Table of Contents
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INSTALLATION & OPERATING
Raytherm™
Residential
Boilers
Models 0042B, 0066B, 0090B
0135B & 0180B
WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death
FOR YOUR SAFETY: 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.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.
CATALOG NO. 2100.50AA
INSTRUCTIONS
– Type H
Effective: 12-26-07
.
Replaces: 01-31-07
P/N 240488 Rev. 28
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Related Manuals for Raypak 0180B Type H
Summary of Contents for Raypak 0180B Type H
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS Raytherm™ Residential Boilers Models 0042B, 0066B, 0090B 0135B & 0180B WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death FOR YOUR SAFETY: 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.
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Page 3: Table Of Contents
Checking the Circulator For Standing Pilot Models with Robertshaw Gas Valve, 2-stage Operation (Models 90, 13 & 180) To Turn Off Gas to the Boiler (Models 90, 135 & 180) For Automatic Ignition Models For Intermittent Ignition (IID) with Honeywell or Robertshaw... -
Page 4: Warnings
Instead, shut off the gas supply at a location external to the heater. NOTE: These instructions are provided to ensure the proper installation and operation of Raypak boilers. Should questions arise regarding the specifications, installation, operation or servicing of these boilers, we suggest that the local Sales representative or the factory be consulted. -
Page 5: Receiving Equipment
Serial Number of the boiler. When ordering under war- ranty conditions, you must also specify date of installation. Raypak recommends that this manual be reviewed thoroughly before installing the boiler. If there are any questions which this manual does not answer, please contact your local Raypak representative. - Page 6 Heating Model Input Capacity H-0042 H-0066 H-0090 H-0135 H-0180 AUTOMATIC VENT DAMPER (FIELD INSTALLED) INLET OUTLET Piping Connections I=B=R Water Rating Gas NPT 1 in. 1/2 in. 1 in. 1/2 in. 1 in. 1/2 in. 1 1/4 in. 1/2 in. 1 1/4 in.
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Page 7: Installation
Boiler must NOT be installed on carpet. In addition, the boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replacement, etc.) -
Page 8: Combustion/Ventilation Air
60-75 percent free area as shown in Sec. 5.3.5 National Fuel Gas Code. 3. If the boiler room is located against an outside wall and air openings can communicate directly with the outdoors, the two openings on the outside wall must each have a net free area as shown in Table D. -
Page 9: Venting Connections
The weight of the vent stack or chimney must not rest on the boiler's drafthood. Support must be provided in compliance with applicable codes. The boiler top and drafthood must be readily removable for maintenance and inspection. - Page 10 3.25 codes. Common Vents Manifolds that connect more than one boiler to a com- mon chimney must be sized to handle the combined load. Consult available guides for proper sizing of the manifold and the chimney. At no time should the area be less than the area of the largest outlet.
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Page 11: Vent Damper Installation Location
At the time of removal of an existing boiler, the follow- ing steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remain- ing connected to the common venting system are not in operation. -
Page 12: Vent Damper Operation
Check vent damper operation as follows: 1. When the boiler is off, check that the vent damper position indicator points to the closed position (see Fig. 11). - Page 13 The name of the person who originally installed your vent damper is shown on the instal- lation label. Damper must be in open position when boiler main burners are operating. Flair Damper 24 VAC 120 VAC...
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Page 14: Vent Damper Wiring
VENT DAMPER... -
Page 15: Gas Supply Connections
0180 Table H: Maximum Equivalent Pipe Length (Feet) Gas Supply Connections The inlet gas connection of the boiler gas valve is 1/2". Provide an adequate gas piping supply line no smaller than 1/2", according to Table H above. Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve locat- ed outside the jacket. - Page 16 12 psi. Install unions and gate or ball valves at inlet and outlet connections at the boiler to facilitate servicing. The pressure relief valve is mounted on the boiler and must be piped to a drain.
