Raypak 88AR-398A Installation & Operating Instructions Manual Download

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www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468

Litho in U.S.A.

Summary of Contents for 88AR-398A

Page 1: ...uctions 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 suppli er Models 88AR 398A Type H C...

Page 2: ...ges 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 Ig...

Page 3: ...nnections 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 Managem...

Page 4: ...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 o...

Page 5: ...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 replace...

Page 6: ...echanical Engineers ASME Boiler and Pressure Vessel Code and bears the ASME H stamp This boiler also complies with the latest edi tion of the ASHRAE 90 1 Standard Installations at Elevation Rated inpu...

Page 7: ...12 0 1 2 3 2 3 108AR 22 0 110 95 13 0 1 3 3 198AR 39 8 199 95 28 4 1 1 4 3 3 278AR 55 0 275 95 36 6 1 1 4 3 3 398A 39 9 399 96 39 9 1 1 2 3 4 3 4 Table A Basic Data Model 398A value is a Thermal Effic...

Page 8: ...AIR INLET PRV FLUE OUTLET 5 6 6 0 Fig 3 Boiler Dimensions Model No A B C D E F H J K L M N P 88AR 108AR 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 198AR 278AR 18 6 36 2 19 4 2 0 3 1 8 2 1...

Page 9: ...2 seconds 155 F About 1 second Table courtesy of The Shriners Burn Institute Table D Time to Produce Serious Burn INSTALLATION Installation Codes Installations must follow these codes Local state prov...

Page 10: ...ndoor Installations When installed according to the listed minimum clear ances from combustible construction these boilers can be serviced without removing permanent structur al construction around th...

Page 11: ...ia conventional means where combustion air is drawn from the area immediately surrounding the boil er or via direct vent where combustion air is drawn directly from outside All installations must comp...

Page 12: ...12 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...

Page 13: ...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 L Clearance above p...

Page 14: ...ning 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 mini mum dimension of air openings shall be not less than 3 in...

Page 15: ...ll combustion air must be drawn from the air outside of the building the mechanical equip ment room must communicate directly with the outdoors Water Piping General The boiler should be located so tha...

Page 16: ...ducing flow in the boiler should not be used 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 Tab...

Page 17: ...is GPM Model No MAXIMUM FLOW 30 F T 40 F T 50 F T MINIMUM FLOW GPM P ft T GPM P ft GPM P ft GPM P ft GPM P ft T 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...

Page 18: ...18 Fig 13 MODE 1 Single Boiler Primary Secondary Piping...

Page 19: ...19 Fig 14 MODE 2 Single Boiler Primary Secondary Piping with Indirect DHW on System Loop...

Page 20: ...20 Fig 15 MODE 3 Single Boiler Primary Secondary Piping with Indirect DHW on Boiler Loop...

Page 21: ...n 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...

Page 22: ...1 WC 2 0 WC 398A 3 4 WC 3 0 WC Electrical Power Connections Installations must follow these codes National Electrical Code and any other national state provincial or local codes or regulations hav in...

Page 23: ...he boiler s rating plate A dedicated circuit breaker should be provided and sized for the boiler and all pumps powered through it 2 Turn off all power to the boiler Verify that power has been turned o...

Page 24: ...n this manual Verify proper operation after servicing DANGER SHOCK HAZARD Fig 20 XPak FT Single Boiler Control Wiring the Thermostat Connect the Enable Disable terminals to the PIM shown in Fig 20 Alt...

Page 25: ...nd sends the firing rate and pump output requests to the PIM so it can activate the Indirect DHW pump and Boiler pump if needed If an optional Indirect DHW sensor is connected to J2 1 and J2 2 the PIM...

Page 26: ...switch 2 to be toggled OFF designating them as followers Follower VERSA s are ignored by their corresponding PIM s Use standard 18 AWG wire to connect the master VERSA to the PIM on the followers A t...

Page 27: ...the J1 connector located on the Master PIM See Fig 20 This connection must be pro vided through dry contacts closure NOTE This dry contacts closure can come from a room thermostat or a remote relay N...

Page 28: ...egorization see the ANSI Z21 13 Standard and the NFGC U S or B149 Canada or applicable provisions of local building codes CAUTION Proper installation of flue venting is critical for the safe and effic...

Page 29: ...regulators relief valves or other equipment 6 Locate and guard vent termination to prevent acci dental contact by people or pets 7 DO NOT terminate vent in window well stairwell alcove courtyard or ot...

Page 30: ...y which is located between two single family dwell ings and serves both dwellings 2 Less than 7 ft 2 13 m above a paved sidewalk or paved driveway located on public property 3 Within 6 ft 1 8 m of a m...

Page 31: ...propylene 2 5 50 Galvanized Steel PVC ABS CPVC 50 3 100 100 108AR 198AR 278AR 398A 3 60 60 4 100 100 NOTE Ensure adequate clearances to allow annual inspection of the venting system Model No Size in A...

Page 32: ...existing boiler the vent system MUST be verified to be of the correct size and of Category IV AL29 4C vent material approved PVC CPVC construction or DuraVent polypropylene in Canada ULC S636 approve...

Page 33: ...ht The vent must be installed to prevent the potential accumulation of condensate in the vent pipes It is required that 1 The vent must be installed with condensate drains as directed by the vent manu...

Page 34: ...zontal Through the Wall Direct Venting Category IV Fig 27 Horizontal Through the Wall Venting Fig 28 Horizontal Through the Wall Direct Venting Fig 29 Horizontal Through the Wall Venting w Single Term...

