Raypak Boiler Gas Fired Boiler User Guide

CATALOG NO.: 2000.52G  
Effective: 06-01-00  
Replaces: 07-01-94  
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.  
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 (ROBERTSHAW)  
MODULATING VALVE CHART —7000  
TEMPERATURE —°F  
N
W
H
R
DIAL POSITION  
Lo  
1
2
3
4
5
6
7
8
110  
117  
124  
130  
137  
143  
150  
156  
163  
170  
150  
157  
164  
170  
177  
183  
190  
196  
203  
210  
Hi  
Fig. # 8936.1  
P/N 240412  
 
GENERAL LOCATION OF CONTROLS  
ELECTRICAL J-BOX  
OUTLET  
T & P GAUGE  
(Not Shown)  
INLET  
MODULATING  
GAS VALVES WITH  
REGULATOR  
HI-LIMIT  
PILOT LOCATIONS  
SEDIMENT TRAP  
(BY OTHERS)  
MANUAL GAS VALVE  
FIG.#S8185.0  
START-UP PROCEDURE  
GENERAL  
LIGHTING INSTRUCTIONS  
BOILERS WITH MANUALLY LIT PILOTS  
FOR YOUR SAFETY READ BEFORE OPERATING  
Before lighting a new installation, water should be  
flowing through the heater.  
WARNING: If you do not follow these instructions  
exactly, afireorexplosionmayresultcausingproperty  
damage, personal injury or loss of life.  
CAUTION: Propane gas is heavier than air and sinks  
to the ground. Exercise extreme care in lighting heater  
in confined areas.  
A. This appliance has a pilot which must be lighted  
by hand. When lighting the pilot, follow these in-  
structions exactly.  
INITIAL START-UP – PUMP AND MOTOR  
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.  
Many pumps are now direct drive. They have no  
coupler or bearing assembly. These pumps do not  
require lubrication. Others require SAE-30 non-deter-  
gent 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 as-  
sure that foreign material does not damage pump  
seals.  
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.  
*
CAUTION:  
A. Pump must be off to check oil in bearing  
assembly.  
B. Do not run pump without water in system.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
3
 
not push in or turn by hand, do not try to repair it,  
call a qualified service technician. Force or at-  
tempted repair may result in a fire or explosion.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
goes out, repeat steps 5 through 9.  
* If knob does not pop up when released, stop  
and immediately call your service technician or  
gas supplier.  
* If the pilot does not stay lit after several tries,  
turn the gas control knob to “OFF” and call  
your service technician or gas supplier.  
10. Stand to the side of the boiler and turn the gas  
replace any part of the control system and any  
gascontrol which has been under water.  
control knob counter clockwise  
11. Replace boiler door panel.  
to “ON”.  
LIGHTING INSTRUCTIONS  
12. Turn on all electric power to the appliance.  
13. Set the thermostat to the desired setting.  
1. STOP! Read the safety information above.  
2. Set the thermostat on the lowest setting.  
3. Turn off all electric power to the appliance.  
4. Remove boiler door panel.  
TO TURN OFF GAS TO APPLIANCE  
5. Push in gas control knob slightly and turn clock-  
1. Set the thermostat to the lowest setting.  
2. Turn off all electric power to the appliance.  
3. Remove boiler door.  
wise  
to “OFF”.  
GAS CONTROL KNOB SHOWN IN "OFF" POSITION  
4. Push in the gas control knob slightly and turn  
clockwise to  
5. Replace boiler door panel.  
"OFF". Do not force.  
GAS CONTROL KNOB  
SHOWN IN "OFF" POSITION  
BOILERS WITH AUTOMATICALLY LIT IID PILOTS  
AND MANUAL GAS VALVES  
FOR YOUR SAFETY READ BEFORE OPERATING  
GAS INLET  
WARNING: If you do not follow these instructions  
exactly, a fire or explosion may result causing property  
damage, personal injury or loss of life.  
Fig.#8081  
Fig. # 8243.0  
NOTE: Knob cannot be turned from “PILOT” to  
“OFF” unless knob is pushed in slightly. Do not  
force.  
A. This appliance is equipped with an ignition device  
which automatically lights the pilot. Do not try to  
light the pilot by hand.  
6. 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.  
B. BEFORE OPERATING Smell all around the  
appliance 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  
7. Locate pilot mounted on the burner drawer.  
8. Turn knob on gas control counter clockwise  
to “PILOT”.  
*
*
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.  
*
*
THERMOCOUPLE  
PILOT  
BURNER  
If you cannot reach your gas supplier, call  
the fire department.  
Fig.# 8083  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, do not try to repir it,  
call a qualified service technician.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
9. Push in control knob all the way and hold in.  
Immediately light the pilot with a match. con  
tinue to hold the control knob in for about one (1)  
minute after the pilot is lit. Release knob and it  
will pop back up. Pilot should remain lit. If it  
4
 
