Raypak Boiler 0180B Type H User Guide

INSTALLATION & OPERATING

INSTRUCTIONS

Raytherm™

Residential

Boilers

Models 0042B, 0066B, 0090B

0135B & 0180B – Type H

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.

CATALOG NO. 2100.50AA

Effective: 12-26-07

Replaces: 01-31-07

P/N 240488 Rev. 28

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CONTENTS

WARNINGS

Heat Exchanger Re-assembly

Combustion Chamber Removal

Pay Attention to These Terms

RECEIVING EQUIPMENT

GENERAL SPECIFICATIONS

INSTALLATION

Code Requirements

Mounting Base

5 TROUBLESHOOTING

Adjustment & Replacement of

Components

Replacement Parts

7 WARRANTY

Clearance Requirements

Combustion/Ventilation Air

Venting Connections

Vent Damper Installation Location

VENT DAMPER WIRING

DIAGRAM

Gas Supply Connections

Gas Pressure

Water Connections & System Piping

Electrical Wiring

WIRING DIAGRAMS

SERVICING PROCEDURES

General Location of Controls

SEQUENCE OF OPERATION

Intermittent Ignition Device (IID)

START-UP PROCEDURES

Lighting the Boiler

For Standing Pilot Models

Filling the System

Checking the Circulator

For Standing Pilot Models with

Robertshaw Gas Valve, 2-stage

Operation (Models 90, 13 & 180)

To Turn Off Gas to the Boiler

(Models 90, 135 & 180)

For Automatic Ignition Models

For Intermittent Ignition (IID)

with Honeywell or Robertshaw

Gas Valve (All Models)

To Turn Off Gas to the Boiler

Shut-down Procedure

Testing the Ignition afety Shut-off

Safe Shut-down Tests

Inspection Procedures

REPAIR PROCEDURES

Tube Cleaning Procedure

Heat Exchanger Removal

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WARNINGS

Pay Attention to These Terms

Indicates the presence of immediate hazards which will cause severe

DANGER:

WARNING:

CAUTION:

NOTE:

personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause

severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause

minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which

are important but not related to personal injury hazards.

DANGER: Make sure the gas on which the heater

will operate is the same type as that specified on the

heater rating plate.

WARNING: To minimize the possibility of improper

operation, serious personal injury, fire, or damage to

the heater:

•

Always keep the area around the heater free of

combustible materials, gasoline, and other flam-

mable liquids and vapors.

WARNING—CALIFORNIA PROPOSITION

65: This product contains chemicals known to the

State of California to cause cancer, birth defects or

other reproductive harm.

•

Heater should never be covered or have any

blockage to the flow of fresh air to the heater.

WARNING: This unit contains refractory ceramic

fiber (RCF) insulation in the combustion chamber.

RCF, as manufactured, does not contain respirable

crystalline silica. However, following sustained

exposure to very high temperatures (>2192F), the

RCF can transform into crystalline silica

(cristabolite). The International Agency for Research

on Cancer (IARC) has classified the inhalation of

crystalline silica (cristabolite) as carcinogenic to

humans.

WARNING: Do not use this heater if any part has

been under water. Immediately call a qualified

service technician to inspect the heater and to

replace any part of the control system and any gas

control which has been under water.

WARNING: Should overheating occur or the gas

supply valve fail to shut, do not turn off or disconnect

the electrical supply to the heater. Instead, shut off

the gas supply at a location external to the heater.

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 as local

exhaust ventilation or dust collecting systems to

minimize airborne dust. Wear appropriate personal

protective equipment including gloves, safety

glasses with side shields, and appropriate NIOSH

certified respiratory protection, to avoid inhalation of

airborne dust and airborne fiber particles.

NOTE: These instructions are provided to ensure

the proper installation and operation of Raypak

boilers. Should questions arise regarding the

specifications, installation, operation or servicing of

these boilers, we suggest that the local Sales

representative or the factory be consulted.

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RECEIVING EQUIPMENT GENERAL

SPECIFICATIONS

On receipt of your equipment, visually check for exter-

nal damage to the carton. If the carton is damaged, it

is suggested that a note be made on the Bill of Lading

when signing for the equipment.

Raytherm hydronic boilers are design certified and

tested under the requirements of the latest edition of

the American 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.

Remove the boiler from the carton, and if it is dam-

aged, report the damage to the carrier immediately. Be

sure that you receive the number of packages indicat-

ed on the Bill of Lading. Claims for shortages and

damages must be filed with carrier by consignee.

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 an intermittent ignition device (IID).

Purchased parts are subject to replacement only

under the manufacturer's warranty. Debits for defec-

tive replacement parts will not be accepted and

defective parts will be replaced in kind only per our

standard warranties.

These boilers are equipped with the following compo-

nents: water circulation pump, pressure relief valve,

temperature/pressure gauge, adjustable high limit

switch, drain valve, fast response temperature sensor,

40 VA transformer, pump relay, vent thermal switch,

flame roll-out switch, and redundant combination gas

valve. Two-stage gas valve (50% firing on first stage)

is standard on models H-0090, H-0135 and H-0180.

When ordering parts, you must specify Model and

Serial Number of the boiler. When ordering under war-

ranty conditions, you must also specify date of

installation.

Raypak recommends that this manual be reviewed

thoroughly before installing the boiler. If there are

any questions which this manual does not answer,

please contact your local Raypak representative.

The automatic ignition models and some standing pilot

models are provided with a plug-in connector that is

compatible with the Honeywell D80D vent damper.

Similar type vent dampers made by other manufactur-

ers, and design certified by a nationally-recognized

testing agency, under the ANSI Z21.66 standard, may

also be used.

Follow the installation instructions furnished with the

vent damper package. The plug-in connector can also

be used with power venters. Refer to the specific

installation instructions supplied by the power vent

manufacturer.

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Piping Connections

Heating

Net

Vent

Dia.

Model

No.

Input

MBH

Capacity I=B=R

Water

Gas NPT

NPT

MBH

Rating

H-0042

H-0066

H-0090

H-0135

H-0180

1 in.

1/2 in.

11 in.

18 in.

5 3/4 in. 5 1/2 in.

5 3/4 in. 5 3/4 in.

6 1/4 in. 6 1/4 in.

4 in.

5 in.

6 in.

7 in.

1 in.

135

180

109

148

1 1/4 in.

129

6 1/4 in.

8 in.

