CATALOG NO.: 2000.52G
Effective: 06-01-00
Replaces: 07-01-94
USERS INFORMATION MANUAL
FOR GAS FIRED BOILERS
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
-
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.
CAUTIONS: Propane gas is heavier than air and sinks to the ground. Exercise extreme care in lighting heater
in confined areas.
Do not use this boiler if any part has been under water. Immediately call a qualified service technician to
inspect the boiler and to replace any part of the control system and any gas control which has been under water.
Should overheating occur or the gas supply fail 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 appliance.
Raypak recommends that this manual be reviewed thoroughly before installing your Raypak Boiler. If there
are any questions which this manual does not answer please contact your local Raypak representative or the
factory.
OPERATING CONTROLS
Model W1 with On/Off Controls
The boiler is equipped with an adjustable tankstat. Set dial for desired temperature.
Models with Mechanical Modulation: H1, H5, W2, N, R
Sizes 133 through 1826. These boilers are equipped with modulating gas valves. They have one or more valves
in addition to the main electric gas valve. Their purpose is to adjust the firing rate to meet the required load. The
modulator will throttle the boiler input to meet the system demand. The valve has a remote capillary bulb immersed
in a well at the header outlet to maintain a constant outlet water temperature. When multiple valves are furnished,
they can be staged to give greater flexibility of control. Consult the dial setting tag attached to the control for your
desired water temperature.
MODULATING VALVE (ROBERTSHAW)
MODULATING VALVE CHART —7000
TEMPERATURE —°F
N
W
H
R
DIAL POSITION
Lo
1
2
3
4
5
6
7
8
110
117
124
130
137
143
150
156
163
170
150
157
164
170
177
183
190
196
203
210
Hi
Fig. # 8936.1
P/N 240412
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GENERAL LOCATION OF CONTROLS
ELECTRICAL J-BOX
OUTLET
T & P GAUGE
(Not Shown)
INLET
MODULATING
GAS VALVES WITH
REGULATOR
HI-LIMIT
PILOT LOCATIONS
SEDIMENT TRAP
(BY OTHERS)
MANUAL GAS VALVE
FIG.#S8185.0
START-UP PROCEDURE
GENERAL
LIGHTING INSTRUCTIONS
BOILERS WITH MANUALLY LIT PILOTS
FOR YOUR SAFETY READ BEFORE OPERATING
Before lighting a new installation, water should be
flowing through the heater.
WARNING: If you do not follow these instructions
exactly, afireorexplosionmayresultcausingproperty
damage, personal injury or loss of life.
CAUTION: Propane gas is heavier than air and sinks
to the ground. Exercise extreme care in lighting heater
in confined areas.
A. This appliance has a pilot which must be lighted
by hand. When lighting the pilot, follow these in-
structions exactly.
INITIAL START-UP – PUMP AND MOTOR
B. BEFORE LIGHTING Smell all around the appli-
ance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and
will settle on the floor.
Many pumps are now direct drive. They have no
coupler or bearing assembly. These pumps do not
require lubrication. Others require SAE-30 non-deter-
gent oil to lubricate both the motor and the bearing
assembly. Consult motor manufacturer's instructions.
Clean dust and lint from pump and motor. Check
pump coupler and tighten if necessary.
Flush system before putting into operation to as-
sure that foreign material does not damage pump
seals.
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
neighbor's phone.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call
the fire department.
*
CAUTION:
A. Pump must be off to check oil in bearing
assembly.
B. Do not run pump without water in system.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
3
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not push in or turn by hand, do not try to repair it,
call a qualified service technician. Force or at-
tempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to
goes out, repeat steps 5 through 9.
* If knob does not pop up when released, stop
and immediately call your service technician or
gas supplier.
* If the pilot does not stay lit after several tries,
turn the gas control knob to “OFF” and call
your service technician or gas supplier.
10. Stand to the side of the boiler and turn the gas
replace any part of the control system and any
gascontrol which has been under water.
control knob counter clockwise
11. Replace boiler door panel.
to “ON”.
LIGHTING INSTRUCTIONS
12. Turn on all electric power to the appliance.
13. Set the thermostat to the desired setting.
1. STOP! Read the safety information above.
2. Set the thermostat on the lowest setting.
3. Turn off all electric power to the appliance.
4. Remove boiler door panel.
TO TURN OFF GAS TO APPLIANCE
5. Push in gas control knob slightly and turn clock-
1. Set the thermostat to the lowest setting.
2. Turn off all electric power to the appliance.
3. Remove boiler door.
wise
to “OFF”.
