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INSTALLATION & OPERATING

INSTRUCTIONS

CATALOG NO. 2100.50AA

Effective: 12-26-07

Replaces: 01-31-07

P/N 240488 Rev. 28

WARNING:

If these instructions are not followed exactly, a fire or explosion may

result causing property damage, personal injury or death

FOR YOUR SAFETY:

Do not store 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.

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.

Installation and service must be performed by a qualified installer, service agency or
the gas supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.

Models 0042B, 0066B, 0090B

0135B & 0180B

– Type H

Raytherm™
Residential
Boilers

Содержание 0180B Type H

Страница 1: ... in an explosion or fire 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 Installation and service must be performed by a qualified installer service age...

Страница 2: ...2 ...

Страница 3: ...7 Lighting the Boiler 27 For Standing Pilot Models 27 Filling the System 27 Checking the Circulator 27 For Standing Pilot Models with Robertshaw Gas Valve 2 stage Operation Models 90 13 180 28 To Turn Off Gas to the Boiler Models 90 135 180 28 For Automatic Ignition Models 28 For Intermittent Ignition IID with Honeywell or Robertshaw Gas Valve All Models 29 To Turn Off Gas to the Boiler 29 Shut do...

Страница 4: ...search on Cancer IARC has classified the inhalation of crystalline silica cristabolite as carcinogenic to humans When removing the burners or heat exchangers take precautions to avoid creating airborne dust and avoid inhaling airborne fibers When cleaning spills use wet sweeping or High Efficiency Particulate Air HEPA filtered vacuum to minimize airborne dust Use feasible engineering controls such...

Страница 5: ...rican National Standard ANSI Z21 13 CSA 4 9 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 These boilers are designed for indoor installation with a built in drafthood and a built in sub base for com bustible flooring Models are available with standing pilot or with ...

Страница 6: ...odel No Input MBH Heating Capacity MBH Net I B R Rating Piping Connections A B C K Vent Dia Water NPT Gas NPT H 0042 42 35 30 1 in 1 2 in 11 in 5 3 4 in 5 1 2 in 4 in H 0066 66 54 47 1 in 1 2 in 11 in 5 3 4 in 5 3 4 in 5 in H 0090 90 74 64 1 in 1 2 in 11 in 5 3 4 in 5 3 4 in 5 in H 0135 135 109 95 1 1 4 in 1 2 in 18 in 6 1 4 in 6 1 4 in 6 in H 0180 180 148 129 1 1 4 in 1 2 in 18 in 6 1 4 in 8 in 7...

Страница 7: ...n 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 are listed in Table B below 2 A front clearance of at least 24 is recommended for adequate service of bur...

Страница 8: ...d in refrigerants aerosol propellants drycleaning fluids degreasers and paint removers Other harmful elements may come from bleaches air fresheners 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 t...

Страница 9: ... 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 Z223 1 The discharge opening must be a minimum of two 2 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 ab...

Страница 10: ... Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of the local building codes Common Vents Manifolds that connect more than one boiler to a com mon 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 5 Mini...

Страница 11: ...ed 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 7 Any improper operation of the common venting system should be corrected so that the installation conforms with the latest edition of the National Fuel Gas C...

Страница 12: ...ing the vent damper on a continuous pilot system as this will create a haz ardous condition Fig 9 Installing The Vent Damper in Horizontal Vertical Vents Fig 10 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 explo sion or carbon monoxide poisoning could result Vent Damper Ope...

Страница 13: ...ler main burners are operating Flair Damper NOTE To place vent damper in the open position to allow burner operation Turn the power off Turn the damper blade to fully open position arrow facing same direction as vent pipe Turn power on SS R2 SS2 ES R SC R1 M 2 3 4 1 JUMPER GV 24 VAC TR HL L L 1 2 120 VAC 60Hz TH 1 Fig 12 System Schematic Abbreviation Description M Damper Motor R Relay ES End Switc...

Страница 14: ...14 VENT DAMPER ...

Страница 15: ...S 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 These boilers are also certified to operate on propane...

Страница 16: ...rop Systems with multiple zones may require an addition al circulator Consult manufacturer s data for valve pressure drops When an indirect water heating sys tem 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 val...

Страница 17: ...Relief Valve to Drain Cold Water Inlet Heating Units Fig 15 Single Zone Piping Air Scoop Air Vent Diaphragm Expansion Tank Feed Valve Pipe Pressure Relief Valve to Drain Cold Water Inlet Heating Units Circulators 12 Max Fig 16 Multiple Zones with Circulators Piping Diagrams ...

