Raypak 1501 User Manual

Catalog No.: 3400.52D

Effective:

Replaces:

04-01-03

02-15-03

OPERATING AND

INSTALLATION

INSTRUCTIONS

Model 751, 1001, 1501

TYPE H, WH, P

ADVANCED

DESIGN

BOILER

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids or other combustible materi-

als in the vicinity of this or any other appliance. To do so may result in an explosion or fire.

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

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

this boiler. Installation and service must be performed by a qualified installer, service agency or

the gas supplier.

FOR YOUR SAFETY

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.

This manual should be maintained in legible condition

and kept adjacent to the boiler or kept in a safe place

for future reference.

P/N 241079

TABLE OF CONTENTS

PAGE

NO.

SECTIONA: BEFORE INSTALLINGTHE BOILER

SECTION B: BOILER INSTALLATION

SECTION C: COMBUSTIONAND VENTILATIONAIR

SECTION D: WATER PIPING - GENERAL

SECTION E:

SECTION F:

HYDRONIC HEATING PIPING

DOMESTIC HOTWATER PIPING

SECTION G: POOLHEATING

SECTION H: GAS SUPPLYCONNECTIONS

SECTION I:

SECTION J:

ELECTRICAL POWER CONNECTIONS

VENTING CONNECTIONS

SECTION K: CONDENSATE DRAIN

SECTION L: CONTROLS

SECTION M: GENERAL SAFETY PRECAUTIONS

SECTION N: PRE-START-UP

SECTION O: ADB INITIALSTART-UP

(MANUFACTURERS CERTIFIED PERSONNELONLY)

SECTION P:

POST START-UPCHECK

SECTION Q: OPERATION

SECTION R:

SECTION S:

MAINTENANCE

CONNECTING CONDENSING HEAT EXCHANGER (CHX)

APPENDIXA: COMBUSTIONAIR CONTAMINATION

ILLUSTRATED PARTS LIST

WARRANTY

Pay attention to these terms:

DANGER

indicates the presence of immediate hazards which will cause severe personal injury, death or

substantial property damage if ignored.

WARNING indicates the presence of hazards or unsafe practices which could cause severe personal injury,

death or substantial property damage if ignored.

CAUTION

NOTICE

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.

SECTION A: BEFORE INSTALLING THE BOILER

Raypak strongly recommends that this manual be reviewed thoroughly before installing your Raypak boiler. Factory

warranty does not apply to boilers that have been improperly installed or operated. 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 factory or your local Raypak representative.

Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our

equipment.

PRODUCT RECEIPT

On receipt of your product it is suggested that you visually 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 boiler from the shipping

packaging. Report any damage to the carrier immediately.

On occasion, some items will be shipped loose. Be sure that you receive the correct number of packages as indicated 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 stocking charge.

When ordering parts, you must specify the Model and Serial Number of the boiler. When ordering under warranty condi-

tions, you must also specify the date of installation.

Purchased parts are subject to replacement only under the manufacturer’s warranty. Debits for defective replacement parts

will not be accepted and will be replaced in kind only per Raypak’s standard warranties.

MODELIDENTIFICATION

The model identification number and boiler serial number are found on the boiler data plate located on the left

inside jacket of the boiler. The model number will have the form H4 0500A ADB or similar depending on the

boiler size and configuration. The first character 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 boiler in 1,000s of BTUH 0500 =

500,000 BTUH). The remaining suffix identifies the control, ignition, and construction configuration. The last

three characters of the model number identifies the model type (ADB = Advanced Design Boiler).

RATINGSAND CERTIFICATION

All Raypak boilers are National Board Approved, design certified and tested under the applicable American

National Standard/CSA Standard for USA and Canada. Each boiler is constructed in accordance with Section IV

of the American Society of Mechanical Engineers (ASME) Boiler Pressure Vessel Code and bears the ASME

stamp. This boiler complies with the latest edition of ASHRAE 90.1 Standard.

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.

No derate 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 settings

adjustment. Consult the factory for installations at altitudes in excess of 7000 feet.

FigureA-1

ADVANCED DESIGN BOILER COMPONENT LOCATIONS

SECTION B: BOILER INSTALLATION

INSTALLATION CODES

Installations must follow these codes:

Local, state, provincial, and national codes, laws, regulations and ordinances.

National Fuel Gas Code (NFGC), ANSI Z223.1- latest edition.

National Electrical Code (NEC), ANSI/NFPA 70 - latest edition.

Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

For Canada only: CAN/CGA B149.1 and .2 Installation Code and C.S.A. C22. 1 C.E.C. Part 1.

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.

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.

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.).

CLEARANCES

TABLE 1

MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES

(INDOORALCOVE INSTALLATIONS)

Boiler Size

Boiler Side

Floor

Rear

751, 1001, 1501

See Note 1.

1”

Right

Left

Top

12” (Water side)

1”

0”

1”

Vent

Note 1. Do not install on carpeting.

Figure B-1

MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACESAND FOR EASY SERVICING

Raypak Advanced Design Boilers are design certified by AGA/CGA for outdoor installation. Roof water drainage must be

diverted away from boilers installed under overhangs.

TABLE 2

OUTDOOR INSTALLATION MINIMUM CLEARANCES

Boiler Size

Boiler Side

Rear

751, 1001, 1501

Right

Left

Top

36” (Water side)

36"

Vent

WARNING:

Combustion air inlet (blower air inlet) should have 6" minimum clearance from any obstruction, i.e. walls or

other appliances.

SECTION C: COMBUSTION AND VENTILATION AIR

COMBUSTIONAND VENTILATIONAIR (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 supplied via conventional venting, where combustion air is drawn from the area immedi-

ately surrounding the boiler, or via direct vent, where combustion air is drawn directly from outside. All installations must

comply with the requirements of NFGC for U.S., CAN/CGA B 149.1 and .2 for Canada, and all local codes.

NOTICE: “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.

DIRECT COMBUSTIONAIR

If outside air is drawn through a vent pipe directly to the unit for combustion:

1. Install combustion air direct vent in accordance with Section J of this manual.

2. Provide for adequate ventilation of the space occupied by the boiler(s) by an opening(s) for ventilation 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 communicating with the outdoors through horizontal duct(s).