Table A: Specifications

AUTOMATIC

VENT DAMPER

(FIELD INSTALLED)

INLET

OUTLET

3/4 NPT PIPE

TO DRAIN

MIN

THERMOSTAT CONN

(ELECTRICAL CONN

ON OTHER SIDE)

GAS

CONN

Fig. 1: Dimensions

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INSTALLATION

Code Requirements

Installation must be in accordance with local codes, or

in the absence of local codes, with the latest editions

of the National Fuel Gas Code, ANSI Z223.1, and the

National Electrical Code, ANSI/NFPA 70. In Canada,

installations must conform with the current CSA B149

and the Canadian Electrical Code Part 1 CSA C22.2

No.1. Where required by the authority having jurisdic-

tion, the installation must conform to American Society

of Mechanical Engineers Safety Code for Controls and

Safety Devices for Automatically Fired Boilers, CSD-1.

Mounting Base

Boiler should be mounted on a level surface. Each

boiler is designed with a built-in sub-base approved for

mounting the boiler on combustible flooring. Boiler

must NOT be installed on carpet.

Fig. 2: Mounting Base

In 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.

NOTE: This boiler should be located in an area

where water leakage will not result in damage to the

area adjacent to the appliance or to the structure.

When such locations cannot be avoided, it is

recommended that a suitable drain pan, adequately

drained, be installed under the appliance. The pan

must not restrict air flow.

2. A front clearance of at least 24" is recommended

for adequate service of burner-tray and controls.

Model

No.

Flue

Vent

Floor

Front

Back Right

Left

Top

0042

0066

Comb.

4 in.

6 in.

6 in. 16 in. 6 in.

0090

0135

0180

Comb. Alcove

Table B: Minimum Clearances From Combustible Materials

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3. Except for carpeted flooring, boilers are certified One opening shall be within 12" of the top, and the

for installation on combustible floors.

other opening within 12" of the floor. If additional gas

appliances are installed in the same space, the total

4. For un-insulated hot water pipes, maintain a 2" input of all gas appliances installed in the same space,

clearance, or consult local authority having juris- must be considered in the calculation. Refer to Sec.

diction.

5.3.5 of the latest edition of the National Fuel Gas

Code for additional requirements.

Combustion/Ventilation Air

WARNING: Air supply to the boiler room must not

be affected by mechanical exhaust vents located in

other parts of the house, such as kitchen or

bathroom fans, or attic blowers. Mechanical exhaust

vents may create a negative pressure condition in

the boiler room that can become a hazard of

asphyxiation, explosion or fire.

CAUTION: Combustion air must not be

contaminated by corrosive chemical fumes which

can damage the boiler. Measures must be taken to

prevent the entry of corrosive chemical fumes to the

combustion and ventilation air supply. Such

chemicals include, but are not limited to, chlorinated

and/or fluorinated hydrocarbons such as 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 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

the heater in order to avoid this problem.

Fig. 3: Location of Openings for

Combustion/Ventilation Air

NOTE: If louvers, grills or screens are used on the

openings, obtain the net free area requirements from

their supplier or manufacturer. If the design free area

of a louver is not known nor available, it shall be

assumed that wood louvers will have 20-25 percent

free area and metal louvers will have 60-75 percent

free area as shown in Sec. 5.3.5 National Fuel Gas

Code.

1. The boiler must be provided with adequate supply

of air for proper combustion and ventilation in

accordance with the latest edition of the National

Fuel Gas Code, ANSI Z223.1, or applicable provi-

sions of the local building codes.

3. If the boiler room is located against an outside wall

and air openings can communicate directly with the

outdoors, the two openings on the outside wall must

each have a net free area as shown in Table D.

2. Models 0042 and 0066 only: When the boiler is

installed in a confined space such as a utility room

or closet where all air is supplied from inside the

building, the boiler room must be provided with

two openings, each one having a minimum net

free area, in square inches as shown in Table C.

Model No.

0042

Sq. in. of Free Area

0066

0090

Model No.

Sq. in. of Free Area

0135

0042

0066

0180

Table C: Minimum Net Free Area

Table D: Minimum Net Free Area

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Location of the openings is the same as in the previ- The discharge opening must be a minimum of two (2)

ous case - that is, within 12" of the top, and within 12" feet vertically from the roof surface and at least two (2)

of the bottom of the enclosure. If horizontal ducts are feet higher than any part of the building within ten (10)

used, the area must be doubled and the duct area feet. Vent stack shall be at least five (5) feet in vertical

shall not be less than the area of the openings they height above the drafthood outlet.

connect, and in no case shall the smallest dimension

be less than 3".

The vent cap location shall have a minimum clearance

of four (4) feet horizontally from, and in no case above

or below, unless a 4-foot horizontal distance is main-

tained, from electric meters, gas meters, regulators

and relief equipment.

Venting Connections

These boilers have built-in drafthoods. Vent piping the

same size or larger than the drafthood outlet is recom-

mended; however, when the total vent height

(drafthood outlet to vent terminal) is at least ten (10)

feet, the vent pipe size may be reduced by one size

only as specified in the latest edition of the National

Fuel Gas Code, ANSI Z223.1.

The weight of the vent stack or chimney must not rest

on the boiler's drafthood. Support must be provided in

compliance with applicable codes. The boiler top and

drafthood must be readily removable for maintenance

and inspection. Vent pipe should be adequately sup-

ported to maintain proper clearances from combustible

construction.

As much as possible, avoid long horizontal runs of

vent pipe and too many elbows. If installation requires

horizontal runs, the vent pipe must have a minimum of

1/4 inch per foot rise and should be supported at not

less than five foot intervals. Maximum vent connector

horizontal length shall be 1-1/2 feet (18 inches) for

each inch of connector diameter as shown in Table E.

Type "B" double-wall (or equivalent) vent pipe is rec-

ommended. However, single-wall metal vent pipe may

be used as specified in the latest edition of the

National Flue Gas Code ANSI Z223.1.

Lowest Discharge

Opening

Listed Cap

Vent

Connector

Diameter (in.)

Max.

Horizontal

Length (ft)

Model No.

Listed Gas Vent

0042

0066, 0090

0135

7.5

Roof Pitch is X/12

0180

10.5

H - Minimum Height from

Roof to Lowest

Discharge Opening

Table E: Maximum Horizontal Length of Vent Pipe

Gas vents supported only by the flashing and extend-

ing above the roof more than five feet should be

securely guyed or braced to withstand snow and wind

loads. We recommend use of insulated vent pipe

spacer through the roofs and walls.

Refer to Table F for detailed information

Fig. 4: Minimum Height from Roof to Lowest Discharge

Opening

For protection against rain or blockage by snow, the

vent pipe 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.

