Raypak 751 User Manual

INSTALLATION AND OPERATING

INSTRUCTIONS

Advanced

Design

Boiler

Models 751, 1001 &

1501 – Types H, WH & P

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property

damage, personal injury or loss of life. Refer to the user’s information manual provided with this boiler.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other

combustible materials in the vicinity of this or 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.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• 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 supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future

reference.

CATALOG NO. 3400.52E

Effective: 02-22-07

Replaces: 04-01-03

P/N 241079 Rev. 6

CONTENTS

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 11

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

WARNINGS

Pay Attention to These Terms

Indicates the presence of immediate hazards which will cause severe

personal injury, death or substantial property damage if ignored.

DANGER:

WARNING:

CAUTION:

NOTE:

Indicates the presence of hazards or unsafe practices which could cause

severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause

minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which

are important but not related to personal injury hazards.

DANGER: Make sure the gas on which the heater

will operate is the same type as that specified on the

heater rating plate.

WARNING - CALIFORNIA PROPOSITION

65: This product contains chemicals known to the

State of California to cause cancer, birth defects or

other reproductive harm.

WARNING: Should overheating occur or the gas

supply valve fail to shut, do not turn off or disconnect

the electrical supply to the heater. Instead, shut off

the gas supply at a location external to the heater.

CAUTION: Operation of this heater in low

temperature systems requires special piping to

ensure correct operation.

WARNING: Do not use this heater if any part has

been under water. Immediately call a qualified

service technician to inspect the heater and to

replace any part of the control system and any gas

control which has been under water.

CAUTION: If this heater is to be installed above

radiation level, it must be provided with a low water

cut-off device at the time of heater installation.

CAUTION: This heater requires forced water

circulation when the burner is operating. See

minimum and maximum flow rates. Severe damage

will occur if the heater is operated without proper

water flow circulation.

WARNING: To minimize the possibility of improper

operation, serious personal injury, fire, or damage to

the heater:

•

Always keep the area around the heater free of

combustible materials, gasoline, and other

flammable liquids and vapors.

•

Heater should never be covered or have any

blockage to the flow of fresh air to the heater.

WARNING: Risk of electrical shock. More than one

disconnect switch may be required to de-energize

the equipment before servicing.

the left inside jacket of the heater. The model number

will have the form H4-0751AADB or similar depending

on the heater size and configuration. The first charac-

ter of the model number identifies application (H =

Hydronic Heating System, W = Hot Water Supply

System, P = Pool Application). The second character

identifies the firing mode (4 = On-Off firing). The next

four places identify the input of the heater in 1,000s of

BTUH 0751 = 750,000 BTUH). The remaining suffix

identifies the control, ignition, and construction config-

uration. The last three characters of the model number

identifies the model type (ADB = Advanced Design

Boiler).

BEFORE INSTALLATION

Raypak strongly recommends that this manual be re-

viewed thoroughly before installing your ADB heater.

Please review the General Safety information before

installing the heater. Factory warranty does not apply

to heaters that have been improperly installed or oper-

ated. (Refer to the warranty at the back of this

manual.) Installation and service must be performed

by a qualified installer, service agency or gas supplier.

If, after reviewing this manual, you still have questions

which this manual does not answer, please contact the

manufacturer or your local Raypak representative.

Ratings and Certifications

Thank you for purchasing a Raypak product. We hope

you will be satisfied with the high quality and durability

of our equipment.

Standards:

•

ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired

Hot Water Boilers

CAN 3.1

Commercial Gas-Fired Package Boilers

ANSI Z21.10.3 · CSA 4.3 - latest edition, Gas Wa-

ter Heaters

Product Receipt

latest edition, Industrial and

On receipt of your heater it is suggested that you visu-

ally check for external damage to the shipping crate. If

the crate is damaged, make a note to that effect on the

Bill of Lading when signing for the shipment. Remove

the heater from the shipping packaging. Report any

damage to the carrier immediately.

SCAQMD Rule 1146.2

All Raypak heaters are National Board Approved, and

design-certified and tested by the Canadian Standards

Association (CSA) for the U.S. and Canada. Each

heater is constructed in accordance with Section IV of

the American Society of Mechanical Engineers

(ASME) Heater Pressure Vessel Code and bears the

ASME stamp. The heater also complies with the latest

edition of ASHRAE 90.1 Standard.

On occasion, items are shipped loose. Be sure that

you receive the correct number of packages as indi-

cated on the Bill of Lading.

Claims for shortages and damages must be filed with

the carrier by consignee. Permission to return goods

must be received from the factory prior to shipping.

Goods returned to the factory without an authorized

Returned Goods Receipt number will not be accepted.

All returned goods are subject to a restocking charge.

WARNING: Altering any RAYPAK pressure vessel

by installing replacement heat-exchangers, tube

bundle headers, or any other ASME part not

manufactured and/or approved by RAYPAK will

instantly void the ASME, and agency listings and any

RAYPAK warranty on the vessel. Altering the ASME,

agency ratings of the vessel also violates national,

state, and local approval codes. The terms "boiler"

and "heater" are used interchangeably in this

manual.

When ordering parts, you must specify the model and

serial number of the heater. When ordering under war-

ranty conditions, you must also specify the date of

installation.

Purchased parts are subject to replacement only

under the manufacturer’s warranty. Debits for defec-

tive replacement parts will not be accepted and will be

replaced in kind only per Raypak’s standard war-

ranties.

Installations at Elevation

No de-rating is required for altitudes up to 7000 feet.

Rated inputs, at sea level settings, are suitable for up

to 5000 feet elevation. At altitudes between 5000 and

7000 feet, rated inputs are achieved with pressure set-

tings adjustment. Consult the factory for installations at

altitudes in excess of 7000 feet.

Model Identification

The model identification number and heater serial

number are found on the heater rating plate located on

Component Locations

Fig. 1: Component Locations

Time/Temperature

Relationships in Scalds

GENERAL SAFETY

To meet commercial water use needs, an external

operating control for this hot water boiler is adjustable

up to 210°F. However, water temperatures over 125°F

can cause instant severe burns or death from scalds.

The preferred starting point for setting the control for

supplying general purpose hot water is 125°F.

The following chart details the relationship of water

temperature and time with regard to scald injury and

may be used as a guide in determining the safest

water temperature for your applications.

Water

Temp.

Time to Produce Serious

Burn

Safety and energy conservation are factors to be con-

sidered when setting the water temperature on the

thermostat. The most energy efficient operation will

result when the temperature setting is the lowest that

satisfies the needs consistent with the application.

120°F

125°F

130°F

135°F

140°F

145°F

150°F

155°F

More than 5 minutes

1-1/2 to 2 minutes

About 30 seconds

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1-1/2 seconds

About 1 second

Table courtesy of The Shriners Burn Institute

Table A: Time to Produce Serious Burn

NOTE: When this water heater is supplying general

purpose hot water for use by individuals, a

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 further

information.

Water temperature over 125°F can

causeinstantsevereburnsordeath

from scalds.

Children, disabled, and elderly are

at highest risk of being scalded.

See instruction manual before set-

ting temperature at water heater.

Feel water before bathing or show-

ering.

Temperature limiting valves are

available, see manual.

Maximum water temperatures occur just after the boil-

er’s burner has shut off. To determine the water

temperature being delivered, turn on a hot water

faucet and place a thermometer in the hot water

stream.

The temperature of the water in the hot water boiler

can be regulated by setting the temperature dial on

front of the thermostat. To comply with safety regula-

tions the thermostat was set at its lowest setting before

the hot water boiler was shipped from the factory. The

illustration below shows the thermostat and how to

adjust the water temperature.

Equipment Base

The boiler should be mounted on a level, structurally

sound surface. The boiler is approved 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 the floor.

To adjust the water temperature, insert a small straight

screwdriver into slotted screw in hole in front of ther-

mostat and turn wheel to desired setting.

CAUTION: The boiler should be located in an area

where water leakage will not result in damage to the

area adjacent to the appliance or to the structure.

When such locations cannot be avoided, it is

recommended that a suitable catch pan, adequately

drained, be installed under the appliance. The pan

must not restrict air flow.

Adjustment

Screw

In addition, the boiler shall be installed such that the

gas ignition system components are protected from

water (dripping, spraying, rain, etc.) during appliance

operation and service (circulator replacement, control

replacement, etc.).

Auto Limit

Clearances

CAUTION: Hotter water increases the risk of

scalding! There is a hot water scald potential if the

thermostat is set too high.

Indoor Installations

Min. Clearance from

Heater Side

Combustible Surfaces

INSTALLATION

Floor

Rear

Right

Left

Installation Codes

12” (water side)

1”

0”

1”

Installations must follow these codes:

•

Local, state, provincial, and national codes, laws,

regulations and ordinances

National Fuel Gas Code, ANSI Z223.1/NFPA 54 –

latest edition (NFGC)

National Electrical Code, ANSI/NFPA 70 - latest

edition (NEC)

Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1,

(CSD-1) when required

Top

Vent

*DO NOT install on carpeting.

Table B: Clearances – Indoor Installations

•

For Canada only: CAN/CSA B149 Installation

Code and CSA C22.1 C.E.C. Part 1 (C22.1)

Combustion and Ventilation Air

Indoor Units

The boiler must be supplied with sufficient quantities of

non-contaminated air to support proper combustion

and equipment ventilation. Combustion air can be sup-

plied via conventional venting, 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 comply with

the requirements of NFGC for U.S., CSA B149 for

Canada, and all local codes.

NOTE: In calculating free area, the required size of

openings for combustion, ventilation, and dilution air

shall be based on net free area of each opening. If

the free area through a design of louver or grill is

known, it shall be used in calculating the size

opening required to provide the free area specified.

For additional information, refer to the latest NFGC

code requirements.

Fig. 2: Minimum Clearances from Combustible

Surfaces

Direct Vent

If outside air is drawn through a vent pipe directly to

the unit for combustion:

Outdoor Installations

Raypak Advanced Design Boilers are design certified

by CSA for outdoor installation. Roof water drainage

must be diverted away from boilers installed under

overhangs.

1. Install combustion air direct vent in accordance

with the Venting section of this manual.

2. Provide for adequate ventilation of the space

occupied by the boiler(s) by an opening(s) for ven-

tilation air at the highest practical point

communicating with the outdoors. The total cross

sectional area shall be at least one (1) square inch

of free area per 20,000 BTUH of total input rating

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 10,000 BTUH of total input rating of all

equipment in the room when the opening is com-

municating with the outdoors through horizontal

duct(s).

Min. Clearance from

Heater Side

Combustible Surfaces

Rear

Right

Left

12” (water side)

36”

0”

Top

Vent

1”

Table C: Clearances – Outdoor Installations

3. In cold climates, and to mitigate potential freeze-

up, Raypak highly recommends the installation of

a motorized sealed damper to prevent the circula-

tion of cold air through the boiler during the

non-operating hours.

WARNING: Combustion air inlet (blower air inlet)

should have 6" minimum clearance from any

obstruction, i.e. walls or other appliances.

CAUTION: Remove the screen off the blower inlet

and install a screen (1/2"-3/4" mesh) on the inlet

elbow.

