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Raypak 1001, Operating And Installation Manual, Page: 76 / 76

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Raypak 1001 Operating And Installation Manual Download Page 76

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

Raypak Australia Pty. Ltd

, 7 Geddes Street, Mulgrave, Victoria, Australia 3170 (613) 9560 4944 FAX: (613) 9560-4974

8/98   Litho in U. S. A.

www.raypak.com

Summary of Contents for 1001

Page 1: ...iler Installation and service must be performed by a qualified installer service agency or the gas supplier FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch a...

Page 2: ...and vapors 2 Never cover the boiler lean anything against it store trash or debris near it stand on it or in any way block the flow of fresh air to the boiler WARNING More than one 1 supply source Th...

Page 3: ...SUPPLYCONNECTIONS 24 SECTION I ELECTRICAL POWER CONNECTIONS 27 SECTION J VENTING CONNECTIONS 49 SECTION K CONDENSATE DRAIN 50 SECTION L CONTROLS 56 SECTION M GENERALSAFETYPRECAUTIONS 57 SECTION N PRE...

Page 4: ...sentative 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 product it is suggested that...

Page 5: ...under the applicable American National Standard CSA Standard for USA and Canada Each boiler is constructed in accordance with Section IV of the American Society of Mechanical Engineers ASME Boiler Pre...

Page 6: ...6 FigureA 1 ADVANCED DESIGN BOILER COMPONENT LOCATIONS...

Page 7: ...pproved 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 t...

Page 8: ...LE SURFACES INDOORALCOVE INSTALLATIONS Boiler Size Boiler Side 751 1001 1501 Floor See Note 1 Rear 1 Right 12 Water side Left 1 Top 0 Vent 1 Note 1 Do not install on carpeting Figure B 1 MINIMUM CLEAR...

Page 9: ...diverted away from boilers installed under overhangs TABLE 2 OUTDOOR INSTALLATION MINIMUM CLEARANCES Boiler Size Boiler Side 751 1001 1501 Rear 6 Right 36 Water side Left 36 Top 0 Vent 1 WARNING Comb...

Page 10: ...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 i...

Page 11: ...s with the outdoors 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 s...

Page 12: ...he 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...

Page 13: ...F Delta T as design Delta T Delta T is the temperature difference between the inlet and outlet water when the boiler is firing at full rate If a Delta T larger than 20 F is necessary the bypass must b...

Page 14: ...illed 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 refrigera...

Page 15: ...Figure E 2b SINGLE BOILER PRIMARY SECONDARY PIPING WITH CHX 15 Figure E 3a DUAL BOILER PIPING...

Page 16: ...16 Figure E 3b DUAL BOILER PIPING WITH CHX Figure E 4a SINGLE BOILER LOWTEMPERATUREAPPLICATION HEAT PUMP PRIMARY SECONDARYPIPING...

Page 17: ...ted flow rates for soft medium and hard water Hardness is specified as grains per gallon TABLEF 1 DOMESTICWATERHEATINGBOILER FLOWRATEREQUIREMENTS Delta T Temperature rise in F GPM Gallons per minute S...

Page 18: ...18 FigureF 1bb SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK AND CHX 2 pump system Figure F 1c SINGLE BOILER DOMESTIC HOTWATER WITH ONE STORAGE TANK ONE PRE HEATTANKAND CHX...

Page 19: ...tment of the bypass valve is critical to proper operation of the heater The bypass valve should be adjusted to achieve an inlet water temperature of 100 F and an outlet water temperature of 120 F When...

Page 20: ...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 p p m If the pH drops below 7 2 t...

Page 21: ...Figure G 3a DOUBLE BOILER POOL APPLICATION 21...

Page 22: ...before reconnecting the boiler and its manual shut off valve to the gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAYDAMAGE THE GAS VALVES Over pressurized gas valves are not covered by warranty T...

Page 23: ...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 connec tion that must be connecte...

Page 24: ...a separate disconnect means for each load Use appropriate sized wire as defined by NEC CSAand or local code All primary wiring should be 125 of minimum rating It is strongly recommended that all indi...

Page 25: ...ve Components damaged by improper electrical installation are not covered by warranty 4 Provide an external surge suppressor capable of maintaining system integrity 5 Provide overload protection and a...

Page 26: ...re for the remote tank control through the boiler transformer DO NOT attach line voltage to the TH leads Before starting boiler check to insure proper voltage to boiler and pump BREAK THE WIRE NUTAT T...

Page 27: ...t 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 i...

Page 28: ...ination for Venting Purpose and Venting Arrangement 28 NOTE PVC or CPVC vent maybe used inconjunction with CHX special piping arrangement has to be made Contact manufacturer for details A D B V E N T...

Page 29: ...sate 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 freez...

Page 30: ...he protective screen on the combustion air blower may be relocated to the air inlet termination elbow to act as an inlet screen WARNING Examine the venting system at least once a year Check all joints...

