Raypak 500 Operating And Installation Manual Download Page 73

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START-UP SETTINGS

TODAY'S DATE:

__________________________________________________

PRESSURE SETTINGS:

Blower (burner off)………………

______ "W.C.

Pilot………………………………

______ "W.C.

Main Burner………………………

______ "W.C.

Blower (burner on) ………………

______ "W.C.

Supply Gas (static) ………………

______ "W.C.

Supply Gas (dynamic) ……………

______ "W.C.

Power Supply……............……….

______ Volts

EMISSION : (Analyzer readings)

………………………………

______ %

CO………………………………

______ PPM

Excess Air………………………… ______ %

………………………………… ______ %

NOx………………………………

______ PPM

Flue Temperature…………………

______ °F

amb. Temperature…………………

______ °F

Summary of Contents for 500

Page 1: ...dedwiththisboiler Installation and servicemustbeperformedbyaqualifiedinstaller service agencyorthe gassupplier FORYOURSAFETY WHAT TO DO IFYOU SMELLGAS Do not trytolightanyappliance Do not touchanyelec...

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: ...H GAS SUPPLY CONNECTIONS 24 SECTION I ELECTRICAL POWER CONNECTIONS 27 SECTION J VENTING CONNECTIONS 49 SECTION K CONDENSATE DRAIN 50 SECTION L CONTROLS 56 SECTION M GENERALSAFETYPRECAUTIONS 57 SECTION...

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: ...OVE INSTALLATIONS Boiler Size Boiler Side 500 750 1000 Floor See Note 1 Rear 1 1 1 Right 12 Water side 12 Water side 12 Water side Left 1 1 1 Top 0 0 0 Vent 1 1 1 Note 1 Do not install on carpeting Fi...

Page 9: ...ilers installed under overhangs TABLE 2 OUTDOOR INSTALLATION MINIMUM CLEARANCES Boiler Size Boiler Side 500 750 1000 Rear 6 6 6 Right 36 Water side 36 Water side 36 Water side Left 36 36 36 Top 0 0 0...

Page 10: ...lding 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 permanen...

Page 11: ...ed 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...

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

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 PRIMARY SECONDARY PIPING...

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

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 TANKAND CHX 2 pump system Figure F 1c SINGLE BOILER DOMESTIC HOTWATER WITH ONE STORAGE TANK ONE PRE HEATTANKAND CHX...

Page 19: ...ss valve is critical to proper operation of the heater The bypass valve should be adjusted to achieve an inlet water temperature in the range of 90 F to 100 F and an outlet water temperature between 1...

Page 20: ...content and dissolved solids in the water become too high scale forms inside the heat exchanger tubes reducing heater efficiency and also damaging the heater If the pH drops below 7 2 the heater will...

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

Page 22: ...st 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 PROCEDURE MAY DAMAGE THE GAS VALVES Over pressurized gas v...

Page 23: ...NGS See Tables O 2 and O 3 for Pressure Settings page 60 VENTING OF DIAPHRAGM GAS COMPONENTS Boilers have gas train components that have diaphragms in their construction that are supplied with a bleed...

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 indiv...

Page 25: ...rovide 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 Inst...

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: ...ent 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 t...

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: ...ocate 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 outsi...

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: ...ALVENT WITHOUTADD 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: ...gn 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 sh...

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: ...lation 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...

Page 35: ...at 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 cod...

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 See notice next page 36...

Page 37: ...t 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...

Page 38: ...4 VERTICAL DIRECT VENTING WITHOUT ADD ON CONDENSING HEAT EXCHANGER 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...

Page 39: ...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...

Page 40: ...ECTION J 5 Vertical Venting With Add On Condensing Heat Exchanger Category IV Domestic Water Figure J 5 VERTICALVENT CATEGORY IV WITHADD ON CONDENSING HEAT EXCHANGER Contact Manufacturer for Details 4...

Page 41: ...alled 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 water...

Page 42: ...ION J 6 HorizontalThru wallVentingWithAdd onCondensingHeatExchanger CHX Figure J 6 HORIZONTAL THRU WALL VENTING WITH ADD ON CONDENSINGHEATEXCHANGER 42 Contact Manufacturer for Details See notice next...

Page 43: ...nsure 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 de...

Page 44: ...zontal Thru Wall Direct Venting Combustion Air With Add On Condensing Heat Exchanger Category IV Figure J 7 HORIZONTAL THRU WALL DIRECT VENTING WITH ADD ON CONDENSINGHEATEXCHANGER 44 Contact Manufactu...

Page 45: ...mp 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...

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

Page 47: ...ic 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 portion of...

Page 48: ...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 walkwa...

Page 49: ...er 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 condensation rates for...

Page 50: ...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...

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: ...drops below the factory setting of 6 W C for Natural gas and 10 W C for propane gas The high gas pressure switch optional mounts down stream of the gas pressure regulator If the gas pressure regulato...

Page 56: ...may 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 TAPLOCATIONS Blower T fitting detail...

Page 59: ...may burn out 120V 24V transformer or may cause other safety control damage or failure 2 2 Attach Manometers to Measure Pressures See Figure O 1 Attach 16 scale manometer to the first main gas shut off...

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 1 If there is still no spark after sever...

Page 61: ...ially manifold pressure within 0 1 of listed values Your ADB is tuned in 3 4 Safety Inspection Check all thermostats and high limit settings Attach thermometers to IN OUT piping and take the temperatu...

Page 62: ...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...

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 NOTREST 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 repl...

Page 65: ...t these procedures 1 If you find soot in top of vent elbow some sediment in bottom of vent is normal remove vent attachment to theADB and clean flue exhaust baffle inside the boiler Also check burner...

Page 66: ...10 Connect the flue vent Category IV venting UL 17 38 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 l...

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 73: ...ff ______ W C Pilot ______ W C Main Burner ______ W C Blower burner on ______ W C Supply Gas static ______ W C Supply Gas dynamic ______ W C Power Supply ______ Volts EMISSION Analyzer readings CO2 __...

Page 74: ...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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Raypak 500, Operating And Installation Manual

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