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Raypak 0090B 0135B Boiler User Manual

1. 90B 004277F 004278F 004279F 004280F 005477F 005478F 004297F 004298F 004299F 004300F 005485F 005486F 004261F 004262F 004264F 004265F 004266F 004711 135B 004281F 004282F 004283F 004284F 005487F 005488F 004268F 004263F 004264F 004265F 004267F 004712 180B 004285F 004286F 004287F 004288F 005489F 005490F www raypak com Raypak Inc 31111 Agoura Road Westlake Village CA 91361 4699 818 889 1500 FAX 818 889 4522 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada LAT 1G2 905 677 7999 FAX 905 677 8036 Raypak Australia Pty Ltd 7 Geddes St Mulgrave Victoria Australia 3170 6139 560 4944 FAX 6139 560 4974 Litho in U S A
2. ROBERTSHAW 7200 GAS VALVE Models 90 135 amp 180 e Replace pilot adjustment cover screw then follow the lighting instructions to get boiler ready for operation 2 Turn on power to the ignition systems and turn gas supply off at the gas valve Check ignition module as follows Set the thermostat or controller above room temperature to call for heat Watch for continuous spark at the pilot burner Time the spark operation Time must be within the lockout timing period 15 or 90 seconds Turn thermostat down to end call for heat and wait 60 seconds on lockout models before beginning step 3 Turn on gas supply set thermostat or controller above room tempera ture to call for heat systems should start as follows a opark will turn on and pilot gas valve will open at once Pilot burner should ignite after gas reaches the pilot burner opark ignition should cut off when pilot flame is established Main gas valve should open and main burner should ignite after gas reaches the burner port SAFE SHUTDOWN TESTS LIMIT ACTION With the burner operating lower the high limit setting to simulate an overheated boiler Normal shut down should occur Restore the normal limit setting and the burner should restart FLAME FAILURE With burner operating close the manual fuel valves to simulate a flame failure System should lock out after safety switch timing 15 seconds After the safety switch has cooled open the m
3. Regulator Min Max Setting Natural 7 0 14 0 9 0 Propane 12 0 14 0 11 0 10 The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and downstream which is the same as the manifold pres sure WATER CONNECTIONS amp SYSTEM PIPING The pipe size for water connections is shown on 3 Typical piping systems are shown on pages 11 to 13 The boiler is supplied as standard with a circulator and a built in by pass to insure the required minimum water flow in the boiler The by pass on models H 0135 and H 0180 is provided with an adjustable valve that is factory set in the full open position The handle is shipped loose The full open position is appropriate for most systems and insures adequate flow through the boiler If system flow is inadequate indicated by excessive temperature drop through the system the by pass valve can be throttled slightly Care must be taken against over throttling which may lead to inadequate flow through the boiler and boiler harmonics a humming sound from the heat exchanger If adequate system flow cannot be obtained without causing harmonics an additional pump is required The factory mounted circulator will provide adequate water flow for systems designed at a 20 F temperature drop and system pressure drop or head not exceeding that is shown below System Maximum Models Flow System Head When the total system head exceeds the availab
4. Code Part 1 CSA C22 2 No 1 Where required by the authority having jurisdiction the installation must con form to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Auto matically Fired Boilers No CSD 1 MOUNTING BASE Boiler should be mounted on level surface Each boiler is designed with a built in sub base approved for mounting the boiler on combustible flooring Boiler must NOT be installed on carpet flooring CARPET ES Fig 8196 0p NOTE The boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliance or to the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be in Stalled under the appliance The pan must not restrict air flow In addition the boiler shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc CLEARANCE REQUIREMENTS 1 Minimum Clearances From Combustible Materials Model Floor Front Back Right Left Top Flue 0030 0135 Comb Alcove 6 6 16 0042 0066 2 A front clearance of at least 24 is recommended for adequate service of burner tray and controls 3 Except for carpeted flooring boilers are certified for installation on combustible floors
5. HSI Burner Tray w Gas Valve Nat IID Burner Tray w Gas Valve Pro IID Burner Spacer Holddown Burner Burner Orifice Nat Sea Level Burner Orifice Pro Sea Level CONTROLS Adj Auto High Limit Staged Controller Electronic Fast ResponseSensor w Probe Probe Fast Response Roll Out Flue Sensor GAS VALVES Combination Valve Nat Combination Valve Pro Combination Valve Nat Combination Valve Pro Combination Valve Nat Combination Valve Pro Combination Valve Nat Combination Valve Pro Combination Valve Nat Combination Valve Pro Combination Valve Nat Combination Valve Pro HEAT EXCHANGER Std Honeywell Std Honeywell Std Robertshaw Std Robertshaw HSI Honeywell HSI Honeywell HSI Robertshaw HSI Robertshaw IID Honeywell IID Honeywell IID Robertshaw IID Robertshaw Heat Exchanger Cast Iron Heat Exchanger Brass Inlet Outlet Header Cast Iron Inlet Outlet Header Brass Return Header Cast Iron Retrun Header Brass Tube Bundle T Heat Exchanger Tube Baffle Kit Bolt Kit Header Gasket Sensor Well Well Retaining Clip CONTROL BOX Control Box Std Complete Control Box HSI Complete Control Box IID Lock Complete Transformer Relay DPST 003938F 004801F 004802F 004803F 004804F 005449F 005450F 003941F 301210 3 350347 3 350353 3 601003 003943F 601017 006021F 601013 601014 601009 601010 601015F 601016F 005095F 005096F 006957F 006958F 005461F 005462F 003945F 00394
6. e Remove screws 2 holding the staged controller f Remove upper access panel g Remove the wedge or retaining clip holding the sensing bulb in the control well in the in out header h Pull out the sensing bulb carefully from the control well i Remove the staged control with capillary from unit j Reverse above procedure to re install 6 REPLACEMENT PARTS LIST NOTE Tosupplythe correct part itis important that you state the model number serial number and type of gas when applicable Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag completely filled in with the heater serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty the part will be returned in kind or equal substitution freight collect Credit will not be issued RAYPAK INC 31111 Agoura Road Westlake Village CA 91361 4699 ROBERTSHAW STANDING PILOT 6 P Fig 9112 35 BOILERS MANUFACTURED AFTER AUGUST 11 1994 WITH SERIAL 9408116901 OR LATER HAVE IID IGNITION IN LIEU OF HSI IGNITION BURNER TRAY Burner Tray w oGas Valve Sea Level Burner Tray w Gas Valve Nat STG Burner Tray w Gas Valve Pro STG Burner Tray w Gas Valve Nat HSI Burner Tray w Gas Valve Pro
7. including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step For Honeywell Valve turn gas control counter clockwise gt For Robertshaw Valve Move gas control lever to On position GAS CONTROL KNOB SHOWN IN OFF POSITION GAS INLET 0 Fig 8199 0 ROBERTSHAW All Models Turn on all electric power to the boiler Set thermostat to desired setting If the boiler will not operate follow the instruction To Turn Off Gas To Boiler and call your service technician or gas supplier 26 TO TURN OFF GAS TO BOILER 1 Setthe thermostat at the lowest setting Turn off all the electric power to the boiler if service is to be performed For Honeywell Valve Turn gas control knob clockwise 3 Off Make sure knob rest against stop For Robertshaw Valve Push in and move gas control lever to Off position to HONEYWELL PILOT SYSTEM SHUTDOWNPROCEDURE To prevent the potential freezing damage to the heating system it is recommended that the following system shut down procedure be performed 1 Setthe room thermostat to OFF or the lowest setting 2 Turn off all electric switches to the boiler 3 Turnoffall gas valves supplying gas to the boiler Refer to operating instruction label on the boiler 4 Shutoffthe water supply to the boiler piping system loop 5 Open drain valve on the boi