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WARNING: These boilers must not be connected

into any portion of mechanical draft systems

operating under positive pressure. To do so may

cause the flue products to be discharged into the

living space causing serious health injury.

Roof Pitch (X/12)

Flat to 6/12

H (Min. ft)

1.25

1.5

6/12 to 7/12

Over 7/12 to 8/12

Over 8/12 to 9/12

Over 9/12 to 10/12

Over 10/12 to 11/12

Over 11/12 to 12/12

Over 12/12 to 14/12

Over 14/12 to 16/12

Over 16/12 to 18/12

Over 18/12 to 20/12

Over 20/12 to 21/12

Refer to Fig. 4 for graphical reference

For connections to gas vents or chimneys, vent instal-

lations shall be in accordance with Part 7, Venting of

Equipment, of the National Fuel Gas Code, ANSI

Z223.1, or applicable provisions of the local building

codes.

2.5

3.25

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.

7.5

Table F: Minimum Height from Roof to Lowest

Discharge Opening

Fig. 6: Common Venting

Fig. 5: Minimum Venting Measurements

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At the time of removal of an existing boiler, the follow-

ing steps shall be followed with each appliance

remaining connected to the common venting system

placed in operation, while the other appliances remain-

ing connected to the common venting system are not

in operation.

Vent Damper Installation

Location

The vent damper supplied with each boiler must be

located in the vent so that it serves only the appliance

for which it is intended.

1. Seal any unused openings in the common venting

system.

If improperly installed, a hazardous condition, such as

an explosion or carbon monoxide poisoning, could

result. Make certain that it is mounted in an accessible

location at least 6 in. (152.4 mm) from any combustible

material or the heat exchanger and that the position

indicator is in a visible location.

2. Visually inspect the venting system for proper size

and horizontal pitch and make sure there is no

blockage or restriction, leakage, corrosion and

other deficiencies which could cause an unsafe

condition.

The vent damper must be installed at the appliance

drafthood, and without modification of the drafthood.

3. Insofar as is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the com-

mon venting system are located and other spaces

of the building. Turn on clothes dryers and any

appliance not connected to the common venting

system. Turn on any exhaust fans, such as range

hoods and bathroom exhausts, so they will oper-

ate at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers.

To connect the vent damper wiring to the boiler wiring,

connect the damper circuit plug to the boiler circuit

plug.

4. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat

so appliance will operate continuously.

5. 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 to visually check spillage.

6. After it has 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 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 Code, ANSI Z223.1. When resizing any

portion of the common venting system, the com-

mon venting system should be resized to

approach the minimum size as determined using

the appropriate tables in Chapter 10 and in

Appendix G of the National Fuel Gas Code, ANSI

Z 223.1 and CSA - B149.

Fig. 7: Vent Damper Location

WARNING:

Carefully read and follow the

installation instructions furnished with the vent

damper package. Failure to follow these instructions

can cause asphyxiation, explosion or fire.

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Mounting

On vertical vents, the vent damper may be mounted

with the actuator in any position. On horizontal vents,

do not mount the actuator either directly above or

directly below the vent pipe; mount the vent damper

actuator to the side of the vent.

The vent damper is set up for a continuous pilot sys-

tem. If the vent damper is installed on a system with an

Intermittent Pilot or Hot Surface Ignition, the energy

savings of the vent damper can be improved by plug-

ging the hole in the vent damper blade using the

knockout plug provided in the parts envelope.

Hole in Vent Damper Blade

Closed Position

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 Operation

DO NOT plug the hole if installing the vent damper on

a continuous pilot system as this will create a haz-

ardous condition.

For safe, efficient operation, the vent damper and all

flue-product-carrying areas of the appliance must be

checked annually, with particular attention given to

deterioration from corrosion or other sources.

Fig. 8: Vent Damper

Check vent damper operation as follows:

1. When the boiler is off, check that the vent damper

position indicator points to the closed position (see

Fig. 11).

Damper Position Indicator

Fig. 9: Installing The Vent Damper in Horizontal

& Vertical Vents

Damper Open

Damper Closed

Fig. 11: Vent Damper Position Indicator

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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.

2. Turn the thermostat or controller up to call for heat

and check that the vent damper indicator points to

the open position, as shown in Fig. 11.

SS₁

R ₂

3. Turn the thermostat or controller down again and

check that the vent damper position indicator

returns to the closed position.

SS₂

The vent damper must be inspected at least once

a year by a trained, experienced service techni-

cian. The name of the person who originally

installed your vent damper is shown on the instal-

lation label. Damper must be in open position

when boiler main burners are operating.

R ₁

Fig. 13: Ladder Diagram

Abbreviation

Description

Damper Motor

Relay

Flair Damper

SS1

SS2

End Switch

N/C Safety Switch

N/O Safety Switch

Transformer, 120/24V

High Limit

R₂

SS₂

24V Gas Valve

SS₁

Thermostat, Heating, Low Voltage

Jumper

R₁

JUMPER

Table G: Legend for Figures 12 & 13

24 VAC

L ₂

120 VAC

60Hz

L₁

Note: Circuit shown with damper in closed position, no call for

heat.

Fig. 12: System Schematic

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VENT DAMPER

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1/2 in. Pipe 3/4 in. Pipe 1 in. Pipe 1 1/4 in. Pipe

Model

No.

Nat. Pro. Nat. Pro. Nat. Pro. Nat.

Pro.

0042 125

350

160

500

175

125

0066

0090

0135

0180

460

300

150

400

200 450

115 300

425

Table H: Maximum Equivalent Pipe Length (Feet)

Gas Supply Connections

NOTE: Do not use teflon tape on gas line pipe

thread. A flexible sealant suitable for use with Natural

and Propane gases is recommended.

The inlet gas connection of the boiler gas valve is 1/2".

Provide an adequate gas piping supply line no smaller

than 1/2", according to Table H above.

These boilers are also certified to operate on propane

gas, when equipped with the combination gas valve

and orifices (pilot and main burners) sized for propane

gas.

Gas piping must have a sediment trap ahead of the

boiler gas controls, and a manual shut-off valve locat-

ed outside the jacket. All gas piping should be tested

after installation in accordance with local codes.

Gas Pressure

The gas valve is provided with pressure taps to meas-

ure gas pressure upstream of the gas valve and

downstream which is the same as the manifold pres-

sure.

Manual

Valve

Union

Inches

Regulator

Setting

Gas Type

Natural

WC Min.

WC Max.

