Velocity Raptor RPTR085 Installation And Operating Instructions Manual Download

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Summary of Contents for Raptor RPTR085

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Page 2: ...al property damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property damage WARNING Indicates a potentially hazardous situatio...

Page 3: ...nect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler...

Page 4: ...l be permanently mounted to the exterior of the building at a minimum height of eight 8 ft above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating ap...

Page 5: ...ENTIRE MANUAL before attempting installation start up or service Improper installation adjustment alteration service or maintenance may cause serious property damage personal injury or death DO NOT D...

Page 6: ...rm InnoFlue Vent Systems 59 I Condensate Trap and Drain 62 J Removing An Existing Boiler From Common Chimney 64 VIII Gas Piping 65 IX System Piping 67 A General System Piping Precaution 67 B Standard...

Page 7: ...ing and or indirect domestic hot water DHW heating Model RPTR155C provides economical tankless domestic hot water DHW heating in addition to central space heating I Product Description II Specificatio...

Page 8: ...70 270 54 251 218 95 4 6 1 1 2 145 80 The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1 15 The manufacturer should be consulted before selecting a boiler for installatio...

Page 9: ...lengths will not be exceeded in the planned installation Also verify that the vent terminal can be located in accordance with Section VII Venting 3 Make sure that the boiler is correctly sized For he...

Page 10: ...ances apply to combustible construction as well as non combustible walls floors ceilings and doors 2 Note the recommended service clearances in Figure 4 1 These service clearances are recommended but...

Page 11: ...CE ACCESS PANEL PROVIDE ACCESS TO THIS AREA FOR INSPECTION AND CLEANOUT OF CONDENSATE TRAP RIGHT SIDE CLEARANCE MAY BE REDUCED TO 1 2 HOWEVER RELIEF VALVE MUST REMAIN IN SAME SPACE AS BOILER 1 2 Figur...

Page 12: ...5 1 to locate holes A and B Make sure that the horizontal centerline of these holes is level Holes C and D may also be drilled at this time or after the boiler is hung on the wall If the 5 16 x 2 lag...

Page 13: ...13 Figure 5 1 Wall Layout Mounting Hole Location V Mounting The Boiler continued...

Page 14: ...14 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting V Mounting The Boiler continued...

Page 15: ...appliances provide adequate air for combustion and or ventilation air in accordance with the manufacturer s installation manual or applicable code VI Air for Ventilation WARNING Outdoor combustion ai...

Page 16: ...NING Asphyxiation Hazard Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage personal injury...

Page 17: ...17 Figure 7 0c Split Venting VII Venting A Vent System Design continued Figure 7 0a Horizontal Twin Pipe Figure 7 0b Vertical Twin Pipe...

Page 18: ...on fittings are never counted It is recommended that all field supplied PVC or CPVC elbows be 1 4 Bend Sanitary 90 El or Long Sweep 1 4 Bend type elbows Figure 7 2 In this manual sanitary and long swe...

Page 19: ...Pitch CPVC PVC vent piping 1 4 per foot Pitch PolyPropylene vent piping 5 8 per foot Les chaudi res de cat gories I II et IV doivent pr senter des tron ons horizontaux dont la pente montante est d au...

Page 20: ...so that the vent system can expand towards the terminal When a straight run of pipe exceeds 20ft and must be restrained at both ends an offset or expansion loop must be provided Figures 7 3a 7 3b When...

Page 21: ...21 VII Venting A Vent System Design continued Figure 7 3 Expansion Loops for CPVC PVC Pipe Figure 7 3b Figure 7 3a Figure 7 3c Figure 7 4 Wall Penetration Clearances for PVC Vent Pipe...

Page 22: ...keled Terminal Option B Ipex Low Profile Terminal Acceptable for Vent Options 1 2 This terminal is shown in Figure 7 7 If the terminal is oriented vertically alternate orientation shown in Fig 7 7 the...

Page 23: ...EP0339 w screen Intake Elbow w screen Note 3 Elbow w screen Note 3 Elbow w screen Elbow w screen Elbow w screen Elbow w screen Elbow w screen Elbow w screen Terminal Option B Ipex Low Profile Ipex 196...

Page 24: ...relief equipment Do not install vent terminal over this equipment In Canada refer to B149 1 Installation Code for clearance to meters regulators and relief equipment Do not locate the vent terminal un...

