Raytherm 181 Installation & Operating Instructions Manual Download Page 9

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a. All Air From Inside The Building:

Each opening shall have a minimum net free
square inches as noted in Table E.

b. All Air From Outdoors:

When air is supplied directly from outside of build-
ing, each opening shall have a minimum net free
square inches as noted in Table F.

CAUTION:

Combustion air must not be

contaminated by corrosive chemical fumes which
can damage the boiler and void the warranty.

Model

Sq. Inches

Model

Sq. Inches

182/181

181

1223

260/261

264

1336

1337

330/331

334

1468

1467

400/401

399

1631

1630

514

512

1826

624

627

2100

724

726

2500

2499

824

825

3001

3000

962

3500

4001

4000

Model

Sq. Inches

Model

Sq. Inches

182/181

1223

306

260/261

1336

335

330/331

1468

367

400/401

100

1631

408

514

128

1826

457

624

157

2100

525

724

182

2500

625

824

207

3001

750

962

241

3500

875

4001

1000

Table E: Minimum Net Free Air from Inside Building

Table F: Minimum Net Free Air from Outside Building

Venting

Outdoor Installations

Models 181-401 & 182-400

Outdoor Top Installation

1.  Remove jacket top panel.
2.  Remove and discard inner stack adapter panel.
3.  Install jacket top panel.
4.  Insert tabs of outdoor top into keyholes located on

jacket top panel (4 places). See Detail A.

5. Snap tabs on outdoor top into the locked position

of the keyhole so the top will not pull out. See
Detail B.

(Part of heater)

Fig. 4: Installing Outdoor Top—Models 181-401 & 182-

400

Outdoor Top

(Shipped Loose with Heater)

Detail A

Detail B

Fig. 5: Installing Outdoor Top—

Models 181-401 & 182-400

Summary of Contents for 181

Page 1: ...pplier s instructions If you cannot reach your gas supplier call the fire department WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Refer to this manual Installation and service must be performed by a qualified installer service agency or the gas supplier FOR YOUR SAFETY Do not store or use gasoline or other flam...

Page 2: ...Fig 23 on page 19 Electronic Ignition on page 20 Mode H2 on page 23 WH Modes on page 23 Fig 31 on page 23 Fig 32 on page 24 Fig 35 on page 24 Auto Reset High Limit on page 24 Low Water Cut Off on page 25 Fig 41 on page 28 Troubleshooting steps on page 35 Additions Outdoor Air Reset Temperature Controller on pages 20 22 includes Table I and Figs 25 27 Fig 37 on page 25 Deletions All references to M...

Page 3: ...nition 20 Outdoor Air Reset Temperature Controller 20 Operating Controls 22 Limit Controls 24 CONTENTS 3 ELECTRICAL CONNECTIONS 25 START UP 26 Before Start Up 26 General 26 Filling System Heating Boilers 26 Ethylene Glycol Systems Heating Boilers 26 Initial Start Up Pump And Motor 26 For Models with Automatic Gas Valves 28 After Start Up 28 Intermittent Pilot System Checkout S8600 28 Inspections 2...

Page 4: ...e required to de energize the equipment before servicing 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 CAUTION Operation of this heater in low temperature systems requires special piping Harmful internal condensation will occur if the inle...

Page 5: ...el num ber represent MODEL NUMBER EXAMPLE H 3 0 5 1 4 A Series Model Size Representative of approximate MBTUH input Model 0514 has input of 511 500 BTUH Firing Mode 1 Mechanical Modulation 2 Motorized Modulation 3 2 Stage Firing 4 On Off Firing 5 Low Temperature Mechanical Modulation 9 4 Stage Firing Application H Heating Boiler Boiler rating plate showing model number 5 ...

Page 6: ...er the manufacturer s warranty Debits for defec tive replacement parts will not be accepted and will be replaced in kind only per our standard warranties CERTIFICATIONS The Raypak hydronic boilers are design certified and tested under the latest requirements of the American National Standard ANSI Z21 13 Each boiler has been constructed and pressure tested in accordance with the requirements of Sec...