BOILERS WITH AUTOMATICALLY LIT IID  
PILOTS AND AUTOMATIC GAS VALVES  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
Lighting Instructions  
1. Close all gas valves. Turn off electric power  
supply. Wait 5 minutes.  
LIGHTING INSTRUCTIONS  
2. Open manual pilot valve. Turn on electric  
power. Pilot is automatically lighted.  
3. Open main gas valve.  
4. Set temperature controls to desired tempera-  
ture.  
1. STOP! Read the safety information above.  
2. Set the thermostat on the lowest setting.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition  
device which automatically lights the pilot. Do  
not try to light the pilot by hand.  
To Shut Down  
Close all manual gas valve. Turn off electric  
power.  
5. Remove boiler door panel.  
6. Turn gas control knob clockwise  
to  
“OFF”. Make sure knob rest against stop.  
7. 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.  
8. Turn gas control knob counter clockwise  
to “OFF” until it stops. Push in gas control knob  
and continue rotating counter clockwise  
to “ON” position. Make sure knob rest against  
stop.  
Fig. # 8929.1  
IGNITION MODULE  
GAS CONTROL  
KNOB SHOWN  
IN "ON"  
BOILERS WITH AUTOMATICALLY LIT C2/IRI  
PILOT AND MANUAL GAS VALVES  
POSITION  
FOR YOUR SAFETY READ BEFORE OPERATING  
GAS INLET  
Fig.# 8082  
WARNING: If you do not follow these instructions  
exactly, a fire or explosion may result causing property  
damage, personal injury or loss of life.  
9. Replace boiler door panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
12. If the appliance will not operate, follow the  
instructions “TO Turn Off Gas To Appliance”  
and call your service technician or gas supplier.  
A. This appliance is equipped with an ignition device  
which automatically lights the pilot. Do not try to  
light the pilot by hand.  
B. BEFORE OPERATING 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.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to the lowest setting.  
2. Turn off all the electric power to the appliance if  
service is to be performed.  
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 neigh-  
bor's phone, follow the gas supplier's instruc-  
tions.  
3. Remove boiler door panel.  
4. Turn gas control knob clockwise  
to  
*
*
"OFF". Make sure knob rest against stop.  
5. Replace boiler door panel.  
If you cannot reach your gas supplier, call the  
fire department.  
5
 
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will not  
2. Turn off all the elctric power to the appliance if  
service is to be performed.  
push in or turn by hand, do not try to repair it, call 3. Remove boiler door panel.  
a qualified service technician. Force or attempted 4. Turn gas control knob clockwise  
to  
repair may result in a fire or explosion.  
"OFF". Make sure knob rest against stop.  
5. Replace boiler door panel.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service BOILERS WITH AUTOMATICALLY LIT C2/IRI  
technician to inspect the appliance and to  
replace any part of the control system and any  
gascontrol which has been under water.  
PILOT AND AUTOMATIC GAS VALVES  
1. Close all gas valves. Turn off electric power  
supply. Wait five (5) minutes.  
LIGHTING INSTRUCTIONS  
2. Open manual pilot valve. Turn on electric  
power. Push and release electric control reset  
button (Center of control cover). Pilot is auto-  
matically lighted.  
3. Open main gas valve.  
4. Set temperature controls to desired tempera-  
ture.  
1. STOP! Read the safety information.  
2. Set the thermostat on the lowest setting.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition  
device which automatically light the pilot. Do  
not try to light the pilot by hand.  
5. Remove boiler door panel.  
To Shut Down  
6. Turn gas control knob clockwise  
to  
Close all manual gas valves. Turn off electric  
power.  
“OFF”. Make sure knob rest against stop.  
7. 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.  
FLAME SAFETY  
CONTROL  
RELAY  
8. Turn gas knob counter clockwise  
from  
"OFF" until it stops. Push in gas control knob  
and continue rotating counter clockwise  
to "ON" position. Make sure knob rest against  
stop.  
Fig.# 9318  
9. Replace boiler door panel.  
INSPECTION PROCEDURES  
GAS CONTROL  
KNOB SHOWN  
IN "ON"  
BURNERS  
Clean main burners and air louvers of dust, lint and  
debris. Keep boiler area clear and free from com-  
bustibles and flammable liquids. Do not obstruct the  
flow of combustion and 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.  
POSITION  
GAS INLET  
Fig.# 8082  
10. Turn on all electric power to the appliance.  
11. Push in and release electric control reset button  
(center of control cover). Pilot is automatically  
lighted.  
12. Set thermostat to desired setting.  
13. If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance” and  
call your service technician or gas supplier.  
NOTE: Modulating burner flame varies in height from  
approximately 1/4" at low fire to approximately 3" at  
high fire.  
CONTROLS  
TO TURN OFF GAS TO APPLIANCE  
Check all controls to see that they are operational.  
To check IID's electronic safety, turn off main burner.  
1. Set the thermostat to the lowest setting.  
6
 