8. Fig 8999 1 EXPANSION FEED TANK gt VALVE A PIPE PRESSURE LA RELIEF VALVE N 4 TODRAIN XI N COLD WATER INLET MULTIPLE ZONES WITH ZONE VALVES Fig 9000 1 13 ELECTRICAL WIRING The electrical power supply requirement for these boilers is 115 volts 60 Hz Field wiring connections and electrical grounding must comply with the local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 1987 Provide a sepa rate fused circuit from the main electrical panel to the boiler and a disconnecting means within sight of the boiler Remove the control box cover and make the power supply connections in the field wiring compartment See general location of controls drawing on page 18 The pump is supplied and factory wired to operate with the boiler The TH wire leads are for the room thermostat or zone valve connections WIRING DIAGRAM KEY Pink Connector The room thermostat should be installed in accordance with the manufacturer s instructions The thermostat heat anticipator should be set at 1 0 ampere automatic ignition and 0 60 ampere standing pilot for single zone installations For multi zone applications the heat anticipator setting should be based on the ampere load in the thermostat circuit NOTE If it is necessary to replace any of the original wiring it must be replaced with 105 C wire or its equivalent except 150 black wire must be replaced with 150 C w
9. K 120V HOT 24V a 120 Cj W 120V COMM GROUND WIRING TEMP TEMP BOX HI LIMIT SWITCH SWITCH e DK ep ADJ VENT ROLL OUT IGNITION MV 1 BK C M UE 2 y 6 ROBERTSHAW GAS PV p O e VALVE GND 4 G 24V 2v 6 E _ K MV 7 R VENT MV e HONEYWELI GAS C O ve VALVE sek 9 O BURNER TRAY HIGH TD TENSION IRAY BURNE REFER TO INSTALLATION OPERATING INSTRUCTIONS AND WIRING DIAGRAM SUPPLIED WITH VENT DAMPER VENT DAMPER OPTIONAL ON CANADIAN MODELS See page 14 wiring diagram key information 16 WIRING DIAGRAM INTERMITTENT IGNITION DEVICE IID MODELS 90 135 amp 180 29 We 6 e e PRO e e CONTROLLER FAST RESPONSE K TEMP SENSO RELAY OUTeT R 4 SEN INe BL R e e BL Ce y oe N L BK gt 120V HOT St 72 24V E 120V x Y Y W gt 120V COMM _ _ WIRING TEMP TEMP pe SWITCH SWITCH BOX 1 e e BK e e L VENT
10. are provided with a plug in connector that is compatible with the Honeywell D80D vent damper Similar type vent dampers made by other manufactur ers and design certified by a nationally recognized testing Agency under the ANSI 221 66 standards may also be used Follow the installation instructions furnished with the vent damper package The plug in connector can also be used with power venters Refer to the specific installation instructions supplied by the power vent manufacturer SPECIFICATIONS AND DIMENSIONS PIPING Lm fas 2 r 2 e 3530 r 812 a jes a ay vz rp 834 8 Coo 74 ea r ir 534 534 8 95 a ve 18 eia 614 380 nae 429 ee ie eia r H 0180 AUTOMATIC VENT DAMPER FIELD INSTALLED INLET 16 gt lt 4 2 3 4 TO DRAIN 33 4 THERMOSTAT CONN 9 Cae 18 ELECTRICAL CONN o ON OTHER SIDE 1 21 Y ww Y 3 INSTALLATION PROCEDURES CODE REQUIREMENTS Installation must be in accordance with local codes or inthe absence of local codes with the latest editions of the National Fuel Gas Code ANSI 2223 1 and the National Electrical Code ANSI NFPA 70 In Canada installations must conform with the current CAN CGA B149 1 or 2 and the Canadian Electrical
11. for leaks at full line pres sure Run system circulating pump for a minimum of 1 2 hour with boiler shut off Shut down entire system and ventall radiation units and high points in system piping Check all strain ers for debris Expansion tank water level should be atthe 1 4 mark and the balance of the tank filled with air when using Air X Tank Install flue collector jacket top and inspection pan els Install top holding screws Install draft diverter and vent piping if so equipped If gas piping was disconnected reconnect gas piping system and check for leakage using a soap solution Check for correct water pressure and water level in the system Make sure that system pump operates immediately on the call for heat The system is ready for operation Within two 2 days of start up recheck all air vents and expansion tank levels COMBUSTION CHAMBER REMOVAL To remove combustion chamber you must first have removed the heat exchanger Unbolt metal com bustion chamber retainer from top and remove com bustion chamber panels individually 5 TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components Installation and service personnel may be required by some states to be licensed Persons not qualified shall not attempt to install this equipment no
12. procedure to re install Pump Relay Replacement a Shut off electrical power to the boiler b Remove control cover screws and open control compartment C Disconnect wiring to the relay d Remove screws 2 holding relay e Reverse above procedure to re install Adjustable High Limit Control a Shut off electrical power to the boiler b Remove control cover screws and open control compartment c Thecontrolis factory setat 180 F Toresetto another setting use a small screw driver and turn dial clockwise lt ito lower the temperature or counter ciockwise to raise the setting d To replace the limit control disconnectthe wir ing connections e Remove screws 2 holding the limit control f Remove upper access panel g Remove the wedge or retaining clip holding the sensing bulb in the control well in the in out header h Pull out the sensing bulb carefully from the control well i Remove the limit control with capillary from unit j Reverse above procedure to re install 9 Fast Response Temperature Sensor Module Replacement a Shut off electrical power to the boiler b Remove control cover screws and open control compartment c Disconnect wiring connections to the board d Carefully pull out the control board from the nylon pin supports e Reverse above procedure to re install 10 Fast Response Temperature Sensor Probe Replacement a Shut off electrical power to the boil
13. 0135 39 0180 45 Location of the openings is the same as in the previous case that is within 12 inches of the top and within 12 inches of the bottom of the enclosure If horizontal ducts are used the area must be doubled and the duct area shall not be less than the area of the openings they connect and in no case shall the small est dimension be less than 3 inches VENTING CONNECTIONS These boilers have built in drafthoods Vent piping the same size or larger than the draft hood outlet is recommended however when the total vent height drafthood outlet to vent terminal is at least ten 10 feet the vent pipe size may be reduced by one size only as specified in Part 11 Note 2 and in Appendix G of the latest edition of the National Fuel Gas Code ANSI Z 223 1 As much as possible avoid horizontal runs of vent pipe and too many elbows If installation requires horizontal runs the vent pipe must have a minimum of 1 4 inch per foot rise and should be supported at notless than five foot intervals Maximum vent connector hori zontal length shall be 1 1 2 feet 18 inches for each inch of connector diameter as follows Boiler Size Vent Connector Max Horizontal Diameter Length FT 30 amp 42 4 6 66 amp 90 5 7 5 135 6 9 180 7 10 5 Gas Vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads We recommend use of insulated vent