Page 25: ...rofile Terminal Vent Options 1 2 Terminal Options B C Figure 7 8 Horizontal CPVC PVC Venting with Concentric Vent Terminal Vent Options 1 2 Terminal Options D E VII Venting B Design Requirements Uniqu...

Page 26: ...InnoFlue Horizontal Venting Vent Option 3 8 Terminal Option A Figure 7 10 Duravent PolyPro Horizontal Venting with Concentric Terminal Vent Options 3 4 Terminal Option F VII Venting B Design Requirem...

Page 27: ...r intake termination not shown refer to Venting Section in Installation Instructions supplied with the boiler Figure 7 11 Location of Vent Terminal Relative to Windows Doors Grades Overhangs Meters an...

Page 28: ...creens is generally recommended for both terminations Two rodent screens suitable for 3 PVC terminals are installed as shown in Figure 7 28 If 2 CPVC is used these screens can be cut to fit into the s...

Page 29: ...F 39UV w Screen 3PF 10UV or 3PF 39UV w Screen ISEP02 or ISEP0239 w Screen ISEP03 or ISEP0339 w Screen Intake 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Scr...

Page 30: ...ent Manufacturer s PN for Flex Termination Components Required 2PPS VFT 2PPS BV 2PPS FLEX 3PPS VFT 3PPS BV 3PPS FLEX IFBK02 IAWP02B IFBK03 IAWP03B Specify size of B vent e g 2PPS BV6 is for use with 6...

Page 31: ...outside wall see Part VII D for additional details All venting is PolyPropylene supplied by the vent manufacturer shown in Table 7 13b The portion of this venting within the B vent is flexible All fle...

Page 32: ...ft 2 Centrotherm InnoFlue Flex 2 0 ft 2 Selkirk Polyflue 2 0 ft 3 DuraVent PolyPro Flex 2 0 ft 3 Centrotherm InnoFlue Flex 2 3 ft 3 Selkirk Polyflue 2 3 ft B Vent Air Chase 1ft 2 Flex Vent in 5 or lar...

Page 33: ...enting Vent Options 10 11 Terminal Option H Figure 7 16 Vertical CPVC PVC Venting with IPEX Concentric Vent Terminal Vent Options 10 11 Terminal Option I J VII Venting C Design Requirements Unique to...

Page 34: ...InnoFlue Vertical Single Wall PP Venting Vent Options 12 17 Terminal Option H Figure 7 18 Duravent PolyPro Vertical Venting with Concentric Terminal Vent Options 12 13 Terminal Option J VII Venting C...

Page 35: ...C Design Requirements Unique to Vertical Venting Systems continued Figure 7 19 Duravent PolyPro B Vent Air Chase System Vent Options 18 19 Figure 7 20 Centrotherm InnoFlue B Vent Air Chase System Vent...

Page 36: ...orizontal Air Intake Terminal Location Observe the following limitations on the intake terminal location also see Figures 7 22 7 23 or 7 24 The bottom of all terminals must be at least 12 above the no...

Page 37: ...uraVent Poly Pro Flex is 2 0ft From Table 7 1 the equivalent length of the second 90 elbow is 8 7ft The equivalent length of the vent system is therefore 4 8 7 30 x 2 0 72 7ft Since Vent Option 34 sho...

Page 38: ...w Screen Coupling w Screen 2PPS 12B or 2PPS 36B w Screen 3PPS 12B or 3PPS 36B w Screen 2PF 10UV or 2PF 39UV w Screen 3PF 10UV or 3PF 39UV w Screen Intake 90 Elbow w Screen 90 Elbow w Screen 90 Elbow...

Page 39: ...S FLEX 3PPS FK 3PPS FLEX 2PF FLEX KIT 2PF FLEX 3PF FLEX KIT 3PF FLEX IFCK02 IFCK03 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen Not Permi...

Page 40: ...40 VII Venting D Design Requirements Unique to Split Vent Systems continued Figure 7 22 Split Rigid Vent System Vent Options 25 32 Figure 7 23 Split Vent System Flex in B Vent Chase Vent Options 33 38...

Page 41: ...41 VII Venting D Design Requirements Unique to Split Vent Systems continued Figure 7 24 Split Vent System Flex in Abandoned Masonry Chimney Vent Options 33 38...

Page 42: ...Venting D Design Requirements Unique to Split Vent Systems continued Figure 7 25 Masonry Chimney Chase Requirements DANGER Venting of Other Appliances Or Fire place into Chase or Adjacent Flues Prohi...