7.0

10.5

13.0

3.5

Sediment Trap

Gas Valve

Propane

12.0

11.0

Must be Supplied by Installer

Fig. 14: Sediment Trap

Table I: Minimum and Maximum Gas Pressure

CAUTION: The boiler and its manual shut-off valve

must be disconnected from the gas supply during

any pressure testing of that system at test pressures

in excess of 1/2 psi (3.45 kPa). Dissipate test

pressure in the gas supply line before reconnecting

the boiler and its manual shut-off valve to gas supply

line. FAILURE TO FOLLOW THIS PROCEDURE

MAY DAMAGE THE GAS 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.

Water Connections & System

Piping

The pipe size for water connections is shown on page

6. Typical piping systems are shown on pages 17 to

19.

This boiler is supplied with a circulator and built-in

bypass as standard to ensure the required minimum

water flow in the boiler. The bypass on models H-0135

and H-0180 is provided with an adjustable valve that is

factory-set in the full open position. The handle is

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shipped loose. The full open position is appropriate for Systems with multiple zones may require an addition-

most systems, and ensures adequate flow through the al circulator. Consult manufacturer's data for valve

boiler.

pressure drops. When an indirect water heating sys-

tem is used, it is recommended that a separate

If system flow is inadequate, (indicated by excessive circulator be installed to meet the required flow and

temperature drop through the system) the bypass pressure drop conditions of the indirect water heater.

valve can be throttled slightly. Care must be taken

against over-throttling which may lead to inadequate We recommend that the make-up water from the cold

flow through the boiler and boiler harmonics (a hum- water line have a check valve, gate valve, and feedwa-

ming sound from the heat exchanger).

ter regulator set at 12 psi. Install unions and gate or

ball valves at inlet and outlet connections at the boiler

If adequate system flow cannot be obtained without to facilitate servicing.

causing harmonics, an additional pump is required.

The factory-mounted circulator will provide adequate The pressure relief valve is mounted on the boiler and

water flow for systems designed at a 20°F temperature must be piped to a drain. We recommend that all high

drop, and system pressure drop or head not exceed- points be vented and that purge valves be installed. A

ing that which is shown in Table J.

boiler installed above radiation level must be provided

with a low water cut-off device. See page 27 for wiring

hook-up.

System Flow

Max. System

Head (ft/WC)

Model No.

(gpm)

The boiler, when used in connection with a refrigera-

tion system, must be installed so that the chilled

medium is piped in parallel with the boiler with appro-

priate valves to prevent the chilled medium from

entering the boiler.

H-0042

H-0066

H-0090

H-0135

H-0180

3.5

5.3

8.0

8.5

7.3

6.5

The boiler piping system of a hot water heating boiler,

that is connected to heating coils located in air han-

dling units where they may be exposed to refrigerated

air circulation, must be equipped with flow control

valves or other automatic means to prevent gravity cir-

culation of the boiler water during the cooling cycle.

11.0

14.6

10.0

7.0

Table J: System Pressure Drop

When the total system head exceeds the available

head pressures, a primary/secondary pumping system A diaphragm expansion tank should be installed in the

is recommended.

return line. A typical 8"-diameter expansion tank can

be used on models H-0042, and H-0066, and an 11"-

The minimum boiler operating temperature should be diameter expansion tank can be used on models

105°F. When operating at low temperature applica- H-0090, H-0135 and H-0180. Consult tank manufac-

tions, ΔT (temperature rise) must be 20°F or less.

turer for correct sizing.

Propylene glycol solution is commonly used in the

heating system when freeze protection is required.

This will affect the system design and pump perform-

ance. As a rule of thumb, 50% solution of propylene

glycol will require the system flow (gpm) to increase by

14%, and the system head (ft/WC) by 23% in order to

maintain the same heat transfer load.

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Piping Diagrams

Air Vent

Air

Scoop

Diaphragm

Expansion Tank

Feed

Valve

Pipe Pressure

Relief Valve

to Drain

Cold Water

Inlet

Heating Units

Fig. 15: Single-Zone Piping

12” Max.

Air Vent

Air

Scoop

Diaphragm

Expansion Tank

Feed

Valve

Pipe Pressure

Relief Valve

to Drain

Circulators

Cold Water

Inlet

Heating Units

Fig. 16: Multiple Zones with Circulators

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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 multi-zone

applications, the heat anticipator setting should be

based on the ampere load in the thermostat circuit.

Electrical Wiring

The electrical power supply requirement for these boil-

ers is 120 VAC, 60 Hz. Field wiring connections and

electrical grounding must comply with the local codes,

or in the absence of local codes, with the latest edition

of the National Electrical Code, ANSI/NFPA 70.

NOTE: If it is necessary to replace any of the

original wiring, it must be replaced with 105°C wire or

its equivalent, except 150°C black wire must be

replaced with 150°C wire or its equivalent. See Fig.

19 for 150°C wire indication.

Provide a separate fused circuit from the main electri-

cal panel to the boiler, and a disconnecting means

within sight of the boiler.

Remove the control box cover and make the power

supply connections in the field wiring compartment.

(See general location of controls 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.

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Wiring Diagrams

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Fig. 17: Single-Zone Taco Valve

NOTE: Maximum three (3) zone valves per one (1) 40 VA transformer.

Fig. 18: Dual-Zone Taco Valve

NOTE: Maximum five (5) zone valves per one (1) 40 VA Transformer.

Fig. 19: Dual-Zone Honeywell Valve

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NOTE: Check VA rating of each relay coil. Total load must not exceed VA rating of transformer.

Fig. 20: System with Three (3) Zone Pumps

Fig. 21: Power Vent System with Zone Valve

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Fig. 22: Primary/Secondary Pumping System Honeywell Zone Valve

Note: Low water cut-off (LWCO) and system switch supplied by others.

Fig. 23: Standing Pilot with Low Water Cut-off Device

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Note: Low water cut-off (LWCO) and system switch supplied by others.

Fig. 24: IID Units with Low Water Cut-off Device

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SERVICING

PROCEDURES

SEQUENCE OF

OPERATION

General Location of Controls

Intermittent Ignition Device

(IID)

2-Stage Controller

Boilers equipped with the IID system will automatical-

ly light the pilot burner first and then the main burner,

each time there is a call for heat from the room ther-

mostat. Whenever the room thermostat is calling for

heat, the circulator supplied with the boiler will be

energized and should be running.

Relay

The ignition control module will also be energized to

initiate the pilot ignition by opening the first 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.