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Page 17: Piping Diagrams
Piping Diagrams Heating Units Circulators Heating Units Scoop Diaphragm Expansion Tank Feed Valve Pipe Pressure Relief Valve to Drain Cold Water Inlet Fig. 15: Single-Zone Piping Scoop Diaphragm Expansion Tank Feed Valve Pipe Pressure Relief Valve to Drain Fig. 16: Multiple Zones with Circulators Air Vent 12”... -
Page 18: Electrical Wiring
(See general location of controls drawing on page 28). The pump is supplied and factory-wired to operate with the boiler. The "TH" wire leads are for the room thermostat or zone valve connections. The room thermostat should be installed in accor- dance with the manufacturer's instructions. -
Page 19: Wiring Diagrams
Wiring Diagrams... - Page 22 Fig. 17: Single-Zone Taco Valve NOTE: Maximum three (3) zone valves per one (1) 40 VA transformer. Fig. 18: Dual-Zone Taco Valve NOTE: Maximum five (5) zone valves per one (1) 40 VA Transformer. Fig. 19: Dual-Zone Honeywell Valve...
- Page 23 NOTE: Check VA rating of each relay coil. Total load must not exceed VA rating of transformer. Fig. 20: System with Three (3) Zone Pumps Fig. 21: Power Vent System with Zone Valve...
- Page 24 Fig. 22: Primary/Secondary Pumping System Honeywell Zone Valve Note: Low water cut-off (LWCO) and system switch supplied by others. Fig. 23: Standing Pilot with Low Water Cut-off Device...
- Page 25 Note: Low water cut-off (LWCO) and system switch supplied by others. Fig. 24: IID Units with Low Water Cut-off Device...
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Page 26: Servicing Procedures
Relay mostat. Whenever the room thermostat is calling for heat, the circulator supplied with the boiler will be energized and should be running. The ignition control module will also be energized to initiate the pilot ignition by opening the first main valve (pilot). -
Page 27: Start-Up Procedures
Force or attempted repair may result in a fire or explosion. D. Do not use this boiler if any part has been under water. Immediately call a qualified service techni- cian to inspect the boiler and to replace any part of the control system and any gas control which has been under water. -
Page 28: For Standing Pilot Models With
*If the pilot does not stay lit after several tries, move the gas control lever to "OFF" and call your service technician or gas supplier. 9. Stand to the side of the boiler and move the gas control lever counter-clockwise 10. Turn on all electrical power to the boiler. -
Page 29: For Intermittent Ignition (Iid) With Honeywell Or Robertshaw Gas Valve (All Models)
Force or attempted repair may result in a fire or explosion. D. Do not use this boiler if any part has been under water. Immediately call a qualified service techni- cian to inspect the boiler and to replace any part of the control system and any gas control which has been under water. -
Page 30: Testing The Ignition Afety Shut-Off
3. Turn off all gas valves supplying gas to the boiler. Refer to operating instruction label on the boiler. 4. Shut-off the water supply to the boiler piping sys- tem loop. 5. Open drain valve on the boiler to remove water from the boiler and the piping circuits. -
Page 31: Inspection Procedures
Inspection Procedures 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 ventilation air. Make visual check of burner and pilot flame. Yellow flame indicates clogging of air openings. -
Page 32: Repair Procedures
5. Lift heat exchanger straight up using caution not to damage refractory. RAYPAK TUBE CLEANING KIT Auger with Carbide Tip Fig. 35: Raypak Tube Cleaning Kit Wire Brush - "... -
Page 33: Heat Exchanger Re-Assembly
7. Open water supply and return shut-off valves. Fill boiler and water piping system with water. Check boiler and piping system for leaks at full line pres- sure. Run system circulating pump for a minimum of 1/2 hour with boiler shut off. -
Page 34: Troubleshooting
ON if temperature exceeds 240°F. It will turn off when sensor temperature falls below 180°F. When either Red or Yel- low LED is ON, boiler will be shut down. 9)Check voltage across output and common terminals. If no 24V is pres-... - Page 35 3) Pilot Outage. (Standing pilot models) 4) Yellow lazy flame. 5) Sooting 10) Defective ignition module or defective gas valve. 1) Too low or too high gas pressures. 2) Restricted pilot. 3) Weak thermocouple. ) Too low gas pressure. 2) Restricted burner intake ports. 3) Restricted gas line.
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Page 36: Gas Valve Replacement
Adjustment & Replacement of Components DANGER—SHOCK HAZARD: 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. -
Page 37: Replacement Parts List
Any part returned for replacement under standard company warranties must be properly tagged with Raypak return parts tag, completely filled in with the heater serial number, model number etc., and shipped to Raypak freight prepaid. - Page 38 SCOPE: Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
- Page 40 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
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