Raypak 750 User Manual Page 1

Catalog No.: 3400.50-IEffective: 12-01-00Replaces: 05-01-00FOR YOUR SAFETYDo not store or use gasoline or other flammable vapors and liquids or other

SECTION C: COMBUSTION AND VENTILATION AIRCOMBUSTION AND VENTILATION AIR (Indoor Units)The boiler must be supplied with sufficient quantities of non-co

Method 2 (normally applied in cold climate regions):1. The mechanical equipment room must be provided with at least one permanent opening, commencing

SECTION D: WATER PIPING - GENERALThe boiler should be located so that any water leaks will not cause damage to the adjacent area or structures.All uni

13SECTION E: HYDRONIC HEATING PIPINGPUMP SELECTIONIn order to insure proper performance of your boiler system, you must install a properly sized pump.

Figure E-2aSINGLE BOILER - PRIMARY/SECONDARY PIPING14PRESSURE DROP IN FEET OF HEADFEEDWATER REGULATORRaypak recommends that a feedwater regulator be i

Figure E-2bSINGLE BOILER - PRIMARY/SECONDARY PIPING WITH CHX15Figure E-3aDUAL-BOILER PRIMARY/SECONDARY PIPING

16Figure E-3bDUAL BOILER -PRIMARY/SECONDARY PIPING WITH CHXFigure E-4aSINGLE BOILER - LOW TEMPERATURE APPLICATION (HEAT PUMP) PRIMARY/SECONDARY PIPING

SECTION F: DOMESTIC HOT WATER PIPINGWhen designing the water piping system for domestic water applications, water hardness should be considered. Table

18Figure F-1bbSINGLE BOILER DOMESTIC HOT WATER WITH ONE STORAGE TANK AND CHX (2 pump system)Figure F-1cSINGLE BOILER DOMESTIC HOT WATER WITH ONE STORA

19SECTION G: POOL HEATINGCAUTION: Power to the heater should be interlocked with the main system pump to make sure the heater does not firewithout the

DANGER: Make sure the gas on which the boiler will operate is the same type as that specified on theboiler model and rating plate.WARNING: Should over

SPA WATER CHEMISTRYNOTE: Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your waterpH between 7.4 and 7.

Figure G-3aDOUBLE BOILER - POOL APPLICATION21

22SECTION H: GAS SUPPLY CONNECTIONSDANGER: Make sure the gas on which the boiler will operate is the same type as specified on the boilermodel and rat

23GAS PRESSURE REGULATORThe gas pressure regulator is nominally preset to the outlet values shown in the table below, within +. 1" W.C. If anadj

24SECTION I: ELECTRICAL POWER CONNECTIONSInstallations must follow these codes:· National Electrical Code and any other national, state, provincial or

25MAKING THE ELECTRICAL CONNECTIONSRefer to Fig. I-2 Wiring Connection, and Fig. L-2 Wiring Diagram.1. Verify circuit breaker is properly sized by ref

26ELECTRICAL CONNECTIONS - DOMESTIC HOT WATERCAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause imprope

27SECTION J: VENTING CONNECTIONSGENERALCAUTION: Proper installation of flue exhaust venting is critical for the safe and efficient operation of the bo

Table J-1 ADB Category Determination for Venting Purpose and Venting Arrangement28NOTE: PVC or CPVC vent maybe used inconjunction with CHX, special pi

29Support of Vent StackThe weight of the vent stack or chimney must not rest on the boiler vent connection. Support must be provided in compliancewith

3TABLE OF CONTENTSPAGENO. 4 SECTION A: BEFORE INSTALLING THE BOILER 7 SECTION B: BOILER INSTALLATION10 SECTION C: COMBUSTION AND VENTILATION AIR12 S

Venting Installation TipsSupport piping:· horizontal runs- at least every five (5) feet.· vertical runs - use braces:· under or near elbowsFollow item

31SECTION J-1 Natural Draft Vertical Venting Without Add-on CondensingHeat Exchanger (Category I)Figure J-1NATURAL DRAFT VERTICAL VENT WITHOUT ADD-ON

• Natural Draft Vertical Venting System InstallationNatural draft venting uses the natural buoyancy of the heated flue products to create a thermal d

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

SECTION J-2 Horizontal Thru-Wall Venting Without Add-on CondensingHeat Exchanger (Category III)Figure J-2HORIZONTAL THRU-WALL VENTING WITHOUT ADD-ONCO

35The total length of the thru-wall exhaust vent system cannot exceed sixty-five (65) feet in length for the flue outlet. Eachelbow used is equal to

SECTION J-3 Horizontal Thru-Wall Direct Venting/Combustion Air(Category III)Figure J-3HORIZONTAL THRU-WALL DIRECT VENTING WITHOUT ADD-ONSECONDARY COND

• Horizontal Thru-wall Direct Venting System (Category III) InstallationThese installations utilize the boiler mounted blower to draw combustion air

SECTION J-4 Vertical Direct Venting/Combustion Air (Category I)Figure J-4VERTICAL DIRECT VENTING WITHOUT ADD-ON CONDENSING HEAT EXCHANGER*Vent lengths

• Vertical Direct Venting System InstallationThese installations utilize the boiler mounted blower to draw combustion air from outdoors and uses the n

Pay attention to these terms:DANGER indicates the presence of immediate hazards which will cause severe personal injury, death orsubstantial property