Page 43: ...irst piece of 3 CPVC installed in Step b to 2 CPVC using a CPVC reducing coupling or elbow Otherwise assemble the 3 CPVC elbow and the remainder of the 30 CPVC piping before transitioning to PVC If 3...

Page 44: ...ir intake connection and drill a 1 8 tap hole into the PVC which lines up with the 7 32 clearance hole and secure them together with a 10 x 1 sheet metal screw Seal the joint between the intake pipe a...

Page 45: ...45 Figure 7 28 Installation of Standard Vertical Terminals Figure 7 27 Installation of Standard Horizontal Terminals VII Venting E Assembly of CPVC PVC Vent Systems continued...

Page 46: ...th vent and intake air pipes through the holes and cement them to the base of the vent termination kit using a primer and cement listed for use with PVC c Fasten the vent base to the wall using the su...

Page 47: ...gure 7 30 Installation of Diversitech Low Profile Terminal Through Sidewall Figure 7 29 Installation of IPEX Low Profile Terminal Through Sidewall VII Venting E Assembly of CPVC PVC Vent Systems conti...

Page 48: ...Venting E Assembly of CPVC PVC Vent Systems continued Figure 7 32 Installation of IPEX and Diversitech Concentric Terminal through Sidewall Figure 7 31 Cutting IPEX and Diversitech Concentric Vent Ter...

Page 49: ...installations orient so that the side outlet on the Wye is on or above the horizontal plane g For horizontal installations seal the gap between the OD of the outer pipe and the exterior side of the wa...

Page 50: ...adaptor has two different inside diameters The smaller lower inside diameter accepts 3 nominal PolyPro Figure 7 26 Lubricate the upper gasket in the vent adaptor with soapy water and insert the first...

Page 51: ...ation instructions included by the original PolyPropylene venting component manufacturer M G DuraVent PolyPropylene pipe sections must be disengaged 1 4 to 5 8 in 6 mm to 16 mm per joint to allow for...

Page 52: ...tion of Duravent PolyPro UV Resistant Single Wall Horizontal Terminal Figure 7 36 Installation of Duravent PolyPro UV Resistant Single Wall Vertical Terminal VII Venting F Assembly of DuraVent PolyPro...

Page 53: ...the termination to the exterior wall plate with weather resistant RTV f Slide the interior wall plate over the termination and attach to the wall from inside the room g Attach the interior wall plate...

Page 54: ...stallation of Duravent PolyPro Concentric Vent Terminal Through Sidewall VII Venting F Assembly of DuraVent PolyPro Vent Systems continued Figure 7 39 Installation of Duravent PolyPro Concentric Termi...

Page 55: ...ale threads Secure the adaptor to the cap using a 2 or 3 electrical conduit lock nut Seal all joints with RTV G Assembly of Selkirk Polyflue Vent Systems WARNING Asphyxiation Hazard When using PolyPro...

Page 56: ...and insert Selkirk 2PF HVST or 3PFHVST in its place c A 180 bend or two 90 elbows are installed on the top of the air intake pipe If two 90 elbows are used the rodent screen provided can be installed...

Page 57: ...he Selkirk Polyflue instruction manual Not all vent configurations shown in the Selkirk vent manual are approved for use with this boiler Refer to Selkirk Polyflue Instructions for assembly of all fle...

Page 58: ...ly of Selkirk Polyflue Vent Systems continued Figure 7 41 Installation of Selkirk Polyflue UV Resistant Single Wall Horizontal Terminal Figure 7 42 Installation of Selkirk Polyflue UV Resistant Single...

Page 59: ...r lower inside diameter accepts 3 nominal InnoFlue Figure 7 26 Lubricate the upper gasket in the vent adaptor with water and insert the first piece of 3 InnoFlue into the adaptor until it bottoms out...

Page 60: ...onent manufacturer Centrotherm PolyPropylene pipe sections must be disengaged 1 4 in 6mm per joint to allow for thermal expansion 4 Installation of Horizontal Fitting Terminals Terminal Option A a See...

Page 61: ...on of Centrotherm InnoFlue UV Stabilized Single Wall Horizontal Terminal Figure 7 45 Installation of Centrotherm InnoFlue UV Stabilized Single Wall Vertical Terminal VII Venting H Assembly of Centroth...