Fast-

Ignition Module

(Auto Ignition Only)

Response

Temperature

Sensor

Ignition spark continues only until the timed trial for

ignition period ends. Then, the module goes into safe-

ty shutdown or lockout. Lockout de-energizes the first

main valve operator and closes the first main (pilot)

valve in the gas control, stopping pilot gas flow. The

ignition control system must be reset by setting the

thermostat below room temperature for one minute or

by turning off power to the module for one minute.

Fig. 25: Control Box Component Locations

Models 135 & 180

CIRCULATOR

VENT SENSOR

BYPASS VALVE

(MODELS 135 & 180 ONLY)

BYPASS LINE

When the pilot flame is established, flame rectification

circuit is completed between the sensor and burner

ground. The flame sensing circuit in the module

detects the flame current, shuts off the spark genera-

tor and energizes the second main valve operator

which opens the second main valve. This allows gas to

flow to the burners where it is ignited by the pilot burn-

er flame.

TEMPERATURE

AND PRESSURE GAUGE

2-STAGED CONTROLLER

(MODEL 90 ONLY)

PRESSURE

RELIEF VALVE

RELAY

ADJUSTABLE

HIGH LIMIT

FIELD WIRING

COMPARTMENT

When the thermostat is satisfied, the valve operators

are de-energized shutting off the pilot and main burn-

ers, and also the circulator.

FAST RESPONSE

TEMPERATURE SENSOR

IGNITION MODULE

(AUTO IGNITION ONLY)

TRANSFORMER

ROLL-OUT SENSOR

GAS VALVE

Fig. 26: Component Locations

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Filling the System

START-UP

PROCEDURES

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.

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.

On multiple-zone systems, purge each zone separate-

ly. Isolate the other zones while one zone is being

purged of air.

CAUTION: Propane gas is heavier than air and

sinks to the ground. Exercise extreme care in lighting

boiler in confined areas.

Checking the Circulator

For Standing Pilot Models

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.

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

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

hand. When lighting the pilot, follow these instruc-

tions exactly.

NOTE: Circulator motor supplied with the boiler

does not require lubrication.

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.

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.

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.

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*If lever does not spring back to "PILOT" position

when released, stop and immediately call your

service technician or gas supplier.

*If the pilot does not stay lit after several tries,

move the gas control lever to "OFF" and call your

service technician or gas supplier.

For Standing Pilot Models with

Robertshaw Gas Valve,

2-stage Operation

(Models 90, 135 & 180)

9. Stand to the side of the boiler and move the gas

1. STOP! Read the safety information.

control lever counter-clockwise

10. Turn on all electrical power to the boiler.

11. Set the thermostat to the desired setting.

to "ON".

2. Set the thermostat to the lowest setting.

3. Turn off all electrical power to the boiler.

4. Push in and move gas control lever counter-

clockwise

to "OFF" position.

To Turn Off Gas to the Boiler

(Models 90, 135 & 180)

GAS CONTROL

LEVER SHOWN

IN "OFF" POSITION

1. Set the thermostat to the lowest setting.

2. Turn off all electrical power to the boiler

3. Push in and move gas control lever counter-

GAS INLET

clockwise

to "OFF" position. Do not force.

For Automatic Ignition Models

Fig. 27: Gas Valve

Please read carefully and understand the following

safety information before operating the boiler.

NOTE: Lever cannot be moved from "ON" to "OFF"

unless lever is pushed in slightly. Do not force.

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

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.

A. This boiler is equipped with an ignition device

which automatically lights the pilot. Do not try to

light the pilot by hand; or this boiler may not have

a pilot and is equipped with a hot surface ignition

device which automatically lights the burners. Do

not try to light the burners by hand.

6. Locate pilot mounted on the right side of the

burner tray, and right of first burner.

B. BEFORE OPERATING smell all around the boiler

area for gas. Be sure to smell next to the floor

because some gases are heavier than air and will

settle on the floor.

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 neigh-

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

If you cannot reach your gas supplier, call the fire

department.

HONEYWELL PILOT

ROBERTSHAW PILOT

Fig. 28: Pilots

•

7. Movecontrolleverclockwise

to "SET"

position and immediately light pilot with a match.

8. Hold lever in "SET" position for 1/2 minute after

pilot is lit. Release lever, and it will spring back

to "PILOT" position. Pilot should remain lit. If it

goes out, repeat steps 4 through 8.

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

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technician. Force or attempted repair may result in

a fire or explosion.

GAS CONTROL

KNOB SHOWN

IN "OFF"

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.

POSITION

GAS INLET

For Intermittent Ignition (IID)

with Honeywell or Robertshaw

Gas Valve (All Models)

ROBERTSHAW

(All Models)

Fig. 30: Robertshaw Gas Valve

1. STOP!Readtheprevioussafetyinformation.

2. Set the thermostat to the lowest setting.

3. Turn off all electrical power to the appliance.

4. Thisboilerisequippedwithanignitiondevicewhich

automatically lights the pilot. Do not try to light the

pilot by hand.

8. Turn on all electrical power to the boiler.

9. Set thermostat to desired setting.

10. If the boiler will not operate, follow the instructions

"To Turn Off Gas To Boiler" and call your service

technician or gas supplier.

To Turn Off Gas to the Boiler

GASCONTROL

KNOBSHOWN

IN"OFF"

1. Set the thermostat at the lowest setting.

2. Turn off all electrical power to the boiler if service

is to be performed.

POSITION

3. For Honeywell valve:

GASINLET

Turn gas control knob clockwise

"Off". Make sure knob rest against stop.

For Robertshaw valve:

HONEYWELL

(Models 30 - 90)

Push in and move gas control lever to "Off"

position.

Fig. 29: Honeywell Gas Valve

5. For Honeywell valve: Turn gas control knob

clockwise

to "Off".

For Robertshaw valve: Push in and move gas

control lever to "Off" position.

6. Wait 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 the

labelaffixedtothefrontoftheunit. Ifyoudon'tsmell

gas, go to the next step.

7. For Honeywell valve: turn gas control counter-

HONEYWELL PILOT

clockwise

to "On".

Fig. 31: Honeywell Pilot

For Robertshaw valve: Move gas control lever

to "On" position.

Shut-down Procedure

To prevent freeze damage to the heating system, it is

recommended that the following system shut-down

procedure be performed.

1. Set the room thermostat to "OFF" or the lowest

setting.

2. Turn off all electrical switches to the boiler.

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3. Turn off all gas valves supplying gas to the boiler.

Refer to operating instruction label on the boiler.

4. Shut-off the water supply to the boiler piping sys-

tem loop.