Page 31: ...CALVENTWITHOUTADD ON CONDENSING HEAT EXCHANGER 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 edit...

Page 32: ...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 shou...

Page 33: ...being inspected Follow the manufacturers instructions for lighting each appli ance Adjust thermostat so appliance will operate continuously e Test for natural draft negative pressure 12 above the out...

Page 34: ...e 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 t...

Page 35: ...ent 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...

Page 36: ...SECTION J 3 Horizontal Thru Wall Direct Venting Combustion Air Category III Figure J 3 HORIZONTAL THRU WALL DIRECT VENTING WITHOUT ADD ON SECONDARY CONDENSING HEAT EXCHANGER 36...

Page 37: ...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 mus...

Page 38: ...e J 4 VERTICALDIRECTVENTINGWITHOUTADD ON CONDENSINGHEATEXCHANGER 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 Z22...

Page 39: ...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 emplo...

Page 40: ...SECTION J 5 Vertical Venting With Add On Condensing Heat Exchanger Category IV Domestic Water Figure J 5 VERTICALVENT CATEGORY IV WITHADD ON CONDENSING HEATEXCHANGER 40...

Page 41: ...nstalled to prevent the flue gas leakage Care must be taken during assembly to insure that all joints are sealed properly and are airtight For certain installations i e pool heat pump domestic hot wat...

Page 42: ...SECTION J 6 HorizontalThru wallVentingWithAdd onCondensingHeatExchanger CHX Figure J 6 HORIZONTALTHRU WALLVENTINGWITHADD ON CONDENSINGHEATEXCHANGER 42...

Page 43: ...sembly to insure 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 manufact...

Page 44: ...SECTION J 7 Horizontal Thru Wall Direct Venting Combustion Air With Add On Condensing Heat Exchanger Category IV Figure J 7 HORIZONTALTHRU WALLDIRECTVENTINGWITHADD ON CONDENSINGHEATEXCHANGER 44...

Page 45: ...ool 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 horizon...

Page 46: ...SECTION J 8 Vertical Direct Venting Combustion Air With Add on Condensing Heat Exchanger Category IV Figure J 8 VERTICALDIRECTVENTINGWITHADD ON SECONDARYCONDENSINGHEAT EXCHANGER 46...

Page 47: ...pump domestic hot water supply with pre heat tank PVC or CPVC may be used Contact manufacturer for details To prevent the condensation accumulation in the vent it is required to install the horizontal...

Page 48: ...nimum 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 w...

Page 49: ...ral laws Refer to NFGC section 7 9 for additional information The Condensing Heat Exchanger CHX can generate up to 1 one gallon per hour GPH of condensate for every 100 000 BTUH The maximum condensati...

Page 50: ...tral 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 C...

Page 51: ...he 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 u...

Page 52: ...ystem 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 hig...

Page 53: ...53 Figure L 2 WIRINGDIAGRAM...

Page 54: ...ly 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...

Page 55: ...sure 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 bo...

Page 56: ...ay be used as a guide in determining the safest water temperature for your applications Temperature Time to Produce Serious Burn Temperature Time to Produce Serious Burn 120 F More than 5 minutes 140...

Page 57: ...ING 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 WHATTO DO IFYOU SMELLGAS Do not try to light any...

Page 58: ...58 Figure O 1 COMPONENTAND PRESSURE TAP LOCATIONS Blower T fitting detail...

Page 59: ...lure to do this may burn out 120V 24V transformer ormay cause othersafety control damage or failure 2 2 Attach Manometers to Measure Pressures See Figure O 1 Attach 16 scale manometer to the first gas...

Page 60: ...observe through view port for spark 4 If you do not see spark turn off power check ignition wire and proper grounding and wiring Turn power back on Repeat Step 3 If there is still no spark after seve...

Page 61: ...s required remove screw cap off the bottom gas pressure regulator and adjust regulator 10 The blower pressure should increase about 3 10 0 3 W C equaling the Firing value in tables O 2 and O 3 11 Lock...

Page 62: ...d 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 sec...

Page 63: ...sired setting The appliance will operate The pilot burner will light after the pre purge time delay 45 seconds Then the pilot will light the main burner 10 If the appliance will not operate follow the...

Page 64: ...ntial of severe burn DO NOT REST HANDS ON OR GRASPPIPES 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 rep...

Page 65: ...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...

Page 66: ...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 10 Connect the flue vent Category IV venting UL 1...

Page 67: ...metallic vent pipe In extremely contaminated area this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solution...

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Page 74: ...t ______ W C Main Burner Top ______ W C Main Burner Bottom ______ W C Blower burner on ______ W C Supply Gas static ______ W C Supply Gas dynamic ______ W C Power Supply ______ Volts EMISSION Analyzer...

Page 75: ...ARTS 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 app...

Page 76: ...AX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada L4T1G2 905 677 7999 FAX 905 677 8036 RaypakAustralia Pty Ltd 7 Geddes Street Mulgrave Victoria Australia 3170 613 9560 4...

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