GAS CONTROL KNOB SHOWN IN "OFF" POSITION
4. Push in the gas control knob slightly and turn
clockwise to
5. Replace boiler door panel.
"OFF". Do not force.
GAS CONTROL KNOB
SHOWN IN "OFF" POSITION
BOILERS WITH AUTOMATICALLY LIT IID PILOTS
AND MANUAL GAS VALVES
FOR YOUR SAFETY READ BEFORE OPERATING
GAS INLET
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
Fig.#8081
Fig. # 8243.0
NOTE: Knob cannot be turned from “PILOT” to
“OFF” unless knob is pushed in slightly. Do not
force.
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
6. 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
above on this label. If you don't smell gas, go to the
next step.
B. BEFORE OPERATING Smell all around the
appliance area for gas. Be sure to smell next to
the floor because some gas is heavier than air
and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
7. Locate pilot mounted on the burner drawer.
8. Turn knob on gas control counter clockwise
to “PILOT”.
*
*
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
neighbor's phone, follow the gas supplier's
instructions.
*
*
THERMOCOUPLE
PILOT
BURNER
If you cannot reach your gas supplier, call
the fire department.
Fig.# 8083
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, do not try to repir it,
call a qualified service technician.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
9. Push in control knob all the way and hold in.
Immediately light the pilot with a match. con
tinue to hold the control knob in for about one (1)
minute after the pilot is lit. Release knob and it
will pop back up. Pilot should remain lit. If it
4
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BOILERS WITH AUTOMATICALLY LIT IID
PILOTS AND AUTOMATIC GAS VALVES
technician to inspect the appliance and to
replace any part of the control system and any
gas control which has been under water.
Lighting Instructions
1. Close all gas valves. Turn off electric power
supply. Wait 5 minutes.
LIGHTING INSTRUCTIONS
2. Open manual pilot valve. Turn on electric
power. Pilot is automatically lighted.
3. Open main gas valve.
4. Set temperature controls to desired tempera-
ture.
1. STOP! Read the safety information above.
2. Set the thermostat on the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
To Shut Down
Close all manual gas valve. Turn off electric
power.
5. Remove boiler door panel.
6. Turn gas control knob clockwise
to
“OFF”. Make sure knob rest against stop.
7. 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
above on this label. If you don't smell gas, go to the
next step.
8. Turn gas control knob counter clockwise
to “OFF” until it stops. Push in gas control knob
and continue rotating counter clockwise
to “ON” position. Make sure knob rest against
stop.
Fig. # 8929.1
IGNITION MODULE
GAS CONTROL
KNOB SHOWN
IN "ON"
BOILERS WITH AUTOMATICALLY LIT C2/IRI
PILOT AND MANUAL GAS VALVES
POSITION
FOR YOUR SAFETY READ BEFORE OPERATING
GAS INLET
Fig.# 8082
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
9. Replace boiler door panel.
10. Turn on all electric 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.
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
B. BEFORE OPERATING Smell all around the appli-
ance area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle
on the floor.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to the lowest setting.
2. Turn off all the electric power to the appliance if
service is to be performed.
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 instruc-
tions.
3. Remove boiler door panel.
4. Turn gas control knob clockwise
to
*
*
"OFF". Make sure knob rest against stop.
5. Replace boiler door panel.
If you cannot reach your gas supplier, call the
fire department.
5
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C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will not
2. Turn off all the elctric power to the appliance if
service is to be performed.
push in or turn by hand, do not try to repair it, call 3. Remove boiler door panel.
a qualified service technician. Force or attempted 4. Turn gas control knob clockwise
to
repair may result in a fire or explosion.
"OFF". Make sure knob rest against stop.
5. Replace boiler door panel.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service BOILERS WITH AUTOMATICALLY LIT C2/IRI
technician to inspect the appliance and to
replace any part of the control system and any
gascontrol which has been under water.
PILOT AND AUTOMATIC GAS VALVES
1. Close all gas valves. Turn off electric power
supply. Wait five (5) minutes.
LIGHTING INSTRUCTIONS
2. Open manual pilot valve. Turn on electric
power. Push and release electric control reset
button (Center of control cover). Pilot is auto-
matically lighted.
3. Open main gas valve.
4. Set temperature controls to desired tempera-
ture.
1. STOP! Read the safety information.
2. Set the thermostat on the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically light the pilot. Do
not try to light the pilot by hand.
5. Remove boiler door panel.
To Shut Down
6. Turn gas control knob clockwise
to
Close all manual gas valves. Turn off electric
power.
