Raypak 0180B Type H manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 2100.50AA Effective: 12-26-07 Replaces: 01-31-07 P/N 240488 Rev . 28 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property damage, personal injury or death . FOR Y OUR SAFETY : Do not store or use gasoline or other flammable vapors and li[...]

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WARNINGS 4 Pay Attention to These T erms 4 RECEIVING EQUIPMENT 5 GENERAL SPECIFICA TIONS 5 INST ALLA TION 7 Code Requirements 7 Mounting Base 7 Clearance Requirements 7 Combustion/V entilation Air 8 V enting Connections 9 V ent Damper Installation Location 1 1 VENT D AMPER WIRING DIAGRAM 14 Gas Supply Connections 15 Gas Pressure 15 W ater Connectio[...]

D ANGER: Indicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored. CA UTION: Indicates the presence of hazards or unsa[...]

RECEIVING EQUIPMENT 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. Remove the boiler from the carton, and if it is dam- aged, report the damage to the carrier immediately . Be sure that you receive t[...]

6 16 33 1 / 4 22 1 / 8 12 1 / 2 5 18 3 1 / 4 2 THERMOST A T CONN (ELECTRICAL CONN ON OTHER SIDE) GAS CONN 3/4 NPT PIPE TO DRAIN 26 1 / 4 1 / 2 C 11 7 / 8 6 INLET OUTLET 3 1 / 8 MIN 19 K A UTOMA TIC VENT DAMPER (FIELD INST ALLED) B A Fig. 1: Dimensions Model No. Input MBH Heating Capacity MBH Net I=B=R Rating Piping Connections A B C K V ent Dia. W [...]

7 INST ALLA TION Code R equir ements 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/NFP A 70. In Canada, installations must conform with the current CSA B149 and the Canadian Electrical Code Part 1 CSA [...]

8 3. Except for carpeted flooring, boilers are certified for installation on combustible floors. 4. For un-insulated hot water pipes, maintain a 2" clearance, or consult local authority having juris- diction. Combustion/V entilation Air 1. The boiler must be provided with adequate supply of air for proper combustion and ventilation in accordan[...]

9 Location of the openings is the same as in the previ- ous 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&[...]

10 Roof Pitch (X/12) H (Min. ft) Flat to 6/12 1 6/12 to 7/12 1.25 Over 7/12 to 8/12 1.5 Over 8/12 to 9/12 2 Over 9/12 to 10/12 2.5 Over 10/12 to 1 1/12 3.25 Over 1 1/12 to 12/12 4 Over 12/12 to 14/12 5 Over 14/12 to 16/12 6 Over 16/12 to 18/12 7 Over 18/12 to 20/12 7.5 Over 20/12 to 21/12 8 T able F: Minimum Height from Roof to Lowest Discharge Ope[...]

11 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. 1. Seal any unused openings in the common venting system. 2. Visually [...]

12 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[...]

13 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. 1 1. 3. T urn the thermostat or controller down again and check that the vent damper position indicator returns to the closed position. The vent damper must be inspected at least once a year by a trained[...]

14 VENT DAMPER[...]

15 Gas Supply Connections 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 T able H above. 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 a[...]

16 shipped loose. The full open position is appropriate for most systems, and ensures adequate flow through the boiler . If system flow is inadequate, (indicated by excessive temperature drop through the system) the bypass valve can be throttled slightly . Care must be taken against over-throttling which may lead to inadequate flow through the boil[...]

17 Air Scoop Air V ent Diaphragm Expansion T ank Feed Va l v e Pipe Pressure Relief V alve to Drain Cold W ater Inlet Heating Units Fig. 15: Single-Zone Piping Air Scoop Air V ent Diaphragm Expansion T ank Feed Va l v e Pipe Pressure Relief V alve to Drain Cold W ater Inlet Heating Units Circulators 12” Max. Fig. 16: Multiple Zones with Circulato[...]

18 Electrical W iring The electrical power supply requirement for these boil- ers is 120 V AC, 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/NFP A 70. Provide a separate fused circuit from the main electri- ca[...]

19 W iring Diag r ams[...]

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22 Fig. 17: Single-Zone T aco V alve Fig. 18: Dual-Zone T aco V alve Fig. 19: Dual-Zone Honeywell V alve NOTE: Maximum three (3) zone valves per one (1) 40 V A transformer . NOTE: Maximum five (5) zone valves per one (1) 40 V A T ransformer.[...]

23 Fig. 20: System with Three (3) Zone Pumps NOTE: Check V A rating of each relay coil. T otal load must not exceed V A rating of transformer . Fig. 21: Power V ent System with Zone V alve[...]

24 Fig. 22: Primary/Secondary Pumping System Honeywell Zone V alve Fig. 23: Standing Pilot with Low W ater Cut-off Device Note: Low water cut-off (L WCO) and system switch supplied by others.[...]

25 Fig. 24: IID Units with Low W ater Cut-off Device Note: Low water cut-off (L WCO) and system switch supplied by others.[...]

26 SER VICING PR OCEDURES General Location of Controls Fast- Response Temperature Sensor 2-Stage Controller Relay Ignition Module (Auto Ignition Only) Fig. 25: Control Box Component Locations Models 135 & 180 CIRCULA TOR VENT SENSOR BYP ASS V AL VE (MODELS 135 & 180 ONL Y) BYP ASS LINE TEMPERA TURE A ND PRESSURE GA UGE 2-ST AGED CONTROLLER [...]

27 ST AR T -UP PR OCEDURES 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. F or Standing Pilot Models A. This boiler has a pilot which must be lighted by han[...]

28 F or Standing Pilot Models with R ober tshaw Gas V alv e, 2-stage Oper ation (Models 90, 135 & 180) 10. T urn on all electrical power to the boiler . 1 1. Set the thermostat to the desired setting. T o T ur n Of f Gas to the Boiler (Models 90, 135 & 180) F or Automa tic Ignition Models Please read carefully and understand the following s[...]

29 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 . F or Inter mittent Ignition (IID) with Honeywe[...]

30 3. T urn 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. T esting the Ignition Safety Shut-of f The ignition system safety shut-off must [...]

31 Inspection Procedur es Bur ner s 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. Y ellow flame indicates clogging of air openings. Lifting or blowing fla[...]

32 Bur ner T r ay R emo val 1. Shut-of f power and gas supply to the boiler . Disconnect union(s) and pilot tubing when pres- ent; then loosen and remove burner hold-down screws. 2. Disconnect wires at gas valve and slide burner tray out. Main Bur ner and Orifice Remo val 1. Remove screws and burner hold-down bracket. 2. Lift burners from slotted s[...]

9. Install flue collector , jacket top and inspection pan- els. Install top holding screws. Install draft diverter and vent piping if so equipped. 10. If gas piping was disconnected, reconnect gas pip- ing system and check for leakage using a soap solution. 1 1. Check for correct water pressure and water level in the system. Make sure that system p[...]

34 TR OUBLESHOO TING 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 ins[...]

35 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 i[...]

36 Adjustment & R eplacement of Components Gas V alve R eplacement 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 bra[...]

37 7. Remove the wedge or retaining clip holding the sensing bulb in the control well in the in/out head- er . 8. Pull out the sensing bulb carefully from the control well. 9. Remove the limit control with capillary from unit. 10. Reverse above procedure to re-install. F ast-Response T emper a tur e Sensor Module R eplacement 1. Shut-of f electrica[...]

38 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 [...]

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ww w .raypa k . com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.[...]