Raypak 0090B 0135B Users Manual 2100.50(residential I O)

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Catalog No.: 2100.50P

Effective: 11-01-99

Replaces: 6-01-99

P/N 240488

THIS MANUAL SHOULD BE MAINTAINED IN LEGIBLE CONDITION

AND KEPT ADJACENT TO THE BOILER OR KEPT IN A SAFE PLACE

FOR FUTURE REFERENCE.

OPERATING AND

INSTALLATION

INSTRUCTIONS

Models

0030B, 0042B, 0066B, 0090B

0135B, 0180B

Type H

RESIDENTIAL BOILERS

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.

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause

property damage, personal injury or loss of life. Refer to the user's information manual provided

with this boiler. Installation and service must be performed by a qualified installer, service agency

or the gas supplier.

FOR YOUR SAFETY

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.

These instructions are provided to assure the proper

installation and operation of Raypak boilers. Should

questions arise regarding the specifications, installa-

tion, operation or servicing of these boilers, we suggest

that the local Sales representative or the factory be

consulted.

3 1. RECEIVING EQUIPMENT

3 2. GENERAL SPECIFICATIONS AND DIMENSIONS

4 3. INSTALLATION PROCEDURES

4 - Code Requirements

4 - Mounting Base

4 - Clearance Requirements

4 - Combustion/Ventilation Air

5 - Venting Connections

7 - Vent Damper Installation

10 - Gas Supply Connections

10 - Water Connections & System Piping

14 - Electrical Wiring

22 4. SERVICING PROCECURES

22 - General Locations of Controls

22 - Sequence of Operation

23 - Start Up Procedures

28 - Safe Shutdown Test

28 - Normal Inspection Procedures

29 - Repair Section

31 5. TROUBLE SHOOTING GUIDE

33 - Adjustments/Replacements of Components

34 6. REPLACEMENT PARTS LIST

Contents

1. RECEIVING EQUIPMENT

On receipt of your equipment it is suggested that

you visually check for external 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 equipment.

Remove the boiler from the carton and if it is damaged

report the damage to the carrier immediately. Be

sure that you receive the number of packages indicated

on the Bill of Lading. Claims for shortages and

damages must be filed with carrier by consignee.

Purchased parts are subject to replacement only

under the manufacturer's warranty. Debits for defective

replacement parts will not be accepted and defective

parts will be replaced in kind only per our standard

warranties.

When ordering parts, you must specify Model and

Serial Number of boiler. When ordering under warranty

conditions, you must also specify date of installation.

Raypak recommends that this manual be re-

viewed thoroughly before installing your Raypak

Boiler. If there are any questions which this manual

does not answer, please contact your local Raypak

representative.

2. GENERAL SPECIFICATIONS

The Raypak hydronic boilers are design certified by

the American Gas Association, and tested under the

requirements of the American National Standard, ANSI

Z21.13. 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.

The boilers are designed for indoor installation with

a built-in drafthood, and a built-in sub-base for combus-

tible flooring. Models are available with standing pilot,

or with intermittent ignition device (I.I.D.). The boilers

are equipped with the following components: water

circulation pump, pressure relief valve, temperature/

pressure gauge, adjustable high limit switch, drain

valve, fast response temperature sensor, 40 VA trans-

former, pump relay, vent thermal switch, flame roll-out

switch, and redundant combination gas valve for use

with either natural or propane gases. Two-staged gas

valve (50% firing on 1st stage) is standard on models

H-0090, H-0135 and H-0180.

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 standards, 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.

SPECIFICATIONS AND DIMENSIONS

THERMOSTAT CONN

(ELECTRICAL CONN

ON OTHER SIDE)

GAS

CONN

3/4 NPT PIPE

TO DRAIN

INLET

OUTLET

MIN

AUTOMATIC

VENT DAMPER

(FIELD INSTALLED)

HEATING NET K

INPUT CAPACITY I=B=R WATER GAS VENT

MODE

MBH MBH RATING NPT. NPT. A B C DIA.

H-0030 30 25 22 1" 1/2" 11" 5 3/4 5 1/2 4"

H-0042 42 35 30 1" 1/2" 11" 5 3/4 5 1/2 4"

H-0066 66 54 47 1" 1/2" 11" 5 3/4 5 3/4 5"

H-0090 90 74 64 1" 1/2" 11" 5 3/4 5 3/4 5"

H-0135 135 109 95 1 1/4" 1/2" 18" 6 1/4 6 1/4 6"

H-0180 180 148 129 1 1/4" 1/2" 18" 6 1/4 8.0 7"

CONNECTIONS

PIPING

Fig. #8978.1

3. INSTALLATION PROCEDURES

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

CAN/CGA B149.1 or .2 and the Canadian Electrical

Code Part 1 CSA C22.2 No.1. Where required by the

authority having jurisdiction, the installation must con-

form to American Society of Mechanical Engineers

Safety Code for Controls and Safety Devices for Auto-

matically Fired Boilers, No. 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 flooring.

CARPET

NOTE: The 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 in-

stalled under the appliance. The pan must not restrict

air flow.

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

Model Floor Front Back Right Left Top Flue

No. Vent

0030

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-tray and controls.

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 jurisdic-

tion.

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 ven-

tilation air supply. Such chemicals include, but are not

limited to, chlorinated and/or fluorinated hydrocarbons

such as found in refrigerants, aerosol propellants, dry-

cleaning fluids, degreasers, and paint removers. Other

harmful elements may come from bleaches, air fresh-

eners, 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.

