Raypak boiler troubleshooting

The American company Raypak has existed for more than 50 Raypak years. In 1996, it received the highest attainable level of registration of worldwide manufacturers of boilers due to its registration to ISO 9001. Raypak has always strived for high quality, reliability and energy efficiency. Below you will find Raypak boiler troubleshooting table.

Raypak 0180B Type H boiler troubleshooting

1)When room thermostat is turned on, boiler does not operate.1)No power to the boiler.1)Check circuit breakers, disconnect switch. Make sure power is on.
2) Defective room thermostat or disconnected wire in thermostat circuit.2) Check continuity on thermostat and wiring circuit. Replace thermostat, or repair wiring connections.
3) Defective transformer.3) Check secondary voltage. If no 24V, replace transformer.
4) Defective pump relay.4) Check relay coil or contacts. Replace as required.
5)Defective pump.5) Replace pump.
2)When room thermostat is calling for heat, pump is on, but burners will not turn on.1)For standing pilot models, pilot burner not lighted.1)Light pilot burner. (Follow lighting instructions on rating plate.)
2)lf pilot burner will not stay lighted, thermocouple or gas valve may be defective.2) Check thermocouple MV generation. If less than 25MV (open circuit), replace thermocouple. If between 2535 MV, replace gas valve.
3)Gas knob in "Pilot" position.3)Turn knob to "ON” position.
4) For automatic ignition models, gas valve knob is in "OFF” position.4)Turn gas knob to "ON". If ignition module locks out, reset by interrupting power to boiler.
5)Vent switch is open.5) Check for blockage of venting system or disconnected vent piping. After problem is corrected push button to reset, or replace single-use type vent switch.
6) Roll-out switch is open.6) Check for blockage of flue or sooted heat exchanger. After problem is corrected push button to reset or replace single use type roll-out switch.
7)High limit is open.7) Setting may be too low. Check water flow and adjust setting to obtain 2030°F temperature rise.
8) Fast Response Temperature Sensor probe is defective.8) Red LED on circuit board will be ON to indicate a loose sensor connection or a shorted sensor. Check terminal connectors or replace sensor as required.
9) Defective ignition module or defective gas valve.9) Before module goes into a lock-out, check voltage across MV and MV/ PV. If no 24V is present, replace module. If 24V is present, replace gas valve.
3) Pilot Outage. (Standing pilot models)1) Too low or too high gas pressures.1) Adjust inlet gas pressure as shown on rating plate.
2) Restricted pilot.2) Clean pilot orifice.
3) Weak thermocouple.3) Replace thermocouple.
4)Yellow lazy flame.1) Too low gas pressure.1) Adjust manifold pressure as shown on rating plate.
2) Restricted burner intake ports.2) Clean burners free of debris or insects.
3) Restricted gas line.3) Clean gas line or increase gas line piping.
5) Sooting1) Insufficient combustion air.1) Refer to installation instructions regarding combustion air requirements.
2) Improper venting.2) Refer to installations instructions.
3) Severe yellow burner flames.3) See yellow flame section above.

Raypak 0133-4001 boiler troubleshooting

When heater is turned on nothing happens.No power to the heater
Bad transformer
Inoperative thermostat
Inoperative toggle switch
Inoperative relay
Check the circuit breaker, outdoor controller, etc., upstream of heater.
If power to Leads L1 and L2 of transformer, but no power on 24V side, replace.
Jumper thermostat, replace with new if heater fires.
If power to toggle switch, but not through switch, replace.
If power to relay, but not operating, replace.
Thermostat in "ON" position causes relay and pump to operate, but heater does not fire.Main gas valve closed
Plugged bleed line on gas valve or gas pressure regulator
Broken pump coupler
Shutdown by low water cut-off, caused by air
Gas valve defective
Open valve.
Loosen bleed line and clean.
Replace coupler. Inspect bearing assembly, and if frozen, lubricate or replace.
Bleed air from system.
Check for power to gas valve. If valve has power but will not open, check vent tube for blockage. If clear, replace valve.
Continuous shut down of manual reset High Limit.Temperature setting too low
Low water flow
Interrupted pump operation
Modulating control set too high
Mechanical modulating control
Reset High Limit to higher temperature. Check system water pumps.
Check pump oil if necessary.
Reset modulator to a lower setting. Check and replace if necessary.
CAUTION-Soot may be combustible. Wet down and exercise caution when cleaning.Air starvation
Toxic fumes which cause a chemical reaction with copper tubes or destroy combustion
Improper venting
Refer to installation instructions regarding combustion air requirements.
Set bypass valve to prevent heater inlet temperature from dropping below 105° F.
Remove all sources of fumes, such as freon or chloride, or isolate the heater. Follow recommended vent installation instructions.