Fig. 3: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

U.S. Installations¹

Canadian Installations²

Clearance above grade, veranda, porch,

deck, or balcony

1 ft (30 cm)

4 ft (1.2m) below or to side

of opening; 1 foot (30 cm)

above opening

Clearance to window or door that may be

opened

3 ft (91 cm)

Clearance to permanently closed window

Vertical clearance to ventilated soffit located

above the terminal within a horizontal dis-

tance of 2 ft (61cm) from the centerline of the

terminal

5 ft (1.5m)

Clearance to unventilated soffit

Clearance to outside corner

Clearance to inside corner

6 ft (1.83m)

3 ft (91 cm) within a height

15 ft above the me-

ter/regulator assembly

Clearance to each side of center line ex-

tended above meter/regulator assembly

Clearance to service regulator vent outlet

6 ft (1.83m)

Clearance to non-mechanical air supply inlet 4 ft (1.2m) below or to side

to building or the combustion air inlet to any

of opening; 1 ft (30 cm)

3 ft (91 cm)

other appliance

above opening

3 ft (91 cm) above if within

10 ft (3m) horizontally

Clearance to mechanical air supply inlet

6 ft (1.83m)

7 ft (2.13m) t

Clearance above paved sidewalk or paved

driveway located on public property

7 ft (2.13m)

Clearance under veranda, porch, deck or

balcony

12 in. (30 cm) TT

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code

In accordance with the current CAN/CGA-B149 Installation Codes

Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves

both dwellings

TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and

underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)

Clearances in accordance with local installation codes and the requirements of the gas supplier

Table D: Vent/Air Inlet Termination Clearances

through vertical ducts. 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.

Conventional Combustion Air

Supply

U.S. Installations

4. Refer to NFGC, Part 5, for additional information.

Refer to Appendix A for additional information

about combustion air quality.

All Air from Inside the Building

If all combustion air is drawn from the air inside the

building (the mechanical equipment room does not Method 2 (normally applied in cold climate regions):

receive air from outside):

1. The mechanical equipment room must be provid-

ed with two permanent openings communicating

directly with additional room(s) of sufficient volume

so that the combined volume of all spaces meets

ed with at least one permanent opening,

commencing within 12 inches of the top of the

enclosure.

the criteria for an unconfined space. (An uncon- 2. The opening must communicate directly or by

fined space is defined as a space whose volume

is more than 50 cubic feet per 1,000 BTUH of the

ducts with outdoors.

aggregate input rating of all appliances installed in 3. The opening must have a minimum free area of 1

that space.)

sq. in per 3000 BTUH of the total input rating of all

equipment in the room, or no less than the sum of

the areas of all vent connectors in the confined

space. Refer to the latest version of NFGC, part 5

for additional information.

2. Each opening must have a minimum free area of

one (1) square inch per 1,000 BTUH of the total

input rating of all gas utilization equipment in the

mechanical equipment room.

WARNING: Do not use one permanent opening

method (Method 2) if the equipment room is under

negative pressure condition or the equipment is

common vented with other gas-fired appliances.

3. One opening must commence within twelve (12)

inches of the top, and one opening must com-

mence within twelve (12) inches of the bottom of

the room.

Canadian Installations

4. Refer to NFGC, Part 5, for additional information.

CAUTION: All combustion air has to be drawn from

the air outside the building (the mechanical

equipment room directly communicates with the

outdoors).

All Air from Outdoors

If all combustion air is drawn from the air outside the

building (the mechanical equipment room directly

communicates with the outdoors), either of the follow-

ing two methods can be used:

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-sectional area of

such an opening(s) shall be at least 10% of the

area required in (2) and (3), but in no case shall

the cross-sectional area be less than 10 square

inches (6500 square mm).

Method 1:

1. The mechanical equipment room must be provid-

ed with two permanent openings, one

commencing within (twelve) 12 inches of the top,

and one commencing within twelve (12) inches of

the bottom of the room.

2. When air supply is provided by natural air flow

from the outdoors for natural draft, partial fan

assisted, 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 1 million BTUH, plus 1 sq. in.

per 14000 BTUH (155 sq. mm per kW) in excess

2. The openings must communicate directly, or by

ducts, with the outdoors.

3. Each opening must have a minimum free area of

one (1) square inch per 4,000 BTUH of total input

rating of all equipment in the room when the open-

ing is communicating directly with the outdoors or

of 1 million BTUH. This opening(s) shall be either

located at or ducted to a point neither more than

18 inches (450 mm) nor less than 6 inches (150

mm) above the floor level. The duct can also

"Goose Neck" through the roof. The duct is pre-

ferred straight down 18 inches from floor, but do

not place near piping. This air supply opening

requirement shall be in addition to the air opening

for ventilation air required in (1).

Relief Valve Piping

WARNING: Pressure relief valve discharge piping

must be piped near the floor close to a floor drain to

eliminate the potential of severe burns. Do not pipe

to any area where freezing could occur. Refer to

local codes.

Hydrostatic Test

3. When air supply is provided by natural air flow

from outdoors for a power burner and there is no

draft regulator, draft hood or similar flue gas dilu-

tion device installed in the same space, in addition

to the opening for ventilation air required in (1),

there shall be a permanent air supply opening(s)

having a total cross-sectional area of not less than

1 sq. in. for each 30,000 BTUH (70 sq. mm per

kW) of total rated input of the burner(s), and the

location of the opening(s) shall not interfere with

the intended purpose of the opening(s) for ventila-

tion air referred to (1). This opening(s) can be

ducted to a point neither more than 18 inches (450

mm) nor less than 6 inches (150 mm) above the

floor level. The duct can also "Goose Neck"

through the roof. The duct is preferred to be

straight down 18 inches from floor, but do not

place near piping.

Unlike many 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

pressure. However, Raypak does recommend hydro-

statically testing the piping connections to the boiler

and the rest of the system prior to operation. This is

particularly true for hydronic systems using expensive

glycol-based antifreeze. Raypak recommends con-

ducting the hydrostatic test before connecting gas

piping or electrical supply.

Leaks must be repaired at once to prevent damage to

the boiler. NEVER use petroleum-based stop-leak

compounds.

1. Connect fill water supply. Fill boiler with water (be

sure bleed valve is open). When water flows from

bleed valve, shut off water. Close bleed valve.

Carefully fill the rest of the system, being sure to

eliminate any entrapped air by using high point

vents. Close feed valve. TEST AT standard oper-

ating pressure for at least 24 hours.

4. Refer to the latest version of CSA B149 for addi-

tional information.

WATER PIPING

2. Make sure constant gauge pressure has been

maintained throughout test.

General

The boiler should be located so that any water leaks

will not cause damage to the adjacent area or struc-

tures.

3. Check for leaks. Repair if found.

Low Temperature System

All units should be plumbed in accordance with the

appropriate diagram from the following sections or per

a suitable engineered piping arrangement.

Boiler requires minimum inlet temperature of 105°F.

Consult the following sections for piping details. (For

Pool temperature requirements, See the Pool Heating

Section).

CAUTION: This boiler requires forced water

circulation when the burner is operating. See Table E

for minimum and maximum flow rates and water

pump selection. The pump must be interlocked with

the boiler to prevent boiler operation without water

circulation.

Temperature & Pressure

Gauge

The temperature and pressure gauge is factory-

mounted in the inlet/outlet header.

Table D-1

40°F

ΔP Should include typical piping To/From a single tank as well as bypass piping.

Table E: Rate of Flow and Pressure Drop

NOTE: gpm flow rates limited by maximum

acceptable velocity through heat exchanger tubes.

May be increased by 10% for closed heating

systems. Pressure drop would increase by 21%.

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 refrigerated

air, must be equipped with flow control valves or other

automatic means to prevent gravity circulation of the

boiler water during the cooling cycle. It is highly recom-

mended that the piping be insulated.

HYDRONIC HEATING

Pump Selection

Air-Separation/Expansion Tank

In order to ensure proper performance of your boiler

system, you must install a properly sized pump.

Raypak recommends using a 20°F ΔT as design ΔT.

(ΔT is the temperature difference between the inlet

and outlet water when the boiler is firing at full rate). If

a ΔT larger than 20°F is necessary, the bypass must

be installed and adjusted to ensure proper hydraulics

through the boiler while still allowing minimum flow to

satisfy the safety flow switch. See Table E for flow rate

requirements.

All boilers should be equipped with a properly sized

expansion tank with an air separation fitting as shown

in the following diagrams.

Three-Way Valves

Valves designed to blend water temperatures or

reduce water circulation through the boiler should not

be used. Raypak heaters are high recovery low mass

heaters not subject to thermal shock. Raypak offers a

full line of electric sequencers that produce direct reset

of boiler water temperature. Refer to the Controls

Section in our Complete Catalog.

Pressure Drop in Feet of Head

Feedwater Regulator

Raypak recommends that a feedwater regulator be in-

stalled and set at 12 psi minimum pressure at the

highest point of the system. Install a check valve or

back flow device upstream of the regulator, with a

manual shut-off valve as required by local codes.

Piping — Heating Boilers

All high points should be vented. Purge valves and a

bypass valve should be installed. A boiler installed

above radiation level must be provided with a low

water cutoff device. The boiler, when used in connec-

tion with a refrigeration system, must be installed so

the chilled medium is piped in parallel with the boiler

with appropriate valves to prevent the chilled medium

from entering the boiler.

Fig. 4: Single Boiler - Primary/Secondary Piping

Fig. 5: Single Boiler - Primary/Secondary Piping with CHX

Fig. 6: Dual Boiler Piping

Fig. 7: Dual Boiler - Piping with CHX

Fig. 8: Single Boiler - Low Temperature Application (Heat Pump) Primary/Secondary Piping

soft, medium and hard water. Hardness is specified as

DOMESTIC HOT WATER

grains per gallon.

PIPING

When designing the water piping system for domestic

water applications, water hardness should be consid-

ered. Table F indicates the suggested flow rates for

ΔT=Temperature rise in °F

GPM=Gallons per minute

See Table D for Pressure Drop

Table F: Domestic Water Heating Boiler Flow Rate Requirements

Fig. 9: Single Boiler - Domestic Hot Water with One Storage Tank

Fig. 10: Single Boiler - Domestic Hot Water with One Storage Tank and CHX

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

Automatic Chlorinators and

Chemical Feeders

POOL HEATING

CAUTION: Power to the heater should be

interlocked with the main system pump to make sure

the heater does not fire without the main system

pump in operation. Improper flow control can

damage the heater. Uncontrolled flow (too high) or

restricted flow (too low) can seriously affect heater

operation. Follow these instructions to make sure

your heater is properly installed.

All chemicals must be introduced and completely dilut-

ed into the pool or spa water before being circulated

through the heater. Do not place chlorine tablets or

bromine sticks in the skimmer. High chemical concen-

trations will result when the pump is not running (i.e.

overnight).

Chlorinators must feed downstream of the heater and

The ADB unit is equipped with an external pump and have an anti-siphoning device to prevent chemical

bypass arrangement that blends outlet water with the backup into the heater when the pump is shut off.

inlet to increase the inlet water temperature, thereby

reducing the likelihood of condensation forming on the

NOTE: High chemical concentrates from feeders

heat exchanger. The pump also serves to circulate

and chlorinators that are out of adjustment will cause

water through the heater form the main system piping.

very rapid corrosion to the heat exchanger in the

heater. Such damage is not covered under the

warranty.

