Raypak Commercial Space Heating and Domestic Water User manual

ANEW ERA INBOILER DESIGN
Commercial Space Heating
and Domestic Water
ADB Advanced Design Boiler
Up to 97%
Thermal Efficiency
Ultra low NOx
Small Footprint
Aerodynamically
Stabilized Burner
Full Diagnostics
Multiple Venting
Options
Reduced Vent
Sizes
New!
1500 MBTU
TM

95
100
8060 100 120 140 160
90
85
80
75
180 200 220
ADB without Condensing Heat Exchanger
ADB with Condensing Heat Exchanger
%Efficiency
°F Return Water Temperature
H
igh efficiency boilers were introduced in
response to the energy crisis of the
seventies. Most first generation high
efficiency boilers were simply standard units that
had been hurriedly modified to boost efficiency.
These boilers obtained higher efficiencies by
permitting steady-state condensation in the heat
exchanger and in the combustion chamber.
Failure to adequately protect the combustion
chamber and heat exchanger from the corrosive
effects of condensate meant that most first
generation units failed prematurely. The units
condensed, eventually corroded, and finally
were discarded.
Manufacturers learned from their mistakes. They
upgraded materials, redesigned heat exchangers
and refined their manufacturing techniques. The
second generation of high efficiency boilers,
which began to appear in the late eighties, was a
vast improvement. However, second generation
units still experience damage from condensation.
Although the materials used in second generation
high efficiency boilers last considerably longer,
they still eventually succumb to corrosion.
THIRD GENERATION TECHNOLOGY
After two decades of trial-and-error, the boiler
industry has finally realized that high efficiency
and long product life can only be obtained by
preventing condensation from occurring in the
combustion chamber. Raypak’s Advanced Design
Boiler is the first of a new generation of boilers
that can obtain ultra-high efficiencies without
compromising product life. The “secret” to the
ADB’s longevity is that condensation occurs only
in a corrosion-resistant condensing heat exchanger.
The ADB is designed so that condensation will not
occur in the primary heat exchanger or the
combustion chamber. The result
is an ultra-high efficiency
product that lasts.
Welcome to the future
of boiler technology.
Efficiencies up to
97%
THE EFFICIENCY YOU WANT AND THE RELIABILITY YOU NEED.
EFFICIENCY
.
THE ADB’S
NON-CONDENSING
PRIMARY HEAT EXCHANGER
THE EFFICIENCY YOU WANT
The Advanced Design Boiler is the first boiler that can
meet your exact efficiency requirements. The ADB, when
used without the Condensing Heat Exchanger (CHX), can
deliver thermal efficiencies up to 84%.
If higher efficiency is required, simply add the Condensing
Heat Exchanger to the installation. The CHX is designed to
capture the maximum amount of available energy by
extracting both sensible and latent heat from the flue
gases. That means ultra-high efficiencies – and substantial
energy savings.
AGA Design Certified Rating

RELIABILITY.
ADVANCED BURNER TECHNOLOGY
The heart of any boiler is the burner. It’s a critical
component that’s got to be designed right. That’s
why Raypak spent over four years perfecting the
ADB burner. The result is an industrial grade, fan-
assisted burner that provides superior perfor-
mance and is practically indestructible.
Standard high efficiency boilers use burners that
are either flimsy flame retention screens that burn
out, or radial perforated burners that eventually
clog and operate at reduced efficiencies. Unlike
these burner designs, the patented advanced
design burner will not clog or burn out. In fact,
Raypak is so confident, the new burner head is
backed with a TEN YEAR UNCONDITIONAL WARRANTY.
The ADB’s burner utilizes a solid metal bluff-body
burner head to generate a high-intensity aerody-
namically stabilized flame. The burner’s turbulent
mixing action reduces residence time and increas-
es flue gas recirculation. The result is clean, effi-
cient combustion with NOx emissions well within
the limits of the most restrictive air quality require-
ments.*
This is one tough burner and the warranty proves it.
* NOx emissions:
0-30 ppm depending on combustion air quality and
gas composition.
ERROR
HEAT
CENTRAL POINT WIRING AND DIAGNOSTICS
Raypak boilers have a well earned reputation for
being easy to service. The ADB is no exception. In
fact, the ADB sets a whole new standard for ser-
viceability – because it’s the first commercial boiler
to incorporate central point wiring (CPW).
Unlike older control technologies, CPW individually
monitors each and every boiler control and safety
function. Using an intuitive LED display referred to
as the Operation Status Center, CPW gives split-
second feedback on boiler firing status. Should
service be required, the ADB will even indicate
which component requires attention by illuminat-
ing the appropriate fault LED located on the ADB’s
U-2 Diagnostics Panel.

