Raypak 751 Operations Instructions

INSTALLATION AND OPERATINGINSTRUCTIONSCATALOG NO. 3400.52E Effective: 02-22-07 Replaces: 04-01-03 P/N 241079 Rev. 6 WARNING: Improper installation,

10U.S. Installations1Canadian Installations2AClearance above grade, veranda, porch, deck, or balcony1 ft (30 cm) 1 ft (30 cm)BClearance to window or d

11Conventional Combustion AirSupplyU.S. InstallationsAll Air from Inside the BuildingIf all combustion air is drawn from the air inside thebuilding (t

of 1 million BTUH. This opening(s) shall be eitherlocated at or ducted to a point neither more than18 inches (450 mm) nor less than 6 inches (150mm) a

HYDRONIC HEATINGPump SelectionIn order to ensure proper performance of your boilersystem, you must install a properly sized pump.Raypak recommends usi

14Fig. 4: Single Boiler - Primary/Secondary PipingFig. 5: Single Boiler - Primary/Secondary Piping with CHX

15Fig. 6: Dual Boiler PipingFig. 7: Dual Boiler - Piping with CHX

16Fig. 8: Single Boiler - Low Temperature Application (Heat Pump) Primary/Secondary PipingDOMESTIC HOT WATERPIPINGWhen designing the water piping syst

17Fig. 9: Single Boiler - Domestic Hot Water with One Storage TankFig. 10: Single Boiler - Domestic Hot Water with One Storage Tank and CHX

18Fig. 11: Single Boiler - Domestic Hot Water with One Storage Tank and CHX (2 pump system)Fig. 12: Single Boiler - Domestic Hot Water with One Storag

19POOL HEATINGThe ADB unit is equipped with an external pump andbypass arrangement that blends outlet water with theinlet to increase the inlet water

2

20Fig. 13: Single Boiler - Pool ApplicationFig. 14: Single Boiler - Pool Application with CHX

21Fig. 15: Double Boiler - Pool ApplicationThis based on average pool depth of 4’ 6” (4.5 ft)Table H: ADB Pool Sizing; Indoor or OutdoorGAS SUPPLYCONN

22Fig. 16: ConnectionsGas Supply ConnectionThe boiler must be isolated from the gas supply pipingsystem by closing the manual shutoff valve during any

23Gas Pressure RegulatorThe gas pressure regulator is nominally preset to theoutlet values shown in Tables T and U, within +.1 in.WC. If an adjustment

"TH" leads. Before starting the boiler, ensure that thereis proper voltage to the boiler and pump.The boiler must be electrically grounded i

25VENTINGCONNECTIONSGeneralDefinition of Appliance CategoriesBoilers are divided into four categories based on thepressure produced in the exhaust and

26Determination of ApplianceCategory for Venting Purposes andVenting ArrangementsSupport of Vent StackThe weight of the vent stack or chimney must not

27e) Terminate vent at least six (6) feet away from adja-cent walls.f) DO NOT terminate vent closer than five (5) feetbelow roof overhang.Canadian I

28Natural Draft Vertical Venting with-out Add-on Condensing HeatExchanger (Category I)Fig. 21: Natural Draft Vertical Venting without Add-on Condensin

29Natural Draft Vertical VentingSystem InstallationNatural draft venting uses the natural buoyancy of theheated flue products to create a thermal driv

WARNINGS 4BEFORE INSTALLATION 5Product Receipt 5Model Identification 5Ratings and Certifications 5Installations at Elevation 5Component Locations 6GEN

30appliance not connected to the common vent sys-tem. Turn on any exhaust fans, such as rangehoods and bathroom exhausts, so they will oper-ate at max

31Horizontal Thru-wall Direct VentingSystem (Category III) InstallationThese installations utilize the boiler-mounted blower tovent the combustion pro

32Table M: Horizontal Thru-wall Direct Venting without Add-onSecondary Condensing Heat ExchangerHorizontal Thru-wall Direct VentingSystem (Category II

33This type of installation can cause non warrantableproblems with components and poor operation of theunit due to the recirculation of flue products.