Page 7: ... 400 401 514 624 724 824 054597 054598 054599 054600 054601 058378 058379 059233 059234 059235 059236 059237 059238 059239 Table B Combustible Floor Shield Ordering Information Models with factory installed floor shield as standard BOLD type indicates Low NOx models Fig 2 Alternate Method for Providing a Non Combustible Base Table C Clearances from Combustible Surfaces All dimensions are in inches...

Page 8: ...4 sheet metal over 1 in glass fiber or mineral wool batts reinforced with wire on rear face with ventilated air space 3 1 2 in thick masonry wall with ventilated air space Unobstructed Unobstructed Unobstructed Unobstructed Unobstructed Unobstructed Table D Reduction of Clearances to Protected Surfaces Derived from National Fuel Gas Code Table 6 2 3 b Outdoor Boilers These boilers are design certi...

Page 9: ... Inches 182 181 46 1223 306 260 261 66 1336 335 330 331 84 1468 367 400 401 100 1631 408 514 128 1826 457 624 157 2100 525 724 182 2500 625 824 207 3001 750 962 241 3500 875 4001 1000 Table E Minimum Net Free Air from Inside Building Table F Minimum Net Free Air from Outside Building Venting Outdoor Installations Models 181 401 182 400 Outdoor Top Installation 1 Remove jacket top panel 2 Remove an...

Page 10: ...e flange near the top side of the stack see Fig 8 Caution must be taken not to over tighten and strip the screw threads 7 Turn the assembled stack and jacket top rightside up The jacket top will be trapped between the brackets and the top of the stack Place the stack over the inner stack adapter panel flanged hole and lower the louvered jacket top panel back into its original position Reinstall th...

Page 11: ...as supply and water supply to the boiler 4 Mount drafthood on top of boiler as shown in Fig 10 Drafthood should be positioned with the vent sensor located on the front right side as shown 5 Remove plastic plug from left side of boiler jacket and install plastic grommet provided 6 Route flue sensor wire harness through the grom met installed in Step 5 Models 181 261 7 Remove door and locate wire fr...

Page 12: ...he absence of such codes to the latest edition of the National Fuel Gas Code ANSI Z223 1 The discharge opening must be a minimum of 2 ft ver tically from the roof surface and at least 2 ft higher than any part of the building within 8 ft for vents small er than 12 in diameter For 12 in diameter vents and larger the termination must be 2 ft higher than any part of the building within 10 ft See Fig ...

Page 13: ...xhaust fan Close fireplace dampers Fig 13 Common Venting d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the drafthood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a ciga rette cigar or pipe f After it has been determined th...

Page 14: ...ent damper actuator to the side of the vent The vent damper ships set up for a continuous pilot system Since the Raytherm is equipped with an Intermittent Pilot the hole in the vent damper blade must be plugged using the knockout plug Part No 105612R provided in the parts envelope Fig 15 Vent Damper Installation on Drafthood WARNING Do not use thermally actuated vent dampers on a modulating boiler...

Page 15: ... controls and a manual shut off valve locat ed outside the heater jacket All gas piping should be tested after installation in accordance with local codes A minimum of 7 0 W C upstream gas pressure under full load and a maximum gas supply pressure setpoint of 10 5 W C under load and no load conditions for natural gas A minimum of 12 0 W C upstream gas pressure under full load and a maximum gas sup...

Page 16: ...clockwise to increase pressure or counter clockwise to decrease pressure For boilers with mechanical modulation gas valves Type H1 and H5 or two stage gas valves Type H3 the gas pressure regulator is preset and sealed and not field adjustable Pressure tap is provided on the outlet side of the gas valve for measurement of gas pressure in the manifold Venting of Diaphragm Gas Components Gas valves t...

Page 17: ...ion level must be provid ed with a low water cut off device The boiler when used in conjunction with a refrigeration system must be installed so that the chilled medium is piped in par allel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler Raypak strongly recommends the use of primary sec ondary piping for all H boilers as shown in the following piping...

Page 18: ...LOCATE BUFFER TANK HERE IF REQUIRED Fig 22 Single Boiler Primary Secondary Piping Models 181 4001 Note Expansion tanks supplied by others should be installed per manufacturer s instructions 18 ...