Page 62: ...ion manual Connection of the PVC air intake pipe to the side outlet of the tee is made using a cap and a PVC socket x male thread adaptor 2 or 3 depending on the Vent Option Cut a clearance hole in th...

Page 63: ...ondensate Trap Installation 8 If the point of condensate disposal is above the trap it will be necessary to use a condensate pump to move the condensate to the drain In such cases select a condensate...

Page 64: ...1 VII Venting J Removing an Existing Boiler From a Common Chimney continued WARNING Never common vent this boiler with other appliances Au moment du retrait d une chaudi re existante les mesures suiva...

Page 65: ...the gas supply system by closing its individual manual shut off valve Locate leaks using approved combustible gas non corrosive leak detector solution VIII Gas Piping WARNING Explosion Hazard Failure...

Page 66: ...onnection fitting located on the bottom of the boiler If an additional regulator is used to reduce boiler inlet pressure below 1 2 psig 3 4 kPa it must be at least 6 to 10 ft upstream of the boiler It...

Page 67: ...r contains dissolved oxygen which causes corrosion In a tight system this oxygen comes out of solution and is quickly removed from the system through the automatic air vent The system then remains ess...

Page 68: ...system to work properly See next section for more information 4 Expansion Tank required If this boiler is replacing an existing boiler with no other changes in the system the old expansion tank can ge...

Page 69: ...ve Ball Valve Temperature Pressure Gauge Drain Valve Return Inlet Supply Outlet INLET TOP OUTLET TOP Automatic Air Vent Temperature Pressure Gauge Relief Valve Drain Valve Copper Piping Cap Return Inl...

Page 70: ...the water flow rate through it remain within the limits shown in Table 9 3 any time the boiler is firing At flow rates below the minimum shown the boiler s temperature rise limit function may prevent...

Page 71: ...the boiler will have the required flow shown in Table 9 3 regardless of the flow in the heating system 1 System Loop Piping Size the system circulator and piping to obtain the design flow rate through...

Page 72: ...6 0011 RPTR270 1 14 3 3 5 0010 16 7 4 6 0010 20 1 6 4 0011 25 1 9 7 0013 Table 9 5b Recommended Grundfos Circulators for 60 Equivalent ft Boiler Loop Piping Boiler Model Minimum Pipe Size in T 35 F T...

Page 73: ...IX System Piping continued Table 9 6 Fitting and Valve Equivalent Length Copper Fitting and Sweat Valve Equivalent Length Ft Fitting or Valve Description Copper Pipe or Valve Size 1 1 1 2 90 Elbow 2...

Page 74: ...rs upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Secondary Unions Not Required Op...

Page 75: ...trainer Recommended From System Full Port Isolation Valves Indirect Circulator Relief Valve Drain Valve Secondary Unions Not Required Optional Locations Shown Full Port Isolation Valves Flow Check Ind...

Page 76: ...ensor As Close As Possible To Downstream Tee Y Strainer Recommended Secondary Unions Not Required Optional Location Shown Drain Valve Relief Valve Header Temperature Sensor When Used Indirect Domestic...

Page 77: ...f Valve Drain Valve From System At least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe fo...

Page 78: ...ht pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Boiler Circulator...

Page 79: ...tional Locations Shown Drain Valve Heating Circulators Flow Check To System Full Port Isolation Valve At least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe...

Page 80: ...stem must be known This method is generally not recommended because it is often very difficult to accurately calculate the pressure drop through the system In replacement installations it may be impos...

Page 81: ...nts All components on the oxygenated side of the heat exchanger such as the pump and expansion tank must be designed for use in oxygenated water 2 Piping with a Chiller If the boiler is used in conjun...

Page 82: ...wiring and grounding must be done in accordance with the authority having jurisdiction or in the absence of such requirements with the National Electrical Code NFPA 70 In Canada all wiring and ground...

Page 83: ...ection XII Operation for information on setting up the pump operation 2 Low Voltage Field Connections Low voltage field connections on the low voltage PCB are shown in Figure 10 3 and are listed from...

Page 84: ...re Pump Fuse Fuse 250 V 6 3 A Slow Blow 5x20mm N L N L N L N L G OUTDOOR SENSOR HONEYWEL HEADER SE TO MODBUS DEVICE if used HEATING RMOSTAT RMOSTAT if used LIMIT S if used O ALARM SYSTEM EnviraCOM THE...