CAUTION: ADB bypass piping should be copper

and/or CPVC. PVC piping should NOT be used.

Winterizing Your Heater

To complete the installation of the pool heater, the pool

When heaters installed outdoors in freezing climate

thermostat needs to be installed in the main return

areas are to be shut down for the winter, please

water line. This will ensure that the heater will be ener-

observe the following procedure:

gized at the right time. If the main water line is too far

away from the heater and the capillary bulb will not

1. Turn off manual main gas and main gas shut off.

reach it, locate the pool thermostat adjacent to the

Remove the drain plug or open the drain valves

main line and run wires back to the heater. See Figure

located on the bottom header.

13 and 14.

Pool and Spa Water Chemistry

Adjustment of the bypass valve is critical to proper

operation of the heater. The bypass valve should be

adjusted to achieve a minimum inlet water tempera-

NOTE: Chemical imbalance can cause severe

ture of 105°F and an outlet water temperature of

damage to your heater and associated equipment.

125°F. When starting with a cold pool, make initial

Maintain your water pH between 7.4 and 7.8 and

adjustments. Make final adjustments when pool water

total alkalinity between 100 and 150 p.p.m. If the

approaches desired temperature. Refer to Table G for

mineral content and dissolved solids in the water

flow rates.

become too high, scale forms inside the heat

exchanger tubes, reducing heater efficiency and also

damaging the heater (max TDS at 3000 ppm). If the

pH drops below 7.2, the heater will be severely

damaged.

NOTE: Heat exchanger damage resulting from

chemical imbalance is not covered under the

warranty.

*Loop is secondary piping to heater from main system

Table G: Flow Rates

Fig. 13: Single Boiler - Pool Application

Fig. 14: Single Boiler - Pool Application with CHX

Fig. 15: Double Boiler - Pool Application

This based on average pool depth of 4’ 6” (4.5 ft)

Table H: ADB Pool Sizing; Indoor or Outdoor

regulator must be installed to reduce to gas supply

pressure to under 14 in. WC. The regulator should be

GAS SUPPLY

CONNECTIONS

placed a minimum distance of 10 times the pipe diam-

eter upstream of the boiler gas controls. All gas piping

must be tested after installation in accordance with

local codes. The boiler and its gas connection must be

leak-tested before placing it in operation.

DANGER: Make sure the gas on which the boiler

will operate is the same type as specified on the

boiler model and rating plate.

Gas piping must have a sediment trap ahead of the

boiler gas controls, and a manual shut-off valve locat-

ed outside the heater jacket. A pounds to inches

Fig. 16: Connections

Gas Supply Connection

Gas Supply Pressure

A minimum of 7 in. WC and a maximum of 10.5 in. WC

upstream gas pressure is required under load and no

load conditions for natural gas. A minimum of 12 in.

WC and a maximum of 13 in. WC is required for

propane gas. The gas pressure regulator supplied is

for low pressure service. If upstream pressure

CAUTION: The boiler and its manual shutoff valve

must be disconnected from the gas supply during

any pressure testing of the gas supply system at test

pressures in excess of 1/2 PSIG (3.45 kPa).

The boiler must be isolated from the gas supply piping exceeds 14 in. WC, an intermediate gas pressure reg-

system by closing the manual shutoff valve during any ulator, of the dead lockup type, must be installed.

pressure testing of the gas supply piping system at

test pressures equal to or less than 1/2 PSIG. Relieve

NOTE: The supply gas pressure must not fluctuate

test pressure in the gas supply line before reconnect-

by more than +/- 1.0 in. WC. For fluctuating gas sup-

ing the boiler and its manual shut off valve to the gas

ply contact the factory.

supply line. FAILURE TO FOLLOW THIS PROCE-

DURE MAY DAMAGE THE GAS VALVES. Over

pressurized gas valves are not covered by warranty. When connecting additional gas utilization equipment

The boiler and its gas connections shall be leak tested to the gas piping system, the existing piping must be

before placing the appliance in operation. Use soapy checked to determine if it has adequate capacity.

water for leak test: DO NOT use open flame.

1-1/2”

NPT

2-1/2”

NPT

Model

2” NPT

3” NPT

CAUTION: Do not use Teflon tape on gas line pipe

thread. A pipe compound rated for use with Propane

gas systems is recommended. Apply sparingly only

on male pipe ends, leaving the 2 end threads bare.

751

1001

1501

200

125

N/A

200

125

N/A

225

CAUTION: Support gas supply piping with

hangers, not by the boiler or its accessories. Ensure

the gas piping is protected from physical damage

and freezing where required.

Maximum equivalent pipe length.

Natural gas 100 BTU/FT .60 specific gravity @.5 in. WC pressure

drop.

Table I: Gas Pipe Sizing

Gas Pressure Regulator

Surge Protection

The gas pressure regulator is nominally preset to the Microprocessor-based and solid state controls are vul-

outlet values shown in Tables T and U, within +.1 in. nerable to damage from voltage and amperage

WC. If an adjustment is needed, turn the adjustment fluctuations in the power supply. All sensitive control

screw clockwise to increase pressure or counterclock- components should be protected by a suitable com-

wise to lower pressure.

mercial-grade surge protection device.

If any of the original wire as supplied with the boiler

must be replaced, it must be replaced with 105°C wire

or its equivalent.

Venting of Diaphragm Gas

Components

Boilers have gas train components that have

diaphragms in their construction that are supplied with

a bleed line connection that must be connected to the

outside atmosphere as required by NFGC or (for

Canada) the B149 Installation code and applicable

provisions of local codes. Under NO circumstances

shall bleed lines terminate in the gas utilization equip-

ment flue or exhaust system.

Check the Power Source

Using a volt-ohm meter (VOM), check the following

voltages at the circuit breaker panel prior to connect-

ing any equipment: Make sure proper polarity is

followed and house ground is proven.

ELECTRICAL POWER

CONNECTIONS

Installations must follow these codes:

· National Electrical Code and any other national,

state, provincial or local codes or regulations having

jurisdiction.

· Safety wiring must be N.E.C. Class 1.

· Boiler must be electrically grounded as required by

N.E.C. ANSI/NFPA 70-latest edition.

Fig. 17: Check Power Source

· In Canada, C.S.A. C22. 1 C.E.C. Part 1.

The boiler 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 connected to the remote tank control

stat, thermostat, or electronic boiler control as applica-

ble. 24 Volts are supplied to this connection through

the boiler transformer. DO NOT attach line voltage to

the “TH” leads. Before starting the boiler check to

insure proper voltage to the boiler and pump.

AC = 108 Volts AC Minimum, 132 Volts MAX

AB = 108 Volts AC Minimum, 132 Volts MAX

BC = Must be less than 1.0 Volts AC

Making the Electrical Connections

Refer to Fig. 18 and the wiring diagram.

1. Verify circuit breaker is properly sized by referring

to boiler rating plate. A dedicated motor duty circuit

breaker should be provided.

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 rating.

2. Turn off all power to the boiler. Verify that power

has been turned off by testing with a volt-ohm

meter prior to working with any electrical connec-

tions or components.

It is strongly recommended that all individually-pow-

ered control modules and the boiler should be

supplied from the same power source.

3. Observe proper wire colors while making electrical

connections. Many electronic controls are polarity

sensitive. Components damaged by improper

electrical installation are not covered by warranty.

BREAK THE WIRE NUTAT THE

BOILER "TH" CONNECTIONSAND

ATTACH TO THE SINGLE TANKSTAT

PER ILLUSTRATION

4. Provide 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. Install boiler controls, thermostats, or building

management systems in accordance with the

applicable manufacturer’s instructions.

7. Conduit should not be used as the ground. There

must be a solid wired ground.

NOTE: A grounding electrode conductor shall be

used to connect the equipment grounding

conductors, the equipment enclosures, and the

grounded service conductor to the grounding

electrode.

Fig. 19: Single Stage Tankstat

"TH" leads. Before starting the boiler, ensure that there

is proper voltage to the boiler and pump.

The boiler must be electrically grounded in accordance

with National Electrical Code ANSI/NFPA No. 70 and

CSA C22.1 C.E.C. Part 1 in Canada.

Fig. 18: Field Wiring Connections

Electrical Connections — Domestic

Hot Water

BREAK THE WIRE NUTAT THE

BOILER "TH" CONNECTIONSAND

ATTACH TO THE DUALTANKSTAT

PER ILLUSTRATION

DANGER — SHOCK HAZARD — Make sure

electrical power to the heater is disconnected to

avoid potential serious injury or damage to

components.

Fig. 20: 2-Stage Tankstat

Notes:

CAUTION: When servicing controls, label all wires

prior to disconnection. Wiring errors can cause

improper and dangerous operation. Verify proper

operation after servicing.

1. Field installed ground to inside of junction box.

2. If any of the original wire as supplied with the boil-

er must be replaced, it must be replaced with

105°C wire or its equivalent.

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 remote tank control through the

boiler transformer. DO NOT attach line voltage to the

temperature that avoids excessive condensate pro-

duction in the vent.

VENTING

CONNECTIONS

Category II:A boiler which operates with a non-pos-

itive vent static pressure and with a vent gas

temperature that may cause excessive condensate

production in the vent.

General

CAUTION: Proper installation of flue exhaust

venting is critical for the safe and efficient operation

of the boiler. For vent systems not shown in this

section please contact your local authorized

representative.

Category III: A boiler which operates with a positive

vent 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 that

may cause excessive condensate production in the

vent.

CAUTION: Stable vent pressure is critical to the

safe and proper operation of the heater. A

combination of barometric dampers, balancing

dampers, extractors, or draft inducers may be

required to stabilize the vent pressure.

See Table J for vent category requirements for the

Advanced Design Boiler.

Definition of Appliance Categories

NOTE: For additional information on appliance

categorization, see appropriate ANSI Z21 Standard

and the latest edition Standard of National Fuel Gas

Code or in Canada, the latest edition of CSA

Standard B149 Installation Code for Gas Burning

Appliances and Equipment, or applicable provisions

of local building codes.

Boilers are divided into four categories based on the

pressure produced in the exhaust and the likelihood of

condensate production in the vent.

Category I: A boiler which operates with a non-pos-

itive vent static pressure and with a vent gas

Tight

NOTE: PVC or CPVC vent may be used in conjunction with CHX, special piping arrangement has to be made. Contact manufacturer for details.

Table J: ADB Category Determination for Venting Purpose and Venting Arrangement

over an area where condensate or vapor could

create a nuisance or hazard or could be detrimen-

tal to the 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.

Determination of Appliance

Category for Venting Purposes and

Venting Arrangements

WARNING: Contact the manufacturer of the vent

material if there is any question about the appliance

categorization and suitability of a vent material for

application on a Category III or IV vent system.

Using improper venting materials can result in

personal injury, death or property damage.

f) Locate and guard vent termination to prevent acci-

dental contact by people and pets.

g) DO NOT terminate vent in window well, stairwell,

alcove, courtyard or other recessed area, unless

previously approved by local authority.