Page 19: ...HERE IF REQUIRED Reverse return piping is a proper method of manifolding multiple boiler hook ups to ensure balanced flow through each boiler Valves on supply and return are needed to isolate any boiler as required Fig 23 Multiple Boiler Reverse Return Hook Up Models 181 4001 19 ...

Page 20: ...Temperature Controller Models 181 through 261 are factory equipped with an electronic outdoor air reset temperature controller This controller is also an available option for models 330 through 401 The standard configuration provides for outdoor air reset of the system target water temperature based on a user defined reset ratio The controller will reset between 120 F system water temperature and ...

Page 21: ... boiler and is cycled off using a 5 minute fixed purge delay after burner operation has ceased S1 Boiler Outlet Sensor S2 System Supply Sensor S3 Outdoor Air Sensor P1 Boiler Pump The DIP switch settings are as follows DIP 1 ON ON OFF OFF 2 STAGE DIP 2 ON OUTDOOR RESET DIP 3 ON WWSD 70 F DIP 4 ON 190 F BOIL MAX DIP 5 ON HYDRONIC Fig 25 Hydronic with Outdoor Air Reset Hydronic Outdoor Air Reset wit...

Page 22: ...ity of control Standard factory setting is at position 5 Consult the dial setting tag attached to the control for your desired temperature See sample tag drawings below INVENSYS INVENSYS Fig 28 Sample Tags Low Temp Range High Temp Range NOTE No external control of the valve position is possible Direct Domestic Hot Water In this configuration the controller will operate to main tain a set temperatu...

Page 23: ...t low fire when there is closure across the stage 1 contacts Thereafter it will fire at high fire when there is closure across the stage 2 contacts Numerous staged controllers are available Mode H4 On Off Firing The boiler will fire at full fire when there is closure across the TH contacts Numerous mechanical staged controllers are available see Fig 39 as well as digital controllers offering addit...

Page 24: ...a pump failure or low water condition It is mounted and wired in series to the main gas valve Standard on all models NOTE Flow switch will not operate if flow is less than 12 gpm Fig 34 Flow Switch 100 Pilot Safety All standard boiler models 181 4001 employ electron ic devices which close the main gas valve within 8 10 of a second whenever the pilot flame is interrupted Pilot flame is automaticall...

Page 25: ...rous operation Verify proper operation after servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components Low Water Cut Off Optional On Models 514 1826 the probe type low water cut off automatically shuts down burner whenever water level drops below the probe for more than 2 seconds A 3 second time delay prevents p...

Page 26: ...eme care in light ing boiler in confined areas CAUTION Pump must be off to check oil in bearing assembly Do not run pump without water in system MECHANICAL MODULATING GAS VALVES WITH REGULATOR T P GAUGE NOT SHOWN INLET HI LIMIT Fig 39 General Location of Controls Ethylene Glycol Systems Heating Boilers Fill through filler opening on the top on the Air X Tank to solution desired Always maintain sol...

Page 27: ...r clockwise to ON 9 Replace boiler door panel 10 Turn on all electrical power to the appliance 11 Set thermostat to desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier HONEYWELL GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET ROBERTSHAW GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET TO TURN OFF ...

Page 28: ...o call for heat b Watch for continuous spark at the pilot burner c Time the spark operation Time must be with in the lockout timing period 15 or 90 seconds d Turn thermostat down to end call for heat and wait 60 seconds on lockout models before beginning step 3 3 Turn on gas supply 4 Set thermostat or controller above room tempera ture to call for heat 5 Systems should start as follows a Spark wil...

Page 29: ...to Troubleshooting Guide for additional directions 1 Remove top of heater and inspect heat exchanger for soot and examine venting system 2 Remove rear header and inspect for scale deposits and or accelerated erosion 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 a Oil pump motor and bearing assembly...

Page 30: ...for continuous spark at the pilot burner c Check the ignition spark operation Time must be within the lockout timing period 90 sec onds d Turn control down to end call for heat and wait 60 seconds before beginning step 3 3 Turn on gas supply 4 Set controller to call for heat 5 System should start as follows a Spark will turn on and pilot gas valve will open b Main valve and blower will be powered ...