Page 85: ...se sources wire the sensor using a 2 conductor UL Type CM AWM Style 2092 shielded cable Connect one end of the shielding on this cable to ground See Section XII Operation for information on enabling t...

Page 86: ...g Circulators DETAIL B SCALE 1 4 Header Temperature Sensor Honeywell 32003971 003 Well Should Extend Into Header Flow As Far As Possible Use Extension Only If Necessary Close Nipple Locate Header Sens...

Page 87: ...87 Figure 10 5 Internal Wiring Ladder Diagram X Wiring continued...

Page 88: ...88 X Wiring continued...

Page 89: ...C LOW VOLTAGE FIELD WIRING LINE VOLTAGE FACTORY WIRING SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 C LINE VOLTAGE FIELD WIRING IGNITER WIRE 250 C WIRE COLOR CODE BK BLACK BL BLUE BR BROWN GR GREEN GY...

Page 90: ...DHW AQUASTAT Low Voltage Connections Fuse F1 250 V 1 6A Slow Blow 5x20mm EnviraCOM MODBUS Boiler To Boiler Communication Network V B A Header Sensor Outdoor Sensor Heat T stat DHW T stat External Lim...

Page 91: ...ation on testing and purging gas lines 8 Confirm vent system is complete and free of obstructions before attempting to fire boiler 9 Inspect all wiring for loose uninsulated or miswired connections 10...

Page 92: ...ctions for required dosage In general these products are a blend of glycol for freeze protection and inhibitors to protect the glycol from attacking metallic system components Do not add any more anti...

Page 93: ...ith a screw cap in the vent adapter Be sure to replace this cap when combustion testing is complete Check CO2 or O2 and CO at both high and low fire The boiler may be temporarily locked into high or l...

Page 94: ...94 Figure 11 2 Burner Flame XI Start Up and Checkout continued Figure 11 1a Home Screen at Power Up No Call for Heat Figure 11 1b Home Screen on Heat Demand Figure 11 1c Home Screen with Active Fault...

Page 95: ...al injury or loss of life due to carbon monoxide CO poisoning WARNING Asphyxiation Hazard The outlet pressure for the gas valve has been factory set and requires no field adjustment This setting is sa...

Page 96: ...opy of which is included with this boiler It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is com...

Page 97: ...97 Operating Instructions XI Start Up and Checkout continued...

Page 98: ...es between themeasuredtemperatureandthesetpointtemperature As the measured temperature approaches the setpoint temperature the fan will slow down and the input will drop The Control also utilizes boil...

Page 99: ...Auxiliary Heat call for heat the setpoint is either the userenteredAuxiliaryHeatSetpointorisautomatically adjusted as Outdoor Air Reset Priority Status Screen Display Boiler Responding to 1st Sequenc...

Page 100: ...ockout results 3 Return Temperature Higher Than Supply Temperature Inversion Limit TheControlmonitorsthesupplyandreturntemperature sensors If the return water temperature exceeds the supply water temp...

Page 101: ...o automatically resume control as a stand alone boiler c Slave Boiler Rate Adjustment Each slave boiler continues to monitor supply return and flue gas temperatures and modifies the Sequence Master s...

Page 102: ...eratureis outside the user selected DiffAbove and Diff Below settings Also in order to minimize temperature deviations the control adjusts the number of boilers running based on the firing rate This c...

Page 103: ...s On After flame is proven the sequence continues with run stabilization and low fire hold time Once the field adjustable low fire hold time is completed normal boiler operation begins modulation rate...

Page 104: ...buttons and symbols The Home Screen and menu selections are shown below When no selection is made while viewing any screen the display reverts to the Home Screen after 4 minutes The Home Screen provid...

Page 105: ...simply walk though boiler operation by repeatedly selecting the right or left arrow symbol These screens are accessed by selected the Status button from the Home screen Figure 12 6 Status Screens Fig...

Page 106: ...Frost Protection and pump Exercise functions This screen provides the status of the boilers five 5 possible heat demands When demand is off the Control has not detected the call for heat This screen...

Page 107: ...sent Central Heat Auxiliary Heat Domestic Hot Water Frost Protection or Warm Weather Shutdown Networked Boiler Status Provides connected start sequence and firing rate status information for all conne...

Page 108: ...Password is 86 and press the return arrow to close the keypad Press the Save button Press the Adjust button to enter Adjustment mode Figure 12 9 Adjust Mode Screens 2 Adjusting Parameters Editing par...