Support of Vent Stack

h) DO NOT terminate above any door, window, or

gravity air intake. Condensate can freeze causing

ice formations.

The weight of the vent stack or chimney must not rest

on the boiler vent connection. Support must be provid-

ed in compliance with applicable codes. The vent

should also be supported to maintain proper clear-

ances from combustible materials.

i) Locate 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.

Use insulated vent pipe spacers where the vent pass-

es through combustible roofs and walls.

j) DO NOT extend exposed vent pipe outside of

building. Condensate could freeze and block vent

pipe.

Vent Terminal Location

k) Multiple direct vent caps, when installed in the

same horizontal plane, should have a three (3)

foot clearance from the side of one vent cap to the

side of the adjacent vent cap(s).

NOTE: During winter months check the vent cap

and make sure no blockage occurs from build up of

snow. Condensate can freeze on the vent cap.

Frozen condensate on the vent cap can result in a

blocked flue condition.

U.S. Installations

Give special attention to the location of the vent termi-

nation to avoid possibility of property damage or

personal injury.

Refer to latest edition of the National Fuel Gas Code.

Vent termination requirements are as follows:

a) Gases may form a white vapor plume in winter.

The plume could obstruct a window view if the ter-

mination is installed in close proximity to windows.

a) Vent must terminate at least four (4) feet below,

four (4) feet horizontally, or one (1) foot above any

door, window or gravity air inlet to the building.

b) Prevailing winds could cause freezing of conden-

sate and water/ice buildup on building, plants or

roof.

b) The vent must not be less than seven (7) feet

above grade when located adjacent to public walk-

ways.

c) The bottom of the vent terminal and the air intake

shall be located at least 12 inches above grade,

including normal snow line.

c) Terminate vent at least three (3) feet above any

forced air inlet located within ten (10) feet.

d) Vent must terminate at least four (4) feet horizon-

tally, and in no case above or below unless four (4)

feet horizontal distance is maintained, from elec-

tric meters, gas meters, regulators, and relief

equipment.

d) Un-insulated single-wall metal vent pipe shall not

be used outdoors on cold climates for venting gas

utilization equipment.

e) Through-the-wall vents for Category II and IV

appliances and non-categorized condensing appli-

ances shall not terminate over public walkways or

e) Terminate vent at least six (6) feet away from adja- Follow items listed below to avoid personal injury or

cent walls. property damage.

f) DO NOT terminate vent closer than five (5) feet · Cut nonmetallic vent pipe with fine-toothed hacksaw

below roof overhang.

(34 teeth per inch).

· Do not use nonmetallic vent pipe or fittings that are

cracked or damaged.

· Do not use nonmetallic vent fittings if they are cut or

altered.

· Do not drill holes, or use screws or rivets, in non-

metallic vent pipe or fittings.

Canadian Installations

Refer to the latest edition of CSA B149 Installation

Code.

A vent shall not terminate:

To make metallic vent joints:

a) Directly above a paved sidewalk or driveway

which is located between two single family

dwellings and serves both dwellings.

· Do not install seams of vent pipe on bottom of runs.

· Completely seal all joints and seams with silicone

sealant.

b) Less than 7 ft. (2.13m) above a paved sidewalk or

paved driveway located on public property.

NOTE: For direct vent installations where the air is

piped in from outside, the protective screen on the

combustion air blower may be relocated to the air

inlet termination elbow to act as an inlet screen.

c) Within 6 ft. (1.8m) of a mechanical air supply inlet

to any building.

d) Above a meter/regulator assembly within 3 ft.

(900mm) horizontally of the vertical center-line of

the regulator.

WARNING: Examine the venting system at least

once a year. Check all joints and vent pipe

connections for tightness, corrosion or deterioration.

e) Within 6 ft. (1.8m) if any gas service regulator vent

outlet.

NOTE: The words "Flue Exhaust", "Flue" and

"Exhaust Vent" are used interchangeably.

f) Less than 1 ft. (300mm) above grade level.

g) Within 3 ft (1m) of a window or door which can be

opened in any building, any non-mechanical air

supply inlet to any building to the combustion air

inlet of any other appliance.

Venting Configurations

The following is a detailed explanation of each venting

system WITHOUT and WITH add-on condensing heat

exchanger (CHX), its installation requirements, the

h) Underneath a verandah, porch or deck, unless:

(i) the verandah, porch or deck is fully open on a components used, and part numbers for each.

minimum of two sides beneath the floor, and

For boilers connected to gas vents or chimneys, vent

(ii) the distance between the top of the vent termi- installations shall be in accordance with Part 7,

nation and the underside of the verandah, Venting of Equipment, of the latest edition of National

porch or deck is greater than 1 ft (30cm).

Venting Installation Tips

Support piping:

Fuel Gas Code, or in Canada, the latest edition of CSA

B149 Installation Code for Gas Burning Appliances

and Equipment, or applicable provisions of local build-

ing codes.

· horizontal runs- at least every five (5) feet.

· vertical runs - use braces:

· under or near elbows

Natural Draft Vertical Venting with-

out Add-on Condensing Heat

Exchanger (Category I)

Fig. 21: Natural Draft Vertical Venting without Add-on Condensing Heat Exchanger (Category I)

ADB-1501

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 for fur-

ther details (ANSI Z223.1), or in Canada, the latest edition of CSA B149.

Table K: Natural Draft Vertical Vent without Add-on Condensing Heat Exchanger

building openings must be consistent with the National

Fuel Gas Code, or in Canada, the latest edition of the

CSA B149 Installation Code for Gas Burning

Appliances and Equipment. Gas vents supported only

by flashing and extended above the roof more than

five feet should be securely guyed or braced to with-

stand snow and wind loads.

Natural Draft Vertical Venting

System Installation

Natural draft venting uses the natural buoyancy of the

heated flue products to create a thermal driving head

that expels the exhaust gases from the flue. The neg-

ative draft must be within the range of 0.01 in. to 0.08

in. WC negative to ensure proper operation. The vent

material must be in accordance with the above instruc-

tions for vent materials. Vent material must be listed by

a nationally recognized test agency.

CAUTION: Listed vent cap terminal must be used

and sized adequately to evacuate the flue products

from the boilers.

The maximum and minimum venting length for

Category I appliance shall be determined per the lat-

est edition of the National Fuel Gas Code (U.S.) or

B149 Installation Code (Canada).

Natural Draft Vertical Venting with

Common Venting System, Category

I Appliance Only

(NOT to be Utilized with Add-on

Condensing Heat Exchanger)

The diameter of vent flue pipe should be sized accord-

ing to Part 11 of the latest edition of the National Fuel

Gas Code (U.S.) and part 7 and appendix B of the

CSA B149 Installation Code (Canada). The flue pipe

diameter for conventional negative draft venting using

double-wall B type vent is 8” for the ADB 751, 10” for

the 1001, and 12” for the ADB 1501.

Manifolds that connect more than one boiler to a com-

mon chimney must be sized to handle the combined

load. Consult available guides for proper sizing of the

manifold and the chimney. At no time should the area

of the vent be less than the area of the largest boiler

exhaust outlet.

NOTE: Vent Adapter will have to be used to connect

B vent to the unit.

WARNING: Vent connectors serving appliances

vented by natural draft shall not be connected into

any portion of mechanical draft systems operating

under a positive pressure.

The connection from the appliance vent to the stack

must be as direct as possible and shall be the same

diameter as, or larger than the vent outlet. The vent

must be installed to prevent accumulation of

condensate and, where necessary, have means

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 of the vent shall

also be supported for the design and weight of the

material employed to maintain clearances and to

prevent physical damage or separation of joints.

CAUTION: Vent connectors for natural draft

venting systems must be type “B” vent or better.

Common venting systems may be too large when an

existing unit is removed. At the time of removal of an

existing appliance, the following steps must be fol-

lowed with each appliance remaining connected to the

common venting system placed in operation, while the

other appliances remaining connected to the common

venting system are not in operation.

Natural Draft Vertical Vent

Termination

a) Seal any unused opening in the common venting

system.

The vent terminal should be vertical and should termi-

nate outside the building at least two (2) feet above the b) Visually inspect the venting system for proper size

highest point of the roof that is within 10 feet. The vent

cap should have a minimum clearance of four (4) feet

horizontally from and in no case above or below

(unless a four (4) foot horizontal distance is main-

and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion or other

unsafe condition.

tained) electric meters, gas meters, regulators and c) Insofar as is practical, close all building doors and

relief equipment.

windows and all doors between the space in which

the appliances remaining connected to the com-

mon venting system are located and other spaces

of the building. Turn on clothes dryers and any

The distance of the vent terminal from adjacent public

walkways, adjacent buildings, open windows and

appliance not connected to the common vent sys-

tem. Turn on any exhaust fans, such as range

hoods and bathroom exhausts, so they will oper-

ate at maximum speed. Do not operate summer

exhaust fan. Close fireplace dampers.

When re-sizing any portion of the common venting

system, the common venting system should be re-

sized to approach the minimum size as

determined using the appropriate tables in

Appendix G in the latest edition of the National

Fuel Gas Code, ANSI Z223.1, in Canada,

Appendix B of the latest edition of the Installation

Code for Gas Burning Appliances and Equipment.

d) Place in operation the appliances being inspected.

Follow the manufacturers instructions for lighting

each appliance. Adjust thermostat so appliance

will operate continuously.

e) Test for natural draft (negative pressure) 12"

above the outlet elbow after 5 minutes of main

burner operation. Use the flame of a match or can-

dle, or smoke from a cigarette, cigar or pipe, toilet

paper trick.

f) After it has been determined that each appliance

remaining connected to the common venting sys-

tem properly vents when tested as outlined above,

return 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 that the installation

conforms with the latest edition of the National

Fuel Gas Code, ANSI Z223.1, in Canada, the lat-

est edition of CSA B149 Installation Code for Gas

Burning Appliances and Equipment.

Fig. 22: Horizontal Thru-Wall Venting without Add-on

Condensing Heat Exchanger (Category III)

ADB-1501

Table L: Horizontal Thru-wall Venting without Add-on

Condensing Heat Exchanger (Category III)

Horizontal Thru-wall Direct Venting

System (Category III) Installation

Horizontal Thru-wall Direct Vent

Termination

These installations utilize the boiler-mounted blower to The direct vent cap MUST be mounted on the exterior

vent the combustion products to the outdoors. of the building. The direct vent cap cannot be installed

Combustion air is taken from inside the room and the in a well or below grade. The direct vent cap must be

vent is installed horizontally through the wall to the out- installed at least one (1) foot above ground level and

doors. Adequate combustion and ventilation air must above normal snow levels. The Raypak supplied direct

be supplied to the boiler room in accordance with the vent cap must be used.

National Fuel Gas Code or, in Canada, the latest edi-

tion of CSA B149 Installation Code for Gas Burning

Appliances and Equipment.

WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

The total length of the thru-wall exhaust vent system

cannot exceed sixty-five (65) feet in length for the flue

outlet. Each elbow used is equal to ten (10) feet of

straight pipe. This will allow installation in one of the

four following combinations:

WARNING: For common vent installations, contact

the factory.

