Raypak 0090B 0135B Manuals

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. 2 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 3 K 16 41/2 331/4 221/8 121/2 5 18 31/4 261/2 C THERMOSTAT CONN (ELECTRICAL CONN ON OTHER SIDE) GAS CONN 3/4 NPT PIPE TO DRAIN A 117/8 6 INLET OUTLET 31/8 MIN 19 AUTOMATIC VENT DAMPER (FIELD INSTALLED) B HEATING NET K INPUT CAPACITY I=B=R WATER GAS VENT MODEL 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.) 4 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