“OFF”. Make sure knob rest against stop.
7. 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
above on this label. If you don't smell gas, go to the
next step.
FLAME SAFETY
CONTROL
RELAY
8. Turn gas knob counter clockwise
from
"OFF" until it stops. Push in gas control knob
and continue rotating counter clockwise
to "ON" position. Make sure knob rest against
stop.
Fig.# 9318
9. Replace boiler door panel.
INSPECTION PROCEDURES
GAS CONTROL
KNOB SHOWN
IN "ON"
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 ventilating air. Make visual
check of burner and pilot flame. Yellow flame indicates
clogging of air openings. Lifting or blowing flame
indicates high gas pressure. Low flame indicates low
gas pressure.
POSITION
GAS INLET
Fig.# 8082
10. Turn on all electric power to the appliance.
11. Push in and release electric control reset button
(center of control cover). Pilot is automatically
lighted.
12. Set thermostat to desired setting.
13. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance” and
call your service technician or gas supplier.
NOTE: Modulating burner flame varies in height from
approximately 1/4" at low fire to approximately 3" at
high fire.
CONTROLS
TO TURN OFF GAS TO APPLIANCE
Check all controls to see that they are operational.
To check IID's electronic safety, turn off main burner.
1. Set the thermostat to the lowest setting.
6
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Observe pilot burner when shutting off pilot gas. Igni- RAYPAK HEATING AND HOT WATER SUPPLY
tion spark should go on. Main gas valve will also drop EQUIPMENT LIMITED WARRANTY
out.
High Limit Switch - to check high limit switch, turn SCOPE: Raypak, Inc. ("Raypak") warrants to the
dial setting down to a point slightly below the tempera- original owner that all parts of this boiler which are
ture of the water leaving the boiler. The reset button actually manufactured by Raypak will be free from
should snap out and the burner should shut off. Reset failure under normal use and service for the specified
dial to 190° F and push reset button. Burner should warranty periods and subject to the conditions set forth
light.
in this Warranty. Labor charges and other costs for
parts removal or reinstallation, shipping and transpor-
tation are not covered by this Warranty but are the
owner's responsibility.
HEAT EXCHANGER WARRANTY: Five (5) Years
from date of boiler installation. This includes only the
copper, bronze and cast iron waterways. Twenty (20)
Years from date of boiler installation against "Thermal
Shock" (excluded, however, if caused by boiler opera-
tion at large changes exceeding 150°F between the
water temperature at intake and boiler temperature, or
operating at boiler temperatures exceeding 230°F).
Fig.# S8144.0
MAIN BURNER FLAME
NORMAL INSPECTION PROCEDURES
ANY OTHER PART MANUFACTURED BY RAYPAK:
First and third month after initial start up and then One (1) Year warranty from date of boiler installation, or
on an annual basis. If problems are found, refer to eighteen (18) months from date of factory shipment
Trouble Shooting guide for additional directions.
1. Remove top of boiler and inspect heat exchanger SATISFACTORY PROOF OF INSTALLATION DATE,
for soot and examine venting system. SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS
2. Remove rear header and inspect for scale depos- WARRANTY WILL BE VOID IF THE BOILER RATING
based on Raypak's records, whichever comes first.
its.
PLATE IS ALTERED OR REMOVED.
*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, if oil
cups are provided.
Examples of misuse or neglect include, but are not
limited to, physical damage from external force, not
following installation instructions, leaving door off for
extended periods, location near corrosive gases, pump
(when supplied by us), not lubricated in accordance
B. Disconnect pump from header and check con- with listed instructions, etc.
dition of pump impeller. Check condition of
bearing by attempting to move impeller from
side to side. Replace any parts showing wear.
C. Check pump coupler for wear and vibration.
7. Check flow switch paddle.
CORPORATE HEADQUARTERS:
RAYPAK,INC.
31111 Agoura Road
8. Clean room air intake openings to assure adequate Westlake Village, CA 91361
flow of combustion and ventilation air. (818) 889-1500
9. Keep boiler area clear and free from combustible FAX (818) 889-4522
materials, gasoline, and other flammable vapors
and liquids.
*Should be checked monthly. (Takes approximately 15
minutes).
When ordering parts, you must specify Model and
Serial number of boiler. When ordering under warranty
conditions, you must also specify date of installation.
7
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Raypak, Inc., 31111 Agoura Road, Westlake Village, CA 91361-4699
(818) 889-1500 FAX (818) 889-4522
Litho In U.S.A.
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