1) The boiler must be provided with adequate supply of

air for proper combustion and ventilation in accor-

dance with Sec. 5.3, of the latest edition of the

National Fuel Gas Code, ANSI Z223.1, or appli-

cable provisions of the local building codes.

CARPET Fig.# 8196.0p

2) When the boiler is installed in a confined space

such as a utility room or closet (Models 0030,0042

and 0066 only), 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 follows:

Model Sq. In. of Free Area

0030, 0042 & 0066 100

One opening shall be within 12 inches of the top,

and the other opening within 12 inches of the floor. If

additional gas appliances are installed in the same

space, the total input of all gas appliances installed in

the same space, must be considered in the calculation.

Refer to Sec. 5.3.5 of the latest edition of the National

Fuel Gas Code for additional requirements.

Fig. #8198.0

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

openings, obtain the net free area 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.

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, in square inches as

follows:

Model Sq. In. Of Free Area

0030 & 0042 12

0066 18

0090 24

0135 35

0180 45

Location of the openings is the same as in the

previous case - that is, within 12 inches of the top, and

within 12 inches 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 small-

est dimension be less than 3 inches.

VENTING CONNECTIONS

These boilers have built-in drafthoods. Vent piping

the same size or larger than the draft hood outlet is

recommended; 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 Part 11, Note 2 and in Appendix G of the

latest edition of the National Fuel Gas Code, ANSI Z

223.1. As much as possible avoid 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 hori-

zontal length shall be 1-1/2 feet (18 inches) for each inch

of connector diameter as follows.

Boiler Size Vent Connector Max Horizontal

Diameter Length - FT

30 & 42 4" 6

66 & 90 5" 7.5

135 6" 9

180 7" 10.5

Gas Vents supported only by the flashing and

extending 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.

For protections 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 Z 223.1.

The discharge opening must be a minimum of two

feet vertically from the roof surface and at least two (2)

feet higher than any part of the building within ten (10)

feet. Vent stack shall be at least five (5) feet in vertical

height above the drafthood outlet. The vent cap location

shall have a minimum clearance of four (4) feet horizon-

tally from, and in no case above or below, unless a 4-foot

horizontal distance is maintained, from electric meters,

gas meters regulators and relief equipment.

12"

The weight of the vent stack or chimney must not

rest on boiler draft hood. Support must be provided in

compliance with applicable codes. The boiler top and

draft hood must be readily removable for maintenance

and inspection. Vent pipe should be adequately sup-

ported to maintain proper clearances from combustible

construction.

Type "B" double wall (or equivalent vent pipe is

recommended. However single wall metal vent pipe

may be used as specified in the latest edition of the

National Flue Gas Code ANSI Z 223.1.

Fig.# 8191.0

10’

2’ MIN.

5’ MIN.

2’ MIN.

OR LESS

VENT CAP

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.

For connections to gas vents or chimneys, vent

installations 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.

COMMON VENTS

Manifolds that connect more than one

boiler to a common 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.

Fig. #9001

Lowest Discharge

Opening

Listed Cap

Listed Gas Vent

Roof Pitch is X/12

H (Min.)-Minimum Height from

Roof to Lowest

Discharge Opening

Roof Pitch H (Min.) Ft.

Flat to 6/12 1.0

6/12 to 7/12 1.25

Over 7/12 to 8/12 1.5

Over 8/12 to 9/12 2.0

Over 9/12 to 10/12 2.5

Over 10/12 to 11/12 3.25

Over 11/12 to 12/12 4.0

Over 12/12 to 14/12 5.0

Over 14/12 to 16/12 6.0

Over 16/12 to 18/12 7.0

Over 18/12 to 20/12 7.5

Over 20/12 to 21/12 8.0

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) Visually inspect the venting system for proper size

and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion and

other deficiencies which could cause an unsafe

condition.

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 operate

at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers.

(d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat

so appliance will operate continuously.

e) Test for spillage at the draft hood relief opening

after 5 minutes of main burner operation. Use the

flame of a match or candle, or smoke from a

cigarette, cigar or pipe to visually check spillage.

(f) 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.

(g) Any improper operation of the common venting

system should be corrected so the installation

conforms with the latest edition of the National Fuel

Gas Code, ANSI Z 223.1. When resizing any

portion of the common venting system, the com-

mon venting system should be resized to ap-

proach the minimum size as determined using the

appropriate tables in Part 11 and in Appendix G

of the National Fuel Gas Code, ANSI Z 223.1 and

CAN/CGA - B149.1 - M91.

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.

If improperly installed, a hazardous condition,

such as an explosion or carbon monoxide poison-

ing, 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.

The vent damper must be installed at the appli-

ance draft hood, and without modification of the draft

hood.

To connect the vent damper wiring to the boiler wiring,

remove the jumper from the circuit plug. (See wiring

diagram) Connect the damper circuit plug to the boiler

circuit plug.

Fig. #8642

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 an Intermittent Pilot

or Hot Surface Ignition equipped system, the energy savings of the vent damper can be improved by plugging the

hole in the vent damper blade using the knockout plug, Part No. 105612R, provided in the parts envelope.

Hole in Vent Damper Blade

Closed Position

Fig. #8994

DO NOT plug the hole if installing the vent damper on a continuous pilot system as this will create a

hazardous condition.

Fig. #8183.0

INSTALLING THE VENT DAMPER IN HORIZONTAL

& VERTICAL VENTS.

