Raypak HD101 Manuals

Project Name / Date Division 23 52 33.13 - 1 DIVISION 23 52 33.13 FINNED WATER-TUBE BOILERS PART 1 - GENERAL 1.1 SUMMARY A. Section includes gas-fired, copper finned-tube hydronic heating boilers B. Related Sections Specifier Note: Use as needed 1. Building Services Piping – Division 23 21 00 2. Breeching, Chimneys, and Stacks (Venting) – Division 23 51 00 3. HVAC Instrumentation and Controls – Division 23 09 00 4. Electrical – Division 23 09 33 1.2 REFERENCES A. ANSI Z21.13/CSA 4.9 B. ASME, Section IV C. 2006 UMC, Section 1107.6 D. ANSI/ASHRAE 15-1994, Section 8.13.6 E. National Fuel Gas Code, ANSI Z223.1/NFPA 54 F. I=B=R G. NEC 1.3 SUBMITTALS A. Product data sheet (including dimensions, rated capacities, shipping weights, accessories) B. Wiring diagram C. Warranty information D. Installation and operating instructions 1.4 QUALITY ASSURANCE A. Regulatory Requirements 1. ANSI Z21.13/CSA 4.9 2. Local and national air quality regulations for low NOx (<20 PPM NOx emissions) boilers B. Certifications 1. CSA 2. ASME H Stamp and National Board Listed 3. ISO 9001 1.5 WARRANTY A. Limited one-year warranty from date of installation B. Limited twenty-year thermal shock warranty C. Limited ten-year closed-system heat exchanger warranty PART 2 - PRODUCTS 2.1 MANUFACTURER A. Raypak, Inc. 1. Contact: 2151 Eastman Ave., Oxnard, CA 93030; Telephone: (805) 278-5300; Fax: (800) 872-9725; Web site: www.raypak.com Catalog No.: 2000.961 Effective: 6-25-09 Replaces: New Hi Delta SS™, TYPE H - MODELS HD101-HD401 SUGGESTED SPECIFICATIONS Project Name / Date Division 23 52 33.13 - 2 2. Product: Hi Delta SS™ copper finned-tube hydronic boiler(s) 2.2 BOILERS A. General 1. The boiler(s) shall be fired with gas at a rated input of BTU/hr. 2. The boiler(s) shall be CSA tested and certified with a minimum thermal efficiency of 84 percent at full fire. 3. The boiler(s) shall be ASME inspected and stamped and National Board registered for 160 PSIG working pressure, complete with a Manufacturer's Data Report. 4. The boiler(s) shall have a floor loading of 45 lbs. /square foot or less. B. Heat Exchanger 1. The heat exchanger shall be of a single-bank, horizontal-grid design with nine integral copper fin tubes, each end of which is rolled into an ASME boiler-quality steel tube sheet. 2. The heat exchanger shall be sealed to 160 PSIG rated cast iron headers with high temperature silicone "O" ring gaskets. 3. The low water volume heat exchanger shall be explosion-proof on the water side and shall carry a twenty-year warranty against thermal shock. 4. The headers shall be secured to the tube sheet by stud bolts with flange nuts to permit inspection and maintenance without removal of external piping connections. 5. The boiler(s) shall be capable of operating at inlet water temperatures as low as 105°F without condensation. C. Burners 1. The tubular burners shall have gas orifices, punched ports and slots, be capable of quiet ignition and extinction without flashback at the orifice, and be manufactured from corrosion- resistant, stainless steel with low expansion coefficient. 2. The burners will be supplied with a fan-assisted, clean burning, and highly efficient fuel-air mixture. D. Pilot Control System 1. The boiler(s) shall be equipped with a 100 percent safety shutdown system. 2. The ignition shall be Hot Surface Ignition type with full flame rectification by remote sensing separate from the ignition source, with a three try-for-ignition sequence, to ensure consistent operation. 3. The igniter will be located away from the water inlet to protect the device from condensation during startup. 4. An external viewing port shall be provided, permitting visual observation of burner operation. E. Gas Train 1. The boiler(s) shall have dual-seated main gas valve(s). 