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manual abstract
Raypak’s Cold Water Start protection system utilizes a proportional three-way valve to bypass water from the boiler outlet to the inlet during start-up, when the system return water temperature is below the minimum acceptable level. Boiler Start-Up Cycle MIN INLET TEMP SETTING START-UP TEMP BLENDED BOILER INLET TEMP SYSTEM RETURN NOW AT OR ABOVE MINIMUM INLET SETTING. BYPASS CLOSED, FULL SYSTEM FLOW STABLE SYSTEM TEMP SYSTEM RETURN TEMPERATURE TIME Raypak’s Cold Water Start system: • Continuously monitors and adjusts inlet water temperature to prevent condensation • Regulates minimum inlet water temperature during system start-up • Shuts down boiler if the minimum inlet water temperature is not achieved • Eliminates job site set-up with proprietary self-tuning controller and system-matched components • Utilizes proportional three-way valve to achieve bypass • Allows high-temperature system operation without cycling on high-limit • Activates alarm if shutdown occurs (option) CCoommmmeerrcciiaall HHyyddrroonniicc HHeeaattiinngg Office Buildings • Factories/Warehouses • Greenhouses • DDoommeessttiicc HHoott WWaatteerr SSuuppppllyy Restaurants • Weekend Shut-down • (e.g. 6-day/week shopping center) Dump Loads • 87% Hot Water Supply Boiler • Intermittent Industrial Process • AAPPPPLLIICCAATTIIOONNSS COLD WATER RUN COLD WATER RUN For the same reason stated for Cold Water Starts, it is even more important to provide protection against condensation from cold inlet water on systems where the return water temperature to the boiler will always be below the acceptable minimum. Raypak’s Cold Water Run system utilizes a variable-speed pump to inject just the right amount of water from the main system loop into the boiler to maintain the optimum inlet temperature. This approach allows the full capacity of the boiler to be utilized to meet the system load, while at the same time continuously maintaining the optimum inlet water temperature to prevent condensation. Boiler Start-Up Cycle MIN INLET TEMP SETTING SYSTEM RETURN BLENDED BOILER INLET TEMP START-UP TEMP TEMPERATURE TIME Raypak’s Cold Water Run system: • Continuously monitors and adjusts inlet water temperature to prevent condensation • Regulates minimum inlet water temperature regardless of system temperature • Shuts down boiler if the minimum inlet water temperature is not achieved • Protects boiler from constant low return water temperatures with its proprietary self-tuning controller • Utilizes variable-speed injector pump to control boiler loop temperature • Activates alarm if shutdown occurs (option) • Pool Heating • Low-temperature Industrial Process • Very Low-temperature Return Water (e.g. convalescent hospital domestic hot water) AAPPPPLLIICCAATTIIOONNSS COLD WATER START BOILER PUMP 3-WAY VALVE BOILER TO FROM SYSTEM SYSTEM SYSTEM PUMP Cold Water Start J-Box Assembly Typical Cold Start Plumbing Pictorial-Not to Scale COLD WATER RUN BOILER PUMP VARIABLE SPEED INJECTOR PUMP TO BOILER FROM SYSTEM SYSTEM SYSTEM PUMP Cold Water Run J-Box Assembly Typical Cold RunPlumbing Pictorial-Not to Scale TECHNICAL DATA COLD WATER START TYPICAL BOILER PIPING* TYPICAL BOILER PIPING* COLD WATER RUN * Items required for cold water operation are shown. Other standard system components have been omitted for clarity. * Items required for cold water operation are shown. Other standard system components have been omitted for clarity. Catalog No.: 1000.19C Effective: 06-15-08 Replaces: 01-01-07 Raypak Inc., 2151 Eastman Ave., Oxnard, CA 93030 (805) 278-5300 Fax (800) 872-9725 MULTIPLE UNIT COLD WATER START Total System Load (MBTUH) Three-Way Diverting Valve Specifications Valve Size Cv GPM P 500-900 2” NPT 57 70 3.5’ 901-1,800 2-1/2” NPT 74 100 4.2’ 1,801-3,000 2-1/2” NPT 100 150 5.2’ 3,001-4,000 4” Flange 152 220 4.8’ 4,001-6,000 4” Flange 254 330 3.9’ 6,001-8,000 4” Flange 327 440 4.2’ Notes: 1. Maximum of 4 boilers per system. 2. Many variables can impact the proper valve sizing for multiple boilers. This sizing is provided as a guide. When in doubt consult the factory. 3. Multi-unit system ALWAYS shipped loose- Not available mounted. 4. 4” flanges, bolts and gaskets supplied by others. Multi-units with 4” valves are to be used on hydronic heating only. The valve body is cast iron. TECHNICAL DATA ...