14. 4 For un insulated hot water pipes maintain a 2 clearance or consult local authority having jurisdic tion COMBUSTION VENTILATION AIR WARNING Air supply to the boiler room must not be affected by mechanical exhaust vents located in other parts of the house such as kitchen or bathroom fans or attic blowers Mechanical exhaust vents may create a negative pressure condition in the boiler room that can become a hazard of asphyxiation explosion or fire CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the boiler Measures must be taken to prevent the entry of corrosive chemical fumes to the combustion and ven tilation air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and paint removers Other harmful elements may come from bleaches air fresh eners or mastics Vapors from these types of products can form corrosive acid compounds when burned in a gas flame The resulting acid condensate can damage or substantially reduce the life of the heater It may be necessary to provide outside air directly to the heater in order to avoid this problem 1 The boiler must be provided with adequate supply of air for proper combustion and ventilation in accor dance with Sec 5 3 of the latest edition of the National Fuel Gas Code ANSI Z223 1 or appli cable pr
15. 5F 004806F 004807F 004808F 005457F 005458F 004229F 301210 11 350080 11 350351 11 601003 600887 003943F 601017 006021F 004824F 004825F 004826F 004827F 005463F 005464F 004231F 004233F 004235F 004237F 004239F 004241F 004243F 003961F 004245F 004247F 800203B 350336 300203 004249F 004250F 005466F 650691 CALL OUT DESCRIPTION 42B 66B 135B 1808 B 004228F 004793F 004794F 004822F 004823F 005459F 005460F 004230F 301210 15 350080 15 350351 15 601003 600887 003943F 601017 006021F 004824F 004825F 004826F 004827F 005463F 005464F 004232F 004234F 004236F 004238F 004240F 004242F 004244F 003961F 004246F 004248F 800203B 350336 300203 004249F 004250F 005466F 650691 BOILERS MANUFACTURED AFTER AUGUST 11 1994 WITH SERIAL 9408116901 OR LATER HAVE IID IGNITION IN LIEU OF HSI IGNITION CALL OUT DESCRIPTION M MISCELLANEOUS 1 M PRV 30 PSI 2 M Deliming Kit 3 M T amp P Gauge 4 M Drain Valve 5 M Pump Inline Taco Pump Inline Grundfos 6 M Pump Cartridge Taco 7 M Wire Harness Std Wire Harness HSI Honeywell Wire Harness HSI Fenwal Wire Harness IID P PILOT 1 P Pilot Nat Std Pilot Pro Std Pilot Nat IID Pilot Pro IID 2 P Pilot Orifice Nat Std Pilot Orifice Pro Std Pilot Orifice Nat IID Pilot Orifice Pro IID 3 P Pilot Thermocouple 4 P Hot Surface Ignitor HSI 5 P Ignition Control HSI Honeywell Ignition Con
16. 8F 003950F 003951F 003954F 003955F 003959F 003961F 003963F 003965F 800203B 350336 300203 003966F 003967F 005465F 650691 003939F 004753F 004754F 004755F 004756F 005451F 005452F 003941F 301210 3 350079 3 350083 3 601003 003943F 601017 006021F 601013 601014 601009 601010 601015F 601016F 005095F 005096F 006957F 006958F 005461F 005462F 003945F 003948F 003950F 003951F 003954F 003955F 003959F 003961F 003963F 003965F 800203B 350336 300203 003966F 003967F 005465F 650691 FOR ALTITUDES ABOVE 2 000 FEET ABOVE SEA LEVEL CONSULT FACTORY T NUMBER OF TUBES VARIES FOR EACH MODEL SIZE 36 004513F 004761F 004762F 004763F 004764F 005453F 005454F 003942F 301210 7 35034717 350353 7 601003 003943F 601017 006021F 601013 601014 601009 601010 601015F 601016F 005095F 005096F 006957F 006958F 005461F 005462F 003946F 003949F 003952F 003953F 003956F 003957F 003960F 003961F 003964F 003965F 800203B 350336 300203 003966F 003967F 005465F 650691 003940F 004769F 004770F 004771F 004772F 005455F 005456F 003942F 301210 7 350080 7 350350 7 601003 600887 003943F 601017 006021F 601013 601014 601009 601010 601015F 601016F 005095F 005096F 006957F 006958F 005461F 005462F 003946F 003949F 003952F 003953F 003956F 003957F 003960F 003961F 003964F 003965F 800203B 350336 300203 003966F 003967F 005465F 650691 004227F 00480
17. 903F 004308F 600003 003976F 601005F 601129F 004935F 306239 400275 002654B R REFRACTORY 1 R Refractory Kit 003977F 003977F 003978F 003978F 004259F 004260F S SHEETMETAL 1 S Jacket Top 2 5 Flue Collector 3 S Access Panel 4 S Control Panel Cover V VENTING 1 V Drafthood 2 V Vent Damper GAS CONVERSION KITS HONEYWELL GAS VALVE Standing Pilot Nat to Pro Standing Pilot Pro to Nat Hot Surface Ignition Nat to Pro Hot Surface Ignition Pro to Nat IID Nat to Pro Honeywell IID Pro to Nat Honeywell ROBERTSHAW GAS VALVE Standing Pilot Nat to Pro Standing Pilot Pro to Nat Hot Surface Ignition Nat to Pro Hot Surface Ignition Pro to Nat IID Nat to Pro Robertshaw IID Pro to Nat Robertshaw IGNITION CONTROL CONVERSION KIT Robertshaw HSI Control to Fenwal HSI Control 003979F 003981F 003983F 003984F 003985F 004709 30B 004269F 004270F 004271F 004272F 005471F 005472F 004289F 004290F 004291F 004292F 005479F 005480F Gas Conversions are to be done only by a Qualified Agency 003979F 003981F 003983F 003984F 003985F 004709 42B 004273F 004274F 004275F 004276F 005473F 005274F 004293F 004294F 004295F 004296F 005481F 005482F 004678F 003980F 003982F 003983F 003984F 003986F 004710 66B 004698F 004699F 004700F 004701F 005475F 005476F 004702F 004703F 004704F 004705F 005483F 005484F 003980F 003982F 003983F 003984F 003986F 004710
18. Carbide Tip Wire Brush Fig 8154 Another method is to remove the heat exchanger ream tubes and immerse heat exchanger in non inhib ited de scale solvent HEAT EXCHANGER REMOVAL 1 Shutwater gas and electricity off close valves and relieve pressure remove relief valve Remove side inspection panels 2 Remove top holding screws 3 Remove draft diverter lift and remove top and flue collector on stack type models Remove inspection panels 4 Loosen bolts and disconnect flange nuts on inlet outlet header loosen union s at gas pipe and slide boiler away from piping until studs clear the heater 5 Remove heat exchanger corner brackets 29 Remove combustion chamber clips at the four corners of the heat exchanger Lift heat exchanger straight up using caution not to damage refractory HEAT EXCHANGER RE ASSEMBLY 1 Heat exchanger water header O rings should be replaced with new ones Install inlet outlet and return water headers and install header retainer nuts and torque nuts evenly Replace V baffles Install thermostat sensing bulbs in header wells and replace bulb retaining clips Install inlet and return pipes in water headers using pipe thread sealant Install water pressure relief valve flow switch and low water cutoff devices if so equipped Open water supply and return shut off valves Fill boiler and water piping system with water Check 30 10 11 13 boiler and piping system
19. Catalog No 2100 50P Effective 11 01 99 Replaces 6 01 99 OPERATING AND INSTALLATION INSTRUCTIONS Models OO30B 0042B OO66B 0090B 0135B 0180B Type H RESIDENTIAL BOILERS FOR YOUR SAFETY Do notstore 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 WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury orloss of life Refer to the user s information manual provided with this boiler Installation and service must be performed by a qualified installer service agency or the gas supplier FOR YOUR SAFETY 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 THISMANUAL SHOULD BEMAINTAINED IN LEGIBLE CONDITION AND KEPT ADJACENT TO THE BOILER OR KEPT IN ASAFE PLACE FOR FUTURE REFERENCE P N 240488 Contents 3 1 RECEIVING EQUIPMENT 3 2 GENERAL SPECIFICATIONS AND DIMENSIONS 4 3 INSTALLATION PROCEDURES 4 Code Requirements 4 Mounting Base 4 Clearance Requirements 4 Combustion Ventilation Air 5 Venting Con