2. Gas control trains shall have a redundant safety shut-off feature, main gas regulator, and plugged pressure tapping to meet the requirements of ANSI Z21.13/CSA 4.9. F. Boiler Control 1. The following safety controls shall be provided: a. High limit control b. Flow switch c. PSIG ASME pressure relief valve, piped by the installer to an approved drain d. Temperature and pressure gauge 2. The boiler(s) shall be equipped with an energy-saving pump control relay (Economaster), mounted and wired, which automatically shuts off the boiler pump at a set period after boiler shut-down (adjustable for two settings of five or ten minutes) to avoid standby losses associated with constant pump operation. G. Firing Mode 1. For models HD101 – HD401, provide two-stage fire control of the gas input to the boiler (on/off fire optional). H. Boiler Diagnostics Project Name / Date Division 23 52 33.13 - 3 1. Provide internal LED displaying the following boiler status/faults: a. Steady on – Internal control failure b. One flash – Air flow fault c. Two flashes – Erroneous flame signal d. Three flashes – Ignition lockout I. Combustion Chamber: The lightweight, high-temperature, multi-piece, interlocking ceramic fiber combustion chamber liner shall be sealed to reduce standby radiation losses, reducing jacket losses and increasing unit efficiency. J. Venting 1. When routed vertically, the boiler’s flue material and size shall be in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA54 latest edition (Category I). 2. When routed horizontally, the boiler(s) flue material and size shall meet or exceed the requirements as specified for Category III in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 latest edition. 3. The boiler(s) shall be TruSeal™ direct vent ready. The boiler(s) shall meet safety standards for direct vent equipment as noted by: the 2006 UMC Section 1107.6; ASHRAE 15-1994, Section 8.13.6; and ANSI Z21.13/CSA 4.9. K. Cabinet 1. The corrosion-resistant galvanized steel jackets shall be finished with a baked-on epoxy powder coat which is suitable for outdoor installation, applied prior to assembly for complete coverage, and shall incorporate louvers in the outer panels to divert air past heated surfaces. 2. The boiler(s), if located on a combustible floor, shall not require a separate combustible floor base. 3. Combustion air intake shall be on the left side of the cabinet. L. Operating Controls 1. The boiler(s) shall feature an optional controller. Specifier Note: The remaining items in this section are options. Delete those that are not being specified. M. Boiler Pump - Refer to Equipment Schedule N. Cold Water Run System 1. The boiler(s) shall be configured with a cold water run automatic proportional bypass system that ensures the boiler will experience inlet temperatures in excess of 105ºF in less than 7 minutes to avoid damaging condensation. The unit will automatically shut down if the inlet temperature is not achieved within the 7 minute time frame. 2. The cold water run system shall be configured with a variable speed pump that is controlled by a system-matched PID control that injects the correct amount of cold water directly into the boiler loop to maintain a minimum inlet temperature. The PID controller temperature sensor shall be located in the inlet header of the boiler. 3. The control shall have a temperature setting dial located on the face of the board. The temperature range of the dial shall be 105ºF to 120ºF. The PID Logic shall be capable of limiting system overshoot to a maximum of 10ºF on initial start-up or call-for-heat. 4. The cold water run system shall be shipped loose for field installation. 5. The cold water run pump shall have the following diagnostic LED’s: a. Power b. Heat Request c. Reduced Out d. % Out 2.3 SOURCE QUALITY CONTROL A. The boiler(s) shall be completely assembled, wired, and fire-tested prior to shipment from the factory. B. The boiler(s) shall be furnished with the sales order, ASME Manufacturer’s Data Report, inspection sheet, wiring diagram, rating plate and Installation and Operating Manual.