5. Open drain valve on the boiler to remove water

from the boiler and the piping circuits.

e. Replace pilot adjustment cover screw, then follow

the lighting instructions to get boiler ready for

operation.

For Automatic Ignition Systems

Intermittent Ignition (IID)

NOTE: It may be necessary to open the purge

valves and/ or manual air vents to facilitate complete

drainage of water from the heating system.

1. Turn on power to the ignition systems and turn gas

supply off at the gas valve.

2. Check ignition module as follows:

a. Set the thermostat or controller above room

temperature to call for heat.

CAUTION: Should overheating occur or the gas

supply fails to shut-off, DO NOT turn off or

disconnect the electrical supply to the pump.

Instead, shut-off the gas supply at a location external

to the boiler. Failure to observe this precaution may

aggravate the overheated condition resulting in

possible damage to the boiler and injury to the user.

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.

Testing the Ignition Safety

Shut-off

5. Systems should start as follows:

a. Spark will turn on and pilot gas valve will open

at once. Pilot burner should ignite after gas

reaches the pilot burner.

The ignition system safety shut-off must be tested by

conducting the following tests:

b. Spark ignition should cut-off when pilot flame

is established.

For Standing Pilot Systems

c. Main gas valve should open and main burner

should ignite after gas reaches the burner

port.

1. With the main burners on, remove the pilot adjust-

ment cover screw. NOTE: There is no pilot

adjustment cover on Robertshaw 7200 gas valve.

2. Insert a small slot screw driver and turn the

Safe Shut-down Tests

adjustment screw clockwise

until pilot

flamegoesout. Noteandcountnumberofturns

made.

Limit Action

3. Gasvalvewillshut-offmainburnersafterabout

three(3)minutes.Ifthegasvalvewillnotshut-off,

followtheinstructions"ToTurnOffGasToBoiler"

and call service technician or your gas supplier.

4. Return pilot adjustment screw counter-clock-

With the burner operating, lower the high limit setting

to simulate an overheated boiler. Normal shutdown

should occur. Restore the normal limit setting, and the

burner should restart.

wise

in step (b).

, using the same number of turns as

Flame Failure

With burner operating, close the manual fuel valves to

simulate a flame failure. System should lock out after

safety switch timing (15 seconds). After the safety

switch has cooled, open the manual valves (relight

standing pilots) and reset the safety switch; the burn-

er should restart.

PILOT KEY

Pilot Adjustment

Fig. 32: Robertshaw 7200 Gas Valve (Models 90, 135, 180)

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*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. Inspect oil pump motor and bearing assembly, if oil

cups are provided.

Inspection Procedures

Burners

Clean main burners and air louvers of dust, lint and

debris. Keep boiler area clear and free from com-

bustibles and flammable liquids. Do not obstruct the

flow of combustion and ventilation air. Make visual

check of burner and pilot flame. Yellow flame indicates

clogging of air openings. Lifting or blowing flame indi-

cates high gas pressure. Low flame indicates low gas

pressure.

7. Check flow switch paddle.

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

time delay prevents premature lockout due to tempo-

rary conditions such as power failure or air pockets.

Flush float type devices at beginning of each heating

season.

NOTE: Modulating burner flame varies in height from approximately

1/4" at low fire to approximately 4" in high fire.

Procedure for Cleaning Flue Gas

Passageways

Fig. 33: Main Burner Flame

Soot will clog areas behind fins and eventually cause

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, see Burner Tray Removal.

4. Take garden hose and wash heat exchanger, mak-

ing sure soot is removed from between fins. (Avoid

excessive water against refractory).

5. Reassemble; when boiler is fired, some steam will

form from wet refractory. This is normal.

NOTE: In extreme cases it may be necessary to

remove the heat exchanger completely for cleaning.

The simplest method is steam cleaning at a local car

wash. DO NOT WIRE BRUSH!

Fig. 34: Pilot Burner Flame (Standing Pilot Units)

Inspection Schedule

To be performed the first and third month after initial

start up and then on an annual basis. If problems are

found, refer to Troubleshooting Guide for additional

directions.

CAUTION: Soot is combustible, so exercise

extreme care.

1. Remove top of boiler and inspect heat exchanger

for soot and examine venting system.

2. Remove rear header and inspect for scale

deposits.

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Burner Tray Removal

REPAIR PROCEDURES

1. Shut-off power and gas supply to the boiler.

Disconnect union(s) and pilot tubing when pres-

ent; then loosen and remove burner hold-down

screws.

Tube Cleaning Procedure

(Typical)

2. Disconnect wires at gas valve and slide burner

tray out.

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.

Main Burner and Orifice Removal

1. Remove screws and burner hold-down bracket.

To clean the tubes, remove the heat exchanger, ream

tubes and immerse heat exchanger in non-inhibited

de-scale solvent.

NOTE: If the heat exchanger is sooted badly, the

burner hold-down bracket and spacer can become

distorted from direct flame impingement and this

usually necessitates replacement of these parts.

Heat Exchanger Removal

1. Shut water, gas and electricity off, close valves,

relieve pressure and remove relief valve. Remove

front inspection panel.

2. Lift burners from slotted spacer and slide from ori-

fices. Clean with a wire brush.

3. Orifices usually do not need to be replaced. To

clean, run either copper wire or wood through ori-

fice. Do not enlarge hole. To remove orifice, use a

socket wrench and remove the manifold. DO NOT

over-tighten when reinstalling.

2. Remove top holding screws.

3. Remove draft diverter, lift and remove top and flue

collector on stack type models.

4. Loosen bolts and disconnect flange nuts on

inlet/outlet header, loosen union(s) at gas pipe,

and slide boiler away from piping until studs clear

the heater.

5. Lift heat exchanger straight up using caution not to

damage refractory.

RAYPAKTUBECLEANINGKIT

Extension Pieces (5)

Auger with Carbide Tip

Wire Brush

5/8" - PN 052871F

7/8" - PN 052870F

Fig. 35: Raypak Tube Cleaning Kit

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9. Install flue collector, jacket top and inspection pan-

els. Install top holding screws. Install draft diverter

and vent piping if so equipped.

Heat Exchanger Re-assembly

1. Heat exchanger water header O-rings should be

replaced with new ones.

10. If gas piping was disconnected, reconnect gas pip-

ing system and check for leakage using a soap

solution.

2. Install in/out and return water headers and install

header retainer nuts and torque nuts evenly.

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.

3. Replace "V" baffles.

4. Install thermostat sensing bulbs in header wells

and replace bulb retaining clips.