20. L EET GAS VALVE TOTAL FULL LOAD AMPS SHOULD MOT ESCEED 12 AMPS 20 Fig 2223 2e WIRING DIAGRAM Standing Pilot With Low Water Cut Off Device VENT DAHFER DAHFER FROEE FAST RESFONSE zEHZOF ER 1200 HOT SHITCH Hie COMM HI LIMIT EHITCH ADJ CUENT gt I SWITCH STAGED R Y t ROLL CONTROL OLIT 3 1 ER GAS VALVE STAGE A E Fig 2223 1 Note Low water cut off LWCO and system switch supplied by others WIRING DIAGRAM IID Units With Low Water Cut Off Device FFEOEE FAST RESPONSE 08 ER e 120 HOT HITCH 200 COMM T EHE HI LIMIT SWITCH SWITCH ek fe telex fart CROLL OUT FILIJ ROBERT SHAH GAS HOHE HELL VALVE Fig 2357E Note Low water cut off and system switch supplied by others 21 4 SERVICING PROCEDURES CIRCULATOR GENERAL LOCATION OF CONTROLS VENT SENSOR CONTROL BOX COMPONENT LOCATIONS MODELS 135 amp 180 BYPASS LINE 2 Staged Controller TEMPERATURE AND PRESSURE GAUGE 2 STAGED CONTROLLER MODEL 90 ONLY PRESSURE RELIEF VALVE RELAY ADJUSTABLE HIGH LIMIT FIELD WIRING COMPARTMENT FAST RESPONSE TEMPERATURE SENSOR IGNITION MODULE Wee H v T iW Fast Response Ignition Module INE N A E Temperature Auto Ign
21. LL GAS Do not try to light any appliance Do not touch any electric 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 e lf you cannot reach your gas supplier call the fire department C Use only your hand to push in move or turn the gas control knob or lever Never use tools If the knob or lever will not push in move or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do notuse this boiler if any part has been underwa ter Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water FOR INTERMITTENT IGNITION IID WITH HONEY WELL OR ROBERTSHAW GAS VALVE For All Mod STOP Read the safety information above set the thermostat to the lowest setting Turn off all electric power to the appliance This boiler is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET abre ees Fig 8201 0 HONEYWELL Models 30 90 5 For Honeywell Valve Turn gas control knob clockwise to Off For Robertshaw Valve Push in and move gas control lever to Off position Wait 5 minutes to clear out any gas Then smell for gas
22. Pitch H Min Ft Flat to 6 12 1 0 6 12 to 7 12 1 23 Over 7 12 to 8 12 1 5 Over 8 12 to 9 12 2 0 Over 9 12 to 10 12 2 Over 10 12 to 11 12 2425 Over 11 12 to 12 12 4 0 Over 12 12 to 14 12 5 0 Over 14 12 to 16 12 6 0 Over 16 12 to 18 12 7 0 Over 18 12 to 20 12 7 5 Over 20 12 to 21 12 8 0 10 OR LESS VENT CAP 5 MIN WARNING These boilers must not be connected into any portion of mechanical draft systems operating under positive pressure To do so may cause the flue Fig 8191 0 products to be discharged into the living space causing serious health injury For connections to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI 2223 1 or applicable provisions of the local building codes COMMON VENTS Manifolds that connect more than one boiler to a common chimney must be sized to handle the combined load Consult available guides for proper sizing of the manifold and the chimney At no time should the area be less than the area of the largest outlet Fig 9001 At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remain ing connected to the common venting system are not operation a Seal any unused openings in the common venting system Visually inspect
23. ROLL OUT BK IGNITION R M Ed BK BK e C V 12 Y e e UE E O i 4 G GAS VALVE 217 y 2 STAGE 24V 6 L VEN TH W 7 R DAMPER SPK PILOT Ll HIGH m TENSION REFER INSTALLATION OPERATING INSTRUCTIONS AND WIRING DIAGRAM SUPPLIED WITH VENT DAMPER VENT DAMPER OPTIONAL ON CANADIAN MODELS Fig 2358 see page 14 wiring diagram key information 17 WIRING DIAGRAM Single Zone Taco Valve Fig 2228e WIRING DIAGRAM Dual Zone Taco Valve rue sdb TOUR a k LI k 1 5 Fig 2229e NOTE Maximum three 3 zone valves per one 1 40 VA transformer WIRING DIAGRAM Dual Zone Honeywell Valve Fig 2230e Maximum five 5 zone valves per one 1 40 VA Transformer WIRING DIAGRAM System with 3 Zone Pumps ig 2232e NOTE Check VA rating of each relay coil Total load must not exceed VA rating of transformer WIRING DIAGRAM Power Vent System w Zone Valve Taco Zone Valve Fig 2233e x ehil y Ims Lu L EX ee Fig 2234e WIRING DIAGRAM Primary Secondary Pumping System Honeywell Zone Valve DAHFER FLUG FEH HALE FROEE PRIMARY FUHF FAST RESFONSE 7 120 HOT ZHL 1 Y COMM I TT GROUND HIRING i eee F Y t ROLL CONTRO
24. anual valves relight standing pilots and reset the safety switch the burner should restart INSPECTION PROCEDURES BURNERS Clean main burners and air louvers of dust lint and debris Keep boiler area clear and free from combus tibles and flammable liquids Do not obstruct the flow of combustion and ventilating air Make visual check of burner and pilot flame Yellow flame indicates clogging of air openings Lifting or blowing flame indicates high gas pressure Low flame indicates low gas pressure 100000000 E oos Ee Fig 8144 MAIN BURNER FLAME NOTE Modulating burner flame varies in height from approximately 1 4 at low fire to approximately 4 in high fire 28 Fig 8964 PILOT BURNER FLAME STG PILOT UNITS NORMAL INSPECTION PROCEDURES Firstand third month after initial startup and then on an annual basis If problems are found refer to Trouble Shooting Guide for additional directions 1 Remove top of boiler and inspect heat exchanger for soot and examine venting system 2 Remove rear header and inspect for scale depos its 3 Inspect pilot and main burner flame and firing rate 4 Inspect and operate all controls and gas valve 5 Visually inspect system for water leaks 6 Oil pump motor and bearing assembly if oil cups are provided 7 Check flow switch paddle 8 Clean room air intake openings to assure adequate flow of combustion and ventilation air 9 Keep boiler area clear and fr
25. damper operation as follows 1 When the boiler is off check that the vent damper position indicator points to the closed position below DAMPER POSITION INDICATOR DAMPER POSITION INDICATOR NOTE To place vent damper in the open position to allow burner operation do the following Turn the power off turn the damper blade to fully open position arrow facing same direction as vent pipe Turn power on ig 8181 0 DAMPER OPEN DAMPER CLOSED Gia katie pal aus asta roars digas es ipse tete emensus c NS GLOSED POSITIONS 2 Turn the thermostat or controller up to call for heat and check that the vent damper indicator points to the open position below 3 Turn the thermostat or controller down again and check that the vent damper position indicator returns to the closed position THE VENT DAMPER MUST BE INSPECTED AT LEAST ONCE A YEAR BY A TRAINED EXPERIENCED SERVICE TECHNICIAN THE NAME OF THE PERSON WHO ORIGINALLY INSTALLED YOUR VENT DAMPER IS SHOWN ON THE INSTALLATION LABEL DAMPER MUST BE IN OPEN POSITION WHEN BOILER MAIN BURNERS ARE OPERATING FLAIR DAMPER SYSTEM SCHEMATIC LEGEND LADDER DIAGRAM M Damper motor Lg 9 R Relay ES End Switch SS1 N C Safety switch SS2 N O Safety switch contacts TR Transformer 120 24V HL High limit GV 24V gas Valve TH Thermostat heating low voltage ES J Jumper SS R Note Circuit shown with damper in closed R ZZ 1 posit
26. ee from combustible materials gasoline and other flammable vapors and liquids Should be checked monthly Takes approximately 15 minutes LOW WATER CUT OFF WHEN INSTALLED The low water cut off automatically shuts down burner whenever water level drops below probe 90 second time delay prevents premature lockout due to temporary conditions such as power failure or air pock ets Flush float type devices at beginning of each heating season PROCEDURE FOR CLEANING FLUE GAS PASSAGE WAYS soot will clog areas behind fins and cause eventual tube failure Any sign of soot at base of burners or around outer jacket indicates a need for cleaning 1 Lift off draft hood and flue collector by removing bolts and screws 2 Remove V baffles from heat exchanger 3 Remove burner tray see Burner Drawer Removal 4 Takegarden hose and wash heat exchanger mak ing sure soot is removed from between fins Avoid excessive water against refractory 5 Reassemble when boiler is fired some steam will form from wet refractory This is normal NOTE n extreme cases it may be necessary to remove the heat exchanger completely for cleaning The simplest method is steam cleaning at a local car wash DO NOT WIRE BRUSH RAYPAK TUBE CLEANING KIT CAUTION Soot is combustible so exercise extreme care BURNER DRAWER REMOVAL 1 Shut power and gas supply to the boiler Dis connect union s and pilot tubing when present then loo