Fig. #152323

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 EXPLOSION OR CARBON

MONOXIDE POISONING, COULD RESULT.

1K1

1K2

D80

MOTOR

N.C.

END

SWITCH N.O. 1K3

432

YELLOW

BLUE

BLACK

ORANGE

CABLE

YES

INSTALL VENT

DAMPER WITH

ACTUATOR TO SIDES

OF VENT ONLY. DO

NOT MOUNT ABOVE OR

BELOW VENT.

TO CHIMNEY

TO BOILER VENT DAMPER

FLOW >

HORIZONTAL INSTALLATION

TO CHIMNEY

AT BOILER

DRAFT

HOOD

VENT

DAMPER

VERTICAL

INSTALLATION

ACTUATOR MAY BE

INSTALLED IN ANY

POSITION ON VERTICAL

PIPE.

VENT DAMPER

NORMAL OPERATION SUMMARY

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.

Check vent damper operation as follows:

1. When the boiler is off, check that the vent damper position indicator points to the closed position, below.

Fig. # 8181.0

FIG. 4- VENT DAMPER POSITION INDICATOR SHOWING OPEN & CLOSED POSITIONS.

2. Turn the thermostat or controller up to call for heat and check that the vent damper indicator points to the

open position, below.

3. Turn 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, EXPERIENCED

SERVICE TECHNICIAN. THE NAME OF THE PERSON WHO ORIGINALLY INSTALLED YOUR VENT

DAMPER IS SHOWN ON THE INSTALLATION LABEL. DAMPER MUST BE IN OPEN POSITION WHEN

BOILER MAIN BURNERS ARE OPERATING.

FLAIR DAMPER

SYSTEM SCHEMATIC LEGEND LADDER DIAGRAM

M - Damper motor

R - Relay

ES - End Switch

SS1 - N/C Safety switch

SS2 - N/O Safety switch

contacts

TR - Transformer 120/24V

HL - High limit

GV - 24V gas Valve*

TH - Thermostat, heating,

low voltage

J - Jumper

* Note: Circuit shown with

damper in closed

position, no call

for heat.

Fig. #9002 Fig. #9003

NOTE: To place vent damper in

the open position to allow burner

operation do the following:

Turn the power off, turn the damper

blade to fully open position (arrow

facing same direction as vent

pipe). Turn power on.

DAMPER

POSITION

INDICATOR

DAMPER

POSITION

INDICATOR

DAMPER OPEN DAMPER CLOSED

2341

JUMPER

24 VAC

120 VAC

60Hz

3JSS HL

24 V AC

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 11

to 13.

The boiler is supplied as standard with a circulator

and a built -in by-pass to insure the required minimum

water flow in the boiler. The by-pass 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

shipped loose. The full open position is appropriate for

most systems, and insures adequate flow through the

boiler. If system flow is inadequate, (indicated by

excessive temperature drop through the system) the by-

pass valve can be throttled slightly. Care must be taken

against over throttling which may lead to inadequate

flow through the boiler and boiler harmonics (a humming

sound from the heat exchanger). If adequate system

flow cannot be obtained without causing harmonics, an

additional pump is required. The factory mounted

circulator will provide adequate water flow for systems

designed at a 20°F temperature drop, and system

pressure drop or head not exceeding that is shown

below.

When the total system head exceeds the available

head pressures, a primary/secondary pumping system

is recommended.

The minimum boiler operating temperature

should be 105°F. When operating at low tempera-

ture applications, ÐT (temperature rise) must be

20°F or less.

Propylene glycol solution is commonly used in the

heating system when freeze protection is required. This

will affect the system design and pump performance. 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/Wtr) by 23% in order to maintain the

same heat transfer load.

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 the chart below:

Maximum Equivalent Pipe Length (Feet)

Gas piping must have a sediment trap ahead of the

boiler gas controls, and a manual shutoff valve located

outside the jacket. All gas piping should be tested after

installation in accordance with local codes.

CAUTION: The boiler and its manual shut off valve must

be disconnected from the gas supply during any pres-

sure testing of that system at test pressures in excess

of 1/2 psig (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.

NOTE: Do not use teflon tape on gas line pipe thread.

A flexible sealant suitable for use with Natural and

Propane gases is recommended.

GAS PRESSURE-SPECIFICATIONS

Inches W.C. Regulator

Min. Max. Setting

Natural 7.0 14.0 3.5

Propane 12.0 14.0 11.0

Sediment Trap Gas Valve

Manual Union

Valve

Fig. # 8192.0

MODEL NAT PRO NAT PRO NAT PRO NAT PRO

0030 &

0042 125 350 500 - - - - -

0066 60 160 175 460 - - - -

0090 30 80 125 325 400 - - -

0135 15 40 60 155 200 500 - -

0180 - 20 35 90 115 300 425 -

1/2" Pipe 3/4" Pipe 1" Pipe 1 1/4" Pipe

System Maximum

Models Flow System Head

(GPM) (Ft/Wtr)

H-0030 2.5 9.0

H-0042 3.5 8.0

H-0066 5.3 8.5

H-0090 7.3 6.5

H-0135 11.0 10.0

H-0180 14.6 7.0

Systems with multiple zones may require an additional circulator. Consult manufacturers 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 from the cold water line have a check valve, gate valve, and feedwater

regulator set at 12 psig. Install unions and gate or ball valves at inlet and outlet connections at the boiler to facilitate

servicing.