· 65′ of straight flue pipe.

The Stainless Steel direct vent cap must be fur-

nished by the boiler manufacturer in accordance

with its listing.

· 55′ of straight flue pipe and one elbow.

· 45′ of straight flue pipe and two elbows.

· 35′ of straight pipe and three elbows.

The direct vent cap is not considered in the overall

length of the venting system. The vent must be

installed to prevent the flue gas leakage. Care must be

taken during assembly to ensure 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 is rec-

ommended that:

a) The vent be installed with a slight downward slope

of not more than 1/4" per foot of horizontal run to

the vent 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 of

not more than 1/4" per foot of horizontal run to the

vent terminal. In this case, an approved conden-

sate trap must be installed per applicable codes.

Fig. 23: Horizontal Thru-Wall Direct

Venting/Combustion Air

(Category III)

b) The vent be insulated through the length of the

horizontal run.

ÁDB-1501

Table M: Horizontal Thru-wall Direct Venting without Add-on

Secondary Condensing Heat Exchanger

The vent must be installed to prevent the potential

accumulation of condensate in the vent pipes. It is rec-

ommended that:

Horizontal Thru-wall Direct Venting

System (Category III) Installation

These installations utilize the boiler mounted blower to

draw combustion air from outdoors and vent combus-

tion products to the outdoors.

a) The vent be installed with a slight downward slope

of not more than 1/4" per foot of horizontal run to

the vent terminal.

The total length of the thru-wall exhaust vent cannot

exceed forty-five (45) feet in length for the flue outlet.

Each elbow used is equal to ten (10) feet of straight

pipe. This will allow installation in one of the three fol-

lowing combinations:

b) The vent be insulated through the length of the

horizontal run.

For appliances installed in extreme cold climate, it is

recommended that:

· 45′ of straight flue pipe.

· 35′ of straight flue pipe and one elbow.

· 25′ of straight flue pipe and two elbows.

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 conden-

sate trap must be installed per applicable codes.

The total length air supply pipe cannot exceed forty-

five (45) feet in length for the combustion air inlet.

Each elbow used is equal to ten (10) feet of straight

pipe. This will allow installation in one of the three fol-

lowing combinations:

b) The vent be insulated through the length of the

horizontal run.

Horizontal Thru-wall Direct Vent

Termination

· 45′ of straight combustion air pipe

· 35′ of straight combustion air pipe and one elbow.

· 25′ of straight combustion air pipe and two elbows.

The direct vent cap MUST be mounted on the exterior

of the building. The direct vent cap cannot be installed

in a well or below grade. The direct vent cap must be

installed at least one (1) foot above ground level and

above normal snow levels.

The direct vent cap is not considered in the overall

length of the venting system.

Care must be taken during assembly that all joints are

sealed properly and are airtight.

Multiple direct vent caps MUST NOT be installed with

one combustion air inlet directly above a direct vent

cap. This vertical spacing would allow the flue prod-

ucts from the direct vent cap to be pulled into the

combustion air intake installed above.

This type of installation can cause non warrantable

problems with components and poor operation of the

unit due to the recirculation of flue products. Multiple

direct vent caps, when installed in the same horizontal

plane, should have three (3) foot 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

particulate and chemical contaminants. To avoid a

blocked flue condition, keep the vent cap clear of

snow, ice, leaves, debris, etc.

WARNING: For common vent installations call

factory.

WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

The Stainless Steel direct vent cap must be fur-

nished by the boiler manufacturer in accordance

with its listing.

Fig. 24: Vertical Direct Venting/Combustion Air

(Category I)

ADB-1501

*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 Z223.1) or in Canada, the latest edition of CSA B149 Installation Code.

Table N: Vertical Direct Venting without Add-on Condensing Heat Exchanger

and Equipment. Gas vents supported only by flashing

and extended above the roof more than five feet

should be securely guyed or braced to withstand snow

and wind loads.

Vertical Direct Venting System

Installation

These installations utilize the boiler mounted blower to

draw combustion air from outdoors and uses the natu-

ral buoyancy of the heated flue products to create a

thermal driving head that expels the exhaust gases

from the flue. The negative draft must be within the

range of -0.01 in. to -0.08 in. WC to ensure proper

operation.

The vertical direct vent cap is designed for roof top

mounting only. The air inlet opening MUST be installed

one (1) foot above the roof line or above normal snow

levels that might obstruct combustion air flow. This

dimension is critical to the correct operation of the boil-

er and venting system and reduces the chance of

blockage from snow. The vent cap must have a mini-

mum 3 foot vertical clearance above the air inlet

opening.

The vent material must be in accordance with the

above instructions for vent materials. Vent material

must be listed by a nationally recognized test agency.

The maximum and minimum venting length for

Category I appliance shall be determined per the lat-

est edition of the National Fuel Gas Code (U.S.) and

CSA B149 Installation Code (Canada).

The diameter of vent flue pipe should be sized accord-

ing to part 11 of the latest edition of the National Fuel

Gas Code (U.S.) and part 7 and Appendix B of CSA

B149 Installation Code (Canada). The flue pipe diam-

eter for conventional negative draft venting using

double-wall B type vent is 12” for the ADB 1501.

The connection from the appliance vent to the stack

must be as direct as possible and should be the same

as or larger than the vent outlet. The vent must be

installed to prevent accumulation of condensate and,

where necessary, have means 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 of the vent shall also be sup-

ported for the design and weight of the material

employed to maintain clearances and to prevent phys-

ical damage or separation of joints.

Fig. 25: Vertical Venting with Add-on Condensing Heat

Exchanger (Category IV) Domestic Water

Vertical Direct Vent Termination

The vent terminal should be vertical and should termi-

nate outside the building at least two (2) feet above the

highest point of the roof within 10 feet. The vent cap

should have a minimum clearance of four (4) feet hor-

izontally from and in no case above or below (unless a

four (4) foot horizontal distance is maintained) electric

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 the National

Fuel Gas Code, or in Canada, the latest edition of CSA

B149 Installation Code for Gas Burning Appliances

Certified Venting

Material

Maximum Vent

Length (feet)

Model

Venting Category

Vent Size (inches)

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

ADB-751 w/CHX

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

ADB-1001 w/CHX

ADB-1501 w/CHX

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

*Contact the manufacturer for details.

Table O: Vertical Vent (CATEGORY IV) with Add-on Condensing Heat Exchanger

For certain installations, i.e. pool, heat-pump domestic

hot water with pre-heat tank, PVC or CPVC may be

used. Contact the manufacturer for details.

Vertical Vent (Category IV) with

Add-on Condensing Heat Exchanger

Installation

To prevent the condensation accumulation in the vent,

it is 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.

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 vertically through the roof to the out-

doors. Adequate combustion and ventilation air must

be supplied to the boiler 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.

WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

UL 1738 Certified Venting Material (e.g. AL29-4C)

MUST be used. The vent must be installed to prevent

the flue gas leakage. Care must be taken during

assembly to ensure that all joints are sealed properly

and are airtight.

The Stainless Steel non-restricted direct vent cap

must be furnished by the boiler manufacturer in

accordance with its listing.

Fig. 26: Horizontal Thru-wall Venting with Add-on Condensing Heat Exchanger (CHX)

Certified Venting

Material

Maximum Vent

Length (feet)

Model

Venting Category

Vent Size (inches)

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

ADB-751 w/CHX

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

ADB-1001 w/CHX

ADB-1501 w/CHX

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

55 Subtract 10 ft per

elbow, Max. 3

elbows

*Contact the manufacturer for details.

Table P: Horizontal Thru-wall Venting with Add-on Condensing Heat Exchanger

Horizontal Thru-wall Venting

WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

System (Category IV) Installation

This installation 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 to the out-

doors. Adequate combustion and ventilation air must

be supplied to the boiler 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.

The Stainless Steel non-restrictive direct vent cap

must be furnished by the boiler manufacturer in

accordance with its listing.

UL 1738 Certified Venting Material (e.g. AL29-4C)

MUST be used. The vent must be installed to prevent

flue gas leakage. Care must be taken during assembly

to ensure that all joints are sealed properly and are air-

tight.

For certain installations, i.e. pool, heat pump, domes-

tic 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 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, so the condensation

in the vent pipe drains back to the boiler.

WARNING: For common vent installations contact

factory.

Fig. 27: Horizontal Thru-Wall Direct Venting/Combustion Air with Add-on

Condensing Heat Exchanger (Category IV)

Combustion Air Air Inlet

Max. Air

Intake Length

(feet)

Venting

Category

Certified Venting

Material

Vent Size

(inches)

Maximum Vent

Length (feet)

Model

Intake Pipe

Material

Size

(inches)

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

Galvanized

Steel

PVC, ABS

CPVC

ADB-751

w/CHX

Subtract 10 ft per

elbow, Max. 3

elbows

Subtract 10 ft

per elbow,

Max. 3 elbows

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

Galvanized

Steel

PVC, ABS

CPVC

ADB-1001

w/CHX

Subtract 10 ft per

elbow, Max. 3

elbows

Subtract 10 ft

per elbow,

Max. 3 elbows

UL 1738 Certified

Venting Material e.g.

AL29-4C Stainless

Steel PVC*, CPVC*

Galvanized

Steel

PVC, ABS

CPVC

ADB-1501

w/CHX

Subtract 10 ft per

elbow, Max. 3

elbows

Subtract 10 ft

per elbow,

Max. 3 elbows

8**

*Contact the manufacturer for details.

**If the boiler is direct vented, a 6 to 8 in. adapter must be installed at the blower inlet.

Table R: Vertical Direct Venting with Add-on

Secondary Condensing Heat Exchanger

Vertical Direct Venting System With Outdoor Installation with Add-On

Add-on Condensing Heat Exchanger Condensing Heat Exchanger

(Category IV) Installation

Outdoor models are self-venting when installed with

the factory-supplied non-restricted direct vent cap and

require no additional vent piping. This special vent cap

is provided with the boiler in accordance with CSA

requirements. It must be installed directly on the boiler

in a horizontal position. Notching of the vent cap

mounting flange may be necessary to clear outlet pip-

ing on some models.

These installations utilize the boiler mounted blower to

draw combustion air from outdoors and vent combus-

tion products to the outdoors.

UL 1738 Certified Venting Material (e.g. AL29-4C)

MUST be used. The vent must be installed to prevent

flue gas leakage. Care must be taken during assembly

to ensure that all joints are sealed properly and are air-

tight.

Care must be taken when locating the outdoor unit

because the flue gases discharged from the vent cap

can condense as they leave the cap. Improper location

can result in damage to adjacent structures or building

finish. For maximum efficiency and safety, the follow-

ing precautions must be observed:

For certain installations, i.e. pool, heat-pump, domes-

tic 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 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.

a) Outdoor models must be installed outdoors and

must use the non-restricted direct vent cap sup-

plied by the manufacturer.

b) Periodically check venting system. The boiler’s

venting areas must never be obstructed in any

way and minimum clearances must be observed to

prevent restriction of combustion and ventilation

air. Keep area clear and free of combustible and

flammable materials.

WARNING: For common vent installations, contact

the factory.

WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

c) Do not locate adjacent to any window, door walk-

way, or gravity air intake. The vent should be

located four (4) feet horizontally from such areas.

The Stainless Steel non-restricted direct vent cap

must be furnished by the boiler manufacturer in

accordance with its listing.

d) Install above grade level and above normal snow

levels.

e) A venting system shall terminate at least 3 feet

above any forced air inlet located within 10 feet.

NOTE: In areas of high winds (alleyways, air

handlers, etc.), a downward 90° - elbow must be

mounted on the combustion air inlet to prevent any

air flow fluctuation.

f) Adjacent brick or masonry surfaces must be pro-

tected with a rust-resistant sheet metal plate.

g) Multiple Outdoor Vent installations require a four

(4) feet clearance between vent caps.

CONDENSATE DRAIN

NOTE: Condensate can freeze on the vent cap.

Frozen condensate on the vent cap can result in a

blocked flue condition.

WARNING:All condensation should be disposed of

according to local, county, state, and federal laws.

Refer to NFGC, section 7.9, for additional

information.

The Stainless Steel non-restricted vent cap must

be furnished by the boiler manufacturer in accor-

dance with its listing.

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

rate for the ADB 751 is 7.5 gph, the ADB 1001 is 10

gph, and the ADB 1501 is 15 gph.

The outdoor vent terminal must be installed in a hori-

zontal position to prevent recirculation of flue products.

The vent cap must be mounted directly on the vent

pipe of the boiler.

Fig. 29: Condensate Trap Alignment

Central Point Wiring (CPW)

CONTROLS

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 Status Center, which

is comprised of two different circuit boards: the CPW

board and one or more U-2 Diagnostic Boards.

WARNING: Installation, adjustment and service of

boiler controls including timing of various operating

functions must be performed by a qualified installer

or service agency. Failure to do so may result in

control damage, boiler malfunction, property

damage, personal injury, or death.

The CPW Board

WARNING: Turn off the power to the boiler before

installation, adjustment or service of the Central

Point Wiring board or any boiler controls. Failure to

do so may result in board damage, boiler

malfunction, property damage, personal injury, or

death.

The Central Point Wiring (CPW) board serves as the

central tie point for connecting all other control compo-

nents in the boiler. The CPW board provides boiler

operating status and fault indication using eight LEDs

which function as described in Table S.

In addition to monitoring and displaying boiler status,

the CPW board controls the timing of various operat-

ing functions including: boiler pump turn-off delay,

blower fan pre-purge, and blower fan post-purge. The

location of each user adjustable timing is shown in

Figure 30.

CAUTION: This appliance has provisions to be

connected to more than one (1) supply source. To

reduce the risk of electric shock, disconnect all such

connections before servicing.

CAUTION: Risk of electric shock. More than one

(1) disconnect switch may be required to de-

energize the equipment before servicing.

Light

Color

Indication

Power

Green

24 VDC is applied to the system

System Error

Pump

Pilot

Red

Overload current on the board. Board is disabled.

Boiler Pump is energized.

Power applied to the Pilot Gas Valve. (PV signal on.)

Power applied to Main Gas Valve. (MV signal on.)

Thermostat is closed. Call for heat present.

One or more of the safeties are open. Refer to U-2 Board

Blower is energized.

Green

Yellow

Green

Main Gas

Call for Heat

Service

Green

Red (Flashing)

Green

Blower

Table S: CPW Board LED Indicators

Fig. 30: CPW Board

Pump Turn-off Delay

Blower Fan Pre-purge

The CPW board has a built-in pump driver with pump The CPW board has a built-in pre-purge delay which

turn-off delay, which allows the operator to set how operates the blower fan for a user-adjustable time

long the pump will run after the boiler shuts off. The period prior to pilot trial for ignition. The pre-purge peri-

delay is factory-set for 7 minutes but can be field- od ensures that the combustion chamber is clear of all

adjusted from 3 minutes to 10 minutes. The pump excess combustible gases prior to commencing the

relay can directly power a pump of up to 12.0 amps pilot ignition cycle. The pre-purge delay is factory set

draw or 3/4 hp capacity. Pumps with larger amp draws for 45 seconds and it can be adjusted in the field from

should be energized through a pump contactor that is 45 seconds to 120 seconds. To optimize boiler

controlled by the CPW board.

response time on call-for-heat, set the pre-purge delay

to the minimum allowed by local, state or national

By properly setting the pump turn-off delay, the boiler code.

pump will continue running for a limited period of time

in order to extract any residual heat from the combus-

Blower Fan Post-purge

tion chamber. The pump will then shut off to conserve

energy until the next call for heat.

The CPW board has a built-in post-purge delay to

exhaust residual combustion products after the main

gas valve closes. The post-purge timing is factory set

at 3 minutes and is not field-adjustable.

The pump-off time delay should be set to the minimum

time required to extract all residual heat from the heat

exchanger. If temperature as monitored at the 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 until outlet temperature does

not spike more than 5°F after pump shut-off following

a prolonged firing cycle (> 5min.)

Freeze Protection Feature

The CPW board is programmed to turn-off the blower

in case there is a lock-out condition. If there is a call for

heat signal, and the pilot valve signal is removed and

not reactivated within a pre-set time for any reason,

the CPW board will turn off the blower to prevent blow-

ing cold air continuously and freezing the heat

exchanger. The blower drives will open and the system

will lock in the off state.

CAUTION: The boiler requires forced water

circulation when the burner is operating and the

pump must be interlocked with the boiler. See the

Water Piping section for minimum and maximum

water flow rates and pump selection.

To restart the system, primary power or the thermostat

signal must be turned off and back on. The pre-set

freeze protection feature time is approximately 5 min-

utes.

NOTE: Pump will come on when power is first

applied to the boiler.

additional light indicates that the diagnostics board is

energized and is currently monitoring for safety faults.

(In order to prevent spurious alarm conditions, the U-2

board monitors safeties only during the actual firing

cycle.)

U-2 Diagnostics Board

The U-2 Diagnostics board is a solid-state electronic

fault indicator that has been engineered to enhance

safety, simplify troubleshooting and minimize equip-

ment down time. The U-2 safety board is the central

point for wiring, operations monitoring, and fault indi-

cation for the boiler safeties. By having each safety

report directly to the U-2 board, each safety function

can be individually monitored.

Once a fault has been detected, the 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 display the priority fault

based on the safety hierarchy as labeled on the U-2

board. Once the first fault is cleared, the second fault

lamp will illuminate until cleared.

The U-2 adds complete diagnostics features that aid in

the rapid diagnosis of irregularities in boiler operation.

A single U-2 Diagnostics Board can monitor a maxi-

mum of eight safeties at one time. If, due to code

requirements, more than eight safety devices must be

monitored, two or more boards will be used to provid-

ed extended diagnostics capabilities. Advanced

Design Boilers equipped with the standard safety suite

will utilize the configuration shown in Table T.

WARNING: Only qualified persons shall attempt to

repair the boiler. Improper adjustment, service or

maintenance may damage the equipment, create a

hazard resulting in asphyxiation, explosion, fire,

electric shock, personal injury or property damage,

and will void the warranty.

The U-2 safety board has a series of red LED lights to

indicate a fault occurring at a monitored safety. An

Light

Color

Yellow

Red

Indication

U-2 Diagnostics safety board is functional.

Water temperature is over the manual high limit setting.

Water temperature is over the auto high limit setting.

Water flow rate is too low.

System Enabled

Manual High Limit

Auto High Limit

Flow Switch

Red

Low Water Cut-off (option)

High/Low Gas Pressure

Red

Insufficient water volume for boiler operation.

Gas supply pressure is below or above the allowed minimum gas supply

pressure to ensure safe operation.

Red

Burner High Limit

Blower/Ignition Lockout

Blocked Vent

Red

Mixer or PVC vent pipe, if installed, is over heated.

Blower failure, not enough combustion air or the equipment has an ignition

lock-out condition.

The vent pressure switch has detected a blocked vent.

Table T: U-2 Diagnostic Board LEDs

WIRING

DIAGRAM

Figure L-2

WIRING DIAGRAM

Ignition Control Module

Flow Switch

The intermittent ignition device conserves energy by Dual-purpose control shuts off boiler in case of pump

automatically extinguishing the pilot when the desired failure or low water condition. Mounted and wired in

temperature is reached. When additional heat is need- series with the main gas valve. Check with the manu-

ed, the combustion air blower starts to purge all air facturer for proper paddle size. Utilize correct paddle

from the combustion chamber for about 45 seconds. size for proper operation.

On proof of air flow, the air proving switch closes and

the pilot reignites electrically, eliminating the fuel costs

NOTE: Flow switch will not operate if flow is less

of maintaining a constant pilot.

than 20 gpm.

To ensure safe operation, the gas valve cannot open

until the pilot relights and is verified. The 100% pilot

safety is an electronic device which closes the main

gas valve within 8/10 of a second whenever the pilot

flame is interrupted. Pilot flame is automatically lit

when 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.

Fig. 33: Flow Switch

High Limit — Auto Reset

This appliance is equipped with an automatic, high

limit, safety device. Set the auto high limit to 30°F

above the desired operating temperature.

Fig. 31: Ignition Module

High Limit — Manual Reset

This appliance is equipped with a manual reset, high

limit, safety device. Push the reset button and adjust

the setting to 40°F above the desired operating tem-

perature.

Fig. 34: Auto Reset — High Limit

Fig. 32: High Limit — Manual Reset

Low Water Cut Off (Optional)

PRE-START-UP

The low water cut off automatically shuts down the

burner whenever water level drops below the level of

the sensing probe. A 3 second time delay prevents

premature lockout due to temporary conditions such

as power fluctuations or air pockets.

Fill the System:

1. Close manual and automatic air vents and drain

cock.

2. Fill to correct system pressure. Correct pressure

will vary with each application.

3. Open automatic air vent two turns.

4. Slowly feed water to boiler.

5. Starting on the lowest floor, open air 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 pipe connections and flue pipe

material.

2. Ensure vent terminations are installed per code

and are clear of all debris or blockage.

Fig. 35: Low Water Cut Off

High and Low Gas Pressure

Switches — Manual Reset

For Your Safety — Read Before

Lighting

The low gas pressure 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 boiler if gas supply drops below the factory setting

of 6 in. WC for Natural gas, and 10 in. WC for Propane

gas.

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

1. This appliance has an intermittent pilot. It is

equipped with an ignition device which automati-

cally lights the pilot. DO NOT try to light the pilot or

burner by hand.

The high gas pressure switch (optional) mounts down-

stream of the gas pressure regulator. If the gas

pressure regulator fails, the high gas pressure switch

automatically shuts down the burner.

2. BEFORE OPERATING, smell all around the appli-

ance 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. WHAT TO DO IF YOU SMELL GAS:

•

Do not try to light any appliance.

Do not touch any electrical switch; do not use

any telephone in your building.

•

Immediately call your gas supplier from a

neighbor's telephone. Follow the gas suppli-

er's instructions.

If you cannot reach your gas supplier, call the

fire department.