27. er b Shut off water supply to the boiler and open drain valve to remove water to the sensor probe level Remove control cover screws and open control compartment Disconnect wire leads from control board Remove upper access panel Remove sensor probe from in out header Reverse above procedure to re install O 0 ee 9 11 Circulator Replacement a Shut off electrical power to the boiler b Shut off water supply and open drain valve to remove water in the piping at the pump level CAUTION 7o avoid damage to electrical components keep water from getting into the control compartments and gas valve C Disconnect wiring and conduit connections to the pump d Disconnect the by pass tube connections to the inlet flange e Remove the nuts and bolts at the inlet and outlet flanges Remove old gaskets f Remove the pump g Reverse the above procedure to re install Use new gaskets and make sure they are seated properly when tightening the nuts and bolts 12 2 Staged Controller Models 90 135 amp 180 a Shut off electrical power to the boiler b Remove control cover screws and open con trol compartment c The control is factory set at 160 F To reset to another setting use a small screw driver and turn dial clockwise 2 to lower the temperature or counter clockwise amp to raise the setting d Toreplace the staged controller disconnect the wiring connections
28. erator and energizes the second main valve operator which opens the second main valve This allows gas to flow to the burners where it is ignited by the pilot burner flame When the thermostat is satisfied the valve operators de energized shutting off the pilot and main burners and also the circulator 22 START UP PROCEDURES SECTION 1 Filling the System Fill system with water Purge all air from the system using purge valve sequence After system is purged of air lower system pressure Open valves for normal system operation fill system through feed pressure regulator to minimum 12 PSI Manually open air vent onthe compression tank until water appears then close vent On multiple zone systems purge each zone sepa rately Isolate the other zones while one zone is being purged of air Flush system before putting into operation to as sure that foreign material does not damage pump seals SECTION 2 Checking the Circulator Before lighting the boiler and after system is filled make sure that circulator is operating properly Manual gas valve should be off By adjusting the wall thermo stat to the maximum setting circulator should run immediately and allow water to flow through the boiler and the entire system NOTE Circulator motor supplied with the boiler does not require lubrication CAUTION In case of a prolonged power failure during freezing weather conditions boiler and piping system must be drained completely
29. f ignition module locks out reset by interrupt ing power to boiler 5 Check for blockage of venting system or disconnected vent piping After problem is corrected push button to reset or replace single use type vent switch 6 Check for blockage of flue or sooted heat exchanger After problem is corrected push button to reset or re place single use type roll out switch 7 Setting may be too low Check water flow and adjust setting to obtain 20 30 F temperature rise 8 Red LED on circuit board will be ON to indicate a loose sensor connection or a shorted sensor Check terminal connectors or replace sensor as re quired NOTE Red LED will also be ON if sensor temperature exceeds 300 F or drops below 20 F It will turn OFF when sensor temperature returns to the proper range Yellow LED will be ON if temperature exceeds 240 F It will turn off when sensor temperature falls below 180 F When either Red or Yellow LED is ON boiler will be shut down 9 Check voltage across output and common terminals If no 24V is pres ent replace board 3 Pilot Outage Standing pilot models 4 Yellow lazy flame 5 Sooting 10 Defective ignition module or defective gas valve 1 Too low or too high gas pressures 2 Restricted pilot 3 Weak thermocouple 1 Too low gas pressure 2 Restricted burner intake ports 3 Restricted gas line 1 Insufficient combustion air 2 Improper venting 3 Severe yel
30. gnition equipped system the energy savings of the vent damper can be improved by plugging the hole in the vent damper blade using the knockout plug Part No 105612R provided in the parts envelope Hole in Vent Damper Blade Closed Position 7 ES C 4 Ns e Fig 8994 DO NOT plug the hole if installing the vent damper on a continuous pilot system as this will create a hazardous condition HORIZONTAL INSTALLATION FLOW 4 _ ODO T TO BOILER VENT DAMPER TO CHIMNEY NO VERTICAL INSTALLATION INSTALL VENT TO CHIMNEY DAMPER WITH ACTUATOR TO SIDES ACTUATOR MAY BE AT BOILER INSTALLED IN ANY OF VENT ONLY DO VENT NOT MOUNT ABOVE OR DAMPER BELOW VENT DRAFT POSITION ON VERTICAL HOOD PIPE 9 u 2 gt lt x lt z 5 a INSTALLING THE VENT DAMPER HORIZONTAL amp VERTICAL VENTS i 3 7 CABLE Fig 152323 D80D GENERAL WIRING DIAGRAM INSTALL THE VENT DAMPER TO SERVICE ONLY THE SINGLE APPLIANCE FOR WHICH IT IS INTENDED IF IMPROPERLY INSTALLED A HAZARDOUS CONDITION SUCH AS AN EXPLOSION OR CARBON MONOXIDE POISONING COULD RESULT VENT DAMPER NORMAL OPERATION SUMMARY For safe efficient operation the vent damper and all flue product carrying areas of the appliance must be checked annually with particular attention given to deterioration from corrosion or other sources Check vent
31. ion no call M for heat 24 V AG Fig 9002 Fig 9003 GAS SUPPLY CONNECTIONS The inlet gas connection of the boiler gas valve is 1 2 Provide an adequate gas piping supply line no smaller than 1 2 according to the chart below Maximum Equivalent Pipe Length Feet 1 2 Pipe 3 4 Pipe 1 Pipe 1 1 4 Pipe MODEL PRO NAT PRO NAT PRO NAT PRO 0030 amp 0042 0066 60 160 175 Gas piping must have a sediment trap ahead of the boiler gas controls and a manual shutoff valve located outside the jacket All gas piping should be tested after installation in accordance with local codes Manual Valve Sediment Trap Gas Valve Fig 8192 0 CAUTION The boiler and its manual shut off valve must be disconnected from the gas supply during any pres sure testing of that system at test pressures in excess of 1 2 psig 3 45 KPA Dissipate test pressure in the gas supply line before reconnecting the boiler and its manual shut off valve to gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVER PRESSURED GAS VALVES ARE NOT COVERED BY WARRANTY The boiler and its gas connections shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use open flame NOTE Do not use teflon tape on gas line pipe thread A flexible sealant suitable for use with Natural and Propane gases is recommended GAS PRESSURE SPECIFICATIONS Inches
32. ire or its equivalent See wiring diagram key for 150 C wire indication Blue Connector CABINET GROUND WRE NUT C TERMINAL 9 THERMOSTAT Fig 8096 2 IRING DIAGRAM STANDING PILOT 24 V 2 STAGE MODELS 90 135 amp 180 ee B 120 HOT B 120V COMM B GROUND WIRING BOX e Be e R e CONTROLLER B 1 GAS VALVE SWITCH 2 STAGE ROLL OUT B Fig 2223e See page 14 wiring diagram key information 15 WIRING DIAGRAM INTERMITTENT IGNITION DEVICE IID MODELS 30 42 amp 66 PROBE PUMP FAST RESPONSE BK TEMP SENSO RELAY OUTe R ee BK SEN IN BL R e ec TRANS uy eoe p TH BL e C