Page 109: ...tection is not used Enable Boiler and system circulators start and boiler fires when low outside air supply and return temperatures are sensed Disabled Enable Disable Warm Weather Shutdown Enable Disa...

Page 110: ...t Rate Central Heat Maximum Expected Heat Rate This parameter defines the highest modulation rate the Control will go to during a central heat call for heat If the rated input of the installed home ra...

Page 111: ...TR 270P 46 Maximum Heat Rate RPM 6900 8100 8500 Minimum Heat rate RPM 1600 1750 2000 Model RPTRC 155N 46 Maximum Heat Rate RPM 6500 Minimum Heat rate RPM 1600 Model RPTRC 155P 46 Maximum Heat Rate RPM...

Page 112: ...ver Any Demand Header Sensor Demand CH Off for DHW Boiler Pump run pump for Activates the boiler pump output according to selected function Never Pump is disabled and not shown on status screen Any De...

Page 113: ...e diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C From System To System F...

Page 114: ...t pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Boiler Circulator...

Page 115: ...It is permissible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat Example Pump Parameter selections continued XII Operation F Changing Adjus...

Page 116: ...e Address Line 1 User defined Contractor Address Line 1 Address Line 2 User defined Contractor Address Line 2 Phone User defined Contractor Phone Press button to access the following screen The Manual...

Page 117: ...troller Proportion Integral Derivative PID values Higher values cause a larger firing rate change for each degree of temperature change If set too high firing rate overshoots required value increases...

Page 118: ...emperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change If set too low the firing rate res...

Page 119: ...ponse will be sluggish and temperature will wander away from setpoint 10 seconds 0 to 300 seconds Low Fire Hold Time Low Fire Hold Time is the number of seconds the control will wait at low fire modul...

Page 120: ...ypically set to the coldest outdoor temperature 70 F 21 1 C 32 F to 100 F 0 C to 37 8 C Central Heat High Outdoor Temperature The High Outdoor Temperature parameter is the outdoor temperature at which...

Page 121: ...0 C to 37 8 C Auxiliary Heat Low Outdoor Temperature The Low Outdoor Temperature parameter is also called Outdoor Design Temperature This parameter is the outdoor temperature used in the heat loss cal...

Page 122: ...n Coil 100 F to 140 F 37 8 C to 60 C In Slab Radiant High Mass Radiant 160 F to 190 F 71 1 C to 87 8 C Convection Baseboard Fin Tube Convective 130 F to 160 F 54 4 C to 71 1 C Staple up Radiant Low Ma...

Page 123: ...rapid load increases 70 50 100 Base Load Common Rate To maximize condensing boiler efficiency the firing rate is limited to an adjustable value Boilers are kept at or below this firing rate as long as...

Page 124: ...4 20mA Input on Control Terminals J8 6 and J10 8 is used as the temperature setpoint The following two parameters may be used to adjust the signal range Modbus Modbus is used as the temperature setpo...

Page 125: ...oose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other l...

Page 126: ...carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects...

Page 127: ...gas shutoff shown in Figure 8 1 is closed e Disconnect the flexible gas line at the gas valve flare connection Figure 13 1 f Unplug the electrical connection to the gas valve g Disconnect the air pro...

Page 128: ...Line Figure 13 2 Igniter and Flame Sensor Location XIII Service and Maintenance continued Flame Sensor Igniter Flexible Gas line Connection When disconnecting flexible gas line place a backup wrench...

Page 129: ...e trap Unscrew the cap Flush any debris found in the trap with water do not use other cleaning agents Reassemble the trap as shown in Figure 13 4 XIII Service and Maintenance continued WARNING Asphyxi...

Page 130: ...CONDENSATE TRAP BRACKET CONDENSATE TRAP COLLAR BOILER JACKET CONDENSATE DRAIN CORRUGATED DRAIN TUBE INLET NUT INLET GASKET OUTLET NUT CONDENSATE TRAP 10 32 SHCS 10 SPLIT LOCK WASHER 10 32 HEX NUT 8 18...

Page 131: ...boiler off immediately Failure to do so could cause severe heat exchanger damage v Follow ALL instructions in Section XI Start up and Checkout to place the boiler back in service including the perfor...

Page 132: ...120Vac Power at Boiler Check breaker and wiring between breaker panel and boiler Blown high voltage fuse Replacement Fuse Kit part number 105349 01 Display Completely Dark Fan running No 24Vac Power t...