3. In cold climates, and to mitigate potential freeze-up, Raypak highly recommends the installation of a motorized

sealed damper to prevent the circulation of cold air through the boiler during the non-operating hours.

CAUTION:

Remove the screen off the blower inlet and install a screen (1/2"-3/4" mesh) on the inlet elbow.

CONVENTIONALCOMBUSTIONAIR SUPPLY (FOR U.S. INSTALLATION ONLY)

AllAir from Inside the Building. If all combustion air is drawn from the air inside the building (the mechanical

equipment room does not receive air from outside):

1. The mechanical equipment room must be provided with two permanent openings communicating directly

with additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for

an unconfined space. (An unconfined space is defined as a space whose volume is more than 50 cubic feet per

1,000 BTUH of the aggregate input rating of all appliances installed in that space.)

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.

3. One opening must commence within twelve (12) inches of the top, and one opening must commence within

twelve (12) inches of the bottom of the room.

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

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 following two methods can be used:

Method 1:

1. The mechanical equipment room must be provided 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. 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 opening is communicating directly with the outdoors or 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.

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

Refer toAppendixAfor additional information about combustion air quality.

Method 2 (normally applied in cold climate regions):

1. The mechanical equipment room must be provided with at least one permanent opening, commencing within

12 inches of the top of the enclosure.

2. The opening must communicate directly or by ducts with outdoors.

3. The opening must have a minimum free area of 1 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.

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.

COMBUSTIONAND VENTILATIONAIR SUPPLY (FOR CANADA INSTALLATION)

CAUTION:

All combustion air has to be drawn from the air outside the building (the mechanical equipment

room directly communicates with the outdoors).

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).

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 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 preferred straight down 18" 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).

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 dilution 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 ventilation 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" from

floor, but do not place near piping.

4. Refer to the latest version of CAN/CGA-B149.1 and B149.2 for additional information.

SECTION D: WATER PIPING - GENERAL

The boiler should be located so that any water leaks will not cause damage to the adjacent area or structures.

All units should be plumbed in accordance with the appropriate diagram from Section E, F or G or per a suitable engineered

piping arrangement.

CAUTION:

This boiler requires forced water circulation when the burner is operating. See Table D-1 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. See Figure L-2 Wiring Diagram and

Figure L-1.

RELIEFVALVE 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

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 factory-tested and is rated for 150 PSI operating pressure. However, Raypak does

recommend hydrostatically 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 conducting 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 operating pressure for at least 24 hours.

2. Make sure constant gauge pressure has been maintained throughout test.

3. Check for leaks. Repair if found.

LOWTEMPERATURE SYSTEM

Boiler requires minimum inlet temperature of 105°F. Consult sections E, F or G for piping details. (For Pool temperature

requirements, See Section G).

TEMPERATURE & PRESSURE GAUGE

The temperature and pressure gauge is factory-mounted in the inlet/outlet header.

Table D-1

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

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%.

SECTION E: HYDRONIC HEATING PIPING

PUMP SELECTION

In order to insure proper performance of your boiler system, you must install a properly sized pump. Raypak recommends

using a 20°F Delta T as design Delta T. (Delta T is the temperature difference between the inlet and outlet water when the

boiler is firing at full rate). If a Delta T larger than 20°F is necessary, the bypass must be installed and adjusted to insure

proper hydraulics through the boiler while still allowing minimum flow to satisfy the safety flow switch. See Table D-1 for flow

rate requirements.

PRESSURE DROP IN FEET OF HEAD

FEEDWATER REGULATOR

Raypak recommends that a feedwater regulator be installed and set at 12 PSIG minimum pressure at the highest point of

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 connection 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.

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 recommended that the piping be insulated.

AIR-SEPARATION/EXPANSION TANK

All boilers should be equipped with a properly sized expansion tank with an air separation fitting as shown in the following

diagrams.

THREE-WAYVALVES

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.

Figure E-2a

SINGLE BOILER - PRIMARY/SECONDARY PIPING

Figure E-2b

SINGLE BOILER - PRIMARY/SECONDARY PIPING WITH CHX

Figure E-3a

DUAL-BOILER PIPING

Figure E-3b

DUAL BOILER - PIPING WITH CHX

Figure E-4a

SINGLE BOILER - LOWTEMPERATUREAPPLICATION (HEAT PUMP) PRIMARY/SECONDARY PIPING

SECTION F: DOMESTIC HOT WATER PIPING

When designing the water piping system for domestic water applications, water hardness should be considered. Table D-

1 indicates the suggested flow rates for soft, medium and hard water. Hardness is specified as grains per gallon.

TABLEF-1

DOMESTICWATER HEATING BOILER

FLOWRATE REQUIREMENTS

Delta T = Temperature rise in °F

GPM = Gallons per minute

See Table D-1 for Pressure Drop

Figure F-1a

SINGLE BOILER DOMESTIC HOTWATER WITH ONE STORAGE TANK

Figure F-1b

SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANKAND CHX

Figure F-1bb

SINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK AND CHX (2 pump system)

Figure F-1c

SINGLE BOILER DOMESTIC HOTWATER WITH ONE STORAGE TANK, ONE PRE-HEAT TANKAND CHX

SECTION G: 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.

The ADB unit is equipped with an external pump and bypass arrangement that blends outlet water with the inlet to increase

the inlet water temperature, thereby reducing the likelihood of condensation forming on the heat exchanger. The pump also

serves to circulate water through the heater form the main system piping.

To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return water line. This

will insure that the heater will be energized at the right time. If the main water line is too far away from the heater and the

capillary bulb will not reach it, locate the pool thermostat adjacent to the main line and run wires back to the heater. See Figure

G1-a and Figure G2-b.

Adjustment of the bypass valve is critical to proper operation of the heater. The bypass valve should be adjusted to achieve

an inlet water temperature of 100°F and an outlet water temperature of 120°F. When starting with a cold pool, make initial

adjustments. Make final adjustments when pool water approaches desired temperature. Refer to flow rate chart below:

AUTOMATIC CHLORINATORSAND CHEMICALFEEDERS

All chemicals must be introduced and completely diluted 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 concentrations will result when the

pump is not running (i.e. overnight).

Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the

heater when the pump is shut off.

NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid

corrosion to the heat exchanger in the heater. Such damage is not covered under the warranty.

WINTERIZINGYOUR HEATER

When heaters installed outdoors in freezing climate areas are to be shut down for the winter, please observe the

following step-by-step procedure:

1. Turn off manual main gas and main gas shut off. Remove the drain plug or open the drain valves located on the

bottom header.

POOLAND SPAWATER CHEMISTRY

NOTE: Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water

pH between 7.4 and 7.8 and total alkalinity between 100 and 150 p.p.m. If the mineral content and dissolved solids in the

water become too high, scale forms inside the heat exchanger tubes, reducing heater efficiency and also damaging the

heater (max TDS at 3000 p.p.m.). 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.

Figure G-1a

SINGLE BOILER - POOL APPLICATION

Figure G-2b

SINGLE BOILER - POOL APPLICATION WITH CHX

Figure G-3a

DOUBLE BOILER - POOL APPLICATION

SECTION H: GAS SUPPLY CONNECTIONS

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 located outside the

heater jacket. A pounds to inches regulator must be installed to reduce to gas supply pressure to under 14" W.C. The

regulator should be placed a minimum distance of 10 times the pipe diameter 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.

Figure H-1

GAS SUPPLY CONNECTION

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 system by closing the manual shutoff

valve during any pressure testing of the gas supply piping system at test pressures equal to or

less than 1/2 PSIG. Relieve test pressure in the gas supply line before reconnecting the boiler

and its manual shut off valve to the gas supply line. FAILURE TO FOLLOW THIS PROCEDURE

MAYDAMAGE THE GAS VALVES. Over pressurized gas valves are not covered by warranty.

The boiler and its gas connections shall be leak tested before placing the appliance in operation.

Use soapy water for leak test: DO NOT use open flame.

CAUTION:

Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with gas systems

is recommended. Apply sparingly only on male pipe ends.

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.

GAS SUPPLY PRESSURE

A minimum of 7” W.C. and a maximum of 14” W.C. upstream gas pressure is required under load and no load conditions

for natural gas. A minimum of 12” W.C. and a maximum of 14” W.C. is required for propane gas. The gas pressure

regulator supplied is for low pressure service. If upstream pressure exceeds 14" W.C, an intermediate gas pressure

regulator, of the dead lockup type, must be installed.

NOTICE:

The supply gas pressure must not fluctuate by more than +/- 1.0" WC. For fluctuating gas supply contact

the factory.

When connecting additional gas utilization equipment to the gas piping system, the existing piping must be checked to

determine if it has adequate capacity

GAS PRESSURE REGULATOR

The gas pressure regulator is nominally preset to the outlet values shown in table O-2 and O-3, within +. 1" W.C. If an

adjustment is needed, turn the adjustment screw clockwise to increase pressure or counterclockwise to lower pressure.

VENTING OF DIAPHRAGM GAS COMPONENTS

Boilers have gas train components that have diaphragms in their construction that are supplied with a bleed line connec-

tion that must be connected to the outside atmosphere as required by NFGC or (for Canada) the B149 Installation Codes

and applicable provisions of local codes. Under NO circumstances shall bleed lines terminate in the gas utilization equip-

ment flue or exhaust system.

SECTION I: 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.

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

The boiler is wired for 120 Volts. The voltage is indicated 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 elec-

tronic boiler control as applicable. 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.

Install a separate disconnect means for each load. Use appropriate-sized wire as defined by NEC, CSAand/or local code. All

primary wiring should be 125% of minimum rating.

It is strongly recommended that all individually-powered control modules and the boiler should be supplied from the same

power source.

SURGE PROTECTION

Microprocessor-based and solid state controls are vulnerable to damage from voltage and amperage fluctuations in the

power supply. All sensitive control components should be protected by a suitable commercial-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.

CHECK THE POWER SOURCE

Using a volt-ohm meter (VOM), check the following voltages at the circuit breaker panel prior to connecting any equipment:

Make sure proper polarity is followed and house ground is proven.

Fig # 9237

FIGURE I-1

CHECK POWER SOURCE

AC = 108 VoltsAC Minimum, 132 Volts MAX

AB = 108 VoltsAC Minimum, 132 Volts MAX

BC = Must be less than 1.0 Volts AC

MAKING THE ELECTRICAL CONNECTIONS

Refer to Fig. I-2 Wiring Connection, and Fig. L-2 Wiring Diagram.

1. Verify circuit breaker is properly sized by referring to boiler rating plate. Adedicated motor duty circuit breaker should

be provided.

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 connections or components.

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.

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.

NOTICE:

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.

Figure I-2

FIELD WIRING CONNECTION

ELECTRICALCONNECTIONS - DOMESTIC HOTWATER

CAUTION:

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and

dangerous operation. Verify proper operation after servicing.

DANGER

- SHOCK HAZARD

Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components.

The boiler is normally wired for 120 volts. The voltage is indicated 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 "TH" leads. Before starting boiler check to insure proper voltage to

boiler and pump.

BREAK THE WIRE NUTAT THE

BOILER "TH" CONNECTIONSAND

ATTACH TO THE SINGLE TANKSTAT

PER ILLUSTRATION

SINGLE

STAGE

TANKSTAT

Boiler must be electrically grounded in accordance with National Electrical CodeANSI/NFPANo. 70, and CSAC22.1

C.E.C. Part 1 in Canada.

2-STAGE

TANKSTAT

BREAK THE WIRE NUTAT THE

BOILER "TH" CONNECTIONSAND

ATTACH TO THE DUALTANKSTAT

PER ILLUSTRATION

NOTES:

1. Field installed ground to inside of junction box.

2. 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.

SECTION J: VENTING CONNECTIONS

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.

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.

Definition of Appliance Categories

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-positive vent static pressure and with a vent gas tempera-

ture that avoids excessive condensate production in the vent.

Category II.

A boiler which operates with a non-positive vent static pressure and with a vent gas tempera-

ture that may cause excessive condensate production in the vent.

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.

See Table J-1 for vent category requirements for the Advanced Design Boiler

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 CGA Standard B149 Installation

Code for Gas Burning Appliances and Equipment, or applicable provisions of local building codes.

Determination ofAppliance Category forVenting Purposes and VentingArrangements

WARNING:

Contact the manufacturer of the vent material if there is any question about the appliance categoriza-

tion 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.