33. ition Only AUTO IGNITION ONLY Sensor TRANSFORMER ROLL OUT SENSOR GAS VALVE Fig 8195 4 SEQUENCE OF OPERATION INTERMITTENT IGNITION DEVICE IID Boilers equipped with the IID system will automatically light the pilot burner first and then the main burner each time there is a call for heat from the room thermostat Whenever the room thermostat is calling for heat the circulator supplied with the boiler will be energized and should be running The ignition control module will also be energized to initiate the pilot ignition by opening the first main valve pilot At the same time the electronic spark generator in the module produces a high voltage spark pulse output that lights the pilot burner If the pilot burner does not light the module will not energize the second main valve and the burners will not light Ignition spark continues only until the timed trial for ignition period ends Then the module goes into safety shutdown or lockout Lockout de energizes the first main valve operator and closes the first main pilot valve in the gas control stopping pilot gas flow The ignition control system must be reset by setting the thermostat below room temperature for one minute or by turning off power to the module for one minute When the pilot flame is established flame rectification circuit is completed between the sensor and burner ground The flame sensing circuit in the module detects the flame current shuts off the spark gen
34. le head pressures a primary secondary pumping system is recommended The minimum boiler operating temperature should be 105 F When operating at low tempera ture applications DT temperature rise must be 20 F or less Propylene glycol solution is commonly used in the heating system when freeze protection is required This will affect the system design and pump performance As a rule of thumb 50 solution of propylene glycol will require the system flow GPM to increase by 14 and the system head Ft Wtr by 23 in order to maintain the same heat transfer load systems with multiple zones may require an additional circulator Consult manufacturers data for valve pressure drops When an indirect water heating system is used it is recommended that a separate circulator be installed to meet the required flow and pressure drop conditions of the indirect water heater We recommend that the make up water from the cold water line have a check valve gate valve and feedwater regulator set at 12 psig Install unions and gate or ball valves at inlet and outlet connections at the boiler to facilitate servicing The pressure relief valve is mounted on the boiler and must be piped to a drain We recommend that all high points be vented and that purge valves be installed A boiler installed above radiation level must be provided with alow water cutoff device See page 21 for wiring hook up The boiler when used in connection with a refrigeration sy
35. ler to remove water from the boiler and the piping circuits Note It may be necessary to open the purge valves and or manual air vents to facilitate complete drainage of water from the heating system CAUTION Should overheating occuror the gas supply FOR AUTOMATIC IGNITION SYSTEMS fails to shut off DO NOT turn off or disconnect the IntermittentlIgnition IID electrical supply to the pump Instead shut off the gas supply at a location external to the boiler Failure to 1 observe this precaution may aggravate the overheated condition resulting in possible damage to the boilerand 2 injury to the user SECTION 4 Testing the Ignition Safety Shutoff The ignition system safety shutoff must be tested by conducting the following method of tests For Standing Pilot Systems a With the main burners on remove the pilot adjustment cover screw 3 NOTE There is no pilot adjustment cover on 4 Robertshaw 7200 gas valve b Inserta small slot screw driver and turn the 5 adjustment screw clockwise M until pilot flame goes out Note and count number of turns made c Gas valve will shut off main burners after about three 3 minutes End of test If the gas valve Will not shut off follow the instructions To Turn Off Gas To Boiler and call service technician or your gas supplier d Return pilot adjustment screw counter clock wise same number of turns as in step b Pilot Adjustment Fig 8935 0
36. low burner flames 32 10 Before module goes into alock out check voltage across MV and MV PV If no 24V is present replace module If 24V is present replace gas valve 1 Adjust inlet gas pressure as shown on rating plate 2 Clean pilot orifice 3 Replace thermocouple 1 Adjust manifold pressure as shown on rating plate 2 Clean burners free of debris or in sects 3 Clean gas line or increase gas line piping 1 Refer to installation instructions re garding combustion air require ments 2 Refer to installations instructions 3 See yellow flame section above ADJUSTMENTS REPLACEMENTS OF COMPONENTS DANGER SHOCK HAZARD Make sure electrical power to the boiler is disconnect ed to avoid potential serious injury or damage to com ponents 1 Gas Valve Replacement a Shut off electrical power and gas supply to the boiler b Remove gas piping to gas valve inlet c Disconnect wiring connections pilot tubing when equipped d Remove screws 2 holding the burner tray e Slide burner tray out f Remove gas valve bracket screws and bracket g Unscrew gas valve from gas pipe h Reverse above procedure to re install 2 Pilot Burner Cleaning or Replacement Standing Pilot a Shut off electrical power and gas supply to the boiler Disconnect gas piping to gas valve Disconnect wiring connections to gas valve Remove screws 2 holding the burner tray Slide burner tray out Remove sc
37. nections 7 Vent Damper Installation 10 Gas Supply Connections 10 Water Connections amp System Piping 14 Electrical Wiring 22 4 SERVICING PROCECURES 22 General Locations of Controls 22 Sequence of Operation 23 Start Up Procedures 28 Safe Shutdown Test 28 Normal Inspection Procedures 29 Repair Section 31 5 TROUBLE SHOOTING GUIDE 33 Adjustments Replacements of Components 34 6 REPLACEMENT PARTS LIST These instructions are provided to assure the proper installation and operation of Raypak boilers Should questions arise regarding the specifications installa tion operation or servicing of these boilers we suggest that the local Sales representative or the factory be consulted 1 RECEIVING EQUIPMENT On receipt of your equipment it is suggested that you visually check for external damage to the carton If the carton is damaged it is suggested that a note be made on the Bill of Lading when signing for equipment Remove the boiler from the carton and if it is damaged report the damage to the carrier immediately Be sure that you receive the number of packages indicated on the Bill of Lading Claims for shortages and damages must be filed with carrier by consignee Purchased parts are subject to replacement only under the manufacturer s warranty Debits for defective replacement parts will not be accepted and defective parts will be replaced in kind only per our standard warranties When ordering pa
