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WARNINGS 4

Pay Attention to These Terms

BEFORE INSTALLATION 5

Product Receipt

Model Identification

Ratings and Certifications

Installations at Elevation

Component Locations

General Information

BOILER DIMENSIONS 8

Time/Temperature Relationships

in Scalds

INSTALLATION 9

Installation Codes

Equipment Room

Clearances

Combustion and Ventilation Air

Direct Vent

Conventional Combustion Air Supply

Water Piping

Hydronic Heating

System Sensor Installation

Applications and Modes

Heater Flow Rates and Pressure Drops 17

MODE 1 Water Plumbing

MODE 2 Water Plumbing

MODE 3 Water Plumbing

Gas Supply

Gas Supply Connection

Equivalent Pipe Length

Gas Supply Pressure

Electrical Power Connections

Making the Electrical Connections

Field Wiring Connections

Heating System Sensor Installation

Venting

Venting Installation Tips

Venting Configurations

Condensate Management

Freeze Protection

Controls

Outdoor Reset Concept

WIRING DIAGRAM 47

Converting Natural to Propane Gas

Gas Valve & Combustion Settings

START-UP 50

Pre Start-up

Pre Start-up Check

Initial Start-up

Preparation

Start-Up

Lighting Instructions

To Turn Off Gas to Appliance

TROUBLESHOOTING 55

XPak FT Error Codes

Heater Errors

Heater Faults

Sensor Resistance Values

XPak FT Fault Text

MAINTENANCE 58

Suggested Minimum

Maintenance Schedule

Preventive Maintenance

Schedule

Combustion Chamber Cleaning

Instructions

APPENDIX 61

Inside Air Contamination

Important Instructions for the

Commonwealth of Massachusetts

WARRANTY 63

START-UP CHECKLIST 64

ILLUSTRATED PARTS LIST 65

CONTENTS

Содержание 88AR-398A

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 65: ...65 ILLUSTRATED PARTS LIST...

Страница 66: ...66...

Страница 67: ...67...

Страница 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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