codes 9 Equipment Room 10 Clearances 10 Combustion and Ventilation Air 11 Direct Vent 14 Conventional Combustion Air Supply 14 Water Piping 15 Hydronic Heating 16 System Sensor Installation 16 Applications and Modes 17 Heater Flow Rates and Pressure Drops 17 MODE 1 Water Plumbing 18 MODE 2 Water Plumbing 19 MODE 3 Water Plumbing 20 Gas Supply 21 Gas Supply Connection 21 Equivalent Pipe Length 21 Gas Supply Pressure 22 Electrical Power Connections 22 Making the Electrical Connections 23 Field Wiring Connections 24 Heating System Sensor Installation 25 Venting 28 Venting Installation Tips 31 Venting Configurations 31 Condensate Management 37 Freeze Protection 38 Controls 39

Outdoor Reset Concept 45

WIRING DIAGRAM 47

Converting Natural to Propane Gas 48 Gas Valve & Combustion Settings 49

START-UP 50

Pre Start-up 51 Pre Start-up Check 51 Initial Start-up 51 Preparation 51 Start-Up 52 Lighting Instructions 54 To Turn Off Gas to Appliance 54

TROUBLESHOOTING 55

XPak FT Error Codes 55 Heater Errors 55 Heater Faults 55 Sensor Resistance Values 55 XPak FT Fault Text 56

MAINTENANCE 58

Suggested Minimum Maintenance Schedule 58 Preventive Maintenance Schedule 58 Combustion Chamber Cleaning Instructions 60

APPENDIX 61

Inside Air Contamination 61 Important Instructions for the Commonwealth of Massachusetts 62

WARRANTY 63 START-UP CHECKLIST 64 ILLUSTRATED PARTS LIST 65

WARNINGS

Pay Attention to These Terms

ndicates the presence of immediate hazards which will cause severe

DANGER:

I personal injury, death or substantial property damage if ignored.

WARNING:

CAUTION:

NOTE:

DANGER: Make sure the gas on which the boiler

will operate is the same type as that specified on the boiler rating plate.

WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the boiler. Instead, shut off the gas supply at a location external to the boiler.

WARNING: Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any 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 boiler:

Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

WARNING: Both natural gas and propane have an odorant added to aid in detecting a gas leak. Some people may not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar with the smell of natural gas or propane, ask your local gas supplier. Other conditions, such as "odorant fade," which causes the odorant to diminish in intensity, can also hide, camouflage, or otherwise make detecting a gas leak by smell more difficult.

WARNING: UL-recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications wherein there is a potential for an explosive mixture of fuel gas to accumulate and their installation should be in accordance with the detector manufacturer's recommendations and/or local laws, rules, regulations, or customs.

• Always keep the area around the boiler free of combustible materials, gasoline, and other flammable liquids and vapors.

• Boiler should never be covered or have any blockage to the flow of fresh air to the boiler.

WARNING: Vent connectors serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure. If an XPak FT an existing unit, the vent system MUST be verified to be of the correct size and of one of the Category IV vent materials identified in this manual. If it is NOT, it MUST be replaced.

boiler is installed to replace

WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the

State of California to cause cancer, birth defects or other reproductive harm.

WARNING: This appliance produces condensate from the flue products that is acidic and highly corrosive. Raypak recommends the use of a condensate neutralizer kit to avoid long-term damage to the drainage system and to meet local code requirements.

WARNING: Risk of electrical shock. More than one disconnect switch may be required to de-energize the equipment before servicing.

CAUTION: This boiler requires forced water circulation when the burner is operating. See minimum and maximum flow rates. Severe damage will occur if the boiler is operated without proper water flow circulation.

OTE: When the boiler has been filled for the first

time or the system has been drained and refilled, it will be necessary to release any air that may have become trapped within the appliance heat exchanger. Open the bleedle valve until all air is purged.

AVERTISSEMENT: N’utilisez pas cette Chaudière si une partie de celle-ci s’est retrouvée sous l’eau. Appelez immédiatement un technician de service qualifié pour inspecter la Chaudière et pour remplacer toute partie du système de contrôle et toute commande de gaz s’étant retrouvée sous l’eau.