Page 133: ...rner conditions and improper operation that may result in PROPERTY LOSS PHYSICAL INJURY OR DEATH Refer to page 110 for boiler size setting instructions XIV Troubleshooting continued C Help Screen Faul...

Page 134: ...it Rate Limit The following messages appear when the firing rate is limited or reduced to help avoid a lockout or save energy Refer to Hard Lockout section for corrective actions High Stack Temperatur...

Page 135: ...Inlet Switch Special Note Before a call for heat the air pressure switch is closed When there is a call for heat with a blocked vent the air pressure switch will open due to excessive pressure of the...

Page 136: ...lower speed to match purge and light off setpoint Normal waiting for blower speed to match purge and light off setpoint 27 Undefined Fault Undefined Fault Consult Factory 28 or 53 Air Proving Switch F...

Page 137: ...n line in trap 18 Light off rate proving failed Blower is not running at Light off rate when it should or blower speed signal not being detected by Control Loose connection in 120 VAC blower wiring Lo...

Page 138: ...om any Velocity Boiler Works distributor To find the closest Velocity Boiler Works distributor consult the area Velocity Boiler Works representative or the factory at Velocity Boiler Works Customer Se...

Page 139: ...epair Kit includes electrode gasket and hardware 103005 02 1I Heat Exchanger Flue Gasket Repair Kit 107000 01 107000 02 1J Flue Pipe Repair Kit includes pipe and gasket 106998 01 106998 02 1K Flue Pip...

Page 140: ...Parts continued 2G 2E 2D 2C 2B 2M 2L 2N 2A 2H 2F 2I 2J 2K 2O 2P 2Q 2R 2S 2T 2W 2U 2V 2U 2BB 2AA 2HH 2DD 2EE 2CC 2Y 2FF 2GG 2Z 2GG 2Z 2BB 2GG 2GG 2GG 2II 2X Combi Domestic Hot Water and Space Heating M...

Page 141: ...Drain Valve 806603061 2T Temperature Pressure Gauge Repair Kit 105894 01 2U Water Gasket Repair Kit supply and return pipes includes 2 gaskets 106995 01 2V Supply Pipe Assembly Repair Kit includes pip...

Page 142: ...142 XV Repair Parts continued 3A 3B 3C 3D 3F 3E 3G 3H 3O 3P 3Q 3R 3J 3K 3I 3M 3N 3L All Models...

Page 143: ...3F Venturi Cork Gasket 106082 01 3G Gas Valve Repair Kit includes gas valve inlet and outlet seals and hardware 107006 01 3H Gas Valve 90 Inlet Flange Repair Kit 107007 01 3I Gas Valve Flange Adapter...

Page 144: ...144 4A 4C 4B 4D 4G 4I 4J 4K 4L 4M 4Q 4N 4R 4J 4P 4O 4F 4H 4E 4H 4E 4S Space Heating Models RPTR085 RPTR110 RPTR155 RPTR205 RPTR270 XV Repair Parts continued...

Page 145: ...62 01 4H Gas Pipe Clamp and Hanging Bracket Screw 1 4 20 x 1 2 Long Type F Self Tapping 80860700 4I Door Latch Keeper 106146 01 4 4J Water Pipe Grommet 106139 01 4 103252 01 4 4K Vent Connector Repair...

Page 146: ...146 XV Repair Parts continued Combi Domestic Hot Water and Space Heating Model RPTR155C 5A 5B 5C 5D 5E 5E 5F 5G 5H 5H 5H 5I 5J 5J 5K 5L 5M 5N 5O 5P 5Q 5R 5T 5S...

Page 147: ...nd Hanging Bracket Screw 1 4 20 x 1 2 Long Type F Self Tapping 80860700 5I Door Latch Keeper 106146 01 2 5J Water Pipe Grommet 106139 01 3 5K Vent Connector Repair Kit includes connector gaskets and h...

Page 148: ...148 XV Repair Parts continued 6D 6B 6A 6E 6I 6G 6L 6N 6H 6C 6K 6M 6C 6C 6J 6J 6F All Models...

Page 149: ...and screws 107020 01 6F High Voltage PCB Cover 106934 01 6G Repair Programmed Control 107097 01 6H Control Foot Gasket 105109 01 4 6I Low Voltage PCB Repair Kit includes PCB fuse and screws 107035 01...