FLEXIBILITY.
THE CONDENSING HEAT EXCHANGER (CHX)
The CHX is a scavenging heat exchanger that has
been specifically designed to capture the maximum
amount of energy from the ADB’s exhaust gases.
When used with a pre-heat tank and a storage tank,
the ADB/CHX system can squeeze out an amazing
97% of all heat of combustion energy contained in
the flue gases.
The CHX is built tough
enough to withstand the
demanding conditions
found in condensing
applications. All materials
used in the CHX are
inherently corrosion
resistant and are treated
with advanced corrosion-
proof coatings for extra
protection. The headers
are bronze, the heat
exchanger tubes are
made of cupro-nickel and
are coated with a
condensate impervious
epoxy enamel. All
non-stainless internal fittings are either epoxy
coated or are chemically immune. The tube bundle
casing is fabricated from AL29-4C stainless steel,
and the outer jacket has an electrostatically applied
powder coat finish that is baked-on for superior
corrosion resistance and extra long life.
By segregating condensation from the primary
heat exchanger and the combustion chamber,
the CHX produces ultra-high efficiency without
sacrificing product life.
VENTING OPTIONS
CONVENTIONAL VENT
THROUGH-WALL VENT
DIRECT VENT/SEALED
COMBUSTION
VERTICAL VENT/SEALED
COMBUSTION
OUTDOOR

THE ADVANCED DESIGN BOILER
WEATHER PROOF JACKET
The heavy gauge steel exterior jacket is protected with
a baked-on UV-resistant Polytuf powder coat finish.
COMBUSTION AIR FAN
With easy-to-adjust combustion
air shutter.
CORROSION RESISTANT
STEEL
All metal fittings are galvanized
against rust.
SPARK TO PILOT
IGNITION
The most dependable ignition
method available.
MINIMUM CLEARANCE
REQUIREMENTS
Only one inch of clearance
is required from combustible
surfaces.
PRIMARY HEAT
EXCHANGER
Vertical, cylindrical, multi-pass
heat exchanger captures all
radiant energy, eliminating
the need for heavy refractory.
CUPRO-NICKEL FINNED TUBES
Provide fast, efficient heat transfer with extended
tube life. Will not corrode or erode and can handle
aggressive and hard water with ease.
SMALL FOOTPRINT
The ADB occupies less than 51/2 sq. ft. of floor space.
VENT PRESSURE SWITCHES
Enhance safety by verifying proper
burner operation.
UP-FRONT CONTROLS
Easy access to all controls and
gas train components.
ADVANCED BLUFF BODY
BURNER
Industrial-tough, solid metal burner
head won’t clog or burn out –
and it’s backed with a
TEN YEAR UNCONDITIONAL WARRANTY.
RUGGED ALL BRONZE
HEADERS
Are naturally corrosion resistant.
VENT OUTLET FLEXIBILITY
The flue gas outlet can be
repositioned in the field to vent from
either the back or right side of the unit.
TUBE SHEET CONSTRUCTION
Eliminates the repair and
maintenance problems associated
with rolling tubes directly into
a casting.
VIEWING PORT
Allows easy fine-tuning of the power burner.
OPERATION STATUS CENTER
Central point wiring, standard operating lights,
full-boiler diagnostics.

SHIP FOOT
MODEL INPUT OUTPUT B D E F G H K M P WGT PRINT AMPS
(MBTU) (MBTU) HEIGHT NPT NPT FLUE Lbs. Ft.2
H 751 750 630 64 38 44-1/2 29-3/4 1-1/2 2 8 17-3/4 41 680 5.4 8
H 1001 999 840 72 46 52-1/2 37-3/4 1-1/2 2-1/2 10 21-1/2 49 720 5.4 10
H 1501 1499 1260 82 56 62-1/2 47-3/4 1-1/2 2-1/2 12 20-1/4 59 780 5.4 12
FEATURES
•
Advanced Fan-Assisted Burner with Aerodynamically Stabilized Flame
•
Design Certified ANSI Z21.13 and Z21.10.3
•
Ultra-Low NOx: Less than 30ppm
•
Reduced Footprint
•
Indoor/Outdoor Construction
•
Thermal Shock Resistant
•
20 Year Limited Warranty
•
Natural Gas or Propane (except 1501)
STANDARD EQUIPMENT
HEAT EXCHANGER
•
Bronze Headers
•
Integral Finned Tube Heat Exchanger
Copper For Type H4
Cupro-Nickel For WH1
•
ASME Inspected and Stamped 150 PSIG
•
National Board Approved
•
Factory Installed ASME Relief Valve
•
Temperature and Pressure Gauge
GAS CONTROL TRAIN
•
Manual Main Gas Shut-Off Cock
•
Main Gas Pressure Regulator
•
Safety Shut-Off Valve, Redundant
•
Firing Mode: On/Off
•
Factory Fire Tested
•
CSD-1 Compliant Gas Train
CONTROLS
•
120V, 60Hz, 1ø Power Supply
•
120/24V Transformer
•
100% Pilot Safety
•
Electronic Intermittent Ignition (IID)
•
High Limit Safeties
•
Central Point Wiring
•
Full Boiler Diagnostics
•
Fan Proving Switch
•
Flow Switch
•
Blocked Flue Switch
CONSTRUCTION
•
Front Controls: Enclosed
•
Polytuf Powder Coat Finish
•
Durable Indoor/Outdoor Construction
•
Right Side or Rear Connections
Dimensions are in inches. Ratings shown for elevations up to 5000 feet. For installation at elevations over 5000 feet, please contact manufacturer.
See catalog 2000.27 for complete installation dimensions.
RAYPAK CORPORATE OFFICE AND
PRINCIPAL MANUFACTURING FACILITY
2151 Eastman Avenue
Oxnard, CA 93030
[phone] FAX: [phone]
RAYPAK CANADA LIMITED
2805 Slough St., Mississauga
Ontario, Canada L4T 1G2
[phone] FAX: [phone]
Raypak, Inc. reserves the right to make product changes
or improvements at any time without notice
Catalog No. 3400.10G Effective: 07-15-03 Replaces: 07-01-01 Litho in USA ©1998-2001 Raypak, Inc.
www.raypak.com