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

Support of Vent Stack

The weight of the vent stack or chimney must not rest on the boiler vent connection. Support must be provided in compliance

with applicable codes. The vent should also be supported to maintain proper clearances from combustible materials.

Use insulated vent pipe spacers where the vent passes through combustible roofs and walls.

Vent Terminal Location

NOTICE:

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.

Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury.

a) Gases may form a white vapor plume in winter. The plume could obstruct a window view if the termination is installed in close

proximity to windows.

b) Prevailing winds could cause freezing of condensate and water/ice buildup on building, plants or roof.

c) The bottom of the vent terminal and the air intake shall be located at least 12 inches above grade, including normal snow line.

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 appliances shall not terminate

over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental

to the operation of regulators, relief valves, or other equipment. Where local experience indicates that condensate is a

problem with Category I and III appliances, this provision shall also apply.

f) Locate and guard vent termination to prevent accidental 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.

h) DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze causing ice formations.

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.

j) DO NOT extend exposed vent pipe outside of building. Condensate could freeze and block vent pipe.

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).

U.S. Installations- Refer to latest edition of the National Fuel Gas Code.

Vent termination requirements are as follows:

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) The vent must not be less than seven (7) feet above grade when located adjacent to public walkways.

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 horizontally, and in no case above or below unless four (4) feet horizontal distance

is maintained, from electric meters, gas meters, regulators, and relief equipment.

e) Terminate vent at least six (6) feet away from adjacent walls.

f) DO NOT terminate vent closer than five (5) feet below roof overhang.

Canada Installations- Refer to the latest edition of CAN/CGA-B149.1 and B149.2

A vent shall not terminate:

a) Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwell-

ings.

b) Less than 7 ft. (2.13m) above a paved sidewalk or paved driveway located on public property.

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.

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

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.

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

(i) the verandah, porch or deck is fully open on a minimum of two sides beneath the floor, and

(ii) the distance between the top of the vent termination and the underside of the verandah, porch or deck is greater than 1 ft

(30cm)

Venting Installation Tips

Support piping:

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

vertical runs - use braces:

under or near elbows

Follow items listed below to avoid personal injury or property damage.

Cut nonmetallic vent pipe with fine-toothed hacksaw (34 teeth per inch).

Do not use nonmetallic vent pipe 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 nonmetallic vent pipe or fittings.

To make metallic vent joints:

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

100% Seal all joints and seams with silicone sealant.

NOTICE:

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.

WARNING:

Examine the venting system at least once a year. Check all joints and vent pipe connections for

tightness, corrosion or deterioration.

NOTE: The words "Flue Exhaust", "Flue" and "Exhaust Vent" are used interchangeably.

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 components used, and part numbers for each.

For boilers connected to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equip-

ment, of the latest edition of National Fuel Gas Code, or in Canada, the latest edition of CAN/CGA-B149.1 and .2 Instal-

lation Code for Gas Burning Appliances and Equipment, or applicable provisions of local building codes.

SECTION J-1

Natural Draft Vertical Venting Without Add-on Condensing

Heat Exchanger (Category I)

Figure J-1

NATURALDRAFTVERTICALVENTWITHOUTADD-ON CONDENSING HEAT EXCHANGER*

NOTE: *Rear venting is recommended to minimize interference with water piping

**Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of the National Fuel Gas Code for further

details. (ANSI Z223.1), or in Canada the latest edition of CAN/CGA-B149.1 and B149.2.

•

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 negative draft must be within the range of 0.01 to 0.08” negative W.C. to insure proper

operation. 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 latest edition of the National

Fuel Gas Code (U.S.) or B179.1 and .2 Installation Code (Canada).

The diameter of vent flue pipe should be sized according to Part 11 of the latest edition of the National Fuel Gas Code

(U.S.) and part 7 and appendix B of the CAN/CGA-B149.1 and .2 installation code (Canada). The flue pipe diameter for

conventional negative draft venting using double-wall B type vent is 8” for theADB 751, 10” for the 1001, and 12” for the

ADB 1501.

NOTICE:

Vent Adapter will have to be used to connect B vent to the unit.

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.

•

Natural Draft Vertical Vent Termination

The vent terminal should be vertical and should terminate outside the building at least two (2) feet above the 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 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 CAN/CGA-B149 Instal-

lation 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 withstand snow and wind loads.

CAUTION:

Listed vent cap terminal must be used and sized adequately to evacuate the flue products from the

boilers.

•

Natural Draft Vertical Venting With Common Venting System, Category I Appliance Only

(NOT To Be Utilized With Add-on Condensing Heat Exchanger)

Manifolds that connect more than one boiler to a common 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.

WARNING:

CAUTION:

Vent connectors serving appliances vented by natural draft shall not be connected into any portion of

mechanical draft systems operating under a positive pressure.

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 followed 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.

a) Seal any unused opening in the common venting system.

b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion or other unsafe condition.

c) Insofar as is practical, close all building doors and windows and all doors between the space in which the appli-

ances remaining connected to the common venting system are located and other spaces of the building. Turn on

clothes dryers and any appliance not connected to the common vent system. Turn on any exhaust fans, such as

range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate summer exhaust fan.

Close fireplace dampers.

d) Place in operation the appliances being inspected. Follow the manufacturers instructions for lighting each appli-

ance. Adjust thermostat so appliance will operate continuously.

e) Test for natural draft (negative pressure) 12" above the outlet elbow after 5 minutes of main burner operation.

Use the flame of a match or candle, 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 system 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 latest edition of CAN/CGA-B

149.1 and .2 Installation Code for Gas Burning Appliances and Equipment. When re-sizing any portion of the

common venting system, the common venting system should be re-sized to approach the minimum size as deter-

mined 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.

SECTION J-2

Horizontal Thru-Wall Venting Without Add-on Condensing

Heat Exchanger (Category III)

Figure J-2

HORIZONTALTHRU-WALLVENTINGWITHOUTADD-ON

CONDENSING HEAT EXCHANGER (CATEGORY III)

•

Horizontal Thru-wall Direct Venting System (Category III) Installation

These installations utilize the boiler-mounted blower to vent the combustion products to the outdoors. Combustion air is

taken from inside the room and the vent is installed horizontally through the wall to the outdoors. 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 edition of CAN/CGA-B149.1 and .2 Installation Code for Gas Burning Appliances and Equipment.

