BURNER DRAWER REMOVAL

1.Shut off main electrical power switch to heater.

2.Shut off gas upstream of heater.

3.Remove front door.

4.Disconnect gas line from gas valve.

5.Remove (2) screws that mount burner tray to unit, and (2) screws that secure gas valve to jacket.

6.Disconnect wires that terminate at gas valve.

7.Slide out burner tray.

8.Reverse above procedure to reinstall.

GAS VALVE REMOVAL

1.Shut off gas supply to the heater. Remove gas piping to gas valve inlet.

2.Disconnect wires, pilot tubing and bleed line, if required.

3.Turn vertical gas pipe from manifold slightly and unscrew gas valve.

4.Reverse above procedure to reinstall.

MAIN BURNER AND ORIFICE REMOVAL

1.Remove burner drawer. See burner drawer removal procedure.

2.Remove screws and burner hold down bracket.

NOTE: If the heat exchanger is sooted badly, the burner hold down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts.

3.Lift burners from slotted spacers and slide from orifices. Clean with a wire brush.

4.Orifices usually do not need to be replaced. To clean, run either copper wire or wood toothpick through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove from manifold. DONOT overtighten when reinstalling.

Burners

Burner Hold Down Bracket

Fig. # 9479

PILOT REMOVAL AND CLEANING

1.Disconnect pilot tubing, and wires from gas valve.

2.Remove pilot assembly from burner tray.

3.Remove pilot from bracket.

4.Remove pilot orifice and air opening (Honeywell MV unit only), and clean with wire or small brush.

CAUTION! Do not enlarge hole in pilot orifice.

5. Reverse above procedure to reinstall.

HONEYWELL PILOT ROBERTSHAW PILOT

PilotPilot

Air

Opening

Orifice

Orifice

Fig. # 8045.1

Fig. # 8102.0

HEAT EXCHANGER REMOVAL

1.Shut water, gas and electricity off, close valves and relieve pressure, remove relief valve. Remove side inspection panels.

2.Remove top holding screws.

3.Remove draft diverter, lift and remove top and flue collector. Remove inspection panels.

4.Disconnect wires from high limits and pressure switch. Remove temperature sensor.

5.Disconnect flange nuts on inlet-outlet header, loosen union(s) at gas pipe and slide boiler away from piping.

6.Lift heat exchanger straight up using caution not to damage refractory.

7.Reverse above procedure to reinstall. Make sure the insulation strips are properly replaced on top of the refractory retainer.

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Raypak P-R185B To P-R405B, C-R185B To P-R405B, P-R185BL To P-R405BL, C-R185BL To C-R405BL, RP2100 Burner Drawer Removal
Page 34 Page 36

P-R185B To P-R405B, C-R185B To P-R405B, P-R185BL To P-R405BL, C-R185BL To C-R405BL, RP2100 specifications

Raypak offers a comprehensive line of boilers and water heaters, notably the P-R185B to P-R405B and C-R185B to P-R405B series, along with the RP2100 model. These products are engineered for efficiency, reliability, and performance in both residential and commercial applications.

The P-R185B to P-R405B series features a range of input capacities from 185,000 to 405,000 BTU/h, making them suitable for various heating requirements. The P-R series is equipped with Raypak's patented Cupro-Nickel heat exchanger, which offers superior corrosion resistance and extended life in challenging water conditions. These units also utilize a sealed combustion system, allowing for efficient operation and reduced energy consumption by drawing air from outside the building.

The C-R185B to P-R405B boilers are specifically designed for commercial applications where reliability is critical. They incorporate similar features to the standard P-R series and are built to handle higher heating demands, making them ideal for larger facilities. The C-R series models are recognized for their durable construction and advanced control systems, offering precise temperature management and enhanced performance.

In addition to these series, the P-R185BL to P-R405BL and C-R185BL to C-R405BL models feature a low-NOx design to comply with stringent environmental regulations. This means they produce lower nitrogen oxides, making them an environmentally friendly option without sacrificing performance.

The RP2100 is another standout model, known for its robust design and cutting-edge technology. It boasts a high efficiency rating and is equipped with an intuitive digital control system, allowing users to monitor and adjust settings with ease. The RP2100 also features a modulating burner system, which adjusts the flame based on the heating demand, optimizing fuel usage and minimizing operational costs.

All Raypak models are designed with safety in mind, incorporating multiple safety features like thermal shutdowns and pressure relief valves. Their compact dimensions make installation straightforward, and the low maintenance requirements ensure longevity and consistent performance.

In summary, Raypak's P-R185B to P-R405B, C-R185B to P-R405B, P-R185BL to P-R405BL, and RP2100 series represent a commitment to quality and innovation in heating solutions, providing efficient and reliable options for both residential and commercial applications.
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