SECTION J-5 Vertical Venting With Add-On Condensing Heat Exchanger(Category IV) Domestic WaterFigure J-5VERTICAL VENT (CATEGORY IV) WITH ADD-ONCONDENS

• Vertical Vent (Category IV) with Add-on Condensing Heat Exchanger InstallationThese installations utilize the boiler mounted blower to vent the com

SECTION J-6 Horizontal Thru-wall Venting With Add-on Condensing Heat Exchanger (CHX)Figure J-6HORIZONTAL THRU-WALL VENTING WITH ADD-ONCONDENSING HEAT

• Horizontal Thru-wall Venting System (Category IV) InstallationThis installation utilize the boiler mounted blower to vent the combustion products t

SECTION J-7 Horizontal Thru-Wall Direct Venting/Combustion Air With Add-OnCondensing Heat Exchanger (Category IV)Figure J-7HORIZONTAL THRU-WALL DIRECT

• Horizontal Thru-wall Direct Venting System With Add-on Condensing Heat Exchanger(Category IV) InstallationThese installations utilize the boiler mo

SECTION J-8 Vertical Direct Venting/Combustion Air With Add-on CondensingHeat Exchanger (Category IV)Figure J-8VERTICAL DIRECT VENTING WITH ADD-ONSECO

47• Vertical Direct Venting System With Add-on Condensing Heat Exchanger (Category IV) InstallationThese installations utilize the boiler mounted blo

Outdoor Installation with Add-On Condensing Heat ExchangerOutdoor models are self -venting when installed with the factory-supplied non-restricted dir

49SECTION K CONDENSATE DRAINWARNING: All condensation should be disposed of according to local, county, state, and federal laws. Refer toNFGC, sectio

MODEL IDENTIFICATIONThe model identification number and boiler serial number are found on the boiler data plate located on the leftinside jacket of th

50SECTION L CONTROLSWARNING: Installation, adjustment and service of boiler controls including timing of various operating functions must be performed

In addition to monitoring and displaying boiler status, the CPW board controls the timing of various operating functionsincluding: boiler pump turn-of

• Freeze Protection FeatureThe CPW board is programmed to turn-off the blower in case there is a lock-out condition. If there is a call for heatsignal

53Figure L-2WIRING DIAGRAM

IGNITION CONTROL MODULEThe intermittent ignition device conserves energy by automatically extinguishingthe pilot when the desired temperature is reach

LOW WATER CUT OFF (OPTIONAL)The low water cut off automatically shuts down the burner wheneverwater level drops below the level of the sensing probe.

SECTION M: GENERAL SAFETY PRECAUTIONSTo meet commercial water use needs, an external operating control for this hot water boiler is adjustable up to 2

57SECTION N: PRE-START-UPFILL THE SYSTEM:1. Close manual and automatic air vents and drain cock.2. Fill to correct system pressure. Correct pressure

58Figure O-1COMPONENT AND PRESSURE TAP LOCATIONSBlower "T" fitting detail.

SECTION O: ADB INITIAL START-UP1.0 TOOLS NEEDED• One 8-0-8 , 16” scale manometer (or larger)• Three 4-0-4, 8” scale manometers (or larger)• “T” fitt

6Figure A-1ADVANCED DESIGN BOILER COMPONENT LOCATIONS

2.4 Check the Gas Supply Pressure, Location (1)• Leave pilot gas valve and main gas shut-off valve closed;• Slowly turn on main gas shut-off valve;• R

3.3 Main Burner Adjustment1. Turn unit off.2. Check to make sure that the pressure equalizer tube is securely connected between the blower and gas pre

SECTION P: POST START-UP CHECKCheck off steps as completed:1. Boiler and heat distribution units or storage tank filled with water?2. Automatic air ve

SECTION Q: OPERATIONOPERATING INSTRUCTIONSLighting Instructions1. STOP! Read the safety information first.2. Set the thermostat to the lowest setting.

SECTION R: MAINTENANCESUGGESTED MINIMUM MAINTENANCE SCHEDULE:Regular service by a qualified service agency and maintenance must be performed to assure

CLEANING BOILER HEATING SURFACES:The following service procedures must be performed ONLY by a qualified service agency. Boiler owner shouldnot attempt

66SECTION S: CONNECTING CONDENSING HEAT EXCHANGER (CHX)Refer to Figure S-1 for the following steps:1. Remove the shroud2. Remove the top cover.3. Se

67APPENDIX AINSIDE COMBUSTION AIR CONTAMINATION:All boilers experience some condensation during start-up.The condensate from flue gas is slightly acid

68

69

SECTION B: BOILER INSTALLATIONINSTALLATION CODESInstallations must follow these codes:· Local, state, provincial, and national codes, laws, regulation

70

71

72

START-UP SETTINGSTODAY'S DATE: __________________________________________________PRESSURE SETTINGS:Blower (burner off)……………… ______ "W.C.Pil

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX: (800) 872-9725Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Ca

8CLEARANCESTABLE 1MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES(INDOOR ALCOVE INSTALLATIONS)Boiler SizeBoiler Side 500 750 1000Floor See Note 1.Rear 1”

9Raypak Advanced Design Boilers are design certified by AGA/CGA for outdoor installation. Roof water drainage must bediverted away from boilers instal