OTE: Minimum 18 AWG, 105°C, stranded wire

must be used for all low voltage (less than 30 Volts)

xternal connections to the unit. Solid conductors

e should not be used because they can cause

xcessive tension on contact points. Install conduit

e as appropriate. All high voltage wires must be the same size (105°C, stranded wire) as the ones on the unit or larger.

AVERTISSEMENT: En cas de surchauffe ou de non fermeture de la vanne d’alimentation en gaz, n’éteignez ou ne débranchez pas l’alimentation électrique de la chaudière. Coupez plutôt l’alimentation en gaz á l’extérieur de la chaudière.

BEFORE INSTALLATION

Raypak strongly recommends that this manual be reviewed thoroughly before installing your XPak FT boiler. Please review the General Safety information before installing the unit. Factory warranty does not apply to units 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 your local Raypak representative or visit our website at www.raypak.com.

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 unit it is suggested that you visually check for external damage to the shipping carton. If the carton is damaged, make a note to that effect on the Bill of Lading when signing for the shipment. Next, remove the boiler from the carton. 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 boiler. 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. Parts will be replaced in kind only per Raypak’s standard warranties.

Model Identification

he model identification number and boiler serial num-

T ber are found on the rating plate located on the inside upper right panel and also on inlet air decal. The model number has the form H7-198AR or similar

epending on the unit size and configuration. The let-

d ter in the first group of characters identifies the application (H = Hydronic Heating). The number which follows identifies the firing mode (7 = electronic modulation). The second group of characters identifies the size of the unit (three numbers representing the approximate MBTUH input), and, where applicable, a letter indicating the manufacturing series.

Ratings and Certifications

Standards:

• ANSI Z21.13 · CSA 4.9 - latest edition, GasFired Hot Water Boilers

• SCAQMD Rule 1146.2

All units are National Board Registered, and designcertified and tested by the Canadian Standards Association (CSA) for the U.S. and Canada. Each boiler is constructed in accordance with Section IV of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code and bears the ASME “H” stamp. This boiler also complies with the latest edition of the ASHRAE 90.1 Standard.

Fig 1: Boiler Carton Contents

Items Included:

1. (1) XPak FT Boiler

2. (1) Wall Mount Bracket

3. (6) Lag Screws

4. (2) Hold Down Brackets

5. (6) Washers

6. (1) Full-Scale Heater Template

7. (1) T & P Gauge

8. (1) Condensate Trap & Hose

9. (2) System Sensor

10. (1) Outdoor Sensor

11. (1) Installation & Operating Instructions Manual

12. (1) Propane Orifice Kit (Models 88AR & 108AR ONLY)

Installations at Elevation

WARNING: Altering any Raypak pressure vessel

by installing replacement heat exchangers or any ASME parts not manufactured and/or approved by Raypak will instantly void the ASME and CSA ratings of the vessel and any Raypak warranty on the vessel. Altering the ASME or CSA ratings of the vessel also violates national, state, and local approval codes.

Rated inputs are suitable for up to 2,000 ft elevation without de-rating. Consult your local representative or the factory for installations at altitudes over 2,000 ft above sea level. No hardware changes are required to the boilers for installations up to 10,000 ft (adjustments may be required).

Component Location

Fig 2: Component Locations

General Information

AFUE Rating

Model

Input (MBH)

% Nat Pro Flue Intake

Min Max

88AR 17.0 85 95 12.0 1” ½” ½” 2”/3”** 2”/3”**

108AR 22.0 110 95 13.0 1” ½” ½” 3” 3”

198AR 39.8 199 95 28.4 1-1/4” ¾” ¾” 3” 3”

278AR 55.0 275 95 36.6 1-1/4” ¾” ¾” 3” 3”

398A 39.9 399 96* 39.9 1-1/2” ¾” ¾” 3”/4”*** 3”/4”***

*Model 398A value is a Thermal Efficiency. **Model 88AR has a 3" standard vent size, but can be reduced to 2" with a shorter run. (See page 31 for details) ***Model 398A has a 4" standard vent size, but can be reduced to 3" with a shorter run. (See page 31 for details)

Minimum

Operating

Input

(MBH)

Table A: Basic Data

Water Conn. (NPT)

Gas conn. (NPT) Vent Size (inches)