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.

65’ of straight flue pipe.

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 insure 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 recommended 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 condensate trap must be installed per applicable codes.

b) The vent be insulated through the length of the horizontal run.

•

Horizontal Thru-wall Direct Vent Termination

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

Raypak supplied direct vent cap must be used.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the

safety and health of inhabitants.

WARNING: For common vent installations contact factory.

The Stainless Steel direct vent cap must be furnished by the boiler manufacturer in accordance with its

listing.

SECTION J-3

Horizontal Thru-Wall Direct Venting/Combustion Air

(Category III)

Figure J-3

HORIZONTAL THRU-WALL DIRECT VENTING WITHOUT ADD-ON

SECONDARY CONDENSING HEAT EXCHANGER

•

Horizontal Thru-wall Direct Venting System (Category III) Installation

These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion products to

the outdoors.

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 following combinations.

45’ of straight flue pipe.

35' of straight flue pipe and one elbow.

25' of straight flue pipe and two elbows.

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 following combinations.

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 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.

The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is recommended 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 condensate trap must be installed per applicable codes.

b) The vent be insulated through the length of the horizontal run.

•

Horizontal Thru-wall Direct Vent Termination

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.

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 products 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 furnished by the boilermanufacturer in accordance with its listing.

SECTION J-4

Vertical Direct Venting/Combustion Air (Category I)

Figure J-4

VERTICALDIRECTVENTINGWITHOUTADD-ON CONDENSINGHEAT EXCHANGER

*Vent lengths are based on a lateral length of 2 feet. Refer to the latest edition of National Fuel Gas Code for further details

(ANSI Z223.1) or in Canada the latest edition of CAN/CGA-B149.1 and B149.2.

•

Vertical Direct Venting System Installation

These installations utilize the boiler mounted blower to draw combustion air from outdoors and uses the natural 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 to 0.08” negative W.C. to insure proper operation. The vent material must be in accor-

dance 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 latest edition of the National

Fuel Gas Code (U.S.) and CAN/CGA-B149.1 and .2 Installation Code (Canada).

The diameter of vent flue pipe should be sized according to part 11 of the latest edition of the National Fuel Gas Code (U.S.)

and part 7 andAppendix B of CAN/CGA-B149.1 and .2 installation code (Canada). The flue pipe diameter for conventional

negative draft venting using double-wall B type vent is 12” for the ADB 1500.

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 supported for the

design and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints.

•

Vertical Direct Vent Termination

The vent terminal should be vertical and should terminate 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 horizontally 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 CAN/CGA-B149.1 and .2. 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 withstand snow

and wind loads.

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 boiler and venting system and reduces the chance of blockage from snow. The vent cap must have

a minimum 3 foot vertical clearance above the air inlet opening.

SECTION J-5

Vertical Venting With Add-On Condensing Heat Exchanger

(Category IV) Domestic Water

Figure J-5

VERTICALVENT (CATEGORY IV) WITHADD-ON

CONDENSING HEAT EXCHANGER

•

Vertical Vent (Category IV) with Add-on Condensing Heat Exchanger Installation

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 outdoors. 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

edition of CAN/CGA-B149.1AND .2. Installation Code for Gas BurningAppliances and Equipment.

UL 17-38 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 insure that all joints are sealed properly and are airtight.

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

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 non-restricted direct vent cap must be furnished by the boiler manufacturer in accordance with its

listing.

SECTION J-6

HorizontalThru-wallVentingWithAdd-on Condensing Heat Exchanger(CHX)

Figure J-6

HORIZONTALTHRU-WALLVENTINGWITHADD-ON

CONDENSINGHEAT EXCHANGER

•

Horizontal Thru-wall Venting 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 outdoors. 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

edition of CAN/CGA-B149.1 and .2 Installation Code for Gas BurningAppliances and Equipment.

UL 17-38 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 insure that all joints are sealed properly and are airtight.

For certain installations, i.e. pool, heat pump, domestic hot water supply with pre-heat tank, PVC or CPVC may be used.

Contact manufacturer for 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.

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 non-restrictive direct vent cap must be furnished by the boiler manufacturer in accor-

dance with its listing.

SECTION J-7

Horizontal Thru-Wall Direct Venting/Combustion Air With Add-On

Condensing Heat Exchanger (Category IV)

Figure J-7

HORIZONTALTHRU-WALLDIRECTVENTINGWITHADD-ON

CONDENSINGHEAT EXCHANGER

•

Horizontal Thru-wall Direct Venting System With Add-on Condensing Heat Exchanger

(Category IV) Installation

These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion products

to the outdoors.

UL 17-38 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 insure that all joints are sealed properly and are airtight.

For certain installations, i.e. pool, heat-pump, domestic hot water supply with pre-heat tank, PVC or CPVC may be used.

Contact manufacturer for 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.

WARNING: For common vent installations contact 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 non-restricted direct vent cap must be furnished by the boiler manufacturer in accordance with its

listing.

SECTION J-8

Vertical Direct Venting/Combustion Air With Add-on Condensing

Heat Exchanger (Category IV)

Figure J-8

VERTICALDIRECTVENTINGWITHADD-ON

SECONDARYCONDENSING HEAT EXCHANGER

•

Vertical Direct Venting System With Add-on Condensing Heat Exchanger (Category IV) Installation

These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combustion prod-

ucts to the outdoors.

UL 17-38 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 insure that all joints are sealed properly and are airtight.

For certain installations, i.e. pool, heat-pump, domestic hot water supply with pre-heat tank, PVC or CPVC may be used.

Contact manufacturer for 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.

WARNING: For common vent installations contact 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 non-restricted direct vent cap must be furnished by the boiler manufacturer in accordance

with its listing.

Outdoor Installation withAdd-On Condensing Heat Exchanger

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 AGA/CGA requirements. It

must be installed directly on the boiler in a horizontal position. Notching of the vent cap mounting flange may be neces-

sary to clear outlet piping on some models. See Section B for correct clearances.