Continuous shut down of low water cut-off or flow switch.Insufficient system flow
Low water due to leaking
Air in system
Line strainer dirty
Lime in Heat Exchanger
Check pumps and piping.
Inspect for leaking and repair.
Inspect for leakage and repair. Install an automatic air vent.
Ream tubes.

Low flame.Low gas supply
Insects or debris clogging
Burner intake ports low gas pressure
Venting or combustion air
Debris in gas line (pipe dope, rocks, etc.). Gas line too small.
Improper size gas meter.
Gas regulator adjustment.
Clean burners.
Adjust gas pressure.
Refer to installation instructions regarding combustion air requirement.
Outer jacket very hot (blistered paint)Broken refractory Replace refractory panels.
Combustion fan not running. (If applicable)Fan relay
Replace fan relay. Loose wire connection. Failed fan motor.

Raypak B6000 boiler troubleshooting

SymptomPossible CauseCorrective Action
No Display.No Primary power.Check power connections to units. Check surge protection devices. Check disconnects, check grounds.
Check power switches.
* Nite set-back time display no longer correct.Time display accidentally Re-Programmed.Initialize system.
Program Nite set-back feature.
* Nite set-back not working properly.Nite set-back turned off. Clock times not set.Initialize system.
* Time display does not maintain proper time.System ground not adequate. Line noise.
Internal battery weak. Prolonged power outage.
Initialize system and / or contact authorized Raypak Representative for further instructions.
System not working automatically.Boiler monitor has Manual Mode selectedSelect Automatic mode on Boiler Monitor.
Display shows incorrect number of boilers.Inadequate grounds. Line noise Power outages.Check primary power check wired ground.
Rework as necessary. Initialize system.
Scrambled control display.Power outages.Initialize system.
Boiler does not function properly after power outage.Internal battery weak.
Line noise.
System ground not adequate.
Boiler "Not on Line" displayed.Primary power at boiler not connected.
Outdoor and water temp, readings Incorrect (-35°F).Inadequate ground Line noise.
Power outage.
Displayed parameters do not make sense.
Power outage.
System Faults indicators do not make sense.
Power outage.
Boiler# x
"Not on Line" Displayed
Boiler not powered.Check primary power.
Correct as necessary.
Check communication cable, check (surge) ground Remove / Replace (R/R) as necessary. Initialize system.
Outdoor Temp. Sensor readings are high.Outdoor sensor not mounted correctly.Refer to installation manual mounting instructions. Possible relocation for sensor.
Sensor reading 220°F.Sensor wiring shortedCheck sensor wiring for damage. R/R as necessary.
Initialize system.
Sensor reading 35°F.Sensor wiring open.R/R as necessary Initialize system.
Low water cut-off alarm.Excessive circuit loading of pump contacts by user supplied system pump.
Low water level in boiler
Check power.
Check pump contactor / relay R/R as necessary.
Replace F1 fusing.
Check main water supply
Power lamp off on Boiler Monitor.Fuse F1 blown.
Excessive circuit loading of pump contacts by user supplied system pump.
Circuit breaker tripped.
Replace F1 fusing.
Remove Relay-K1 to isolate circuit loading.
R/R as necessary.
Reset circuit breaker.
Pump not running.Excessive circuit loading of pump contacts by user supplied system pump.Replace F1 fusing.
Pump going off on thermal overload circuit breaker trippedCheck pump.
Reset circuit breaker
Off at flow switch.Paddle damaged or missing. Pump off on thermal overload.Check paddle on flow switch. Check pump, contact or relay. Replace F1 fusing.
Off on High Limit.Low limit settings. Intermittent power or pump failure.Check and correct settings. Meter amperage on pump. R/R as needed.