Dimensions

3.79

WATER INLET

GAS SUPPLY CONNECTION

WATER OUTLET

CONDENSATE

OUTLET

AIR INLET

PRV

FLUE OUTLET

Fig 3: Boiler Dimensions

Model

88AR/

108AR

198AR/

278AR

398A 21.4 38.6 22.1 2.7 4.0 10.1 12.0 13.0 8.9 2.6 15.3 4.0 2.1

A B C D E F H J K L M N P

16.4 35.8 16.5 2.1 2.7 6.3 7.8 9.5 5.5 1.5 4.6 2.8 2.3

18.6 36.2 19.4 2.0 3.1 8.2 10.0 11.3 7.1 1.7 12.3 3.6 2.3

Table B: Basic Data

odel No.

8AR

Boiler Water Volume

(gallons)

108AR 2.9

198AR 5.2

278AR 4.5

398A 5.9

Table C: Heater Water Volume

WARNING: This boiler cannot supply hot water for

use by individuals directly. A heat exchanger must be used in conjunction with this boiler to meet DHW needs.

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.

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 –•

atest edition (NFGC)

l 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 Natural Gas• and Propane Installation Code and CSA C22.1 C.E.C. Part 1 (C22.1)

CAUTION: This boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliances 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.

Water Temp.

Time to Produce

Serious Burn

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

Table D: Time to Produce Serious Burn

Fig 4: Wall Mount Installation

Equipment Room

Install CO detectors per local regulations. Boiler requires yearly maintenance, see chapter “Checks, adjustments and fault finding”.

Operating Limits of the boiler: Max. Boiler Outlet Temperature: 200°F (99°C) Max. Operating Pressure: 80 psi (5.5 bar)

The hot water distribution system must comply with all applicable codes and regulations. When replacing an existing boiler, it is important to check the condition of the entire hot water distribution system to ensure safe operation.

In addition, the unit shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation or service.

NOTE: Use of this boiler in construction areas where fine particulate matter, such as concrete or dry-wall dust, is present may result in damage to the boiler that is not covered by the warranty. If operated in a construction environment, a clean source of combustion air must be provided directly to the boiler.

Clearances Indoor Installations

When installed according to the listed minimum clearances from combustible construction, these boilers can be serviced without removing permanent structural construction around the unit. However, for ease of servicing, we recommend a clearance of at least 24 in. in front, on the rear and 24 in. above the top of the boiler. This will allow the unit to be serviced in its installed location without movement or removal of the heater.

Service clearances less than the minimum may require removal of the unit to service either the heat exchanger or the burner components. In either case, the boiler must be installed in a manner that will enable the unit to be serviced without removing any structure around the boiler.

Min.

Boiler Side

Clearances

from

Combustible

Minimum

Service

Clearances

Surfaces

Right Side 0” 1”

Left Side 0” 1”

Top 0” 24”

Front Open 24”

Vent 1” 1”

Bottom 6” 12”

Table E: Clearances — Indoor Installations

ombust

lie

(

min

TE: It

insulat

and

ion

min

ila

l me

imme

l c

ll lo

)

ile

)

is reco

in cold climates t

mmended that the in

Vent

lie

lla

o minimize swe

u e

mb io

u s

n C

mic

ila

(

n n s

f a

r ir

ion

)

ke ven

ating.

t w

(

s t

ir b a

h S

e h

Venting not shown for clarity. Boiler must be vented per

instructions in this manual

Fig. 5: Minimum Clearances from Combustible

Surfaces

Fig 6: Indoor Air Duct

Fig 7: Two Vertical Air Ducts - Floor

Fig 8: Single Air Duct

Fig 9: Two Vertical air Ducts - Ceiling

Fig 10: Two Horizontal Air Ducts

U.S. Installations

Canadian Installations

Clearance above grade, veranda, porch, deck, or balcony

1 ft (30 cm) 1 ft (30 cm)

Clearance to window or door that may be opened

4 ft (1.2 m) below or to side

of opening; 1 foot (30 cm)

above opening

3 ft (91 cm)

C Clearance to permanently closed window * *

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the terminal

5 ft (1.5 m) *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner 6 ft (1.83 m) *

Clearance to each side of center line extended 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 (1.83 m)

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance

4 ft (1.2 m) below or to side

of opening; 1 ft (30 cm)

above opening

3 ft (91 cm)