Page 35: ...35 Fig 32 Direct Venting w Elbow Terminations Fig 33 Vertical Concentric Venting Fig 31 Vertical Venting w Stainless Termination Cap Fig 30 Direct Vent Vertical...

Page 36: ...36 Fig 36 Vertical Concentric Vent Termination Fig 34 Vertical Elbow Vent Termination Fig 35 Vertical Stainless Termination Cap Fig 37 Vertical Stainless Tee Termination...

Page 37: ...ps installed in the same horizontal plane must have a 4 ft 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 particul...

Page 38: ...r year to ensure that the pH of the effluent is 5 0 or higher and the chips should be replenished as nec essary When replacing the chips they should be no smaller than to avoid blockage in the condens...

Page 39: ...lock out press and release the RESET button located on the user inter face Optional The optional adjustable setting manual reset high limit is located behind the front panel To reset a high limit lock...

Page 40: ...ply Fig 40 Low Water Cut Off Fig 41 Low Water Cut Off pressure drops below the factory setting of 3 0 in WC for natural gas or propane gas The high gas pressure switch connection mounts downstream of...

Page 41: ...2 3 Current target temperature available when TARGET SETP in ADJUST menu Defautl EMS MODB SUPPLY MODE 1 2 3 Current system supply temperature IND SUPPLY MODE 3 Current temperature being supplied to th...

Page 42: ...value Target boiler temperature for the DHW heat exchanger during indirect DHW operation requires IND Sensor OFF 180 F DHW PRIORITY MODE 2 OFF ON Selects whether or not Indirect DHW priority is activ...

Page 43: ...CFH will resume after the soft lockout fault has been corrected and a 15 min waiting period has expired N A LIMIT TEMP ALL Current Outlet Limit temperature N A EMS Vdc ALL Current EMS signal in Volts...

Page 44: ...All Records the lowest boiler outlet temperature Press UP DOWN for 1 sec to clear INLET HI All Records the highest boiler inlet temperature Press UP DOWN for 1 sec to clear INLET LO All Records the lo...

Page 45: ...e the outdoor temperature drops the tempera ture of the heating water will increase one degree With the VERSA both ends of the slope are adjustable It is factory set at 70 F water temperature Boil STA...

Page 46: ...g heat loss calculations for the building Boiler Design Boil DESIGN The Boil DESIGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the OUT DE...

Page 47: ...47 WIRING DIAGRAM Fig 46 Wiring Diagram...

Page 48: ...8AR thru 108AR ROTATE R ROT ROTA ROTAT ROTATE TO OFF ROTATE T ROTATE TO OFF Fig 49 Rubber Seal Propane Orifice RUBBER R RUBBER GROMMET RUBBER G RUBBER GRO RUBBER GROM RUBBER GROMM RUBBER GROMME RUBBER...

Page 49: ...st 0 10 VDC signal back to 10 VDC 5 Verify combustion is still within range given in Table U Adjust if necessary Fig 52 Propane Venturi BLOWER B BLO BLOW BLOWE BLOWER SCREW BLOWER SCREW SCREW BLOWER S...

Page 50: ...rsonal injury or loss of life If you cannot reach your gas supplier call the fire department Use only your hand to close the gas supply shutoff valve inside the boiler Never use tools If the knob will...

Page 51: ...e heater see Fig 54 3 Attach a 12 scale manometer to the offset pres sure testport for Models 88AR 108AR For Models 198AR 398A attach manometer to manifold pres sure tap see Fig 54 Check Gas Supply Pr...

Page 52: ...rol to ON Set USER TEST ON in the ToolBox Menu to start the user test function USER TEST is displayed in the Title Field UP keystrokes are used to advance through the user test The Boil MIN MAX steps...

Page 53: ...view all instructions shipped with this boiler with owner or maintenance person return to envelope and give to owner or place the instructions inside front panel on boiler Safety Inspection 1 Check al...

Page 54: ...54 Fig 55 Boiler Lighting Shut Off Instructions...

Page 55: ...itions will also cause the boiler pump to run in an attempt to cool the unit 2 Note the error code either through the flash code on the PIM and or from the Toolbox menu on the user interface and refer...

Page 56: ...AC Low 24 VAC power Check power supply wiring and transformer BLOW SPEED Blower speed out of range Check blower wiring and blower 3 16 NOTE If receiving a NO FLAME check the gap spacing between points...

Page 57: ...re information 4 flashes N A N A 5 flashes Low Voltage Fault Check the 24 VAC input voltage The voltage must be above 18 0 VAC 6 flashes N A N A 7 flashes Hi Limit Fault Check for proper water flow Ch...

Page 58: ...re that condensate is being directed to appropriate con densate management system or drain as required by local codes 3 Check that area is free from combustible materi als gasoline and other flammable...

Page 59: ...nit is operating Test other oper ating parts of all safety shut off and control valves and increase or decrease settings depending on the type of control until the safety circuit opens Reset to origin...

Page 60: ...e any buildup then vacuum the debris from the heat exchanger 4 Spray the heat exchanger with clear water making sure to confine the spray to the area being cleaned Flush the combustion chamber with fr...

Page 61: ...ck for areas and products listed above before in stalling boiler If found remove products permanently OR install TruSeal direct vent APPENDIX Inside Air Contamination Combustion air can be contaminate...

Page 62: ...wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 I...

Page 63: ...led 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...

Page 64: ...ze _____________ Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material ________________...

Page 65: ...65 ILLUSTRATED PARTS LIST...

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Page 68: ...68 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A...

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