The pressure relief valve is mounted on the boiler and must be piped to a drain. We recommend that all high

points be vented and that purge valves be installed. A boiler installed above radiation level must be provided with

a low water cutoff device. See page 21 for wiring hook-up. The boiler, when used in connection with a refrigeration

system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent

the chilled medium from entering the boiler.

The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units

where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other

automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

A diaphragm expansion tank should be installed in the return line. A typical 8" diameter expansion tank can

be used on the models H-0030, H-0042, and H-0066 and an 11" diameter expansion tank can be used on the

model H-0090, H-0135 and H-1080. Consult tank manufacturer for correct sizing.

TYPICAL PIPING

SINGLE ZONE PIPING

Fig.# 8997.1

AIR

SCOOP

AIR

VENT

FEED

VALVE

DIAPHRAGM

EXPANSION TANK

HEATING UNITS

COLD

WATER

INLET

PIPE PRESSURE

RELIEF VALVE

TO DRAIN

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

MULTIPLE ZONES WITH CIRCULATORS Fig. #8999.1

MULTIPLE ZONES WITH ZONE VALVES Fig. #9000.1

HEATING UNITS

CIRCULATORS COLD

WATER

INLET

FEED

VALVE

PIPE PRESSURE

RELIEF VALVE

TO DRAIN

DIAPHRAGM

EXPANSION

TANK

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

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

anticipator setting should be based on the ampere load

in the thermostat circuit.

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° black wire must be replaced

with 150°C wire or its equivalent. See wiring diagram

key for 150°C wire indication.

ELECTRICAL WIRING

The electrical power supply requirement for these

boilers is 115 volts, 60 Hz. Field wiring connections and

electrical grounding must comply with the local codes,

or in the absence of local codes, with the National

Electrical Code, ANSI/NFPA 70-1987. Provide a sepa-

rate fused circuit from the main electrical 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 18).

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.

Fig. # 2223e

See page 14 wiring diagram key information.

WIRING DIAGRAM: STANDING PILOT 24 V 2 STAGE

MODELS 90, 135 & 180

WIRING DIAGRAM:INTERMITTENT IGNITION DEVICE (IID)

MODELS 30, 42, & 66

See page 14 wiring diagram key information.

*REFER TO INSTALLATION/OPERATING INSTRUCTIONS

AND WIRING DIAGRAM SUPPLIED WITH VENT DAMPER.

VENT DAMPER OPTIONAL ON CANADIAN MODELS.

WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID)

MODELS 90, 135 & 180

Fig. #2358

See page 14 wiring diagram key information.

*REFER TO INSTALLATION/OPERATING INSTRUCTIONS

AND WIRING DIAGRAM SUPPLIED WITH VENT DAMPER.

VENT DAMPER OPTIONAL ON CANADIAN MODELS.

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

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

Taco Zone Valve

Honeywell Zone Valve

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.

Fig. # 2357E

4. SERVICING PROCEDURES

GENERAL LOCATION OF CONTROLS

Fast

Response

Temperature

Sensor

CONTROL BOX COMPONENT

LOCATIONS MODELS 135 & 180

2-Staged Controller

Relay

Fig.# 8195.1

Ignition Module

(Auto Ignition Only)

Fig.# 8195.4

SEQUENCE OF OPERATION

INTERMITTENT IGNITION DEVICE (IID)

Boilers equipped with the IID system will automatically light the pilot burner first and then the main burner, each

time there is a call for heat from the room thermostat. Whenever the room thermostat is calling for heat, the

circulator supplied with the boiler, will be energized and should be running. 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 generator in the module produces a high voltage spark pulse 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. Ignition

spark continues only until the timed trial for ignition period ends. Then, the module goes into safety 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. 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 generator 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

burner flame. When the thermostat is satisfied, the valve operators are de-energized shutting off the pilot and main

burners, and also the circulator.

CIRCULATOR

VENT SENSOR

BYPASS VALVE

(MODELS 135 & 180 ONLY)

BYPASS LINE

TEMPERATURE

AND PRESSURE GAUGE

2-STAGED CONTROLLER

(MODEL 90 ONLY)

PRESSURE

RELIEF VALVE

RELAY

ADJUSTABLE

HIGH LIMIT

FIELD WIRING

COMPARTMENT

FAST RESPONSE

TEMPERATURE SENSOR

IGNITION MODULE

(AUTO IGNITION ONLY)

TRANSFORMER

ROLL-OUT SENSOR

GAS VALVE

START-UP PROCEDURES

SECTION 1. Filling the System

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

system 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.

On multiple zone systems, purge each zone sepa-

rately. Isolate the other zones while one zone is being

purged of air.

Flush system before putting into operation to as-

sure that foreign material does not damage pump seals.

SECTION 2. Checking the Circulator

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.

NOTE: Circulator motor supplied with the boiler does

not require lubrication.

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.

SECTION 3. Lighting the Boiler

Safe lighting and other performance criteria were

met with the gas manifold and control assembly pro-

vided on the boiler when the boiler underwent tests

specified in ANSI-Z21.13a 1983 Standard.

CAUTION: Liquefied petroleum gas is heavier than air

and sinks to the ground. Exercise extreme care in

lighting boiler in confined areas.

For Standing Pilot Models

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 instructions

exactly.

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 settle on the floor.

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.

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 technician to inspect

the boiler and to replace any part of the control system

and any gas control which has been under water.

