Raypak 0042B User Manual

USER’S INFORMATION MANUAL

CATALOG NO. 2100.51L Effective: 09-19-08 Replaces: 04-10-08 P/N 240490 Rev. 13

Models

0042B, 0066B, 0090B, 0135B,

0180B—Type H

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.

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.

Installation and service must be performed by a qualified installer, service agency
or the gas supplier.

WARNING: If the information in this manual is not followed exactly, a fire or
explosion may result causing property damage, personal injury or loss of life.

Gas Fired Residential

Heating Boilers

2

Introduction

This User's Information Manual is provided with the
necessary information for the proper operation and
maintenance of these Raypak boilers. Please review
and follow these procedures carefully. Keep this man­ual in a safe and accessible place for easy reference
in the future.

Blocked Vent Shut-Off System

This boiler is equipped with a blocked vent shut-off
system designed to shut off main burner gas in the
event the venting system is totally blocked. In the
event the blocked vent shut-off system is actuated, do
not attempt to place the boiler in operation, contact a
qualified service agency.

Flame Roll-Out Safety Shut-Off
System

This boiler is equipped with a flame roll-out safety
shutoff system designed to shut-off the main burner
gas in the event of sustained flame roll-out. In the
event the flame roll-out safety system is actuated, do
not attempt to place the boiler in operation, contact a
qualified service agency.

Lighting Instructions For
Standing Pilot Models

Some safety information you need to read and under­stand before operating the boiler.

A. This boiler has a pilot which must be lighted by
hand. When lighting the pilot, follow these instructions
exactly.

B. BEFORE LIGHTING Smell all around the boiler
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric 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 you gas supplier, call the fire
department.

C. Use only your hand to push in, move or turn the gas
control knob or lever. Never use tools. If the knob or
lever will not push in, move or turn by hand, don't try to
repair it, call a qualified service technician. 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 technician
to inspect the boiler and to replace any part of the con­trol system and any gas control which has been under
water.

For Standing Pilot Models with
Robertshaw Gas Valve, 2-Stage
Operation. (Models 90, 135 & 180)

5. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information
above in this manual. If your don't smell gas, go to
the next step.

6. Locate pilot mounted on the right side of the burn­er drawer, and right of first burner.

WARNING: Improper care and maintenance of flue
and venting system can cause a hazardous
condition which may result in injury, property
damage or loss of life.

WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.

NOTE: Lever cannot be moved from "ON" to "OFF"
unless lever is pushed in slightly. Do not force.

Fig. 1: Gas Control Lever

1. STOP! Read the safety information.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. Push in and move gas control lever counter­clockwise to "OFF" position.

GAS CONTROL
LEVER SHOWN
IN "OFF" POSITION

GAS INLET

3

Lighting Instructions For
Automatic Ignition Models

Please read carefully and understand the following
safety information before operating the boiler.

A. This boiler does not have a pilot. It is equipped with
a hot surface ignition device which automatically lights
the burners. Do not try to light the burners by hand.

B. BEFORE OPERATING smell all around the boiler
area for gas. Be sure to smell next to the floor because
some gases are heavier than air and will settle on the
floor.

WHAT TO DO IF YOU SMELL GAS

* Do not try to light any appliance.
* Do not touch any electric 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.

C. Use only your hand to push in, move or turn the gas
control knob or lever. Never use tools. If the knob or
lever will not push in, move or turn by hand, don't try to
repair it, call a qualified service technician. 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 technician
to inspect the boiler and to replace any part of the con­trol system and any gas control which has been
underwater.

For Intermittent Ignition (IID) with
Honeywell or Robertshaw Gas Valve
(For All Models)

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. This boiler is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.

THERMOCOUPLE THERMOCOUPLE

Fig. 2: Pilots

To Turn Off Gas to the Boiler

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.

Fig. 3: Honeywell Gas Valve

ROBERTSHAW PILOT HONEYWELL PILOT

7. Move control lever clockwise to "SET"
position and immediately light pilot with a match.

8. Hold lever in "SET" position for 1/2 minute after
pilot is lit. Release lever, and it will spring back to
"PILOT" position Pilot should remain lit. If it goes
out, repeat steps 4 through 8.
*If lever does not spring back to "PILOT" position
when released, stop and immediately call your

service technician or gas supplier.
*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 heater and move the gas

control lever counter-clockwise to "ON".

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance.

3. Push in and move gas control lever counter-

clockwise to "OFF" position. Do not
force.