K Clearance to mechanical air supply inlet

3 ft (91 cm) above if within

10 ft (3 m) horizontally

6 ft (1.83 m)

Clearance above paved sidewalk or paved driveway located on public property

7 ft (2.13 m)

7 ft (2.13 m) t

Clearance under veranda, porch, deck or balcony

* 12 in. (30 cm) TT

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

In accordance with the current CAN/CSA-B149 Installation Codes

t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single-family dwellings that serves

both dwellings

TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of term inal and

underside of veranda, porch, deck or balcony is greater than 1 ft (30 cm)

* Clearances in accordance with local installation codes and the requirements of the gas supplier

Fig. 11: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table F: Vent/Air Inlet Termination Clearances

Direct Vent

If outside air is drawn through the intake pipe directly

o the unit for combustion:

1. Install the combustion air ducting kit.

. Install combustion air direct vent in accordance

with Fig. 24 (horizontal) or Fig. 26 (vertical) of this manual.

3. Ventilation of the space occupied by the boiler(s) is recommended and can be provided by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area should be at least 1 in² of free area per 20,000 BTUH (111 mm² per kW) 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 should be at least 1 in² of free area per 10,000 BTUH (222 mm² per kW) of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct(s). Damage to the equipment due to inadequate ventilation of the space is not a warrantable failure.

4. In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of a motorized sealed damper on the air intake to prevent the circulation of cold air through the boiler during non-operating hours.

Conventional Combustion Air Supply

U.S. Installations

All Air from Inside the Building

The confined space shall be provided with TWO permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for a room large in comparison (NFGC). The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 in.2 per 1,000 BTUH (2,225 mm2 per kW) of the total input rating of all gas utilization equipment in the con- fined space, but not less than 100 in.2 (645 cm2). One opening shall commence within 12 in. (305 mm) of the top, and one opening shall commence within 12 in. (305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 in. (76 mm) in any direction.

ll Air from Outdoors

The confined space shall communicate with the out-

oors in accordance with one of the methods below.

d The minimum dimension of air openings shall not be less than 3 in. (76 mm) in any direction. Where ducts are used, they shall be of the same cross-sectional

rea as the net free area of the openings to which they

a connect.

1. Two permanent openings, one commencing within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

a. Where directly communicating with the out-

doors or where communicating to the outdoors through vertical ducts, each open- ing shall have a minimum free area of 1 in. per 4,000 BTUH (550 mm2per kW) of total input rating of all equipment in the enclosure.

b. Where communicating with the outdoors

through horizontal ducts, each opening shall have a minimum free area of 1 in.2per 2,000 BTUH (1,100 mm2per kW) of total input rating of all equipment in the enclosure.

2. One permanent opening, commencing within 12 in. (305 mm) of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 in. (25 mm) from the sides, top and bottom and 6 in. (152 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors, and shall have a minimum free area of:

a. 1 in.2per 3,000 BTUH (740 mm2per kW) of

the total input rating of all equipment located in the enclosure, and

b. Not less than the sum of the areas of all vent

connectors in the confined space.

WARNING: Do not use the “one permanent opening” method if the equipment room is under negative-pressure conditions.

Canadian Installations

. 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 the outdoors. The total cross-sectional area of

uch an opening(s) shall be at least 10% of the

s area required in 2. and 3. (below), but in no case shall the cross-sectional area be less than 10 in.2 (65 cm2).

CAUTION: All combustion air must be drawn from the air outside of the building; the mechanical equipment room must communicate directly with the outdoors.

2. For boilers using a barometric damper in the vent system, there shall be a permanent air supply opening(s) having a cross section area of not less than 1 in. to and including 1 million BTUH, plus 1 in.2per 14,000 BTUH (160 mm2per kW) in excess of 1 million BTUH. This opening(s) shall be either located at or ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down and terminated 18 in. (450 mm) from the floor, but not near piping. This air supply opening requirement shall be in addition to the air opening for ventilation air required in 1. (above).

3. For heaters when air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator, drafthood 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 in.2for each 30,000 BTUH (74 mm2per 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 in 1. This opening(s) can be ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down 18 in. (450 mm) from the floor, but not near piping.