FOR STANDING PILOT MODELS WITH ROBERT-

SHAW GAS VALVE, 2 STAGE OPERATION

(Models 90, 135 & 180)

1. STOP! Read the safety information.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the boiler.

4. Push in and move gas control lever counter-

clockwise to "OFF" position.

GAS CONTROL

LEVER SHOWN

IN "OFF" POSITION

GAS INLET

Fig. #8934.0

NOTE: Lever cannot be moved from "ON" to

"OFF" unless lever is pushed in slightly. Do not

force.

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

above on this label. If you don't smell gas, go to the

next step.

6. Locate pilot mounted on the right side of the

burner drawer, and right of first burner.

HONEYWELL PILOT ROBERTSHAW PILOT

7. Move control lever clockwise 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.

*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.

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

control lever counter-clockwise to "ON".

10. Turn on all electric 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 electric power to the boiler

3. Push in and move gas control lever counter-

clockwise to "OFF" position. Do not force.

FOR AUTOMATIC IGNITION MODELS.

Please read carefully and understand the following

safety information before operating the boiler.

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 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 auto-

matically lights the burners. Do not try to light the

burners by hand.

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 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.

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 underwa-

ter. 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.

Fig.# 8041.2

Fig.# 8083.2

FOR INTERMITTENT IGNITION (IID) WITH HONEY-

WELL OR ROBERTSHAW GAS VALVE (For All Mod-

els)

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electric 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 by hand.

GAS CONTROL

KNOB SHOWN

IN "ON"

POSITION

GAS INLET

Fig. #8201.0

HONEYWELL

(Models 30 - 90)

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 above

on this label. If you don't smell gas, go to the next

step.

7. For Honeywell Valve: turn gas control counter-

clockwise to "On".

For Robertshaw Valve: Move gas control lever

to "On" position.

GAS CONTROL

KNOB SHOWN

IN "OFF"

POSITION

GAS INLET

Fig. #8199.0

ROBERTSHAW

(All Models)

8. Turn on all electric power to the boiler.

9. Set thermostat to desired setting.

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

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

technician or gas supplier.

TO TURN OFF GAS TO BOILER

1. Set the thermostat at the lowest setting.

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

is to be performed.

3. For Honeywell Valve:

Turn gas control knob clockwise to

"Off". Make sure knob rest against stop.

For Robertshaw Valve:

Push in and move gas control lever to "Off"

position.

HONEYWELL PILOT

SYSTEM SHUT DOWN PROCEDURE

To prevent the potential freezing 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 electric switches to the boiler.

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 system

loop.

5. Open drain valve on the boiler to remove water from

the boiler and the piping circuits.

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.

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 possible damage to the boiler and

injury to the user.

SECTION 4. Testing the Ignition Safety Shutoff.

The ignition system safety shutoff must be tested by

conducting the following method of tests:

For Standing Pilot Systems

a. With the main burners on, remove the pilot

adjustment cover screw.

* NOTE: There is no pilot adjustment cover on

Robertshaw 7200 gas valve.

b. Insert a small slot screw driver and turn the

adjustment screw clockwise until pilot

flame goes out. Note and count number of turns

made.

c. Gas valve will shut off main burners after about

three (3) minutes. End of test. If the gas valve

will not shut off, follow the instructions "To Turn

Off Gas To Boiler" and call service technician or

your gas supplier.

d. Return pilot adjustment screw counter-clock-

wise , same number of turns as in step (b).

ROBERTSHAW 7200 GAS VALVE

(Models 90, 135 & 180)

e. Replace pilot adjustment cover screw, then

follow the lighting instructions to get boiler

ready for operation.

FOR AUTOMATIC IGNITION SYSTEMS

Intermittent Ignition (IID)

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.

b. Watch for continuous spark at the pilot burner.

c. Time the spark operation. Time must be within

the lockout timing period (15 or 90 seconds).

d. Turn thermostat down to end call for heat and

wait 60 seconds on lockout models before

beginning step 3.

3. Turn on gas supply.

4. Set thermostat or controller above room tempera-

ture to call for heat.

5. Systems should start as follows:

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

at once. Pilot burner should ignite after gas

reaches the pilot burner.

b. Spark ignition should cut off when pilot flame is

established.

c. Main gas valve should open and main burner

should ignite after gas reaches the burner port.

Pilot Adjustment

Fig.# 8935.0

Fig. #8964

PILOT BURNER FLAME (STG PILOT UNITS)

NORMAL INSPECTION PROCEDURES

First and third month after initial start up and then on

an annual basis. If problems are found, refer to Trouble

Shooting Guide for additional directions.

1. Remove top of boiler and inspect heat exchanger

for soot and examine venting system.

2. Remove rear header and inspect for scale depos-

its.

*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. Oil pump motor and bearing assembly, if oil cups

are provided.

7. Check flow switch paddle.

8. Clean room air intake openings to assure adequate

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).

SAFE SHUTDOWN TESTS

LIMIT ACTION

With the burner operating, lower the high limit

setting to simulate an overheated boiler. Normal shut-

down should occur. Restore the normal limit setting,

and the burner should restart.

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 burner

should restart.

INSPECTION PROCEDURES

BURNERS

Clean main burners and air louvers of dust, lint and

debris. Keep boiler area clear and free from combus-

tibles 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.

Fig. #8144

MAIN BURNER FLAME

NOTE: Modulating burner flame varies in height from

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

high fire.

Max.

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

temporary conditions such as power failure or air pock-

ets. Flush float type devices at beginning of each

heating season.

