Raypak 0030B, 0066B, 0090B, 0180B, 0042B User Manual

...

OPERATING AND INSTALLATION INSTRUCTIONS

Models 0030B, 0042B, 0066B, 0090B 0135B, 0180B

Type H

RESIDENTIAL BOILERS

Catalog No.: 2100.50P Effective: 11-01-99 Replaces: 6-01-99

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.

THIS MANUAL SHOULD BE MAINTAINED IN LEGIBLE CONDITION AND KEPT ADJACENT TO THE BOILER OR KEPT IN A SAFE PLACE FOR FUTURE REFERENCE.

P/N 240488

Contents

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

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 these boilers, we suggest that the local Sales representative or the factory be consulted.

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 reviewed 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 combustible 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 transformer, 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 manufacturers, 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

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"

OUTLET

THERMOSTAT CONN (ELECTRICAL CONN ON OTHER SIDE)

CONNECTIONS

B K

PIPING

AUTOMATIC VENT DAMPER (FIELD INSTALLED)

INLET

GAS CONN

MIN

3/4 NPT PIPE TO DRAIN

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 conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically 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.

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 jurisdiction.

COMBUSTION/VENTILATION AIR

CARPET

Fig.# 8196.0p

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 installed 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.)

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 ventilation air supply. Such chemicals include, but are not limited to, chlorinated and/or fluorinated hydrocarbons such as found in refrigerants, aerosol propellants, drycleaning fluids, degreasers, and paint removers. Other harmful elements may come from bleaches, air fresheners, 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 accordance with Sec. 5.3, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, or applicable provisions of the local building codes.

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.

12"

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 smallest 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 horizontal length shall be 1-1/2 feet (18 inches) for each inch of connector diameter as follows.

12"

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

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 horizontally 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.

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 supported 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.

Lowest Discharge

Listed Cap

Listed Gas Vent

Opening

10’

OR LESS

2’ MIN.

VENT CAP

2’ MIN.

5’ MIN.

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

Fig.# 8191.0

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

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 remaining 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. (c) Insofar as is practical, close all building doors and

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 poisoning, 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.

HORIZONTAL INSTALLATION

FLOW >

TO BOILER VENT DAMPER

VERTICAL INSTALLATION

TO CHIMNEY

VENT DAMPER

AT BOILER

DRAFT

HOOD

YES

INSTALL VENT DAMPER WITH ACTUATOR TO SIDES OF VENT ONLY. DO NOT MOUNT ABOVE OR BELOW VENT.

ACTUATOR MAY BE INSTALLED IN ANY POSITION ON VERTICAL PIPE.

YES

Fig. #8183.0

INSTALLING THE VENT DAMPER IN HORIZONTAL & VERTICAL VENTS.

1K1

D80 MOTOR

END SWITCH

YELLOW

N.C.

N.O.

1K3

BLUE

BLACK

1K2

ORANGE

D80D GENERAL WIRING DIAGRAM

CABLE

Fig. #152323

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.

VENT DAMPER

24 V AC

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.

DAMPER

POSITION

INDICATOR

DAMPER

POSITION

INDICATOR

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.

Fig. # 8181.0

DAMPER OPEN DAMPER CLOSED

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

GV 24 VAC

120 VAC 60Hz

JUMPER

Fig. #9002 Fig. #9003

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.

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:

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 pressure.

Maximum Equivalent Pipe Length (Feet)

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

MODEL NAT PRO NAT PRO NAT PRO NAT PRO

0030 &

0042 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 -

125 350 500 - - - - -

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.

Manual Union Valve

Sediment Trap Gas Valve

Fig. # 8192.0

CAUTION: The boiler and its manual shut off valve must be disconnected from the gas supply during any pressure 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

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 bypass 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.

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

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 temperature 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.

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

AIR

VENT

HEATING UNITS

SINGLE ZONE PIPING

AIR

SCOOP

DIAPHRAGM

EXPANSION TANK

FEED

VALVE

PIPE PRESSURE

RELIEF VALVE

TO DRAIN

COLD

WATER

INLET

Fig.# 8997.1

FEED

VALVE

AIR

VENT

AIR

SCOOP

DIAPHRAGM

EXPANSION

TANK

PIPE PRESSURE

RELIEF VALVE

TO DRAIN

ZONE

VALVES

HEATING UNITS

COLD

WATER

INLET

CIRCULATOR

COLD

WATER

SUPPLY

HOT WATER

SUPPLY

ZONE HEATING WITH INDIRECT DOMESTIC HOT WATER SUPPLY

Fig.# 8998.1

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