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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. 2100.50AF
INSTRUCTIONS
– Type H
Effective: 10-09-12
.
Replaces: 09-21-12
P/N 240488 Rev. 33
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Related Manuals for Raytherm 0042B
Summary of Contents for Raytherm 0042B
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS Raytherm™ Residential Boilers Models 0042B, 0066B, 0090B 0135B & 0180B – Type H 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.
- Page 2 Rev. 33 reflects the following: Changes to: Wiring Diagram for IID On/Off on page 20, Wiring Diagram for IID 2-Stage on page 21. Additions: None Deletions: None...
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Page 3: Table Of Contents
CONTENTS WARNINGS Intermittent Ignition Device (IID) START-UP PROCEDURES Pay Attention to These Terms RECEIvING EqUIPMENT Lighting the Boiler GENERAL SPECIFICATIONS Filling the System INSTALLATION Checking the Circulator Code Requirements Safety Information Mounting Base Operating the Boiler Clearance Requirements To Turn Off Gas to the Boiler Combustion/Ventilation Air Shut-down Procedure Venting Connections... -
Page 4: Warnings
WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. -
Page 5: Receiving Equipment
On receipt of your equipment, visually check for exter- nal damage to the carton. If the carton is damaged, it Raytherm hydronic boilers are design certified and is suggested that a note be made on the Bill of Lading tested under the requirements of the latest edition of when signing for the equipment. - Page 6 Piping Connections Heating Model Input Capacity AFUE Vent Water Dia. Gas NPT H-0042 1 in. 1/2 in. 11 in. 5 3/4 in. 5 1/2 in. 4 in. H-0066 1 in. 1/2 in. 11 in. 5 3/4 in. 5 3/4 in. 5 in.
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Page 7: Installation
INSTALLATION Code Requirements Installation must be in accordance with local codes, or in the absence of local codes, with the latest editions of the National Fuel Gas Code, ANSI Z223.1, and the National Electrical Code, ANSI/NFPA 70. In Canada, installations must conform with the current CSA B149 and the Canadian Electrical Code Part 1 CSA C22.2 No.1. -
Page 8: Combustion/Ventilation Air
3. Except for carpeted flooring, boilers are certified One opening shall be within 12" of the top, and the for installation on combustible floors. other opening within 12" of the floor. If additional gas appliances are installed in the same space, the total 4. -
Page 9: Venting Connections
Location of the openings is the same as in the previ- The discharge opening must be a minimum of two (2) ous case - that is, within 12" of the top, and within 12" feet vertically from the roof surface and at least two (2) of the bottom of the enclosure. - Page 10 WARNING: These boilers must not be connected Roof Pitch (X/12) H (Min. ft) into any portion of mechanical draft systems Flat to 6/12 operating under positive pressure. To do so may cause the flue products to be discharged into the 6/12 to 7/12 1.25 living space causing serious health injury.
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Page 11: Vent Damper Installation Location
vent Damper Installation At the time of removal of an existing boiler, the follow- ing steps shall be followed with each appliance Location remaining connected to the common venting system placed in operation, while the other appliances remain- The vent damper supplied with each boiler must be ing connected to the common venting system are not located in the vent so that it serves only the appliance in operation. - Page 12 The vent damper ships set up for a continuous pilot system. Since the Raytherm Residential is equipped with an Intermittent Pilot, the hole in the vent damper blade must be plugged using the knockout plug provid- ed in the parts envelope.
- Page 13 NOTE: To place vent damper in the open position to allow burner operation: Turn the power off. Turn the damper blade to fully open position (arrow facing same direction as vent pipe). Turn power on. 2. Turn the thermostat or controller up to call for heat and check that the vent damper indicator points to the open position, as shown in Fig.