38. on when released stop and immediately call your service technician or gas supplier If the pilot does not stay lit after several tries move the gas control lever to OFF and call your service technician or gas supplier 9 Stand to the side of the boiler and move the gas control lever counter clockwise to 25 10 Turn on all electric power to the boiler 11 Set the thermostat to the desired setting TO TURN OFF GAS TO THE BOILER Models 90 135 amp 180 1 Set the thermostat to the lowest setting 2 Turn off all electric power to the boiler 3 Push in and move gas control lever counter clockwise z to OFF position Do not force FOR AUTOMATIC IGNITION MODELS Please read carefully and understand the following safety information before operating the boiler WARNING f you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This boiler is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand or this boiler may not have a pilot and is equipped with a hot surface ignition device which auto matically lights the burners Do not try to light the burners by hand B BEFORE OPERATING smell all around the boiler area for gas Be sure to smell next to the floor because some gases are heavier than air and will settle on the floor WHAT TO DO IF YOU SME
39. ovisions of the local building codes 2 When the boiler is installed in a confined space such as a utility room or closet Models 0030 0042 and 0066 only where all air is supplied from inside the building the boiler room must be provided with two openings each one having a minimum net free area in square inches as follows Model 0030 0042 amp 0066 Sq In of Free Area 100 One opening shall be within 12 inches of the top and the other opening within 12 inches of the floor If additional gas appliances are installed in the same space the total input of all gas appliances installed in the same space must be considered in the calculation Refer to Sec 5 3 5 of the latest edition of the National Fuel Gas Code for additional requirements 1 2 S NOTE f louvers grills or screens are used on the openings obtain the net free area from their supplier or manufacturer f the design free area of a louver is not known nor available it shall be assumed that wood louvers will have 20 25 percent free area and metal louvers will have 60 75 percent free area as shown in oec 5 3 5 National Fuel Gas Code Fig 8198 0 3 Ifthe boiler room is located against an outside wall and air openings can communicate directly with the outdoors the two openings on the outside wall must each have a net free area in square inches as follows Model Sq In Of Free Area 0030 amp 0042 12 0066 18 0090 24
40. pipe spacer through the roofs and walls For protections against rain or blockage by snow the vent pipe must terminate with a listed vent cap which complies with the local codes or in the absence of such codes to the latest edition of the National Fuel Gas Code ANSI Z 223 1 The discharge opening must be a minimum of two feet vertically from the roof surface and at least two 2 feet higher than any part of the building within ten 10 feet Vent stack shall be at least five 5 feet in vertical height above the drafthood outlet The ventcap location shall have a minimum clearance of four 4 feet horizon tally from and in no case above or below unless a 4 foot horizontal distance is maintained from electric meters gas meters regulators and relief equipment The weight of the vent stack or chimney must not rest on boiler draft hood Support must be provided in compliance with applicable codes The boiler top and draft hood must be readily removable for maintenance and inspection Vent pipe should be adequately sup ported to maintain proper clearances from combustible construction Type B double wall or equivalent vent pipe is recommended However single wall metal vent pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI Z 223 1 Lowest Discharge Listed Cap Opening Listed Gas Vent J Roof Pitch is X 12 Min Minimum Height from Roof to Lowest Discharge Opening Roof
41. r attempt repairs according to these instructions PROBLEM S 1 When room thermostat is turned on boiler does not operate 2 When room thermostat is calling for CAUSE S 1 No power to the boiler 2 Defective room thermostat or discon nected wire in thermostat circuit 3 Defective transformer 4 Defective pump relay 5 Defective pump SOLUTION S 1 Check circuit breakers disconnect switch Make sure power is on 2 Check continuity on thermostat and wiring circuit Replace thermostat or repair wiring connections 3 Check secondary voltage If no 24V replace transformer 4 Check relay coil or contacts Replace as required 5 Replace pump 1 Light pilot burner Follow lighting 1 For Standing pilot models pilot burner heat pump is on but burners will not turn on not lighted 2 If pilot burner will not stay lighted thermocouple or gas valve may be defective 3 Gas knob in Pilot position 4 For automatic ignition models gas valve knob is in off position 5 Vent switch is open 6 Roll out switch is open 7 High limit is open 8 Fast Response Temperature Sensor probe is defective 9 Fast Response Temperature sensor board is defective 31 instructions on rating plate 2 Check thermocouple MV generation If less than 25MV open circuit re place thermocouple If between 25 35 MV replace gas valve 3 Turn knob to ON position 4 Turn gas knob to ON I
42. re or explosion D Donotusethis boilerifany parthas been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water 24 FOR STANDING PILOT MODELS WITH ROBERT SHAW GAS VALVE 2 STAGE OPERATION Models 90 135 amp 180 STOP Read the safety information set the thermostat to the lowest setting Turn off all electric power to the boiler Push in and move gas control lever counter clockwise amp to OFF position p I GAS CONTROL LEVER SHOWN IN OFF POSITION Fig 8934 0 GAS INLET NOTE Lever cannot be moved from ON to OFF unless lever is pushed in slightly Do not force 5 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 6 Locate pilot mounted on the right side of the burner drawer and right of first burner ig 8083 2 Fig 8041 2 HONEYWELL PILOT ROBERTSHAW PILOT 7 Move control lever clockwise Sto SET position and immediately light pilot with a match 8 Hold lever in SET position for 1 2 minute after pilot is lit Release lever and it will spring back to PILOT position Pilot should remain lit If it goes out repeat steps 4 through 8 If lever does not spring back to PILOT positi
43. resizing any portion of the common venting system the com mon venting system should be resized to ap proach the minimum size as determined using the appropriate tables in Part 11 and in Appendix G of the National Fuel Gas Code ANSI Z 223 1 and CAN CGA B149 1 M91 b e VENT DAMPER INSTALLATION LOCATION The vent damper supplied with each boiler must be located in the vent so that it serves only the appliance for which it is intended If improperly installed a hazardous condition such as an explosion or carbon monoxide poison ing could result Make certain that it is mounted in an accessible location at least 6 in 152 4 mm from any combustible material or the heat exchanger and that the position indicator is in a visible location The vent damper must be installed at the appli ance draft hood and without modification of the draft hood To connect the vent damper wiring to the boiler wiring remove the jumper from the circuit plug See wiring diagram Connect the damper circuit plug to the boiler circuit plug Fig 8642 MOUNTING On vertical vents the vent damper may be mounted with the actuator in any position On horizontal vents do not mount the actuator either directly above or directly below the vent pipe mount the vent damper actuator to the side of the vent The vent damper is set up for a continuous pilot system If the vent damper is installed on an Intermittent Pilot or Hot Surface I
