Raypak 0066B manual

Catalog No.: 2100.50W Effective: 10-01-04 Replaces: 04-01-04 P/N 240488 THIS MANUAL SHOULD BE MAINTAINED IN LEGIBLE CONDI- TION AND KEPT ADJACENT TO THE BOILER OR IN A SAFE PLACE FOR FUTURE REFERENCE. INST ALLA TION AND OPERA TING INSTRUCTIONS Raytherm TM T ype H RESIDENTIAL BOILERS Models 0042B, 0066B,0090B 0135B, 0180B FOR YOUR SAFETY Do not stor[...]

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. These instructions are provided to assure the proper installation and operation of Raypak boilers. Should questions arise regarding the specifications, installation, operation or servicing of[...]

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. SPECIFICATIONS AND DIMENSIONS 3 Fig. #8978.1 RECEIVING EQUIPMENT On receipt of your equipment, visually check for external da[...]

4 CLEARANCE REQUIREMENTS 1) Minimum Clearances From Combustible Materials Model Floor Front Back Right Left Top Flue N o . Vent 0042 Comb. 4" 6" 6" 6" 16" 6" 0066 0090 0135 Comb. Alcove 6" 6" 6" 16" 6" 0180 2 ) A front clearance of at least 24" is recommended for adequate service of burner[...]

5 Location of the openings is the same as in the previous case - that is, within 12" of the top, and within 12" of the bottom of the enclosure. If horizontal ducts are used, the area must be doubled and the duct area shall not be less than the area of the openings they connect, and in no case shall the smallest dimension be less than 3&qu[...]

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 supported to maintain proper clearances from combustible construc- tion. Type "[...]

7 At the time of removal of an existing boiler, the following 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. ( a ) Seal any unused openings in the common venting system. ( b ) Visuall[...]

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 system. If the vent damper is installed on a syst[...]

SS R 2 SS 2 ES R SC R 1 M 2 3 4 1 JUMPER GV 24 V AC TR HL L L 12 120 V AC 60Hz TH 1 9 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. R 2 4 3 J SS HL GV 1 ES R 2 SC M 24 V AC R 1 SS 2 TH DAMPER POSIT[...]

VENT DAMPER WIRING DIAGRAM 10[...]

The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and downstream which is the same as the manifold pres- sure. WATER CONNECTIONS & SYSTEM PIPING The pipe size for water connections is shown on page 3. Typical piping systems are shown on pages 12 to 14. The boiler is supplied with a circulator and bui[...]

Systems with multiple zones may require an additional circulator. Consult manufacturer's data for valve pressure drops. When an indirect water heating system is used, it is recommended that a separate circulator be installed to meet the required flow and pressure drop conditions of the indirect water heater. We recommend that the make-up water[...]

13 ZONE HEATING WITH INDIRECT DOMESTIC HOT WATER SUPPLY Fig.# 8998.1 ZONE VALVES HEATING UNITS FEED VALVE COLD WATER INLET CIRCULATOR PIPE PRESSURE RELIEF VALVE TO DRAIN DIAPHRAGM EXPANSION TANK AIR SCOOP AIR VENT HOT WATER SUPPLY COLD WATER SUPPLY[...]

14 MULTIPLE ZONES WITH CIRCULATORS MULTIPLE ZONES WITH ZONE VALVES AIR SCOOP AIR VENT 12" MAX. AIR VENT AIR SCOOP COLD WATER INLET FEED VALVE PIPE PRESSURE RELIEF VALVE TO DRAIN DIAPHRAGM EXPANSION TANK HEATING UNITS ZONE VALVES DIAPHRAGM EXPANSION TANK PIPE PRESSURE RELIEF VALVE TO DRAIN FEED VALVE COLD WATER INLET CIRCULATORS HEATING UNITS F[...]

15 WIRING DIAGRAM KEY Fig.# 8096.2 The room thermostat should be installed in accordance with the manufacturer's instructions. The thermostat heat anticipator should be set at 1.0 ampere (automatic ignition) and 0.60 ampere (standing pilot) for single- zone installations. For multi-zone applications, the heat antici- pator setting should be ba[...]

16 WIRING DIAGRAMS[...]

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WIRING DIAGRAM: Single-Zone Taco Valve WIRING DIAGRAM: Dual-Zone Taco Valve WIRING DIAGRAM: Dual-Zone Honeywell Valve NOTE: Maximum three (3) zone valves per one (1) 40 VA transformer. NOTE: Maximum five (5) zone valves per one (1) 40 VA Transformer. Fig. # 2230e Fig. # 2229e Fig. # 2228e 19[...]