PROCEDURE FOR CLEANING FLUE GAS

PASSAGE-WAYS

Soot will clog areas behind fins and cause eventual

tube failure. Any sign of soot at base of burners or

around outer jacket indicates a need for cleaning.

1. Lift off draft hood and flue collector by removing

bolts and screws.

2. Remove "V" baffles from heat exchanger.

3. Remove burner tray, see Burner Drawer 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!

CAUTION:

Soot is combustible, so exercise extreme care.

BURNER DRAWER REMOVAL

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

connect union(s) and pilot tubing when present;

then loosen and remove burner hold down screws.

2. Disconnect wires at gas valve and slide burner

drawer out.

MAIN BURNER AND ORIFICE REMOVAL

1. Remove screws and burner hold down bracket.

NOTE: If the heat exchanger is sooted badly, the

burner hold down bracket and spacer can become

distorted from direct flame impingement and this usu-

ally necessitates replacement of these parts.

2. Lift burners from slotted spacer and slide from

orifices. Clean with a wire brush.

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

clean, run either copper wire or wood through

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

a socket wrench and remove the manifold. DO

NOT overtighten when reinstalling.

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-inhib-

ited de-scale solvent.

HEAT EXCHANGER REMOVAL

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

relieve pressure, remove relief valve. Remove side

inspection panels.

2. Remove top holding screws.

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

collector on stack type models. Remove inspection

panels.

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. Remove heat exchanger corner brackets.

REPAIR SECTION

TUBE CLEANING PROCEDURE (TYPICAL)

Establish a regular inspection schedule, the fre-

quency depending on the local water condition and

severity of service. Do not let the tubes clog up solidly.

Clean out deposits over 1/16" in thickness.

The boiler may be cleaned from the side opposite

the water connections as shown, without breaking pipe

connections. It is preferable, however, to remove both

headers for better visibility through the tubes and to be

sure the residue does not get into the system.

Note that you do not remove the top pan or the heat

exchanger generally.

After reaming with the auger, mount the wire brush

and clean out the debris remaining in the tubes.

RAYPAK TUBE CLEANING KIT

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 inlet-outlet and return water headers and

install header retainer nuts and torque nuts evenly.

3. Replace "V" baffles.

4. Install thermostat sensing bulbs in header wells

and replace bulb retaining clips.

5. Install inlet and return pipes in water headers using

pipe thread sealant.

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

low water cutoff devices if so equipped.

7. Open water supply and return shut-off valves. Fill

boiler and water piping system with water. Check

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 strain-

ers 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).

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

piping system and check for leakage using a soap

solution.

11. Check for correct water pressure and water level in

the system. Make sure that system pump operates

immediately on the call for heat. The system is

ready for operation.

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

and expansion tank levels.

COMBUSTION CHAMBER REMOVAL

To remove combustion chamber you must first

have removed the heat exchanger. Unbolt metal com-

bustion chamber retainer from top and remove com-

bustion chamber panels individually.

5. TROUBLE SHOOTING 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 not attempt to install this

equipment nor attempt repairs according to these instructions.

PROBLEM(S)

1)When room thermostat is turned on,

boiler does not operate.

2)When room thermostat is calling for

heat, pump is on, but burners will not

turn on.

CAUSE(S)

1)No power to the boiler.

2)Defective room thermostat or discon-

nected wire in thermostat circuit.

3)Defective transformer.

4)Defective pump relay.

5)Defective pump

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)Gas knob in "Pilot" position.

4)For automatic ignition models,

gas valve knob is in "off" position.

5)Vent switch is open.

6)Roll-out switch is open.

7)High limit is open.

8) Fast Response Temperature

Sensor probe is defective.

9) Fast Response Temperature

sensor board is defective.

SOLUTION(S)

1)Check circuit breakers, disconnect

switch. Make sure power is on.

2)Check continuity on thermostat and

wiring circuit. Replace thermostat, or

repair wiring connections.

3) Check secondary voltage. If no 24V,

replace transformer.

4) Check relay coil or contacts. Replace

as required.

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.

3)Turn knob to "ON" position.

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

module locks out, reset by interrupt-

ing power to boiler.

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.

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.

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.

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 ON, if

temperature exceeds 240°F. It will turn

off when sensor temperature falls below

180°F. When either Red or Yellow LED

is ON, boiler will be shut down.

9)Check voltage across output and

common terminals. If no 24V is pres-

ent, replace board.

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-

sects.

3) Clean gas line or increase gas line

piping.

1) Refer to installation instructions re

garding combustion air require-

ments.

2) Refer to installations instructions.

3) See yellow flame section above.

10) Defective ignition module or

defective gas valve.

1) Too low or too high gas pressures.

2) Restricted pilot.

3) Weak thermocouple.

1) Too low gas pressure.

2) Restricted burner intake ports.

3) Restricted gas line.

1) Insufficient combustion air.

2) Improper venting.

3) Severe yellow burner flames.

3)Pilot Outage.

(Standing pilot models)

4)Yellow lazy flame.

5)Sooting

ADJUSTMENTS/REPLACEMENTS 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

(when equipped).

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

e) Slide burner tray out.

f) Remove gas valve bracket screws and bracket.

g) Unscrew gas valve from gas pipe.

h) Reverse above procedure to re-install.

2. Pilot Burner Cleaning or Replacement (Standing

Pilot)

a) Shut off electrical power and gas supply to the

boiler.

b) Disconnect gas piping to gas valve.

c) Disconnect wiring connections to gas valve.