GAS CONTROL
KNOB SHOWN
IN "ON" POSITION

GAS INLET

HONEYWELL

(Models 30 - 90)

4

8. Turn on all electric power to the boiler.

9. Set thermostat to desired setting.

10. If the boiler will not operate, follow the instruction
"To Turn Off Gas To Boiler" and call your service
technician or gas supplier.

To Turn Off Gas to the Boiler

1. Set the thermostat at the lowest setting.

2. Turn off all the electric power to the boiler if serv­ice is to be performed.

Inspection and Maintenance
Procedures

It is a good practice to make a periodic inspection of
the boiler. It is recommended that the home owner or
user check the boiler after the first and third month of
operation, and then on an annual basis, or more often
if desired. It is also recommended to have a qualified
service agency check the boiler before each heating
season, or at anytime there may be an indication of a
problem.

Burner Inspection

Clean the main burners and air louvers of dust, lint and
debris. With burner in operation, make a visual check
of the burner flame and the pilot flame (when
equipped). Yellow flames indicate some restriction of
combustion air openings. A bright orange, luminous
flame is not normal and can cause sooting under pro­longed operation. Should this condition be observed,
immediately contact a qualified service agency to cor­rect the problem.

5. For Honeywell Valve: Turn gas control knob

Fig. 4: Robertshaw Gas Valve

Fig. 5: Honeywell Pilot

CAUTION: Should overheating occur or the gas
supply fail to shut off, DO NOT turn off or disconnect
the electrical supply to the pump. Instead, shut off
the gas supply at a location external to the
appliance. Failure to observe this precaution may
aggravate the overheated condition resulting in
possible damage to the boiler and injury to the user.

DANGER: Keep boiler area clear and free from
combustibles and flammable materials. Do not
obstruct the flow of combustion and ventilating air
into the boiler enclosure. Failure to observe these
safety precautions can cause fire, explosion, or
asphyxiation.

Fig. 6: Burner Flame

clockwise to "OFF".
For Robertshaw Valve: Push in and move gas
control lever to "OFF" position.

6. Wait 5 minutes to clear out any gas. Then smell for
gas, including near the floor. If you smell gas,
STOP! Follow "B" in the safety information above
in this manual. If you don't smell gas, go to the next
step.

7. For Honeywell Valve: Turn gas control counter-
clockwise to "ON".
For Robertshaw Valve: Move gas control lever to
"ON" position.

PILOT

S

ON

GAS CONTROL
KNOB SHOWN
IN "OFF"
POSITION

GAS INLET

ROBERTSHAW

(All Models)

OFF

E

T

3. For Honeywell Valve:

Turn gas control knob clockwise to "OFF".
Make sure knob rest against stop.

For Robertshaw Valve:

Push in and move gas control lever to "OFF"
position.

BLUE FLAME

5

Venting System Inspection

Visually inspect the venting system. Make sure the
vent connections are secure and have not become
disengaged. Look for any indication of corrosion, or
carbon (soot) streaks which could cause leakage of
products of combustion into the living space. Inspect
the vent terminal outside the building. Make sure it is
not damaged to cause blockage or restriction of the
flue gas. Look for any indication of soot. The presence
of soot accumulation in the vent terminal would indi­cate an abnormal operating condition. This should be
investigated and corrected by a qualified service
agency.

Circulator (Water Pump) Inspection

The circulator is permanently lubricated and thus, will
not require any lubrication. Inspect for evidence of
water leakage. This should be corrected to prevent
any possible damage to electrical components of the
boiler.

To prevent the potential freezing damage to the heat­ing system, it is recommended that the following
system shut down procedure be performed.

System Shut Down Procedure

1. Set the room thermostat to "OFF" or the lowest
setting.

2. Turn off all electric switches to the boiler.

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 sys­tem loop.

5. Open drain valve on the boiler to remove water
from the boiler and the piping circuits.

Service Assistance

If service is required on the boiler, contact your local
service agency or Raypak can refer you to the proper
qualified service agency. It is important and very often
will save time if you state the model number, serial
number and type of gas used. This information will be
found on the nameplate of the boiler.

Fig. 7: Inspect the Venting System

CAUTION: In case of a prolonged power failure
during freezing weather conditions, boiler and piping
system must be drained completely to avoid possible
damage to the heating system.

NOTE: It may be necessary to open the purge
valves and/or manual air vents to facilitate complete
drainage of water from the heating system.

SOOT

CORROSION

DISENGAGED

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] Fax [phone]

Litho in U.S.A.