Raypak 751 Installation And Operating Instructions Manual Download Page 3

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WARNINGS

BEFORE INSTALLATION

Product Receipt

Model Identification

Ratings and Certifications

Installations at Elevation

Component Locations

GENERAL SAFETY

Time/Temperature Relationships in
Scalds

INSTALLATION

Installation Codes

Equipment Base

Clearances

Combustion and Ventilation Air

Conventional Combustion Air Supply

Water Piping

Hydronic Heating

Gas Supply Connections

Electrical Power Connections

Venting Connections

Venting Installation Tips

Venting Configurations

Condensate Drain

Controls

WIRING DIAGRAM

PRE START-UP

ADB Initial Start-Up

OPERATION

Lighting Instructions

To Turn Off Gas to Appliance

MAINTENANCE

Suggested Minimum
Maintenance Schedule

CONNECTING THE CHX

APPENDIX

Inside Combustion Air Contamination 54

START-UP CHECKLIST

WARRANTY

CONTENTS

Summary of Contents for 751

Page 1: ...r 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...

Page 2: ...2...

Page 3: ...bustion 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 Conden...

Page 4: ...pect 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 d...

Page 5: ...ication 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 th...

Page 6: ...6 Component Locations Fig 1 Component Locations...

Page 7: ...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 f...

Page 8: ...d 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...

Page 9: ...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...

Page 10: ...e 4 ft 1 2m 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 3m horizontally 6 ft 1 83m L Clearance above pav...

Page 11: ...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 t...

Page 12: ...any other types of boilers Raypak boilers do not require hydrostatic testing prior to being placed in operation The heat exchanger has already been fac tory tested and is rated for 160 PSI operating p...

Page 13: ...is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler 13 The boiler piping system of a hot water heating boiler connected to heating coils...

Page 14: ...14 Fig 4 Single Boiler Primary Secondary Piping Fig 5 Single Boiler Primary Secondary Piping with CHX...

Page 15: ...15 Fig 6 Dual Boiler Piping Fig 7 Dual Boiler Piping with CHX...

Page 16: ...piping system for domestic water applications water hardness should be consid ered Table F indicates the suggested flow rates for Table F Domestic Water Heating Boiler Flow Rate Requirements T Tempera...

Page 17: ...17 Fig 9 Single Boiler Domestic Hot Water with One Storage Tank Fig 10 Single Boiler Domestic Hot Water with One Storage Tank and CHX...

Page 18: ...18 Fig 11 Single Boiler Domestic Hot Water with One Storage Tank and CHX 2 pump system Fig 12 Single Boiler Domestic Hot Water with One Storage Tank One Pre Heat Tank and CHX...

Page 19: ...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 c...

Page 20: ...20 Fig 13 Single Boiler Pool Application Fig 14 Single Boiler Pool Application with CHX...

Page 21: ...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 diam eter upstream of the boiler gas con...

Page 22: ...pressure exceeds 14 in WC an intermediate gas pressure reg ulator of the dead lockup type must be installed When connecting additional gas utilization equipment to the gas piping system the existing p...

Page 23: ...oper 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 rat...

Page 24: ...ions Domestic Hot Water The ADB is wired for 120 VAC The voltage is indicat ed on the tie in leads Consult the wiring diagram shipped with the boiler in the instruction packet The TH leads are for the...

Page 25: ...or 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 sho...

Page 26: ...operation of regulators relief valves or other equipment Where local experience indi cates that condensate is a problem with Category I and III appliances this provision shall also apply f Locate and...

Page 27: ...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...

Page 28: ...er 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...

Page 29: ...ectric 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 t...

Page 30: ...eturn 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 tha...

Page 31: ...st be installed to prevent the potential accumulation of condensate in the vent pipes It is rec ommended that a The vent be installed with a slight downward slope of not more than 1 4 per foot of hori...

Page 32: ...ting 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...

Page 33: ...of snow ice leaves debris etc The Stainless Steel direct vent cap must be fur nished by the boiler manufacturer in accordance with its listing WARNING For common vent installations call factory WARNIN...

Page 34: ...foot from the boiler to the vent terminal The horizontal portions of the vent shall also be sup ported for the design and weight of the material employed to maintain clearances and to prevent phys ica...

Page 35: ...rdance with the National Fuel Gas Code or in Canada the latest edi tion of CSA B149 Installation Code for Gas Burning Appliances and Equipment UL 1738 Certified Venting Material e g AL29 4C MUST be us...

Page 36: ...room in accordance with the National Fuel Gas Code or in Canada the latest edi tion of CSA B149 Installation Code for Gas Burning Appliances and Equipment UL 1738 Certified Venting Material e g AL29...

Page 37: ...ss Steel PVC CPVC 10 35 Subtract 10 ft per elbow Max 3 elbows Galvanized Steel PVC ABS CPVC 6 35 Subtract 10 ft per elbow Max 3 elbows ADB 1501 w CHX IV UL 1738 Certified Venting Material e g AL29 4C...

Page 38: ...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 o...

Page 39: ...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...

Page 40: ...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 Hea...

Page 41: ...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 serv...

Page 42: ...eriod prior to pilot trial for ignition The pre purge peri od ensures that the combustion chamber is clear of all excess combustible gases prior to commencing the pilot ignition cycle The pre purge de...

Page 43: ...U 2 board will illu minate 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...

Page 44: ...44 Figure L 2 WIRING DIAGRAM WIRING DIAGRAM...

Page 45: ...the device is powered and pre purged Unit per forms 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 man...

Page 46: ...vents one at a time until water squirts out Close vent 6 Repeat with remaining vents 7 Close manual water feed valve when correct boil er pressure is reached Inspect Venting System 1 Check all vent p...

Page 47: ...ol 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 Repe...

Page 48: ...ear 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...

Page 49: ...You will hear a click from pilot gas valve you will not hear the spark ing 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 se...

Page 50: ...ome ters 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...

Page 51: ...t 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...

Page 52: ...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 reli...

Page 53: ...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 disc...

Page 54: ...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...

Page 55: ...Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size...

Page 56: ...additives to water PARTS 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...

Page 57: ...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...

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