Страница 18: ...trols drawing on page 28 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 The room thermostat should be installed in accor dance with the manufacturer s instructions The thermostat heat anticipator should be set at 1 0 ampere automatic ignition and 0 60 ampere stand ing pilot for single zone installations For ...

Страница 19: ...19 Wiring Diagrams ...

Страница 20: ...20 ...

Страница 21: ...21 ...

Страница 22: ... 17 Single Zone Taco Valve Fig 18 Dual Zone Taco Valve Fig 19 Dual Zone Honeywell Valve NOTE Maximum three 3 zone valves per one 1 40 VA transformer NOTE Maximum five 5 zone valves per one 1 40 VA Transformer ...

Страница 23: ...23 Fig 20 System with Three 3 Zone Pumps NOTE Check VA rating of each relay coil Total load must not exceed VA rating of transformer Fig 21 Power Vent System with Zone Valve ...

Страница 24: ...24 Fig 22 Primary Secondary Pumping System Honeywell Zone Valve Fig 23 Standing Pilot with Low Water Cut off Device Note Low water cut off LWCO and system switch supplied by others ...

Страница 25: ...25 Fig 24 IID Units with Low Water Cut off Device Note Low water cut off LWCO and system switch supplied by others ...

Страница 26: ...st main valve pilot At the same time the electronic spark genera tor in the module produces a high voltage spark 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 safe ty shutdown or lockout Loc...

Страница 27: ...lace any part of the control system and any gas control which has been under water Filling the System Flush system before putting into operation to ensure that foreign material does not damage pump seals 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 sys tem operation fill system through fee...

Страница 28: ...he lowest setting 3 Turn off all electrical power to the boiler 4 Push in and move gas control lever counter clockwise to OFF position GAS CONTROL LEVER SHOWN IN OFF POSITION GAS INLET 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 on thelabelaffixedtotheunit Ifyoudon tsmellgas go to the next step 6 Lo...

Страница 29: ...y information on the label affixed to the front of the unit If you don t smell gas go to the next step 7 For Honeywell valve turn gas control counter clockwise to On For Robertshaw valve Move gas control lever to On position GAS CONTROL KNOB SHOWN IN OFF POSITION GAS INLET ROBERTSHAW All Models Fig 29 Honeywell Gas Valve Fig 30 Robertshaw Gas Valve 8 Turn on all electrical power to the boiler 9 Se...

Страница 30: ...ter clock wise using the same number of turns as in step b Pilot Adjustment Fig 32 Robertshaw 7200 Gas Valve Models 90 135 180 e Replace pilot adjustment cover screw then follow the lighting instructions to get boiler ready for operation For Automatic Ignition Systems Intermittent Ignition IID 1 Turn on power to the ignition systems and turn gas supply off at the gas valve 2 Check ignition module ...

Страница 31: ...ddle 8 Clean room air intake openings to ensure ade quate flow of combustion and ventilation air 9 Keep boiler area clear and free 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 t...

Страница 32: ...PAIR PROCEDURES Tube Cleaning Procedure Typical Establish a regular inspection schedule the frequency of which depends on the local water condition and severity of service Do not let the tubes clog up solid ly Clean out deposits over 1 16 in thickness To clean the tubes remove the heat exchanger ream tubes and immerse heat exchanger in non inhibited de scale solvent Heat Exchanger Removal 1 Shut w...

Страница 33: ...should be replaced with new ones 2 Install in out and return water headers and install header retainer nuts and torque nuts evenly 3 Replace V baffles 4 Install thermostat sensing bulbs in header wells and replace bulb retaining clips 5 Install inlet and return pipes in water headers using pipe thread sealant 6 Install water pressure relief valve flow switch and low water cut off devices if so equ...

Страница 34: ... 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 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 posi...

Страница 35: ...lean 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 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 Ins...

Страница 36: ...eplacement 1 Shut off electrical power to the boiler 2 Remove wiring connections to switch 3 Remove screws 2 holding the switch 4 Reverse above procedure to re install Vent Thermal Switch Replacement 1 Shut off electrical power to the boiler 2 Remove wiring connections to switch 3 Remove the screws 2 4 Reverse above procedure to re install Ignition Module Replacement 1 Shut off electrical power to...

Страница 37: ...the above procedure to re install Use new gaskets and make sure they are seated prop erly when tightening the nuts and bolts CAUTION To avoid damage to electrical components keep water from getting into the control compartments and gas valve 2 Stage Controller Models 90 135 180 1 Shut off electrical power to the boiler 2 Remove control cover screws and open control compartment 3 The control is fac...

Страница 38: ...y conditions satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts manufactured by others but Raypak will apply any such warranty as may be provided by the parts manufacturers TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of install...

Страница 39: ...39 ...

Страница 40: ...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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