4. Use only your hand to push in or turn the gas con-

trol knob. Never use tools. If the knob will not turn

by hand, do not try to repair it, call a qualified serv-

ice technician. Forced or attempted repair may

Fig. 36: Gas Pressure Switch

result in a fire or explosion.

5. Do not use this appliance if any part has been

under water, immediately call a qualified service

technician to inspect the appliance and to replace

any part of the control 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. Repeat steps 4 and 5 under

“Fill the System.” Air in system can interfere with

water circulation and cause improper heat distribu-

tion.

Fig. 38: Blower “T” Fitting Detail

Fig. 37: Component and Pressure Tap locations

Turn Off The 1 1/2” Manual Gas Valve;

Turn Off Pilot Gas Valve;

Reset Low Gas Pressure Cut-off Switch;

ADB INITIAL START-UP

CAUTION: Verify that the vent system and

combustion air supply have been approved.

Bleed Air from Gas Line

CAUTION: Make sure there is no ignition source in

the boiler room.

Tools Needed

•

One 8-0-8 , 16” scale manometer (or larger)

Four 4-0-4, 8” scale manometers (or larger)

“T” fitting

7/16” and 1/2" open end wrenches

Small and large flat-head screwdrivers

Volt meter

•

With power off, slightly open union outside the

cabinet to bleed air.

Close union when you smell gas.

Wait minimum 5 minutes to clear the gas out of the

boiler room before continuing.

•

Amp probe

Elec. Dual reading thermometer with strap on sen-

sors

3/16” Allen wrench

Check the Gas Supply Pressure,

Location (1)

•

Combustion analyzer

•

Leave pilot gas valve and first manual gas valve

closed;

Slowly turn on main gas shut-off valve (outside the

unit);

Read the gas supply pressure from the manome-

ter (Location 1);

If pressure is > 14" W.C., Turn off the valve;

Check if the service regulator is installed and/or

adjust the service regulator.

Preparation for Start-up

WARNING: DO NOT TURN ON GAS AT THIS

TIME.

•

Check Power Supply

With voltmeter at incoming power check voltage

between:

START-UP

NOTE: Reference the start-up pressures settings

located on the side of the control box.

Hot - Common (»120 VAC)

Hot – Ground (»120 VAC)

Common - Ground (< 1 VAC)

Blower Adjustment

If Common - Ground is > 1 VAC - STOP: Contact elec-

trician to correct ground failure.

1. Main gas shut-off valve is still closed;

2. Turn power on;

WARNING: Failure to do this may burn out 120V-

24V transformer, or may cause other safety control

damage or failure.

3. Check blower manometer reading, Location (5).

Compare your reading to the “Pre-Fire” values

shown in tables T and U. If not, adjust the air shut-

ter on the blower to attain the correct value;

4. Turn power off.

Attach Manometers to Measure

Pressures (See Fig. 37)

Pilot Adjustment

•

Attach 16" scale manometer to the first gas shut-

off valve pressure tapping, Location (1)

1. Turn on the gas shut-off valve, the main gas man-

ual valve, and the pilot manual valve;

2. Turn off the manual gas valves at Locations (2)

and (3);

3. Turn power on, after 40-45 seconds, ignition con-

trol will energize and send spark to ignition,

observe through view port for spark;

Attach one 8" scale manometer to each manual

gas valve pressure tapping, Locations (2) and (3).

Attach one 8" scale manometer to the outlet side

of pilot gas valve pressure tapping, Location (4).

Attach one 8" manometer to “T” fitting, air pressure

switch, and aluminum tubing, Location (5).

4. If you do not see spark, turn off power, check igni-

tion wire and proper grounding and wiring. Turn

power back on. Repeat Step 3. If there is still no

from pilot gas valve (you will not hear the spark-

ing);

spark after several attempts the igniter may be 8. The pilot may not light at first trial; leave the unit

misaligned;

running until you have pilot. If you still do not see

pilot over 90 seconds; turn off the unit; repeat

steps 6-8;

5. Check to see if igniter is grounded out by pulling

the spark wire and doing a continuity check

between the igniter and burner. If the igniter is 9. Check pilot manifold pressure, Location (4).

grounded out, it must be realigned. Remove the

burner. Loosen the igniter nut, locate the igniter in

Compare the reading to the value listed in the

tables;

the center of the burner head and tighten igniter 10. Check pilot flame; 8 distinct circular blue flames

nut. Confirm it is centered and reinstall burner

head;

6. If you have spark, turn off unit;

around the center of the pilot;

11. Replace the cap for pilot manifold adjustment

screw; do not over-tighten.

7. Turn on power. Unit will pre-purge 40-45 seconds

and move onto ignition trial. You will hear a click

Note: For different gas control options, call the factory for proper pressure settings.

Table U: Pressure Settings and Emission Guidelines (True Readings) for NAT. GAS

Note: For different gas control options, call the factory for proper pressure settings.

Table V: Pressure Settings and Emission Guidelines (True Readings) for LP GAS

temperature measurement, see Table E and G for

correct flow balance.

NOTE: Emissions will vary with different

applications (hydronic, water heater, or pool),

venting (including direct vent), ambient conditions (T,

P, and humidity), and the condition of the boiler.

During the following safety checks leave manome-

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.

NOTE: For high altitude (above 5000 ft), call the

factory for proper pressure settings.

Remember, supply gas should always be

between 7 in. and 14 in. WC.

Main Burner Adjustment

Check thermostat control for ON/OFF operation;

Check safety Hi Limits for ON/OFF operation;

While in operation inspect flow switch;

Check the low gas pressure switch, it is factory set

at 6 in. WC for natural gas;

High gas pressure switch (optional) at 1 in. WC

above manifold pressure;

Insert ignition control lockout test as safety check

1. Turn on the unit; about 45 seconds later, the pilot

should light. If the pilot fails to light, repeat pilot

adjustment.

2. Turn the top manual valve on, Location (2). The

inner burner will fire.

3. Make sure that the supply gas manometer reads

between 7 – 14 in. WC (dynamic pressure).

4. Check manifold pressure, Location (2); this should

read to within 0.1 in. WC of the values shown in

tables U and V.

Follow-up

5. If adjustment is required, remove screw cap off the

top gas pressure regulator, and adjust regulator.

6. Slowly turn the bottom manual valve on, Location

(3). The outer burner will fire.

7. Make sure that the supply gas manometer reads

between 7 – 14 in. WC (dynamic pressure).

8. Check manifold pressure, Location (3); this should

read to within 0.1 in. WC of the values shown in

tables U and V.

9. If adjustment is required, remove screw cap off the

bottom gas pressure regulator, and adjust regula-

tor.

10. The blower pressure should increase about 3/10

in. (0.3 in.) WC equaling the “Firing” value in tables

U and V.

•

Safety checks must be recorded as performed;

Turn unit on;

After main burner ignition. Check Manometers for

proper readings;

Verify that the blower shutter is locked;

Cycle unit several times and recheck readings;

Re-analyze with unit running record or print

results;

Turn unit off, remove all Manometers and replace

blower switch hose, replace all gas pressure caps

and plugs;

Check for gas leak one more time;

Check around unit for debris and remove com-

bustible and flammable products, i.e. paper,

gasoline etc.

•

11. Lock the blower shutter by tightening the shutter

nut while holding the black knob fixed.

12. Allow minimum 5 minutes of run time; then attach

flue analyzer, check emission and compare the

CO2 reading to that of table U and V.

13. If CO2 is high, reduce bottom manifold gas pres-

sure.

14. If CO2 is low, increase the bottom manifold gas

pressure.

15. All pressure readings especially manifold pres-

sures should be within 0.1 in. of listed values.

16. Replace the screw caps back on the gas regula-

tors.

POST START-UP CHECK

Check off steps as completed:

1. Boiler and heat distribution units or storage tank

filled with water?

2. Automatic air vent, if used, open two full turns dur-

ing venting procedure?

3. Air purged from system?

4. Air purged from gas piping? Piping checked for

leaks?

5. Followed start-up procedure for proper start-up?

6. Is burner flame visible?

Your ADB is tuned in!

7. Test safety controls: If boiler is equipped with a low

water cutoff or additional safety controls, test for

operation as outlined by manufacturer. Burner

should be operating and should go off when con-

trols are tested. When safety devices are restored,

Safety Inspection

Check thermostat and high limit settings.

Attach thermometers to IN/OUT piping and take

burners should reignite after pre-purge time delay. 7. Wait five (5) minutes to clear out any gas. Then

8. Test limit control: While burner is operating, move

indicator on high limit control below actual boiler

water temperature. Burner should go off while

blower circulator continues to operate. Raise set-

smell for gas, especially near the floor. If you then

smell gas. STOP! Follow the steps in the safety

information. If you do not smell gas, go to next

step.

ting on limit control above boiler water 8. Turn on all electric power to the appliance.

temperature and burner should reignite after pre- 9. Set thermostat to desired setting. The appliance

purge time delay.

9. Test ignition system safety device:

will operate. The pilot burner will light after the pre-

purge time delay (45 seconds). Then the pilot will

light the main burner.

•

Turn power off.

Close the pilot manual valve.

Turn power on; after about 45 seconds of pre-

purge, the pilot comes on. The pilot (and

10. If the appliance will not operate, follow the instruc-

tion "To Turn Off Gas to Appliance", and contact a

qualified service technician.

therefore the burner) should fail to light. The 11. Replace upper front panel.

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 the power off; open the pilot manual

valve; (reset the lockout module if applicable).

Wait 30 seconds, then turn power on. The

burner should ignite after pre-purge time

delay.

To Turn Off Gas to Appliance

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if serv-

ice is to be performed.

3. Remove upper front panel.

4. Turn off main manual gas valve and manual pilot

gas valve.

•

10. To restart system, follow the lighting instructions.

11. High limit control set to design temperature

requirements of system? For multiple zones: flow

adjusted as required in each zone?

12. Boiler cycled with thermostat? Raise to highest

setting and verify boiler goes through normal start-

up cycle. Reduce to lowest setting and verify boiler

goes off.

13. Observed several operating cycles for proper

operation?

14. Set room thermostat or tankstat to desired temper-

ature?

5. Replace access panel.

If boiler fails to start, check for:

•

Loose connections, blown fuse or service

switch off?

•

High temperature limit switch set below boiler

water temperature?

•

Thermostat set below room temperature?

Gas not turned on at meter or boiler?

Incoming dynamic gas pressure less than 6 in.

WC for Natural gas, 10 in. WC for Propane?

15. Reviewed all instructions shipped with this boiler

with owner or maintenance personnel, returned to

envelope and given to owner or placed in pocket

inside front panel on boiler?

MAINTENANCE

Suggested Minimum

Maintenance Schedule:

OPERATION

Regular service by a qualified service agency and

maintenance must be performed to ensure maximum

boiler operating efficiency.

Operating Instructions

Lighting Instructions:

Maintenance as outlined below may be performed by

the owner.

1. STOP! Read the safety information first.

2. Set the thermostat 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.

5. Remove upper front panel.

6. Turn on main manual gas valve and pilot manual

gas valve.

Yearly (Beginning of each heating

season):

1. Annual service call by qualified service agency.

2. Visually check top of vent for soot. Call service

person to clean. Some sediment at bottom of vent

is normal.