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 effi-

ciency and safety, the following precautions must be observed:

a) Outdoor models must be installed outdoors and must use the non-restricted direct vent cap supplied 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.

c) Do not locate adjacent to any window, door walkway, or gravity air intake. The vent should be located four (4) feet

horizontally from such areas.

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.

f) Adjacent brick or masonry surfaces must be protected with a rust-resistant sheet metal plate.

g) Multiple Outdoor Vent installations require a four (4) feet clearance between vent caps.

NOTICE:

:Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue

condition.

The Stainless Steel non-restricted vent cap must be furnished by the boiler manufacturer in accordance with its listing.

The outdoor vent terminal must be installed in a horizontal position to prevent recirculation of flue products. The vent cap

must be mounted directly on the vent pipe of the boiler.

NOTICE:

: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.

SECTION K CONDENSATE DRAIN

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 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 theADB 751 is 7.5 GPH, theADB 1001 is 10 GPH, and theADB1501 is

15GPH.

Figure K-1

CONDENSATE TRAP ALIGNMENT

SECTION L CONTROLS

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.

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.

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.

Risk of electric shock. More than one (1) disconnect switch may be required to de-energize the

equipment before servicing.

CENTRAL POINT WIRING (CPW)

Central Point Wiring is an advanced control integration technique that provides complete boiler diagnostic capability

and greatly simplifies troubleshooting. At the heart of CPW is the Operations Status Center, which is comprised of two

different circuit boards: the CPW board and one or more U-2 Diagnostic Boards.

THE CPW BOARD

The Central Point Wiring (CPW) board serves as the central tie point for connecting all other control components in the

boiler. The CPW board provides boiler operating status and fault indication using eight LEDs which function as described

in Table L-1

Table L-1 CPW Board LED Indicators

Light

Color

Indication

Power

Green

24 VDC is applied to the system

System Error

Pump

Red

Green

Overload current on the board. Board is disabled.

Boiler Pump is energized.

Pilot

Yellow

Green

Red (Flashing)

Green

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.

Main Gas

Call for Heat

Service

Blower

In addition to monitoring and displaying boiler status, the CPW board controls the timing of various operating 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 L-1.

Figure L-1

CPW Board

•

Pump Turn-off Delay

The CPW board has a built-in pump driver with pump turn-off delay, which allows the operator to set how long the

pump will run after the boiler shuts off. The delay is factory-set for 7 minutes but can be field-adjusted from 3 minutes to

10 minutes. The pump relay can directly power a pump of up to 12.0 amps draw or 3/4 Hp capacity. Pumps with larger amp

draws should be energized through a pump contactor that is controlled by the CPW board.

By properly setting the pump turn-off delay, the boiler pump will continue running for a limited period of time in order

to extract any residual heat from the combustion chamber. The pump will then shut off to conserve energy until the

next call for heat. 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.)

CAUTION:

The boiler requires forced water circulation when the burner is operating and the pump must be

interlocked with the boiler. See Section D for minimum water maximum flow rates and pump

selection.

NOTICE:

Pump will come on when power is first applied to the boiler.

•

Blower Fan Pre-purge

The CPW board has a built-in pre-purge delay which operates the blower fan for a user-adjustable time period prior to

pilot trial for ignition. The pre-purge period ensures that the combustion chamber is clear of all excess combustible gases

prior to commencing the pilot ignition cycle. The pre-purge delay is factory set for 45 seconds and it can be adjusted in

the field from 45 seconds to 120 seconds. To optimize boiler response time on call-for-heat, set the pre-purge delay to the

minimum allowed by local, state or national code.

•

Blower Fan Post-purge

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 .

•

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 blowing cold air continuously and freezing the heat exchanger. The blower drives

will open and the system will lock in the off state. 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 minutes.

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 equipment down time. The U-2 safety board is the central point for wiring, operations

monitoring, and fault indication for the boiler safeties. By having each safety report directly to the U-2 board, each

safety function can be individually monitored. The U-2 adds complete diagnostics features that aid in the rapid diagno-

sis of irregularities in boiler operation.

A single U-2 Diagnostics Board can monitor a maximum 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 provided extended diagnostics

capabilities. Advanced Design Boilers equipped with the standard safety suite will utilize the configuration shown in

Table L-2.

Table L-2. U-2 Diagnostic Board LEDs

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

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.

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.

The U-2 safety board has a series of red LED lights to indicate a fault occurring at a monitored safety. An 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.) Once a fault has been

detected, the U-2 board will illuminate 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.

WARNING

Only qualified persons shall attempt to repair the boiler. Improper adjustment, service or mainte-

nance may damage the equipment, create a hazard resulting in asphyxiation, explosion, fire, electric shock, personal

injury or property damage, and will void the warranty.

Figure L-2

WIRING DIAGRAM

IGNITION CONTROL MODULE

The intermittent ignition device conserves energy by automatically extinguishing

the pilot when the desired temperature is reached. When additional heat is needed,

the combustion air blower starts to purge all air from the combustion chamber for

about 45 seconds. On proof of air flow, the air proving switch closes and the pilot

reignites electrically, eliminating the fuel costs of maintaining a constant pilot. To

assure 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 performs its own

safety check and opens the main valve only after the pilot is proven to be lit.

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 temperature.

MANUAL RESET HIGH LIMIT

FLOW SWITCH

Dual-purpose control shuts off boiler in case of pump failure or low water condi-

tion. Mounted and wired in series with the main gas valve. Check with Manufac-

turer for proper paddle size. Utilize correct paddle size for proper operation.

NOTICE:

Flow switch will not operate if flow is less than 20 GPM.

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.

AUTO RESET HIGH LIMIT

LOW WATER CUT OFF (OPTIONAL)

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.

LOW WATER CUT OFF

HIGH AND LOW GAS PRESSURE SWITCHES - MANUAL RESET

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" W.C. for Natural gas, and 10" W.C. for

propane gas.

The high gas pressure switch (optional) mounts down-stream of the gas

pressure regulator. If the gas pressure regulator fails, the high gas pressure

switch automatically shuts down the burner.

GAS PRESSURE SWITCH

SECTION M: GENERAL SAFETY PRECAUTIONS

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.

Safety and energy conservation are factors to be considered 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.

Water temperature over 125°Fcan cause severe burns

instantly or death from scalds.

