Adjustment & Replacement of Components

DANGER—SHOCK HAZARD: Make sure electrical power to the boiler is disconnected to avoid potential serious injury or damage to components.

Gas Valve Replacement

1.Shut-off electrical power and gas supply to the boiler.

2.Remove gas piping to gas valve inlet.

3.Disconnect wiring connections, pilot tubing (when present).

4.Remove screws (2) holding the burner tray.

5.Slide burner tray out.

6.Remove gas valve bracket screws and bracket.

7.Unscrew gas valve from gas pipe.

8.Reverse above procedure to re-install.

Pilot Burner Cleaning or Replacement (Standing Pilot)

1.Shut-off electrical power and gas supply to the boiler.

2.Disconnect gas piping to gas valve.

3.Disconnect wiring connections to gas valve.

4.Remove screws (2) holding the burner tray.

5.Slide burner tray out.

6.Remove screw holding pilot lighter tube.

7.Remove screws (2) holding pilot bracket on the burner tray.

8.Disconnect thermocouple and pilot tubing from the gas valve.

9.Remove pilot burner from pilot bracket.

10.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.

11.Reverse above procedure to re-install.

PilotPilot

Air

Opening

Orifice Orifice

Fig. 37: Pilots, Honeywell (Left) and Robertshaw (Right)

Flame Roll-out Switch Replacement

1.Shut-off electrical power to the boiler.

2.Remove wiring connections to switch.

3.Remove screws (2) holding the switch.

4.Reverse above procedure to re-install.

Vent Thermal Switch Replacement

1.Shut-off electrical power to the boiler.

2.Remove wiring connections to switch.

3.Remove the screws (2).

4.Reverse above procedure to re-install.

Ignition Module Replacement

1.Shut-off electrical power to the boiler.

2.Remove control cover screws and open control compartment.

3.Disconnect wiring connections to module.

4.Remove screws (2) holding module.

5.Reverse above procedure to re-install.

Transformer Replacement

1.Shut-off electrical power to the boiler.

2.Remove control cover screws and open control compartment.

3.Disconnect wiring connections from transformer leads.

4.Remove screws (2) holding transformer.

5.Reverse above procedure to re-install.

Pump Relay Replacement

1.Shut-off electrical power to the boiler.

2.Remove control cover screws and open control compartment.

3.Disconnect wiring to the relay.

4.Remove screws (2) holding relay.

5.Reverse above procedure to re-install.

High Limit Control

1.Shut-off electrical power to the boiler.

2.Remove control cover screws and open control compartment.

3.The control is factory set at 180°F. To adjust set- ting, use a small screw driver and turn dial clockwise to lower the temperature or counter- clockwise to raise the setting.

4.To replace the limit control, disconnect the wiring connections.

5.Remove screws (2) holding the limit control.

6.Remove upper access panel.

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Raypak 0066B, 0180B, 0042B manual Adjustment & Replacement of Components