WARNING: Care must be taken to ensure that the equipment room is not under negative pressure conditions.

per 7,000 BTUH (320 mm2per kW) up

Water Piping

NOTE: Refer to the VERSA IC®Applications Guide

(Catalog #5000.72) for detailed instructions regarding the various applications supported by the

ERSA IC control system.

General

The boiler should be located so that any water leaks will not cause damage to the adjacent area or structures.

CAUTION: This boiler requires forced water circulation when the burner is operating. See Table H for minimum and maximum flow rates. The pump must be interlocked with the boiler to prevent heater operation without water circulation.

WARNING: Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur. Refer to local codes.

Relief Valve Installation and Piping

The boiler is supplied with a Section IV “H” stamped relief valve sized for the full input of the unit. Relief valve discharge piping shall provide no less than the cross-sectional area of the relief valve outlet and must be routed to a safe point of discharge. Installation must comply with all national, state and local codes.

Temperature & Pressure Gauge

The temperature and pressure gauge is shipped loose for field installation and must be installed within 12 inches of the boiler outlet (if possible) in an easily readable location. Installation must comply with ASME Section IV as well as all applicable national, state and local codes.

Hydrostatic Test

Unlike many types of heaters, this boiler does not require hydrostatic testing prior to being placed in operation. The heat exchanger is ASME certified for 80 PSI maximum working pressure. However, Raypak does recommend hydrostatic testing of the piping connections to the unit and the rest of the system prior to operation. This is particularly true for hydronic systems using expensive glycol-based anti-freeze. Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply.

4. Refer to the B149 Installation Code for additional information.

eaks must be repaired at once to prevent damage to

L the heater. NEVER use petroleum-based stop-leak compounds.

o perform hydrostatic test:

. Connect fill water supply. With bleed valve open,

fill boiler with water. When water flows from bleed valve, shut off water. Close bleed valve. Carefully fill the rest of the system, making 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.

Hydronic Heating

Pump Selection

In order to ensure proper performance of your boiler system, you must install a correctly-sized pump. Raypak recommends designing for a ∆T within the range of 20°F to 60°F (8°C to 19°C). See Table H for acceptable flow rates for each model (∆T is the temperature difference between the inlet and outlet water when the heater is firing at full rate).

System Sensor Installation

The System Sensor (S3) is required for all selectable modes unless the unit’s firing rate will be controlled by an external source such as our Temp Tracker MOD+ Hybrid sequencer. Proper placement and method of installation are critical for proper operation of the system. (See Fig. 12) The sensor must be installed in a drywell in conjunction with heat conductive compound as shown in the following images. The drywell must be installed no more than 5 equivalent feet of pipe/tubing downstream of the de-coupler and installed in such a way that ensures the sensor bulb is in the flow path.

CAUTION: Be careful when installing the drywell not to over-tighten the well as this can damage the well and may prevent the sensor from fitting properly.

NPT Fitting

Thermal Paste

Drywell

System Sensor (S3)

Boiler Model

Standard Boiler Pump*

Pump HP

H7-88AR TACO 007 1/25

H7-108AR TACO 007 1/25

H7-198AR TACO 010 1/8

H7-278AR TACO 012 1/8

H7-398A TACO 012 1/8

* Pump selection based on 30° ∆T with up to 50 eq. ft. of tubing.

Table G: Pump Selection

NOTE: The 50 eq. feet of tubing typically represents

25 linear feet of tubing and 25 eq. feet of fittings.

Fig 12: System Sensor Installation

Three-Way Valves

Three-way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used.

Applications & Modes

The VERSA IC Control system is designed for a wide range of applications. The installer/design engineer should refer to the following Modes to determine which best fits the intended application and functionality for

he unit being installed.

The XPak FT has three modes available to them to address the various applications the units can be applied to.

Mode 1

This mode is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4). The system temperature is controlled by the System sensor (S3). The Boiler Pump (P1) runs during any call for heat. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the warm weather shut down (WWSD) temperature setting (if utilized). The Boiler Pump and System Pump are delayed “off” as user-defined in the ADJUST menu. See Fig. 13 for piping example.