Page 31: ...the control box 8 Disconnect pilot wire from the ignition module 9 Disconnect wire harness from the combustion blower 10 Carefully slide out the burner tray assembly 11 Reverse above procedure to re install Gas Valve Adjustment Robertshaw Invensys 7000 Series 2 Stage Gas Valve with Solenoid Valve 1 Turn the heater off 2 Remove the 3 8 nut or the 10 Torx screw 3 Lift solenoid valve up keeping the w...

Page 32: ... Valve Removal 1 Remove burner tray See Burner Tray Removal procedure 2 Disconnect pilot tubing from gas valve 3 Turn vertical gas pipe from manifold slightly and unscrew gas valve 4 Reverse above procedure to re install Main Burner and Orifice Removal 1 Remove burner tray See Burner Tray Removal procedure 2 Remove pilot See Pilot Removal procedure 3 Remove 8 total screws from the hold down bracke...

Page 33: ...ace module Check for 24 Vac across MV MV PV terminals If no voltage replace module Check electrical connections between module and gas control If okay replace gas valve or gas control operator i e pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system Check continuity of ignition cable and ground wire NOTE If ground is poor or erratic shutdowns may occur occasionally even th...

Page 34: ...TYPICAL ON OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM 34 ...

Page 35: ...he circuit breaker outdoor con troller etc upstream of boiler If power to Leads L1 and L2 of trans former but no power on 24V side re place Jumper thermostat Replace with new if boiler fires DO NOT leave thermostat jumpered If power to toggle switch but not through switch replace If power to relay but not operating replace Open valve Loosen bleed line and clean Replace coupler Inspect bearing as s...

Page 36: ... Wear Of Coupling 1 Misalignment or a bent shaft 2 Sagging motor mounts over oiling Pump Loses Prime 1 Air leaks in suction line 2 Excessive amount of air in water 3 Water seal in stuffing box not functioning 4 Excessive suction lift and pump operating too near shut off point Overloaded Driving Unit 1 Head much lower than that for which pump is designed 2 Speed too high or higher than that contemp...

Page 37: ...lly After reaming with the auger mount the wire brush and clean out the debris remain ing in the tubes Another method is to remove the heat exchanger ream tubes and immerse heat exchanger in noninhibited de scale solvent Burner Tray Removal 1 Shut off power and gas supply to the boiler Disconnect union s and pilot tubing then loosen and remove burner hold down screws 2 Disconnect wires at gas valv...

Page 38: ...ts 2 Remove front inspection panel 3 Remove wires to high limit and loosen screws holding high limit to cabinet 4 Remove wedge clip holding sensing bulb in con trol well 5 Remove high limit and install a new one 6 Check control operation before leaving job Heat Exchanger Removal 1 Shut water gas and electricity off close valves and relieve pressure remove relief valve Remove side inspection panels...

Page 39: ...tion pan els Install top holding screws Install draft diverter and vent piping if so equipped 10 If gas piping was disconnected reconnect gas pip ing system and check for leakage using a soapy solution 11 Check for correct water pressure and water level in the system Make sure that system pump oper ates immediately on the call for heat The system is ready for operation 12 Within two 2 days of star...

Page 40: ...ays 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 drafthood and flue collector by removing bolts and screws 2 Remove V baffles from heat exchanger 3 Remove burner tray 4 Take garden hose and wash heat exchanger mak ing sure soot is removed from between fins Avoid excessive water a...

Page 41: ...n with the heater serial number model number etc and shipped to Raypak freight prepaid If determined defective by Raypak and within warranty the part will be returned in kind or equal substitution freight collect Credit will not be issued RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 NOTE To supply the correct part it is important that you supply the model number serial number and type of gas whe...

Page 42: ... Limited Warranty if it fails in normal use and service during its specified warranty period The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The repair or replacement part will be warranted for only the unexpired portion of the original Limited Warranty Raypak makes no warranty whatsoever on pa...

Page 43: ...43 ...

Page 44: ...44 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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