Children, disabled and elderly are at highest risk of

being scalded.

See instruction manual before setting temperature at

waterheater.

Feel water before bathing or showering.

Temperature limiting valves are available, see note below.

Maximum water temperatures occur just after the boiler’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 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.

Temperature

120°F.

Time to Produce Serious Burn

More than 5 minutes

1-1/2 to 2 minutes

Temperature

140°F.

Time to Produce Serious Burn

Less than 5 seconds

125°F.

145°F.

Less than 3 seconds

130°F.

135°F.

About 30 seconds

About 10 seconds

150°F.

155°F.

About 1-1/2 seconds

About 1 second

Table courtesy of The Shriners Burn Institute

TIME/TEMPERATURE RELATIONSHIPS IN SCALDS

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 regulations 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.

To adjust the water temperature, insert a small straight

screwdriver into slotted screw in hole in front of thermostat

and turn wheel to desired setting.

Adjustment

Screw

CAUTION!! - Hotter water Increases the risk of SCALDING!

There is a Hot Water SCALD Potential if the tank thermostat is set too high.

NOTE: When this hot water boiler is supplying general purpose hot water requirements for use by individuals, a thermo-

statically 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.

SECTION N: PRE-START-UP

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 boiler 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.

FOR YOUR SAFETY READ BEFORE LIGHTING

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 does have an intermittant pilot. It is equipped with an ignition device which automatically lights the

pilot. Do Not try to light the pilot or burner by hand.

2. BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some

gas is heavier than air and will settle on the floor.

3. WHATTO DO IFYOU SMELLGAS

•

Do not try to light any 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 supplier'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 control knob. Never use tools. If the knob will not turn by hand, do

not try to repair it, call a qualified service technician. Forced or attempted repair may 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-UPCHECK

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 distribution.

Blower "T" fitting detail.

Figure O-1

COMPONENTAND PRESSURE TAP LOCATIONS

SECTION O: ADB INITIAL START-UP

CAUTION:

Verify that the vent system and combustion air supply have been approved.

1.0 TOOLSNEEDED

• 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

• Amp probe

• Elec. Dual reading thermometer with strap on sensors

• 3/16”Allen wrench

• Combustion analyzer

2.0 PREPARATIONFORSTART-UP

WARNING: DO NOTTURN ON GASATTHIS TIME

2.1 Check Power Supply

With voltmeter at incoming power check voltage between:

Hot - Common

Hot – Ground

Common - Ground

(»120VAC)

(<1VAC)

If Common - Ground is > 1 VAC - STOP: Contact electrician to correct ground failure.

WARNING: Failure to do this may burn out 120V-24V transformer, or may cause other safety control damage or

failure.

2.2 Attach Manometers to Measure Pressures (See Figure: O-1)

• Attach 16" scale manometer to the first gas shut-off valve pressure tapping, Location (1)

• 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).

Turn Off The 1 ½ “ Manual Gas Valve;

Turn Off Pilot Gas Valve;

Reset Low Gas Pressure Cut-off Switch;

2.3 BleedAir from Gas Line

CAUTION: Make sure there is no ignition source in the boiler room

• 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.

2.4 Check the Gas Supply Pressure, Location (1)

• Leave pilot gas valve and first manual gas valve closed;

• Slowly turn on main gas shut-off valve (outside the unit);

• Read the gas supply pressure from the manometer (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.

3.0 START-UP

NOTICE:

Reference the start-up pressures settings located on the side of the control box.

3.1 BlowerAdjustment

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

2. Turn power on;

3. Check blower manometer reading, Location (5). Compare your reading to the “Pre-Fire” values shown in tables O-2

and O-3. If not, adjust the air shutter on the blower to attain the correct value;

4. Turn power off.

3.2 PilotAdjustment

1. Turn on the gas shut-off valve, the main gas manual 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 control will energize and send spark to ignition, observe through view

port for spark;

4. If you do not see spark, turn off power, check ignition wire and proper grounding and wiring. Turn power back on.

Repeat Step 3. If there is still no spark after several attempts the igniter may be misaligned;

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 grounded out, it must be realigned. Remove the burner. Loosen the igniter nut, locate the

igniter in the center of the burner head and tighten igniter nut. Confirm it is centered and reinstall burner head;

6. If you have spark, turn off unit;

7. Turn on power. Unit will pre-purge 40-45 seconds and to ignition trial. You will hear a click from pilot gas valve (you

will not hear the sparking);

8. The pilot may not light at first trial; leave the unit running until you have pilot. If you still do not see pilot over 90

seconds; turn off the unit; repeat steps 6-8;

9. Check pilot manifold pressure, Location (4). Compare the reading to the value listed in the tables;

10. Check pilot flame; 8 distinct circular blue flames around the center of the pilot;

11. Replace the cap for pilot manifold adjustment screw; do not over-tighten.

TABLE O-2: Pressure Settings and Emission Guidelines (True Readings) for NAT. GAS

Note:For different gas control options, call factory for proper pressure settings (ie; IRI, etc)

TABLE O-3: Pressure Settings and Emission Guidelines (True Readings) for LPGAS

Note: For different gas control options, call the factory for proper pressure settings (i.e. IRI, etc)

NOTICE:

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.

NOTICE:

For high altitude (above 5000 ft), call the factory for proper pressure settings.

3.3 Main BurnerAdjustment

1. Turn on the unit; about 45 seconds later, the pilot should light. If the pilot fails to light, repeat step 3.2 for 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” W.C. (dynamic pressure);

4. Check manifold pressure, Location (2); this should read to within ± 0.1” W.C. of the values shown in tables O-2 and

O-3;

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” W.C. (dynamic pressure);

8. Check manifold pressure, Location (3); this should read to within ± 0.1” W.C. of the values shown in tables O-2 and

O-3;

9. If adjustment is required, remove screw cap off the bottom gas pressure regulator, and adjust regulator;

10. The blower pressure should increase about 3/10” (0.3”) W.C. equaling the “Firing” value in tables O-2 and O-3;

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 CO₂reading to that

of table O-2 & O-3;

13. If CO₂is high, reduce bottom manifold gas pressure;

14. If CO₂is low, increase the bottom manifold gas pressure;

15. All pressure readings especially manifold pressures should be within ±0.1” of listed values;

16. Replace the screw caps back on the gas regulators.

YourADB is tuned in!

