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27

START-UP

PROCEDURES

Lighting the Boiler

Safe-lighting and other performance criteria were met

with the gas manifold and control assembly provided

on the boiler when the boiler underwent tests specified

in the latest edition of the ANSI-Z21.13/CSA 4.9

Standard.

For Standing Pilot Models

A. This boiler has a pilot which must be lighted by

hand. When lighting the pilot, follow these instruc-

tions 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 set-

tle on the floor.

WHAT TO DO IF YOU SMELL 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 neigh-

bor's phone. Follow the gas supplier's instructions.

• If 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 not use this boiler if any part has been under

water. Immediately call a qualified service techni-

cian to inspect the boiler and to replace 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 feed pressure

regulator to minimum 12 psi. Manually open air vent

on the compression tank until water appears, then

close vent.

On multiple-zone systems, purge each zone separate-

ly. Isolate the other zones while one zone is being

purged of air.

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.

CAUTION:

Propane gas is heavier than air and

sinks to the ground. Exercise extreme care in lighting

boiler in confined areas.

WARNING:

If you do not follow these instructions

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

CAUTION:

In case of a prolonged power failure

during freezing weather conditions, boiler and piping

system must be drained completely to avoid possible

damage to the heating system.

NOTE:

Circulator motor supplied with the boiler

does not require lubrication.

Содержание RAYTHERM 0042B

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...

Страница 2: ...2 Rev 29 reflects the following Changes to Note on Page 8 text on Page 10 Item 7 on Page 11 mounting instructions on Page 12...

Страница 3: ...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...

Страница 4: ...earch 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...

Страница 5: ...ican 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 a...

Страница 6: ...del 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...

Страница 7: ...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 c...

Страница 8: ...s found 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...

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...

Страница 10: ...e Venting of Equipment section 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 chim...

Страница 11: ...s 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 g...

Страница 12: ...amper 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 t...

Страница 13: ...er 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 di...

Страница 14: ...14 VENT DAMPER...

Страница 15: ...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...

Страница 16: ...op 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 separa...

Страница 17: ...elief 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...

Страница 18: ...rols 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 installe...

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 Tran...

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: ...t 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 n...

Страница 27: ...ace 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 sea...

Страница 28: ...e 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 mi...

Страница 29: ...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 contr...

Страница 30: ...er 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 instructio...

Страница 31: ...dle 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 liq...

Страница 32: ...AIR 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...

Страница 33: ...hould 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...

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 b...

Страница 35: ...ean 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 Defectiv...

Страница 36: ...placement 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...

Страница 37: ...he 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 int...

Страница 38: ...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...

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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