Mode 2

This mode is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4) with indirect DHW on the system loop (with or without priority). The system temperature is controlled by the System sensor (S3). The Indirect DHW sensor (S5) determines the indirect call/tank setpoint. The system temperature is boosted to Target Max when using the Indirect DHW sensor (S5) during an indirect call for heat. Priority mode toggles off the System Pump (P2) when an indirect call for heat is present. The Boiler Pump (P1) runs during any call for heat. The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The boiler

ump (P1) and System Pump (P2) delay “off” as user-

P defined in the ADJUST menu. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD

emperature setting (if utilized) unless an indirect call

t for heat is present with priority. See Fig. 14 for piping

xample.

Mode 3

This mode is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4) with indirect DHW on the boiler loop (with priority). The system temperature is controlled by the Supply sensor (S3) whenever the indirect call for heat is not active. The DHW Supply sensor (S5) determines the indirect call/tank setpoint. During an indirect call for heat the boiler firing rate is determined by the water temperature at the Indirect Supply sensor (S6) and the Target Max setting when using the Indirect DHW sensor (S5).

The Boiler Pump (P1) runs during all heat calls regardless of priority. The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The Boiler Pump (P1) and System Pump (P2) delay “off” as user-defined in the ADJUST menu. The system pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect call for heat is present. See Fig. 15 for piping example.

WARNING: All potable water heating with this boiler must be by an indirect heat exchanger. Only non-potable water will go through the boiler.

System flow must exceed 120% of boiler flow.

Water Flow Rates

Model

No.

H7-88A 8.1 5.4 20 5.4 3.3 4.0 2.3 3.2 1.8 2.7 1.4 60

H7-108A 10.5 7.4 20 7.0 4.5 5.2 3.2 4.2 2.4 3.5 2.0 60

H7-198A 18.9 11.6 20 12.6 6.2 9.5 4.3 7.6 3.5 6.3 3.0 60

H7-278A 26.1 20.3 20 17.4 10.1 13.1 6.5 10.5 4.9 8.7 4.0 60

H7-398A 38.3 14.1 20 25.5 7.4 19.2 5.0 15.3 4.0 12.8 3.4 60

Notes: Basis for minimum flow is ∆T . Basis for maximum flow is GPM.

MAXIMUM

FLOW

GPM ΔP (ft) ΔT GPM ΔP (ft) GPM ΔP (ft) GPM ΔP (ft) GPM ΔP (ft) ΔT

Table H: Heater Rates of Flow and Pressure Drops

30°F

∆T

40°F

∆T

50°F

∆T

MINIMUM

FLOW

Fig 13: MODE 1 - Single Boiler - Primary/Secondary Piping

Fig 14: MODE 2 - Single Boiler - Primary/Secondary Piping

with Indirect DHW on System Loop

Fig 15: MODE 3 - Single Boiler - Primary/Secondary Piping

with Indirect DHW on Boiler Loop

Gas Supply

ANGER: Make sure the gas on which the unit will

operate is the same type as specified on the rating plate.

Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve located outside the boiler jacket. It is recommended that a union be installed in the gas supply piping adjacent to the boiler for servicing. Refer to Table J for maximum pipe lengths.

Gas Supply Connection

CAUTION: The boiler must be disconnected from

the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 PSI (3.45 kPa).

The boiler must be isolated from the gas supply piping system by closing the upstream manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1/2 PSI (3.45 kPa). Relieve test pressure in the gas supply line prior to re-connecting the boiler and its manual shut-off valve to the gas supply line. FAIL-

URE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. 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 an open flame.

Fig. 16: Gas Supply Connection

CAUTION: Do not use Teflon tape on gas line pipe

thread. A pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.

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

Model

88AR

108AR

198AR

278AR

398A

Maximum Equivalent Pipe Length

N: Natural Gas 1000 BTU/FT٨3 .60 Specific Gravity @ 0.5” WC pressure Drop

P: Propane Gas 2500 BTU/FT٨3 1.53 Specific Gravity @ 0.5” WC pressure Drop

Input

(KBTU)

88 35 75 135 305 440 990

110 20 50 90 205 290 720 1045

199 15 30 65 95 220 365 880 830

275 15 35 50 120 205 460 425 980

399 20 25 60 100 230 220 485

1/2” 3/4” 1” 1-1/4” 1-1/2”

N P N P N P N P N P

Table J: Maximum Equivalent Pipe Length

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