INSTALLATION & OPERATING INSTRUCTIONS CATALOG NO. 1000.52B Effective: 11-19-09 Replaces: 09-25-09 P/N 241356 Rev. 3 WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference. Models HD101–HD401 Types H & WH ® L W 2 Rev. 3 reflects the following: Changes to: Updated Table E on page 14, Table G on page 18, Troubleshooting flowchart on page 35, Table O on page 38. Additions: Commonwealth of Massachusetts information on page 45 Deletions: None WARNINGS 4 Pay Attention to These Terms 4 BEFORE INSTALLATION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 Time/Temperature Relationships in Scalds 8 INSTALLATION 9 Installation Codes 9 Equipment Base 9 Clearances 9 Combustion and Ventilation Air 11 Conventional Combustion Air Supply 11 Water Piping 12 Hydronic Heating 14 Domestic Hot Water Piping 16 Gas Supply 17 Electrical Power Connections 19 Venting 21 Outdoor Installation 31 CONTROLS 32 Ignition Control Module 32 Modulating Temperature Control (Optional) 32 High Limit (Manual Reset) 32 High Limit — Auto Reset (Optional) 32 Flow Switch 33 High and Low Gas Pressure Switches (Optional) 33 Low Water Cut Off (Optional) 33 WIRING DIAGRAM—MODELS HD101–HD401 34 HD TROUBLESHOOTING 35 PRE-START-UP 36 Filling System-Heating Heaters 36 Domestic Hot Water Heaters 36 Inspect Venting System 36 Pre-Start-Up Check 36 INITIAL START-UP 36 Tools Needed 36 Preparation for Start-Up 36 Start-Up 38 Main Burner Adjustment 38 Gas Valve Adjustment 38 Gas Type Conversion on Valve 39 Safety Inspection 39 Follow-Up 39 POST START-UP CHECK 40 Air Filter Inspection/Removal 40 Heat Exchanger Removal 41 MAINTENANCE 42 Suggested Minimum Maintenance Schedule 42 APPENDIX 43 Inside Combustion Air Contamination 43 Important Instructions for the Commonwealth of Massachusetts 45 CONTENTS 3 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: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored. NOTE: Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. DANGER: Make sure the gas on which the heater will operate is the same type as that specified on the heater rating plate. WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the heater. Instead, shut off the gas supply at a location external to the heater. WARNING: Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water. WARNING: To minimize the possibility of improper operation, serious personal injury, fire, or damage to the heater: • Always keep the area around the heater free of combustible materials, gasoline, and other flammable liquids and vapors. • Heater should never be covered or have any blockage to the flow of fresh air to the heater. WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING: Risk of electrical shock. More than one disconnect switch may be required to deenergize the equipment before servicing. CAUTION: Operation of this heater in low- temperature systems requires special piping. Harmful internal condensation will occur if the inlet water temperature does not exceed 105°F. Warranty claims will be denied when condensation occurs. CAUTION: If this heater is to be installed above radiation level, it must be provided with a low water cut-off device at the time of heater installation. CAUTION: If this heater is to be installed in a negative or positive pressure equipment room, there are special installation requirements. Consult factory for details. WARNINGS — Pay Attention to These Terms 4 CAUTION: This heater requires forced water circulation when the burner is operating. See minimum and maximum flow rates. Severe damage will occur if the heater is operated without proper water flow circulation. WARNING: This unit contains refractory ceramic fiber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high temperatures (>2192F), the RCF can transform into crystalline silica (cristabolite). The International Agency for Research on Cancer (IARC) has classified the inhalation of crystalline silica (cristabolite) as carcinogenic to humans. When removing the burners or heat exchangers, take precautions to avoid creating airborne dust and avoid inhaling airborne fibers. When cleaning spills, use wet sweeping or High Efficiency Particulate Air (HEPA) filtered vacuum to minimize airborne dust. Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment including gloves, safety glasses with side shields, and appropriate NIOSH certified respiratory protection, to avoid inhalation of airborne dust and airborne fiber particles.