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

e) Slide burner tray out.

f) Remove screw holding pilot lighter tube.

g) Remove screws (2) holding pilot bracket on the

burner tray.

h) Disconnect thermocouple and pilot tubing from

the gas valve.

i) Remove pilot burner from pilot bracket.

j) 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.

k) Reverse above procedure to re-install.

3. Flame Roll-out Switch Replacement

a) Shut off electrical power to the boiler.

b) Remove wiring connections to switch.

c) Remove screws (2) holding the switch.

d) Reverse above procedure to re-install.

4. Vent Thermal Switch Replacement

a) Shut off electrical power to the boiler.

b) Remove wiring connections to switch.

c) Remove the screws (2).

d) Reverse above procedure to re-install.

5. Ignition Module Replacement

a) Shut off electrical power to the boiler.

b) Remove control cover screws and open control

compartment.

c) Disconnect wiring connections to module.

d) Remove screws (2) holding module.

e) Reverse above procedure to re-install.

6. Transformer Replacement

a) Shut off electrical power to the boiler.

b) Remove control cover screws and open control

compartment.

c) Disconnect wiring connections from trans-

former leads.

d) Remove screws (2) holding transformer.

e) Reverse above procedure to re-install.

7. Pump Relay Replacement

a) Shut off electrical power to the boiler.

b) Remove control cover screws and open control

compartment.

c) Disconnect wiring to the relay.

d) Remove screws (2) holding relay.

e) Reverse above procedure to re-install.

8. Adjustable High Limit Control

a) Shut off electrical power to the boiler.

b) Remove control cover screws and open

control compartment.

c) The control is factory set at 180°F. To reset to

another setting, use a small screw driver

and turn dial clockwise to lower the

temperature or counter-clockwise to

raise the setting.

d) To replace the limit control, disconnect the wir-

ing connections.

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

f) Remove upper access panel.

g) Remove the wedge or retaining clip holding

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

header.

h) Pull out the sensing bulb carefully from the

control well.

i) Remove the limit control with capillary from

unit.

PILOT

HONEYWELL PILOT ROBERTSHAW PILOT

AIR

OPENING

ORIFICE

PILOT

Fig.# 8045.2 Fig.# 8102.1

j) Reverse above procedure to re-install.

9. Fast Response Temperature Sensor Module

Replacement

a) Shut-off electrical power to the boiler.

b) Remove control cover screws and open

control compartment.

c) Disconnect wiring connections to the board.

d) Carefully pull out the control board from the

nylon pin supports.

e) Reverse above procedure to re-install.

10. Fast Response Temperature Sensor Probe

Replacement

a) Shut off electrical power to the boiler.

b) Shut off water supply to the boiler and open

drain valve to remove water to the sensor

probe level.

c) Remove control cover screws and open

control compartment.

d) Disconnect wire leads from control board.

e) Remove upper access panel.

f) Remove sensor probe from in/out header.

g) Reverse above procedure to re-install.

11. Circulator Replacement

a) Shut off electrical power to the boiler.

b) Shut off water supply and open drain valve

to remove water in the piping at the pump

level.

CAUTION: To avoid damage to electrical components

keep water from getting into the control compartments

and gas valve.

c) Disconnect wiring and conduit connections to

the pump.

d) Disconnect the by-pass tube connections to

the inlet flange.

e) Remove the nuts and bolts at the inlet and

outlet flanges. Remove old gaskets.

f) Remove the pump.

g) Reverse the above procedure to re-install.

Use new gaskets and make sure they are

seated properly when tightening the nuts

and bolts.

12. 2-Staged 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 reset

to another setting, use a small screw driver

and turn dial clockwise to lower the

temperature or counter-clockwise to

raise the setting.

d) To replace the staged controller, disconnect

the wiring connections.

e) Remove screws (2) holding the staged

controller.

f) Remove upper access panel.

g) Remove the wedge or retaining clip holding

the sensing bulb in the control well in the in/

out header.

h) Pull out the sensing bulb carefully from the

control well.

i) Remove the staged control with capillary

from unit.

j) Reverse above procedure to re-install.

6. REPLACEMENT PARTS LIST

NOTE: To supply the correct part it is important that you

state the model number, serial number and type of gas

when applicable.

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 the Company freight prepaid.

If determined defective by the Company and within

warranty, the part will be returned in kind or equal

substitution, freight collect. Credit will not be issued.

RAYPAK, INC.

31111 Agoura Road

Westlake Village, CA 91361-4699

HONEYWELL STANDING PILOT HONEYWELL IID ROBERTSHAW STANDING PILOT

*Bypass valve supplied on sizes H-0135 and H-0180 only.

Fig. # 8190.0

3-P

1-P

2-P

6-P

8-P

3-P

1-P

2-P

6-P

8-P

Fig. # 8189.3

1-P

2-P

9-P

6-P

8-P Fig. # 9112

4-C

5-M

3-H

3-M

6-H

1-M

9-H 2-H 1-H 7-H

1-V 2-V

2-S

1-R (30 & 42)

1-S 6-H

4-M

3-C

4-H

3-S 1-R

5-H

8-H

3-J

1-J

1-R

1-C

4-S

2-C 5-P

2-J

4-P

2-B

1-B

3-B

4-C

1-G

4-B

BOILERS MANUFACTURED AFTER AUGUST 11, 1994 WITH SERIAL #9408116901 OR LATER, HAVE IID IGNITION IN

LIEU OF HSI IGNITION.

