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Fig. 8: Indoor Installation—Models 181-401 & 182-400

Indoor Installations

Models 181-401 & 182-400

Indoor Stack Installation

1. Remove the louvered jacket top by removing four

(4) #10 flathead screws.

2. If originally installed, remove outdoor top from the

louvered jacket top.

3. Place the inner stack adapter panel over the flue

collector inside the heater. Make sure the flanged
side of the flue opening is up.

4. Turn the stack (drafthood) upside down and set it

down bottom side up.

5. Turn the jacket top panel (removed in step 1)

upside down and place it over the stack.

6. Attach the three (3) mounting brackets to the stack

using the screws provided and the holes that are
pre-drilled in the stack.

Make sure the brackets

are positioned with the 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 the four (4) #10 flat-
head screws removed in step 1 above.

Models 514-824

1. Lower outdoor top onto unit. Position top so it is

centered on unit from side to side and front to rear.

2. Tighten the (4) screws (as indicated in Fig. 7) until

they come in contact with the unit jacket top, then
evenly tighten all (4) screws to secure to unit.

Models 926-1758

Boilers are shipped with outdoor vent terminal factory
installed.

Fig. 6: Installing Outdoor Top—Models 514–824

JACKET TOP

FASTENING
SCREW

Fig. 7: Installing Outdoor Top Detail—Models 514–824

10

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Содержание 181

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 43: ...43 ...

Страница 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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