Observe pilot burner when shutting off pilot gas. Igni- RAYPAK HEATING AND HOT WATER SUPPLY  
tion spark should go on. Main gas valve will also drop EQUIPMENT LIMITED WARRANTY  
out.  
High Limit Switch - to check high limit switch, turn SCOPE: Raypak, Inc. ("Raypak") warrants to the  
dial setting down to a point slightly below the tempera- original owner that all parts of this boiler which are  
ture of the water leaving the boiler. The reset button actually manufactured by Raypak will be free from  
should snap out and the burner should shut off. Reset failure under normal use and service for the specified  
dial to 190° F and push reset button. Burner should warranty periods and subject to the conditions set forth  
light.  
in this Warranty. Labor charges and other costs for  
parts removal or reinstallation, shipping and transpor-  
tation are not covered by this Warranty but are the  
owner's responsibility.  
HEAT EXCHANGER WARRANTY: Five (5) Years  
from date of boiler installation. This includes only the  
copper, bronze and cast iron waterways. Twenty (20)  
Years from date of boiler installation against "Thermal  
Shock" (excluded, however, if caused by boiler opera-  
tion at large changes exceeding 150°F between the  
water temperature at intake and boiler temperature, or  
operating at boiler temperatures exceeding 230°F).  
Fig.# S8144.0  
MAIN BURNER FLAME  
NORMAL INSPECTION PROCEDURES  
ANY OTHER PART MANUFACTURED BY RAYPAK:  
First and third month after initial start up and then One (1) Year warranty from date of boiler installation, or  
on an annual basis. If problems are found, refer to eighteen (18) months from date of factory shipment  
Trouble Shooting guide for additional directions.  
1. Remove top of boiler and inspect heat exchanger SATISFACTORY PROOF OF INSTALLATION DATE,  
for soot and examine venting system. SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS  
2. Remove rear header and inspect for scale depos- WARRANTY WILL BE VOID IF THE BOILER RATING  
based on Raypak's records, whichever comes first.  
its.  
PLATE IS ALTERED OR REMOVED.  
*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. A. Oil pump motor and bearing assembly, if oil  
cups are provided.  
Examples of misuse or neglect include, but are not  
limited to, physical damage from external force, not  
following installation instructions, leaving door off for  
extended periods, location near corrosive gases, pump  
(when supplied by us), not lubricated in accordance  
B. Disconnect pump from header and check con- with listed instructions, etc.  
dition of pump impeller. Check condition of  
bearing by attempting to move impeller from  
side to side. Replace any parts showing wear.  
C. Check pump coupler for wear and vibration.  
7. Check flow switch paddle.  
CORPORATE HEADQUARTERS:  
RAYPAK,INC.  
31111 Agoura Road  
8. Clean room air intake openings to assure adequate Westlake Village, CA 91361  
flow of combustion and ventilation air. (818) 889-1500  
9. Keep boiler area clear and free from combustible FAX (818) 889-4522  
materials, gasoline, and other flammable vapors  
and liquids.  
*Should be checked monthly. (Takes approximately 15  
minutes).  
When ordering parts, you must specify Model and  
Serial number of boiler. When ordering under warranty  
conditions, you must also specify date of installation.  
7
 
Raypak, Inc., 31111 Agoura Road, Westlake Village, CA 91361-4699  
(818) 889-1500 FAX (818) 889-4522  
Litho In U.S.A.  
 

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