BOILERS MANUFACTURED AFTER AUGUST 11, 1994 WITH SERIAL #9408116901 OR LATER, HAVE IID IGNITION IN

LIEU OF HSI IGNITION.

CALL OUT DESCRIPTION 30B 42B 66B 90B 135B 180B

M MISCELLANEOUS

1-M PRV 30 PSI 501410 501410 501410 501410 501410 501410

2-M Deliming Kit 052871F 052871F 052871F 052871F 052871F 052871F

3-M T & P Gauge 600671 600671 600671 600671 600671 600671

4-M Drain Valve 006536F 006536F 006536F 006536F 006536F 006536F

5-M Pump Inline Taco 003968F 003968F 003968F 004251F 005097F 005097F

Pump Inline Grundfos 004714F 004714F

6-M Pump Cartridge (Taco) 951116F 951116F 951116F 951116F 951166F 951166F

7-M Wire/Harness Std. 003969F 003969F 003969F 003969F 004256F 004256F

Wire/Harness HSI Honeywell 003970F 003970F 003970F 003970F 004257F 004257F

Wire/Harness HSI Fenwal 003971F 003971F 003971F 003971F 004258F 004258F

Wire/Harness IID 005602F 005602F 005602F 005602F 005603F 005603F

P PILOT

1-P Pilot Nat. Std. 003972F 003972F 003972F 003972F 003972F 003972F

Pilot Pro. Std. 003973F 003973F 003973F 003973F 003973F 003973F

Pilot Nat. IID 005467F 005467F 005467F 005467F 005467F 005467F

Pilot Pro. IID 005468F 005468F 005468F 005468F 005468F 005468F

2-P Pilot Orifice Nat. Std. 003974F 003974F 003974F 003974F 003974F 003974F

Pilot Orifice Pro Std. 003975F 003975F 003975F 003975F 003975F 003975F

Pilot Orifice Nat. IID 003903F 003903F 003903F 003903F 003903F 003903F

Pilot Orifice Pro. IID 004308F 004308F 004308F 004308F 004308F 004308F

3-P Pilot Thermocouple 600003 600003 600003 600003 600003 600003

4-P Hot Surface Ignitor HSI 003976F 003976F 003976F 003976F 003976F 003976F

5-P Ignition Control HSI Honeywell 601005F 601005F 601005F 601005F 601005F 601005F

Ignition Control HSI Fenwal 601129F 601129F 601129F 601129F 601129F 601129F

Ignition Control IID Honeywell 004935F 004935F 004935F 004935F 004935F 004935F

6-P Pilot Mtg. Bracket 306239 306239 306239 306239 306239 306239

8-P Pilot Tube 400275 400275 400275 400275 400275 400275

8-P High Tension Wire IID 002654B 002654B 002654B 002654B 002654B 002654B

R REFRACTORY

1-R Refractory Kit 003977F 003977F 003978F 003978F 004259F 004260F

S SHEETMETAL

1-S Jacket Top 003979F 003979F 003980F 003980F 004261F 004268F

2-S Flue Collector 003981F 003981F 003982F 003982F 004262F 004263F

3-S Access Panel 003983F 003983F 003983F 003983F 004264F 004264F

4-S Control Panel Cover 003984F 003984F 003984F 003984F 004265F 004265F

V VENTING

1-V Drafthood 003985F 003985F 003986F 003986F 004266F 004267F

2-V Vent Damper 004709 004709 004710 004710 004711 004712

GAS CONVERSION KITS ** 30B 42B 66B 90B 135B 180B

HONEYWELL GAS VALVE

Standing Pilot Nat. to Pro. 004269F 004273F 004698F 004277F

Standing Pilot Pro. to Nat. 004270F 004274F 004699F 004278F

Hot Surface Ignition Nat. to Pro. 004271F 004275F 004700F 004279F

Hot Surface Ignition Pro. to Nat. 004272F 004276F 004701F 004280F

IID Nat. to Pro. Honeywell 005471F 005473F 005475F 005477F

IID Pro. to Nat. Honeywell 005472F 005274F 005476F 005478F

ROBERTSHAW GAS VALVE

Standing Pilot Nat. to Pro. 004289F 004293F 004702F 004297F 004281F 004285F

Standing Pilot Pro. to Nat. 004290F 004294F 004703F 004298F 004282F 004286F

Hot Surface Ignition Nat. to Pro. 004291F 004295F 004704F 004299F 004283F 004287F

Hot Surface Ignition Pro. to Nat. 004292F 004296F 004705F 004300F 004284F 004288F

IID Nat. to Pro. Robertshaw 005479F 005481F 005483F 005485F 005487F 005489F

IID Pro. to Nat. Robertshaw 005480F 005482F 005484F 005486F 005488F 005490F

** Gas Conversions are to be done only by a Qualified Agency.

IGNITION CONTROL CONVERSION KIT

Robertshaw HSI Control to Fenwal HSI Control 004678F

Raypak, Inc., 31111 Agoura Road, Westlake Village, CA 91361-4699 (818) 889-1500 FAX (818) 889-4522

Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036

Raypak Australia Pty. Ltd, 7 Geddes St., Mulgrave, Victoria, Australia 3170 (6139) 560 4944 FAX (6139) 560 4974

Litho in U.S.A.

www.raypak.com

Raypak 0090B 0135B Users Manual 2100.50(residential I O)

0090B 0135B to the manual 5fc10e28-a3c7-49e3-918b-e5bc4b3aa934

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