Raypak Gas Fired Boiler User Manual

CATALOG NO.: 2000.52G

USERS INFORMATION MANUAL

FOR GAS FIRED BOILERS

WARNING: If the information in this manual is not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.

- 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.

- 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.

- Installation and service must be performed by a qualified installer, service agency or the gas
supplier.

CAUTIONS: Propane gas is heavier than air and sinks to the ground. Exercise extreme care in lighting heater

in confined areas.

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.

Should overheating occur or the gas supply fail 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 appliance.

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 or the
factory.

Effective: 06-01-00
Replaces: 07-01-94

OPERATING CONTROLS

Model W1 with On/Off Controls

The boiler is equipped with an adjustable tankstat. Set dial for desired temperature.

Models with Mechanical Modulation: H1, H5, W2, N, R

Sizes 133 through 1826. These boilers are equipped with modulating gas valves. They have one or more valves
in addition to the main electric gas valve. Their purpose is to adjust the firing rate to meet the required load. The
modulator will throttle the boiler input to meet the system demand. The valve has a remote capillary bulb immersed
in a well at the header outlet to maintain a constant outlet water temperature. When multiple valves are furnished,
they can be staged to give greater flexibility of control. Consult the dial setting tag attached to the control for your
desired water temperature.

MODULATING VALVE CHART —7000

TEMPERATURE —°F

N H

DIAL POSITION W R

Lo 110 150
1 117 157
2 124 164
3 130 170
4 137 177
5 143 183
6 150 190
7 156 196
8 163 203
Hi 170 210

MODULATING VALVE (ROBERTSHAW)

Fig. # 8936.1

P/N 240412

Models with Motorized Modulation: H2, H6, W2

Sizes 2100-4001 are equipped with a single motorized modulating valve controlled by a temperature

controller that offers full modulation down to 20% of rated input BTU.

HIGH LIMIT AND

TEMP CONTROL

LIMIT CONTROLS

1. HIGH LIMIT
If boiler is equipped with a manual reset High Limit,

push the reset button and set the Limit(s) to 30° - 40°F
above operating temperature.

2. FLOW SWITCH
Dual purpose control shuts off boiler in case of

pump failure or low water condition.

3. 100% PILOT SAFETY
All standard boilers above 400,000 BTUH input are

equipped with pilot safety(ies), which close the main
valve within 8/10 of a second whenever the pilot flame
is interrupted. Pilot flame is automatically lit when the
device is powered. Unit performs its own safety check
and opens the main valve only after the pilot is proven
to be lit.

4. LOW WATER CUTOFF
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 pock­ets.

1 2

MANUAL RESET

HI LIMIT

FLOW SWITCH PILOT SAFETY LOW WATER

TEMP CONTROL

FOR MOTORIZED MODULATION

5. HIGH AND LOW GAS PRESSURE SWITCHES
These switches sense either high or low gas pres-

sures and automatically shut down burners if abnormal
pressures exist.

6. BLOCKED VENT SHUT-OFF SYSTEM
All indoor boilers below 300,000 BTUH input em-

ploy a blocked vent shut-off system designed to shut off
main burner gas in the event the venting system is
totally blocked.

In the event the blocked vent shut-off system is

actuated, do not attempt to place the boiler in operation,
but contact a qualified service agency.

7. FLAME ROLL-OUT
SAFETY SHUT-OFF SYSTEM
All boilers below 300,000 BTUH input employ a

flame roll-out safety shut-off system designed to shut­off the main burner gas in the event of sustained flame
roll-out.

In the event the flame roll-out safety system is

actuated, do not attempt to place the boiler in operation,
but contact a qualified service agency

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4 5

HIGH OR LOW GAS

CUTOFF

PRESSURE SWITCH

Fig # 9314 Fig # 9317 Fig # 8929 Fig # 9316 Fig # 9312

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GENERAL LOCATION OF CONTROLS

OUTLET

T & P GAUGE

(Not Shown)

INLET

HI-LIMIT

SEDIMENT TRAP

(BY OTHERS)

START-UP PROCEDURE

GENERAL

Before lighting a new installation, water should be

flowing through the heater.

CAUTION: Propane gas is heavier than air and sinks
to the ground. Exercise extreme care in lighting heater
in confined areas.

INITIAL START-UP – PUMP AND MOTOR

Many pumps are now direct drive. They have no
coupler or bearing assembly. These pumps do not
require lubrication. Others require SAE-30 non-deter­gent oil to lubricate both the motor and the bearing
assembly. Consult motor manufacturer's instructions.

Clean dust and lint from pump and motor. Check
pump coupler and tighten if necessary.

Flush system before putting into operation to as­sure that foreign material does not damage pump
seals.

CAUTION:

A. Pump must be off to check oil in bearing

assembly.

B. Do not run pump without water in system.

ELECTRICAL J-BOX

MODULATING
GAS VALVES WITH
REGULATOR

PILOT LOCATIONS

MANUAL GAS VALVE

FIG.# S8185.0

LIGHTING INSTRUCTIONS
BOILERS WITH MANUALLY LIT PILOTS

FOR YOUR SAFETY READ BEFORE OPERATING

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 appliance has a pilot which must be lighted

by hand. When lighting the pilot, follow these in­structions exactly.

B. BEFORE LIGHTING Smell all around the appli-

ance 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 or turn the gas

control knob. Never use tools. If the knob will

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