12. Within two (2) days of start-up, recheck all air

vents and expansion tank levels.

5. Install inlet and return pipes in water headers

using pipe thread sealant.

Combustion Chamber Removal

6. Install water pressure relief valve, flow switch, and

low water cut-off devices if so equipped.

To remove combustion chamber panels, you must first

7. Open water supply and return shut-off valves. Fill remove the heat exchanger. Remove combustion

boiler and water piping system with water. Check chamber panels individually.

boiler and piping system for leaks at full line pres-

sure. Run system circulating pump for a minimum

of 1/2 hour with boiler shut off.

8. Shut down entire system and vent all radiation

units and high points in system piping. Check all

strainers for debris. Expansion tank water level

should be at the 1/4 mark and the balance of the

tank filled with air (when using Air-X-Tank).

Fig. 36: Combustion Chamber Panels—Top View

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TROUBLESHOOTING

These instructions are primarily intended for the use of qualified personnel specifically trained and experienced

in the installation of this type of heating equipment and related system components. Installation and service per-

sonnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this

equipment nor attempt repairs according to these instructions.

SOLUTIONS

PROBLEM

CAUSES

1)Check circuit breakers, disconnect

switch. Make sure power is on.

1)When room thermostat is turned on,

boiler does not operate.

1)No power to the boiler.

2)Check continuity on thermostat and

wiring circuit. Replace thermostat, or

repair wiring connections.

2)Defective room thermostat or discon-

nected wire in thermostat circuit.

3) Check secondary voltage. If no 24V,

replace transformer.

4) Check relay coil or contacts. Replace

as required.

3)Defective transformer.

4)Defective pump relay.

5)Defective pump.

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.

2)When room thermostat is calling for

heat, pump is on, but burners will not

turn on.

1)For standing pilot models, pilot

burner not lighted.

2)If pilot burner will not stay lighted,

thermocouple or gas valve may be

defective.

3)Turn knob to "ON" position.

3)Gas knob in "Pilot" position.

4)Turn gas knob to "ON". If ignition

module locks out, reset by interrupt-

ing power to boiler.

4)For automatic ignition models,

gas valve knob is in "OFF" position.

5) Check for blockage of venting system

or disconnected vent piping. After

problem is corrected push button to

reset, or replace single-use type vent

switch.

5)Vent switch is open.

6)Check for blockage of flue or sooted

heat exchanger. After problem is

corrected push button to reset or re-

place single use type roll-out switch.

7)Setting may be too low. Check water

flow and adjust setting to obtain 20-

30°F temperature rise.

6)Roll-out switch is open.

7)High limit is open.

8)Red LED on circuit board will be ON

to indicate a loose sensor connection

or a shorted sensor. Check terminal

connectors or replace sensor as re-

quired.

8) Fast Response Temperature

Sensor probe is defective.

NOTE: Red LED will also be ON if

sensor temperature exceeds 300°F or

drops below - 20°F. It will turn OFF

when sensor temperature returns to

the proper range. Yellow LED will be

ONiftemperatureexceeds240°F. Itwill

turn off when sensor temperature falls

below 180°F. When either Red or Yel-

low LED is ON, boiler will be shut down.

9)Check voltage across output and

common terminals. If no 24V is pres-

ent, replace board.

9) Fast Response Temperature

sensor board is defective.

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10) Defective ignition module or

defective gas valve.

10)Beforemodulegoesintoalock-out,

check voltage across MV and MV/

PV. If no 24V is present, replace

module. If 24V is present, replace

gas valve.

3)Pilot Outage.

(Standing pilot models)

1) Too low or too high gas pressures.

1) Adjust inlet gas pressure as shown

on rating plate.

2) Restricted pilot.

2) Clean pilot orifice.

3) Weak thermocouple.

3) Replace thermocouple.

4)Yellow lazy flame.

1) Too low gas pressure.

2) Restricted burner intake ports.

3) Restricted gas line.

1) Adjust manifold pressure as shown

on rating plate.

2) Clean burners free of debris or in-

sects.

3) Clean gas line or increase gas line

piping.

5)Sooting

1) Refer to installation instructions re-

garding combustion air require-

ments.

1) Insufficient combustion air.

2) Improper venting.

3) Severe yellow burner flames.

2) Refer to installations instructions.

3) See yellow flame section above.

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Flame Roll-out Switch Replacement

Adjustment & Replacement of

Components

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.

DANGER—SHOCK HAZARD: Make sure

electrical power to the boiler is disconnected to avoid

potential serious injury or damage to components.

Vent Thermal Switch Replacement

Gas Valve Replacement

1. Shut-off electrical power to the boiler.

2. Remove wiring connections to switch.

3. Remove the screws (2).

1. Shut-off electrical power and gas supply to the

boiler.

2. Remove gas piping to gas valve inlet.

3. Disconnect wiring connections, pilot tubing (when

present).

4. Remove screws (2) holding the burner tray.

5. Slide burner tray out.

6. Remove gas valve bracket screws and bracket.

7. Unscrew gas valve from gas pipe.

8. Reverse above procedure to re-install.

4. Reverse above procedure to re-install.

Ignition Module Replacement

1. Shut-off electrical power to the boiler.

2. Remove control cover screws and open control

compartment.

3. Disconnect wiring connections to module.

4. Remove screws (2) holding module.

5. Reverse above procedure to re-install.

Pilot Burner Cleaning or

Replacement (Standing Pilot)

Transformer Replacement

1. Shut-off electrical power and gas supply to the

boiler.

2. Disconnect gas piping to gas valve.

3. Disconnect wiring connections to gas valve.

4. Remove screws (2) holding the burner tray.

5. Slide burner tray out.

6. Remove screw holding pilot lighter tube.

7. Remove screws (2) holding pilot bracket on the

burner tray.

8. Disconnect thermocouple and pilot tubing from the

gas valve.

9. Remove pilot burner from pilot bracket.

10. Remove pilot orifice and blow away lint or dirt.

Clean with wire or small brush. NOTE: Make sure

pilot orifice is clear, but do not enlarge the hole.

11. Reverse above procedure to re-install.

1. Shut-off electrical power to the boiler.

2. Remove control cover screws and open control

compartment.

3. Disconnect wiring connections from transformer

leads.

4. Remove screws (2) holding transformer.

5. Reverse above procedure to re-install.

Pump Relay Replacement

1. Shut-off electrical power to the boiler.

2. Remove control cover screws and open control

compartment.