Page 150: ...Termination 101870 01 Not Permitted 7F 2 SS Termination Screen 102191 04 2 Not Permitted 7G 2 x 3 CPVC Reducing Bushing 106611 01 Not Permitted 7H 2 x 3 PVC Reducing Bushing 106619 01 Not Permitted 7A...

Page 151: ...t 107037 01 8C Ignition Cable Harness Repair Kit 107038 01 8D Blower Control Harness Repair Kit 4 wire harness 107002 01 8E Blower Power Harness Repair Kit 3 wire harness 107003 01 8F DHW to Circulato...

Page 152: ...ue to carbon monoxide poisoning WARNING This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer s instructions and all applicable codes and requirement...

Page 153: ...isoning 3 Before attempting to start the boiler turn the throttle Figure A 3 clockwise until it stops several full turns 4 Turn throttle counter clockwise the exact number of turns shown in Table A 4...

Page 154: ...le Turns for Conversion to LP Gas Appendix A continued WARNING All combustion performance numbers MUST be verified with a combustion analyzer Failure to do so will result in substantial property damag...

Page 155: ...1 0 4 2 6 5 155 9 5 11 0 4 2 6 5 205 9 5 11 0 4 2 6 5 270 9 5 11 0 4 2 6 5 Table A 5 Acceptable Combustion Readings for LP Operation 0 4 500 ft 9 Verify that the gas inlet pressure is between 8 0 and...

Page 156: ...P see Table B 5 3 Start boiler as described in boiler Installation manual and lock boiler in high fire See XI Startup and Checklist If boiler does not light turn throttle screw in 1 8 turn increments...

Page 157: ...ppm while ensuring CO2 remains in the range specified in Table B 3 If CO Air Free is still above 200 ppm reduce fan speed in 100 rpm increments until CO Air Free is less than 200 ppm 6 Start boiler f...

Page 158: ...NG 2 0 RPTR205 LP 2 6 RPTR270 NG LP 3 4 De rate s per 1000 ft are approximate Based on minimum vent length 0 2000 ft is Sea Level Input Rate 2000 4500 ft derate 1 7 1000 ft Altitude Model Natural Gas...

Page 159: ...izes Field Installed Model Size LP Gas Orifice Dia 85 not used 110 not used 155 not used 205 0 224 in 270 0 224 in Model Fuel HF Target FS RPM LF Target FS RPM 4501 6000 ft 6001 7800 ft 7801 10 100 ft...

Page 160: ...ger and DHW through a flat plate heat exchanger DHW is activated by a flow switch Water temperatures are regulated by the boiler controls and a thermostatic mixing valve III Specifications RPTR155C Bo...

Page 161: ...egulations enforced in the area where the installation is to be made These regulations shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations...

Page 162: ...cause property damage personal injury or loss of life Read and understand the entire Raptor boiler manual before attempting installation start up operation or service Installation and service must be...

Page 163: ...own in Figure C 2 Please note there is no top and bottom supply return connection available on combi 155 boiler only bottom supply and return piping 4 Install DHW piping included in miscellaneous part...

Page 164: ...re Sensor To System Flow Check Close Nipple Locate Header Sensor As Close As Possible To Downstream Tee Hydrolic Separator May Be Substituted For Tees Y Strainer Recommended Cold Water Line Boiler Cir...

Page 165: ...nstallation compliance 2 Confirm that all electrical water and gas supplies are shut off at sources 3 Unpack and identify all parts Retain all instructions IX DHW Section on bench 4 Unpack mixing valv...

Page 166: ...ping instructions in the System Piping Section of this manual 16 Installing isolation valves and drain valves on DHW inlet and outlet is recommended to permit flat plate heat exchanger to be flushed p...

Page 167: ...mperature setting should be done by a licensed contractor per local code requirements To ensure correct temperature control use the water thermometer at faucet outlet XIV Mixing Valve Set up 23 Set an...

Page 168: ...g them Unscrew top and bottom flat plate heat exchanger connections including bottom fasteners Loosen S pipe attached to circulator to facilitate remove of flat plate 2 Pull Flat Plate Heat Exchanger...

Page 169: ...anual open position 3 Remove actuator by depressing locking button and lifting straight up 4 To Install Line up motor coupling to slot in shaft of body and fit the head onto the valve body ensuring it...

Page 170: ...of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED...

Page 171: ...shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting system...

Page 172: ...172...

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