3.4 Safety Inspection

· Check thermostat and high limit settings.

· Attach thermometers to IN/OUT piping and take temperature measurement, see Table D-1and F-1 for correct flow

balance.

· During the following safety checks leave manometers, and analyzer hooked up, check and record.

· If other gas fired equipment in the room and on same gas main, check gas pressures on ADB with them running.

Remember supply gas should always be between 7” and 14" W.C.

· 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" W.C. for natural gas;

· High gas pressure switch (optional) at 1" W.C. above manifold pressure;

· Insert ignition control lockout test as safety check.

3.5 Follow-up

• 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 combustible and flammable products, i.e. paper, gasoline etc.

SECTION P: 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 during 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?

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 controls are tested. When safety devices

are restored, burners should reignite after pre-purge time delay.

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 setting on limit control above

boiler water temperature and burner should reignite after pre-purge time delay.

9. Test ignition system safety device:

• 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 therefore the burner) should fail

to light. The standard lockout time is 90 seconds; then the pilot light goes off and the boiler goes into post-purge. (If

the lockout module is attached to boiler, a lockout light comes on.)

• Turn 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.

10. To restart system, follow lighting instructions in Section O.

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 temperature?

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?

SECTION Q: OPERATION

OPERATING INSTRUCTIONS

Lighting Instructions

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.

7. Wait five (5) minutes to clear out any gas. Then 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.

8. Turn on all electric power to the appliance.

9. Set thermostat to desired setting. The appliance will operate. The pilot burner will light after the pre-purge time

delay (45 seconds). Then the pilot will light the main burner.

10. If the appliance will not operate, follow the instruction "To Turn Off Gas ToAppliance", and contact a qualified service

technician.

11. Replace upper front panel.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove upper front panel.

4. Turn off main manual gas valve and manual pilot gas valve.

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" W.C. for Natural gas, 10" W.C. for Propane?

SECTION R: MAINTENANCE

SUGGESTED MINIMUM MAINTENANCE SCHEDULE:

Regular service by a qualified service agency and maintenance must be performed to assure maximum boiler operating

efficiency.

Maintenance as outlined below may be performed by the owner.

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 function, deterioration or leakage.

4. Check that boiler area is free from combustible 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.

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 manufacturer’s instructions.

9. Follow oil-lubricating instructions on circulator. Over-oiling will damage circulator. Water-lubricated

circulators do not need oiling.

10. Visually inspect condensate drain piping for proper operation or deterioration (if appropriate). Check for plugged

condensate trap. Use cleanout plug to clear trap.

11. To avoid potential of severe burn, DO NOT REST HANDS ON OR GRASPPIPES. Use a light touch - return

piping will heat up quickly.

12. If mixing valve does not seem to be working, the spring and thermostat may need to be replaced. Call a qualified

service technician.

13. Check for piping leaks around circulators, mixing valves, relief valves and other fittings. Repair, if found. DO NOT

use petroleum based stop leak.

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.

Monthly:

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 function, deterioration or leakage.

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:

1. Check relief valve. Refer to manufacturer’s instructions on valve.

2. Test low water cutoff, if used. Refer to manufacturer’s instructions.

3. Visually inspect condensate drain hose for proper 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.

CLEANINGBOILER HEATING SURFACES:

The following service procedures must be performed ONLY by a qualified service agency. Boiler owner should

not attempt these procedures.

1. If you find soot in top of vent elbow (some sediment in bottom of vent is normal) - remove vent attachment to the ADB

and clean flue exhaust baffle inside the boiler. Also check burner, replace if damaged.

2. If you find rust deposits in vent elbow - check for high water flowrate or low inlet water temperatures. Clean boiler as

above.

SECTION S: CONNECTING CONDENSING HEAT EXCHANGER (CHX)

Refer to Figure S-1 for the following steps:

NOTICE:

Connect the vent before connecting the water piping.

Install unions on water inlet and outlet of CHX for ease of maintenance. The CHX require cleaning as often

as once the year.

1. Remove the shroud.

2. Remove the top cover.

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 leveling screws at the base.

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

9. Secure the flue connection from step 7 above with the stainless steel screws (supplied).

10. Connect the flue vent (Category IV venting, UL 17-38 Certified Venting Material) to the 15° elbow of the CHX flue

outlet.

11. Connect the PVC pipe (not supplied) for condensate water disposal (check with local authority regarding condensate

disposal).

12. Replace the shroud.

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

VENTSWITCHADJUSTMENT:

In order to insure proper operation of theADB 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 1½ turn clockwise.

Seal with silicone.

Reinstall in reverse order.

Figure S-1

Connecting Add-On Condensing Heat Exchanger to ADB

APPENDIX A

INSIDECOMBUSTIONAIRCONTAMINATION:

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 commonly used in high efficiency systems.

The boiler can use special corrosion-resistant nonmetallic vent material. You may, however, choose to use outside com-

bustion 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

furniture refinishing areas and establishments

new building construction

remodeling areas.

Check for areas and products as listed above before installing boiler. If found:

•

remove products permanently, OR

provide outdoor combustion air.

START-UP SETTINGS

TODAY'S DATE:

__________________________________________________

PRESSURE SETTINGS:

Blower (burner off)………………

______ "W.C.

Pilot……………………………… ______ "W.C.

Main Burner (Top)…………….

Main Burner (Bottom)…………

Blower (burner on) ………………

Supply Gas (static) ………………

______ "W.C.

Supply Gas (dynamic) …………… ______ "W.C.

Power Supply……............………. ______ Volts

EMISSION : (Analyzer readings)

CO₂……………………………… ______ %

CO………………………………

______ PPM

ExcessAir………………………… ______ %

O₂………………………………… ______ %

NOx……………………………… ______ PPM

Flue Temperature………………… ______ °F

amb. Temperature………………… ______ °F

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 covered 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 operation 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 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 available, 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 LIABILITY 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 EastmanAvenue, Oxnard, CA93030 (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

RaypakAustralia Pty. Ltd, 7 Geddes Street, Mulgrave, Victoria,Australia 3170 (613) 9560 4944 FAX: (613) 9560-4974

8/98 Litho in U. S. A.

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