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Page 14: Vent Damper Wiring
VENT DAMPER... -
Page 15: Gas Supply Connections
1/2 in. Pipe 3/4 in. Pipe 1 in. Pipe 1 1/4 in. Pipe Model Nat. Pro. Nat. Pro. Nat. Pro. Nat. Pro. 0042 0066 0090 0135 0180 Table H: Maximum Equivalent Pipe Length (Feet) Gas Supply Connections NOTE: Do not use teflon tape on gas line pipe thread. -
Page 16: Electrical Wiring
shipped loose. The full open position is appropriate for ball valves at inlet and outlet connections at the boiler most systems, and ensures adequate flow through the to facilitate servicing. boiler. The pressure relief valve is mounted on the boiler and If system flow is inadequate, (indicated by excessive must be piped to a drain. -
Page 17: Outdoor Air Reset Temperature Controller
The primary functions of the controller are set using NOTE: If it is necessary to replace any of the the Operating Temperature dial and the DIP switches. original wiring, it must be replaced with 105°C wire or See Table K. The controller has 4 LEDs to indicate the its equivalent, except 150°C black wire must be its condition: replaced with 150°C wire or its equivalent. -
Page 18: Piping Diagrams
Hydronic with Outdoor Air Reset Hydronic, Outdoor Air Reset with Indirect DHW For hydronic operation with outdoor air reset, the System Supply Sensor (S2) is used as the operating For hydronic operation with outdoor air reset and sensor. Boiler Outlet Sensor (S1) is used for boiler out- Indirect DHW, the System Supply Sensor (S2) is used let maximum limiting. - Page 19 Fig. 17: Multiple Zones with Circulators Fig. 18: Multiple Zones with Circulators and Indirect DHW Tank...
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Page 20: Wiring Diagrams
Wiring Diagrams... - Page 22 (PROVIDED BY OTHERS) Fig. 19: Single-Zone Taco Valve (PROVIDED BY OTHERS) NOTE: Maximum three (3) zone valves per one (1) 40 VA transformer. Fig. 20: Dual-Zone Taco Valve...
- Page 23 (PROVIDED BY OTHERS) NOTE: Maximum five (5) zone valves per one (1) 40 VA Transformer. Fig. 21: Dual-Zone Honeywell Valve (PROVIDED BY OTHERS) NOTE: Check VA rating of each relay coil. Total load must not exceed VA rating of transformer. Fig.
- Page 24 Fig. 23: Power Vent System with Zone Valve (Taco)
- Page 25 Fig. 23: Power Vent System with Zone Valve (Honeywell)
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Page 26: Servicing Procedures
SERvICING SEqUENCE OF PROCEDURES OPERATION General Location of Controls Intermittent Ignition Device (IID) Relay Boilers equipped with the IID system will automatical- ly light the pilot burner first and then the main burner, each time there is a call for heat from the room ther- mostat. -
Page 27: Start-Up Procedures
START-UP Safety Information PROCEDURES Please read carefully and understand the following safety information before operating the boiler. Lighting the Boiler WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing Safe-lighting and other performance criteria were met property damage, personal injury or loss of life. -
Page 28: To Turn Off Gas To The Boiler
To Turn Off Gas to the Boiler GAS CONTROL KNOB SHOWN 1. Set the thermostat at the lowest setting. IN "OFF" 2. Turn off all electrical power to the boiler if service POSITION is to be performed. 3. For Honeywell valve: GAS INLET Turn gas control knob clockwise "Off". -
Page 29: Testing The Ignition Safety Shut-Off
Testing the Ignition Safety debris. Keep boiler area clear and free from com- bustibles and flammable liquids. Do not obstruct the Shut-off flow of combustion and ventilation air. Make visual check of burner and pilot flame. Yellow flame indicates The ignition system safety shut-off must be tested by clogging of air openings. -
Page 30: Repair Procedures
REPAIR PROCEDURES 2. Remove "V" baffles from heat exchanger. 3. Remove burner tray, see Burner Tray Removal. 4. Take garden hose and wash heat exchanger, mak- Tube Cleaning Procedure ing sure soot is removed from between fins. (Avoid (Typical) excessive water against refractory). 5. -
Page 31: Heat Exchanger Re-Assembly
Heat Exchanger Re-assembly 9. Install flue collector, jacket top and inspection pan- els. Install top holding screws. Install draft diverter and vent piping if so equipped. 1. Heat exchanger water header O-rings should be replaced with new ones. 10. If gas piping was disconnected, reconnect gas pip- ing system and check for leakage using a soap 2. -
Page 32: Adjustment & Replacement Of Components
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. - Page 33 Pump Relay Replacement Circulator Replacement 1. Shut-off electrical power to the boiler. 1. Shut-off electrical power to the boiler. 2. Remove control cover screws and open control 2. Shut-off water supply and open drain valve to compartment. remove water in the piping at the pump level. 3.
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Page 34: Replacement Parts List
Replacement Parts List (see Raypak Catalog No. 9300.9.1, located in the Document Library at www.raypak.com) NOTE: To supply the correct part it is important that you supply the model number, serial number and type of gas when applicable. 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... -
Page 35: Warranty
Catalog No.: 1910.10 I Effective: 10-01-08 Replaces: 01-01-04 LIMITED PARTS WARRANTY RESIDENTIAL HEATING BOILERS MODELS 0042 TO 0180 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. - Page 36 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
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