Raypak 0066B, 0180B, 0042B manual Adjustment/Replacementof Components, Danger - Shock Hazard

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ADJUSTMENT/REPLACEMENTOF

ADJUSTMENT/REPLACEMENTOF

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 present).

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.

HONEYWELL PILOT

ROBERTSHAW PILOT

PILOT

PILOT

AIR

OPENING

ORIFICE

ORIFICE

Fig.# 8045.2

Fig.# 8102.1

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.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 adjust setting, use a small screw driver and turn dial

clockwise DANGER - SHOCK HAZARD to lower the temperature or

counter-clockwise Manual background 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.

j)Reverse above procedure to re-install.

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Contents RaythermTM Type H RESIDENTIAL BOILERS Models FOR YOUR SAFETY0042B, 0066B,0090B 0135B, 0180B INSTALLATION AND OPERATING INSTRUCTIONSGENERAL SPECIFICATIONS ContentsINSTALLATION PROCEDURES SERVICING PROCEDURESRECEIVING EQUIPMENT GENERAL SPECIFICATIONSCODE REQUIREMENTS 3. INSTALLATION PROCEDURESMOUNTING BASE CLEARANCEREQUIREMENTSVENTING CONNECTIONS COMMON VENTS VENT DAMPER INSTALLATION Hole in Vent Damper Blade Closed Position FLAIR DAMPER VENT DAMPER OPERATIONVENT DAMPER WIRING DIAGRAM GAS SUPPLY CONNECTIONS GASPRESSUREWATER CONNECTIONS & SYSTEM PIPING SINGLE-ZONEPIPING PIPING DIAGRAMSHOT WATER SUPPLY ZONE HEATING WITH INDIRECT DOMESTICZONE VALVES HEATINGUNITS AIR SCOOP DIAPHRAGM EXPANSION FEED TANK VALVEMULTIPLE ZONES WITH ZONE VALVES MULTIPLE ZONES WITH CIRCULATORSWIRING DIAGRAM KEY ELECTRICAL WIRINGWIRING DIAGRAMS Page Page WIRING DIAGRAM Dual-ZoneTaco Valve WIRING DIAGRAM Single-ZoneTaco ValveWIRING DIAGRAM Dual-ZoneHoneywell Valve Fig. # 2228eWIRING DIAGRAM: Power Vent System w/ Zone Valve WIRING DIAGRAM System with 3 Zone PumpsFig. #2232e Fig. #2233e Fig. #2234eWIRING DIAGRAM Primary/Secondary Pumping System Honeywell Zone ValveFig. #2223.2e Note Low water cut-offLWCO and system switch supplied by others GENERAL LOCATION OF CONTROLS SERVICING PROCEDURESFor Standing Pilot Models START-UPPROCEDURES Lighting the BoilerFilling the System Checking the CirculatorROBERTSHAW PILOT HONEYWELL PILOTTO TURN OFF GAS TO THE BOILER Models FOR AUTOMATIC IGNITION MODELSTO TURN OFF GAS TO BOILER SHUT-DOWNPROCEDURE3.For Honeywell valve For Robertshaw valveFOR AUTOMATIC IGNITION SYSTEMS SAFE SHUT-DOWNTESTS LIMIT ACTION INSPECTION PROCEDURES BURNERSFLAME FAILURE INSPECTIONSCHEDULEREPAIRPROCEDURES RAYPAK TUBE CLEANING KITHEAT EXCHANGER RE-ASSEMBLY PROBLEM TROUBLESHOOTING GUIDESOLUTIONS IMPORTANT NOTICE10Defective ignition module or defective gas valve DANGER - SHOCK HAZARD ADJUSTMENT/REPLACEMENTOF COMPONENTSRAYPAK, INC 2151 Eastman Avenue Oxnard, CA REPLACEMENT PARTS LISTPage Page Page HEAT EXCHANGER WARRANTY LIMITED PARTS WARRANTYADDITIONAL WARRANTY EXCLUSIONS PARTS REPLACEMENT
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