3. Disconnect wiring to the relay.

4. Remove screws (2) holding relay.

5. Reverse above procedure to re-install.

High Limit Control

Pilot

1. Shut-off electrical power to the boiler.

2. Remove control cover screws and open control

compartment.

Air

Opening

3. The control is factory set at 180°F. To adjust set-

ting, use a small screw driver and turn dial

clockwise to lower the temperature or counter-

clockwise to raise the setting.

Orifice

4. To replace the limit control, disconnect the wiring

connections.

5. Remove screws (2) holding the limit control.

6. Remove upper access panel.

Fig. 37: Pilots, Honeywell (Left) and Robertshaw (Right)

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7. Remove the wedge or retaining clip holding the

sensing bulb in the control well in the in/out head-

er.

2-Stage Controller

(Models 90, 135 & 180)

8. Pull out the sensing bulb carefully from the control

well.

1. Shut-off electrical power to the boiler.

2. Remove control cover screws and open control

compartment.

3. The control is factory set at 160°F. To adjust to

another setting, use a small screw driver and turn

dial clockwise to lower the temperature or counter-

clockwise to raise the setting.

4. To replace the stage controller, disconnect the

wiring connections.

9. Remove the limit control with capillary from unit.

10. Reverse above procedure to re-install.

Fast-Response Temperature Sensor

Module Replacement

1. Shut-off electrical power to the boiler.

2. Remove control cover screws and open control 5. Remove screws (2) holding the staged controller.

compartment.

6. Remove upper access panel.

3. Disconnect wiring to the board.

4. Carefully pull out the control board from the nylon

pin supports.

7. Remove the wedge or retaining clip holding the

sensing bulb in the control well in the in/ out head-

er.

Reverse above procedure to re-install.

8. Pull out the sensing bulb carefully from the control

well.

9. Remove the stage control with capillary from unit.

10. Reverse above procedure to re-install.

Fast-Response Temperature Sensor

Probe Replacement

Replacement Parts List

1. Shut-off electrical power to the boiler.

2. Shut-off water supply to the boiler and open drain

valve to remove water to the sensor probe level.

3. Remove control cover screws and open control

compartment.

NOTE: To supply the correct part it is important that

you supply the model number, serial number and

type of gas when applicable.

4. Disconnect wire leads from control board.

5. Remove upper access panel.

6. Remove sensor probe from in/out header.

7. Reverse above procedure to re-install.

Any part returned for replacement under standard

company warranties must be properly tagged with

Raypak return parts tag, completely filled in with the

heater serial number, model number etc., and shipped

to Raypak freight prepaid.

Circulator Replacement

1. Shut-off electrical power to the boiler.

2. Shut-off water supply and open drain valve to

remove water in the piping at the pump level.

If determined defective by Raypak and within warran-

ty, the part will be returned in kind or equal

substitution, freight collect. Credit will not be issued.

CAUTION: To avoid damage to electrical

components, keep water from getting into the control

compartments and gas valve.

RAYPAK, INC.

2151 Eastman Avenue

Oxnard, CA 93030

3. Disconnect wiring and conduit connections to the

pump.

4. Disconnect the bypass tube connections to the

inlet flange.

5. Remove the nuts and bolts at the inlet and outlet

flanges. Remove old gaskets.

6. Remove the pump.

7. Reverse the above procedure to re-install. Use

new gaskets and make sure they are seated prop-

erly when tightening the nuts and bolts.

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Catalog No.: 1910.10H

Effective: 01-01-04

Replaces: 05-15-03

LIMITED PARTS WARRANTY

RESIDENTIALHEATING BOILERS

MODELS 42 TO 180

SCOPE:

Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak will be free

from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor

charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the

owner’s responsibility.

ANY PART MANUFACTURED BY RAYPAK:

One (1) year warranty from date of boiler installation, or eighteen (18) months from date of factory shipment based on Raypak’s records,

whichever comes first.

SATISFACTORY PROOF OF INSTALLATION DATE, SUCHAS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILLBE VOID IF THE

BOILER RATING PLATE ISALTERED OR REMOVED.

HEAT EXCHANGER WARRANTY:

Second through tenth years from date of installation, Raypak warrants that the copper and cast iron waterway are free from defects in

material and workmanship. If any of these parts are found defective Raypak will replace or repair free of charge subject to conditions

listed under “Scope” above.

Eleventh through twentieth years from date of installation, Raypak warrants that the copper and cast iron waterways are free from

defects in material and workmanship. If any of these parts are found defective Raypak will replace the original parts and payment of a

proportionate charge equal to 1/120^thof the list price of such parts, at the time the warranty claim is made, for each month, or portion there

of, beyond the tenth year.

ADDITIONAL WARRANTY EXCLUSIONS:

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the boiler in accordance with our printed instructions provided;

2. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding boiler design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the boiler system;

7. Failure to eliminate air from, or replenish water in, the connected water system;

8. Chemical contamination of combustion air or use of chemical additives to water;

9. Boilers installed in buildings other that one- or two-family dwellings.

PARTS REPLACEMENT:

Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested,

with transportation charges prepaid, and all applicable warranty 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 installation and description of the problem.

The installer must then notify a Raypak distributor for instructions regarding the claim. If neither the installer nor the distributor is available,

contact Service Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authoriza-

tion must first be received from Raypak before replacement of any part.

EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY:

This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IS

IN LIEU OFALLOTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUTNOTLIMITEDTO IMPLIED WARRANTIES OF MERCHANTABIL-

ITYAND FITNESS FORAPARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITYANDTHE SOLE REMEDYAGAINST RAYPAK WITH RESPECT

TO DEFECTIVE PARTS SHALLBEAS PROVIDED IN THIS WARRANTY. ITISAGREED THAT RAYPAK SHALLHAVE NO LIABILITY, WHETHER

UNDERTHIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FORANYSPECIAL, CONSEQUENTIAL, OR INCIDENTAL,

DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states do not allow limitations on how long an implied warranty lasts, or

for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not apply to you.

This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that

you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective

date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the date of manufacture plus

thirty (30) days.

_____________________________________________________

Name of Owner

______________________________________________

Name of Installer

_____________________________________________________

Address

______________________________________________

Address

_____________________________________________________

______________________________________________

_____________________________________________________

ModelNo.

______________________________________________

Serial No.

Date of Installation_____________________________________

Date of Initial Operation___________________________

RAYPAK, INC. • 2151 Eastman Avenue • Oxnard, CA 93030 • (805) 278-5300 • Fax (800) 872-9725 • www.raypak.com

P/N:240419

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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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