44. rew holding pilot lighter tube g Remove screws 2 holding pilot bracket on the burner tray h Disconnect thermocouple and pilot tubing from the gas valve i Remove pilot burner from pilot bracket j Remove pilot orifice and blow away lint or dirt Clean with wire or small brush NOTE Make sure pilot orifice is clear but do not enlarge the hole k Reverse above procedure to re install b d e f HONEYWELL PILOT ROBERTSHAW PILOT PILOT PILOT AIR OPENING ORIFICE ORIFICE Fig 8045 2 Fig 8102 1 33 Flame Roll out Switch Replacement a Shut off electrical power to the boiler b Remove wiring connections to switch c Remove screws 2 holding the switch d Reverse above procedure to re install Vent Thermal Switch Replacement a Shut off electrical power to the boiler b Remove wiring connections to switch c Remove the screws 2 d Reverse above procedure to re install Ignition Module Replacement a Shut off electrical power to the boiler b Remove control cover screws and open control compartment C Disconnect wiring connections to module d Remove screws 2 holding module e Reverse above procedure to re install Transformer Replacement a Shut off electrical power to the boiler b Remove control cover screws and open control compartment C Disconnect wiring connections from trans former leads d Remove screws 2 holding transformer e Reverse above
45. rts you must specify Model and serial Number of boiler When ordering under warranty conditions you must also specify date of installation Raypak recommends that this manual be re viewed thoroughly before installing your Raypak Boiler If there are any questions which this manual does not answer please contact your local Raypak representative 2 GENERAL SPECIFICATIONS The Raypak hydronic boilers are design certified by the American Gas Association and tested under the requirements of the American National Standard ANSI 221 13 Each boiler has been constructed and pressure tested in accordance with the requirements of Section IV of the American Society of Mechanical Engineers Code and factory fire tested The boilers are designed for indoor installation with a built in drafthood and a built in sub base for combus tible flooring Models are available with standing pilot or with intermittent ignition device 1 1 D The boilers are equipped with the following components water circulation pump pressure relief valve temperature pressure gauge adjustable high limit switch drain valve fast response temperature sensor 40 VA trans former pump relay vent thermal switch flame roll out switch and redundant combination gas valve for use with either natural or propane gases Two staged gas valve 50 firing on 1st stage is standard on models H 0090 H 0135 and H 0180 The automatic ignition models and some standing pilot models
46. sen and remove burner hold down screws 2 Disconnect wires at gas valve and slide burner drawer out MAIN BURNER AND ORIFICE REMOVAL 1 Remove screws and burner hold down bracket NOTE If the heat exchanger is sooted badly the burner hold down bracket and spacer can become distorted from direct flame impingement and this usu ally necessitates replacement of these parts 2 Lift burners from slotted spacer and slide from orifices Clean with a wire brush 3 Orifices usually do not need to be replaced To clean run either copper wire or wood through orifice Do not enlarge hole To remove orifice use a socket wrench and remove the manifold DO NOT overtighten when reinstalling QJ 7 0 2 le Extension Pieces 5 REPAIR SECTION TUBE CLEANING PROCEDURE TYPICAL Establish a regular inspection schedule the fre quency depending on the local water condition and severity of service Do notlet the tubes clog up solidly Clean out deposits over 1 16 in thickness The boiler may be cleaned from the side opposite the water connections as shown without breaking pipe connections It is preferable however to remove both headers for better visibility through the tubes and to be sure the residue does not get into the system Note that you do not remove the top pan or the heat exchanger generally After reaming with the auger mount the wire brush and clean out the debris remaining in the tubes Auger with
47. stem mustbe installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle A diaphragm expansion tank should be installed in the return line A typical 8 diameter expansion tank can be used on the models H 0030 H 0042 and H 0066 and an 11 diameter expansion tank can be used on the model H 0090 H 0135 and H 1080 Consult tank manufacturer for correct sizing TYPICAL PIPING AIR VENT 34 x AIR SCOOP DIAPHRAGM EXPANSION TANK E Y A 2 76 FEED S VALVE gt q PIPE PRESSURE 5 RELIEF VALVE DRAIN N N i LS WATER INLET HEATING UNITS Fig 8997 1 SINGLE ZONE PIPING 11 AIR VENT DIAPHRAGM EXPANSION FEED TANK gt VALVE PIPE PRESSURE YA RELIEF VALVE TO DRAIN X X INLET HEATING UNITS A 5 7 A Con WN CIRCULATOR Z COLD p d WATER SUPPLY Fig 8998 1 ZONE HEATING WITH INDIRECT DOMESTIC HOT WATER SUPPLY 12 MAX FEED EXPANSION VALVE TANK PIPE PRESSURE jl RELIEF VALVE T TODRAIN MULTIPLE ZONES WITH CIRCULATORS
48. the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the com mon venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Testfor spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe to visually check spillage f After it has been determined that each appliance remaining connected to the common venting sys tem properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so the installation conforms with the latest edition ofthe National Fuel Gas Code ANSI Z 223 1 When
49. to avoid possible damage to the heating system 23 SECTION 3 Lighting the Boiler Safe lighting and other performance criteria were met with the gas manifold and control assembly pro vided on the boiler when the boiler underwent tests specified in ANSI Z21 13a 1983 Standard CAUTION Liquefied petroleum gas is heavier than air and sinks to the ground Exercise extreme care in lighting boiler in confined areas For Standing Pilot Models WARNING f you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This boiler has a pilot which must be lighted by hand When lighting the pilot follow these instructions exactly B BEFORE LIGHTING Smell all around the boiler area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electric 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 f you cannot reach your gas supplier call the fire department C Use only your hand to push in move or turn the gas control knob or lever Never use tools If the knob or lever will not push in move or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fi
50. trol HSI Fenwal Ignition Control IID Honeywell 6 P Pilot Mtg Bracket 8 P Pilot Tube 8 P High Tension Wire IID 30B 501410 052871F 600671 006536F 003968F 951116F 003969F 003970F 003971F 005602F 003972F 003973F 005467F 005468F 003974F 003975F 003903F 004308F 600003 003976F 601005F 601129F 004935F 306239 400275 002654B 42B 501410 052871F 600671 006536F 003968F 951116F 003969F 003970F 003971F 005602F 003972F 003973F 005467F 005468F 003974F 003975F 003903F 004308F 600003 003976F 601005F 601129F 004935F 306239 400275 002654B 66B 501410 052871F 600671 006536F 003968F 951116F 003969F 003970F 003971F 005602F 003972F 003973F 005467F 005468F 003974F 003975F 003903F 004308F 600003 003976F 601005F 601129F 004935F 306239 400275 002654B 90B 501410 052871F 600671 006536F 004251F 951116F 003969F 003970F 003971F 005602F 003972F 003973F 005467F 005468F 003974F 003975F 003903F 004308F 600003 003976F 601005F 601129F 004935F 306239 400275 002654B 135B 501410 052871F 600671 006536F 005097F 004714F 951166F 004256F 004257F 004258F 005603F 003972F 003973F 005467F 005468F 003974F 003975F 003903F 004308F 600003 003976F 601005F 601129F 004935F 306239 400275 002654B 180B 501410 052871F 600671 006536F 005097F 004714F 951166F 004256F 004257F 004258F 005603F 003972F 003973F 005467F 005468F 003974F 003975F 003

Raypak 0090B 0135B Boiler User Manual

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