3. Visually inspect venting system for proper func- 2. Test low water cutoff, if used. Refer to manufactur-

tion, deterioration or leakage. er’s instructions.

4. Check that boiler area is free from combustible 3. Visually inspect condensate drain hose for proper

materials, gasoline, and other flammable vapors

and liquids.

5. Check for and remove any obstruction to the flow

of combustion or ventilation air to boiler.

operation or deterioration (if appropriate). Check

for plugged condensate trap. Use cleanout plug to

clear trap.

4. Clean screen in vent termination and air intake.

6. Follow pre-start-up check in Section N.

7. Visually inspect burner flame. Should see light

blue flame, with some orange at flame edge.

8. Check operation of safety devices. Refer to manu-

facturer’s instructions.

9. Follow oil-lubricating instructions on circulator.

Over-oiling will damage circulator. Water-lubricat-

ed circulators do not need oiling.

Cleaning Boiler Heating

Surfaces:

The following service procedures must be performed

ONLY by a qualified service agency. Boiler owner

should not attempt these procedures:

10. Visually inspect condensate drain piping for prop-

er operation or deterioration (if appropriate).

Check for plugged condensate trap. Use clean-out

plug to clear trap.

11. To avoid potential of severe burn, DO NOT REST

HANDS ON OR GRASP PIPES. 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 replaced.

Call a qualified service technician.

1. If you find soot in top of vent elbow (some sedi-

ment in bottom of vent is normal) - remove vent

attachment to the ADB and clean flue exhaust baf-

fle inside the boiler. Also check burner, replace if

damaged.

2. If you find rust deposits in vent elbow - check for

high water flow rate or low inlet water tempera-

tures. Clean boiler as above.

13. Check for piping leaks around circulators, mixing

valves, relief valves and other fittings. Repair, if

found. DO NOT use petroleum based stop leak.

CONNECTING THE

CONDENSING HEAT

EXCHANGER (CHX)

Daily:

1. Check that boiler area is free from combustible

materials, gasoline, and other flammable vapors

and liquids.

2. Check for and remove any obstruction to the flow

of combustion or ventilation air to boiler.

NOTE: Connect the vent before connecting the

water piping. Install unions on water inlet and outlet

of CHX for ease of maintenance. The CHX requires

cleaning as often as once a year.

Refer to Fig. 39 for the following steps:

Monthly:

1. Remove the shroud.

2. Remove the top cover.

1. Check for piping leaks around circulators, mixing

valves, relief valves, and other fittings. If found,

repair at once. DO NOT use petroleum-based stop

leak compounds.

2. Visually inspect burner flame.

3. Visually inspect venting system for proper func-

tion, deterioration or leakage.

3. Secure the 15° elbows (supplied) as shown one

on each side of the CHX, using the stainless steel

screws (supplied).

4. Seal the connection with high temperature RTV

(supplied).

5. Replace the top cover.

6. Level the CHX with the ADB by adjusting the lev-

eling screws at the base.

7. Place a line of RTV on the crimped end of the flue

outlet from the ADB and slide the CHX to join the

ADB flue outlet to the CHX flue inlet.

8. Connect the CHX water as specified in the piping

diagram. Check for water leak.

4. Check air vents for leakage.

5. 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:

9. Secure the flue connection from step 7 above with

the stainless steel screws (supplied).

1. Check relief valve. Refer to manufacturer’s

instructions on valve.

10. Connect the flue vent (Category IV venting, UL

1738 Certified Venting Material) to the 15° elbow

of the CHX flue outlet.

11. Connect the PVC pipe (not supplied) for conden-

sate water disposal (check with local authority

regarding condensate disposal).

12. Replace the shroud.

13. Allow the silicone (RTV) to cure over-night.

Vent Switch Adjustment:

In order to ensure proper operation of the ADB 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; disconnect the electrical wiring

and the rubber hose.

Remove the switch (it has a black plastic orifice at

the hose connection).

On the backside, remove the (purple) seal from

atop the adjusting screw.

•

Turn the plastic hex screw 1-1/2 turn clockwise.

Seal with silicone.

Reinstall in reverse order.

Table W: CHX Rate of Flow and Pressure Drop

Fig. 39: Connecting Add-on Condensing Heat Exchanger to ADB

•

furniture refinishing areas and establishments

new building construction

remodeling areas

APPENDIX

Inside Combustion Air

Contamination:

Check for areas and products as listed above before

installing boiler. If found:

All boilers experience some condensation during start-

up. The condensate from flue gas is slightly acidic. In

most cases the pH level is not harmful to vents or

drains. When combustion air is contaminated by

vapors from products in areas listed below, the acidic

levels in the condensate increase. Higher acidic levels

attack many materials, including stainless steel com-

monly used in high efficiency systems.

•

remove products permanently, OR

provide outdoor combustion air

The ADB can use special corrosion-resistant non-

metallic vent material. You may, however, choose to

use outside combustion air for one or more of these

reasons:

•

installation is in an area containing contaminants

listed below which will induce acidic condensation.

you want to reduce infiltration into your building

through openings around windows and doors.

you are using AL29-4C stainless steel vent pipe,

which is more corrosion-resistant than standard

metallic vent pipe. In extremely contaminated

area, this may also experience deterioration.

Products causing contaminated combustion air:

•

spray cans containing chloro/fluorocarbons

permanent wave solutions

chlorinated waxes/cleaners

chlorine-based swimming pool chemicals

calcium chloride used for thawing

sodium chloride used for water softening

refrigerant leaks

paint or varnish removers

hydrochloric acid/muriatic acid

cements and glues

anti-static fabric softeners used in clothes dryers

chloride-type bleaches, detergents, and cleaning

solvents found in household laundry rooms

adhesives used to fasten building products

... and other similar products

•

Areas causing contaminated combustion air:

•

dry cleaning/laundry areas and establishments

metal fabrication plants

beauty shops

refrigeration repair shops

photo processing plants

auto body shops

plastic manufacturing plants

START-UP CHECKLIST FOR FAN-ASSISTED

RAYPAK PRODUCTS ADB, HI-DELTA & MVB

This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater

for the first time. All information may be used for warranty purposes and to ensure that the installation is correct.

Additionally this form will be used to record all equipment operation functions and required settings.

GAS SUPPLY DATA

Regulator Model & Size

Gas Line Size (in room)

Length of Gas Line

Low Gas Pressure Setting

High Gas Pressure Setting

Gas Shut-Off Valve Type

( Ball, Lube cock)

CLEARANCES

Front Clearance

Right Side Clearance

Left Side Clearance

Rear Clearance

_________ / ______CFH

________________In. NPT

________________Eq Ft

________________In. WC

________________

_______________In.

Overhead Clearance

ELECTRICAL

Sediment Trap

Port

________________Y/N

_______Std______Full

Voltage Supply (VAC)

Voltage -24 VAC

Voltage Com to Ground

Hot Surface Igniter

Auto High Limit Setting

Manual Reset High Limit Setting

Operating Control Setting

No Load______ Load_____

_______________VAC

_______________Ohms

_______________deg F

VISUAL INSPECTION OF COMPONENTS

Verify inspection was done and condition of components are in

good working order with a “yes”

Wiring Harness

Burner/s (flame)

Refractory (visual)

Remote flame sense

Covers in place for outdoor

_________________ Y/N

Sketch plumbing on reverse side

WATER SUPPLY

Flow Rate in GPM or Delta T

Measure flow rate at full fire

Pump Economaster setting

Low Water Cutoff

_______________If Avail

_______________Minutes

_______________Test

Qty____ _______Gallons

_______________

Pump HP: ______

Pump Model___________

Screens________________

VENTING

Vent Size: _____________

Category: _________

Vent Material:

Vent Termination Type:

Combustion Air Openings:

Ventilation air

Stack Height:_______

sketch vent on reverse side *** Number of Tanks and Size

__________________

Low __________ in2

High __________ in2

Plumbing Size

Pump Size: _________(boiler)

Impeller trim____________

Louvers __________________

EMISSIONS SETTINGS AND TEST INFORMATION

(AT FULL FIRE)

Nominal Factory Recommended Settings

Blower Pressure Setting

Supply Gas Pressure

_________________In. WC

See manual or card tag

Verify stable pressure static & dynamic condition

Pilot Gas Pressure

Manifold Gas Pressure

_________________In. WC

See manual or card tag

The following measurements must be obtained with a Combustion Analyzer.

NOX

Free Oxygen

_________________PPM

_________________%

_________________PPM

_________________%

Less than 20 PPM (If required by Certifying Agency)

See manual

Less than 150 PPM

See manual

CO2

Model Number: ______________________________

*** Note: draw venting with details, such as extractors,

barometric dampers, blast dampers or draft inducers

Serial Number: _______________________________

Site Altitude Above Sea Level __________________Ft.

Job Name _______________________________________________________________________________________

Address _________________________________________________________________________________________

Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; Roof______; Below Grade______

Mechanical Contractor / Installer _______________________________________________________________________

Date and Time of Start-up _____________Print Name and Signature of Start-up Technician_________________________

Information must be faxed to: (805) 278-5471 in order to ensure warranty consideration Attn: Service Manager

LIMITED PARTS WARRANTY

ADVANCED DESIGN BOILER™

SCOPE:

Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak

will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth

in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not cov-

ered by this Warranty but are the owner's responsibility.

HEAT EXCHANGER WARRANTY:

° Ten (10) Years from date of boiler installation. This includes only cupro-nickel with bronze or cast iron waterways.

° Twenty (20) Years from date of boiler installation against "Thermal Shock" (excluded, however, if caused by boiler opera-

tion at large changes exceeding 150°F between the water temperature at intake and boiler temperature, or operating at boiler

temperatures exceeding 230°F).

BLUFF HEAD BODY BURNER WARRANTY:

° Ten (10) Years from date of boiler installation.

ANY OTHER PART MANUFACTURED BY RAYPAK:

One (1) Year warranty from date of boiler installation, or eighteen (18) months from date of factory shipment based on

Raypak's records, whichever comes first.

SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY

WILL BE VOID IF THE BOILER RATING PLATE IS ALTERED OR REMOVED.

ADDITIONAL WARRANTY EXCLUSIONS:

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the boiler in accordance with our printed instructions provided;

2. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding boiler design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the boiler system;

7. Failing to eliminate air from, or replenish water in, the connected water system;

8. Chemical, particulate matter or other airborne contamination of combustion air or use of chemical 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 prepaid, and all applicable warranty conditions found satisfied. The replacement part

will be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not

manufactured by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer.

TO MAKE WARRANTY CLAIM:

Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description

of the problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not avail-

able, contact Service Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases

proper authorization must first be received from Raypak before replacement of any part.

EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY:

This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak's behalf. THIS

WARRANTY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK'S SOLE LIA-

BILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED

IN THIS WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY,

OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL

DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states do not allow limitations on how long an implied

warranty lasts, or for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not

apply to you.

This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We

suggest that you complete the information below and retain this certificate in the event warranty service is needed.

Reasonable proof of the effective date of the warranty (date of installation) must be presented, otherwise, the effective date

will be based on the date of manufacture plus thirty (30) days.

www.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. S. A.

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