WIRING DIAGRAM: System with (3) Zone Pumps NOTE: Check VA rating of each relay coil. Total load must not exceed VA rating of transformer. Fig. #2232e Fig. #2233e Fig. #2234e WIRING DIAGRAM: Power Vent System w/ Zone Valve 20[...]

21 WIRING DIAGRAM: Primary/Secondary Pumping System Honeywell Zone Valve Fig. #2223.2e[...]

WIRING DIAGRAM: Standing Pilot With Low Water Cut-off Device Fig. # 2223.1e Note : Low water cut-off (LWCO) and system switch supplied by others. WIRING DIAGRAM: IID Units With Low Water Cut-off Device Note : Low water cut-off (LWCO) and system switch supplied by others. 22 Fig. # 2357E[...]

SERVICING PROCEDURES GENERAL LOCATION OF CONTROLS Fast- Response Temperature Sensor CONTROL BOX COMPONENT LOCATIONS MODELS 135 & 180 2-Stage Controller Relay Fig.# 8195.1 Ignition Module (Auto Ignition Only) 23 Fig.# 8195.4 SEQUENCE OF OPERATION INTERMITTENT IGNITION DEVICE (IID) Boilers equipped with the IID system will automatically light the[...]

24 START-UP PROCEDURES Lighting the Boiler Safe-lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in the latest edition of the ANSI-Z21.13 Standard. CAUTION: Propane gas is heavier than air and sinks to the ground. Exercise extreme care in lig[...]

25 10 . Turn on all electrical power to the boiler. 11 . Set the thermostat to the desired setting. TO TURN OFF GAS TO THE BOILER: (Models 90, 135 & 180) 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- clockwise to "OFF" position. Do not force. [...]

26 FOR INTERMITTENT IGNITION (IID) WITH HONEY- WELL OR ROBERTSHAW GAS VALVE (All Models) 1. STOP! Read the previous safety information. 2. Set the thermostat to the lowest setting. 3. Turn off all electrical power to the appliance. 4. This boiler is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot[...]

3 2 1 S E T P I L O T O N O F F PILOT ADJ PILOT KEY 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 poss[...]

Fig. #8964 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 direc- tions. 1. Remove top of boiler and inspect heat exchanger for soot and examine venting system. 2. Remove re[...]

29 Extension Pieces (5) Auger with Carbide Tip Wire Brush Fig. #8154 Another method is to remove the heat exchanger, ream tubes and immerse heat exchanger in non-inhibited de-scale solvent. HEAT EXCHANGER REMOVAL 1. Shut water, gas and electricity off, close valves, relieve pressure and remove relief valve. Remove side inspection panels. 2. Remove [...]

6. Remove combustion chamber clips at the four corners of the heat exchanger. 7. Lift heat exchanger straight up using caution not to damage refractory. HEAT EXCHANGER RE-ASSEMBLY 1. Heat exchanger water header O-rings should be replaced with new ones. 2. Install in/out and return water headers and install header retainer nuts and torque nuts evenl[...]

TROUBLESHOOTING GUIDE IMPORTANT NOTICE 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 personnel may be required by some states to be licensed. Persons not qualified shall no[...]

10) Before module goes into a lock-out, check voltage across MV and MV/ PV. If no 24V is present, replace module. If 24V is present, replace gas valve. 1) Adjust inlet gas pressure as shown on rating plate. 2) Clean pilot orifice. 3) Replace thermocouple. 1 ) Adjust manifold pressure as shown on rating plate. 2) Clean burners free of debris or in- [...]

ADJUSTMENT/REPLACEMENT OF COMPONENTS DANGER - SHOCK HAZARD Make sure electrical power to the boiler is disconnect- ed to avoid potential serious injury or damage to com- ponents. 1. Gas Valve Replacement a) Shut-off electrical power and gas supply to the boiler. b) Remove gas piping to gas valve inlet. c) Disconnect wiring connections, pilot tubing[...]

12 . 2-Stage Controller (Models 90, 135 & 180) a ) Shut-off electrical power to the boiler. b) Remove control cover screws and open con- trol compartment. c) 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. d )[...]

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LIMITED P ARTS W ARRANTY RESIDENTIAL HEA TING 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 W a[...]

Raypak, Inc. , 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX (800) 872-9725 Raypak Canada LTD , 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036 Litho in U.S.A. www .raypak.com[...]