INSTALLATION & OPERATING INSTRUCTIONS CATALOG NO. 1000.52 Effective: 06-11-09 Replaces: NEW P/N 241356 Rev. 1 WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference. Models HD101–HD401 Types H & WH ® L W 2 WARNINGS 4 Pay Attention to These Terms 4 BEFORE INSTALLATION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 7 GENERAL SAFETY 8 Time/Temperature Relationships in Scalds 8 INSTALLATION 9 Installation Codes 9 Equipment Base 9 Clearances 9 Combustion and Ventilation Air 11 Conventional Combustion Air Supply 11 Water Piping 12 Hydronic Heating 14 Domestic Hot Water Piping 16 Gas Supply 17 Electrical Power Connections 19 Venting 21 Outdoor Installation 31 CONTROLS 32 Ignition Control Module 32 Modulating Temperature Control (Optional) 32 High Limit (Manual Reset) 32 High Limit — Auto Reset (Optional) 32 Flow Switch 33 High and Low Gas Pressure Switches (Optional) 33 Low Water Cut Off (Optional) 33 WIRING DIAGRAM—MODELS HD101–HD401 34 HD TROUBLESHOOTING 35 PRE-START-UP 36 Filling System-Heating Heaters 36 Domestic Hot Water Heaters 36 Inspect Venting System 36 Pre-Start-Up Check 36 INITIAL START-UP 36 Tools Needed 36 Preparation for Start-Up 36 Start-Up 38 Main Burner Adjustment 38 Gas Valve Adjustment 38 Gas Type Conversion on Valve 39 Safety Inspection 39 Follow-Up 39 POST START-UP CHECK 40 Air Filter Inspection/Removal 40 Heat Exchanger Removal 41 MAINTENANCE 42 Suggested Minimum Maintenance Schedule 42 APPENDIX 43 Inside Combustion Air Contamination 43 CONTENTS 3 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: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored. NOTE: Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. DANGER: Make sure the gas on which the heater will operate is the same type as that specified on the heater rating plate. WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the heater. Instead, shut off the gas supply at a location external to the heater. WARNING: Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water. WARNING: To minimize the possibility of improper operation, serious personal injury, fire, or damage to the heater: • Always keep the area around the heater free of combustible materials, gasoline, and other flammable liquids and vapors. • Heater should never be covered or have any blockage to the flow of fresh air to the heater. WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING: Risk of electrical shock. More than one disconnect switch may be required to deenergize the equipment before servicing. CAUTION: Operation of this heater in low- temperature systems requires special piping. Harmful internal condensation will occur if the inlet water temperature does not exceed 105°F. Warranty claims will be denied when condensation occurs. CAUTION: If this heater is to be installed above radiation level, it must be provided with a low water cut-off device at the time of heater installation. CAUTION: If this heater is to be installed in a negative or positive pressure equipment room, there are special installation requirements. Consult factory for details. WARNINGS — Pay Attention to These Terms 4 CAUTION: This heater requires forced water circulation when the burner is operating. See minimum and maximum flow rates. Severe damage will occur if the heater is operated without proper water flow circulation. WARNING: This unit contains refractory ceramic fiber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high temperatures (>2192F), the RCF can transform into crystalline silica (cristabolite). The International Agency for Research on Cancer (IARC) has classified the inhalation of crystalline silica (cristabolite) as carcinogenic to humans. When removing the burners or heat exchangers, take precautions to avoid creating airborne dust and avoid inhaling airborne fibers. When cleaning spills, use wet sweeping or High Efficiency Particulate Air (HEPA) filtered vacuum to minimize airborne dust. Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment including gloves, safety glasses with side shields, and appropriate NIOSH certified respiratory protection, to avoid inhalation of airborne dust and airborne fiber particles.