34Vertical Direct Venting SystemInstallationThese installations utilize the boiler mounted blower todraw combustion air from outdoors and uses the nat

35Table O: Vertical Vent (CATEGORY IV) with Add-on Condensing Heat ExchangerModel Venting CategoryCertified VentingMaterialVent Size (inches)Maximum V

36Model Venting CategoryCertified VentingMaterialVent Size (inches)Maximum VentLength (feet)ADB-751 w/CHX IVUL 1738 CertifiedVenting Material e.g.AL29

37ModelVentingCategoryCertified VentingMaterialVent Size(inches)Maximum VentLength (feet)Combustion AirIntake PipeMaterialAir InletSize (inches)Max. A

38Horizontal Thru-wall Direct VentingSystem with Add-on CondensingHeat Exchanger (Category IV)InstallationThese installations utilize the boiler mount

39ModelVentingCategoryCertified VentingMaterialVent Size(inches)Maximum VentLength (feet)Combustion AirIntake PipeMaterialAir InletSize (inches)Max. A

4DANGER:Indicates the presence of immediate hazards which will cause severepersonal injury, death or substantial property damage if ignored.WARNING:In

40e) A venting system shall terminate at least 3 feetabove any forced air inlet located within 10 feet.f) Adjacent brick or masonry surfaces must be

41CONTROLSCentral Point Wiring (CPW)Central Point Wiring is an advanced control integrationtechnique that provides complete boiler diagnosticcapabilit

42Fig. 30: CPW Board Pump Turn-off DelayThe CPW board has a built-in pump driver with pumpturn-off delay, which allows the operator to set howlong the

43U-2 Diagnostics BoardThe U-2 Diagnostics board is a solid-state electronicfault indicator that has been engineered to enhancesafety, simplify troubl

44Figure L-2WIRING DIAGRAMWIRINGDIAGRAM

45Ignition Control ModuleThe intermittent ignition device conserves energy byautomatically extinguishing the pilot when the desiredtemperature is reac

46Low Water Cut Off (Optional)The low water cut off automatically shuts down theburner whenever water level drops below the level ofthe sensing probe.

47result in a fire or explosion.5. Do not use this appliance if any part has beenunder water, immediately call a qualified servicetechnician to inspe

48ADB INITIAL START-UPTools Needed• One 8-0-8 , 16” scale manometer (or larger)• Four 4-0-4, 8” scale manometers (or larger)• “T” fitting• 7/16” and

49tion wire and proper grounding and wiring. Turnpower back on. Repeat Step 3. If there is still nospark after several attempts the igniter may bemisa

5BEFORE INSTALLATIONRaypak strongly recommends that this manual be re-viewed thoroughly before installing your ADB heater.Please review the General Sa

50Main Burner Adjustment1. Turn on the unit; about 45 seconds later, the pilotshould light. If the pilot fails to light, repeat pilotadjustment.2. T

51burners should reignite after pre-purge time delay.8. Test limit control: While burner is operating, moveindicator on high limit control below actu

523. Visually inspect venting system for proper func-tion, deterioration or leakage.4. Check that boiler area is free from combustiblematerials, gas

5310. Connect the flue vent (Category IV venting, UL1738 Certified Venting Material) to the 15° elbowof the CHX flue outlet.11. Connect the PVC pipe (

54APPENDIX Inside Combustion AirContamination:All boilers experience some condensation during start-up. The condensate from flue gas is slightly acidi

55START-UP CHECKLIST FOR FAN-ASSISTEDRAYPAK PRODUCTS ADB, HI-DELTA & MV BThis start-up checklist is to be completely filled out by the service tec

56LIMITED PARTS WARRANTYADVANCED DESIGN BOILER™SCOPE:Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this boiler wh

www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX: (800) 872-9725Raypak Canada LTD, 2805 Slough Street, Mississaug

6Component LocationsFig. 1: Component Locations

7GENERAL SAFETYTo meet commercial water use needs, an externaloperating control for this hot water boiler is adjustableup to 210°F. However, water tem

Equipment BaseThe boiler should be mounted on a level, structurallysound surface. The boiler is approved for and can beinstalled on a combustible surf

9Outdoor InstallationsRaypak Advanced Design Boilers are design certifiedby CSA for outdoor installation. Roof water drainagemust be diverted away fro