Raypak 0066B, 0042B, 0180B User Manual

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. 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.

– Type H

.

This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.

CATALOG NO. 2100.50AB Effective: 09-02-09 Replaces: 12-26-07 P/N 240488 Rev. 29

Rev. 29 reflects the following:
Changes to: Note on Page 8, text on Page 10, Item 7 on Page 11, mounting instructions on Page 12

2

CONTENTS

WARNINGS 4

Pay Attention to These Terms 4

RECEIVING EQUIPMENT 5
GENERAL SPECIFICATIONS 5
INSTALLATION 7

Code Requirements 7
Mounting Base 7
Clearance Requirements 7
Combustion/Ventilation Air 8
Venting Connections 9
Vent Damper Installation Location 11

VENT DAMPER WIRING
DIAGRAM 14

Gas Supply Connections 15
Gas Pressure 15
Water Connections & System Piping 15
Electrical Wiring 18

WIRING DIAGRAMS 19
SERVICING PROCEDURES 26

General Location of Controls 26

SEQUENCE OF OPERATION 26

Intermittent Ignition Device (IID) 26

START-UP PROCEDURES 27

Lighting the Boiler 27
For Standing Pilot Models 27
Filling the System 27
Checking the Circulator 27
For Standing Pilot Models with
Robertshaw Gas Valve, 2-stage
Operation (Models 90, 13 & 180) 28
To Turn Off Gas to the Boiler
(Models 90, 135 & 180) 28
For Automatic Ignition Models 28
For Intermittent Ignition (IID)
with Honeywell or Robertshaw
Gas Valve (All Models) 29
To Turn Off Gas to the Boiler 29
Shut-down Procedure 29
Testing the Ignition afety Shut-off 30
Safe Shut-down Tests 30
Inspection Procedures 31

REPAIR PROCEDURES 32

Tube Cleaning Procedure 32
Heat Exchanger Removal 32

Heat Exchanger Re-assembly 33
Combustion Chamber Removal 33

TROUBLESHOOTING 34

Adjustment & Replacement of
Components 36
Replacement Parts 37

WARRANTY 38

3

WARNINGS

Pay Attention to These Terms

ndicates the presence of immediate hazards which will cause severe

DANGER:

I
personal injury, death or substantial property damage if ignored.

WARNING:

CAUTION:

NOTE:

DANGER: Make sure the gas on which the heater

will operate is the same type as that specified on the
heater rating plate.

WARNING—CALIFORNIA PROPOSITION
65: This product contains chemicals known to the

State of California to cause cancer, birth defects or
other reproductive harm.

WARNING: This unit contains refractory ceramic
fiber (RCF) insulation in the combustion chamber.
RCF, as manufactured, does not contain respirable
crystalline silica. However, following sustained
exposure to very high temperatures (>2192F), the
RCF can transform into crystalline silica
(cristabolite). The International Agency for Research
on Cancer (IARC) has classified the inhalation of
crystalline silica (cristabolite) as carcinogenic to
humans.

When removing the burners or heat exchangers,
take precautions to avoid creating airborne dust and
avoid inhaling airborne fibers. When cleaning spills,
use wet sweeping or High Efficiency Particulate Air
(HEPA) filtered vacuum to minimize airborne dust.
Use feasible engineering controls such as local
exhaust ventilation or dust collecting systems to
minimize airborne dust. Wear appropriate personal
protective equipment including gloves, safety
glasses with side shields, and appropriate NIOSH
certified respiratory protection, to avoid inhalation of
airborne dust and airborne fiber particles.

Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.

WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:

• Always keep the area around the heater free of
combustible materials, gasoline, and other flam­mable liquids and vapors.

• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.

WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.

WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. 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.

4

RECEIVING EQUIPMENT

GENERAL

On receipt of your equipment, visually check for exter­nal damage to the carton. If the carton is damaged, it
is suggested that a note be made on the Bill of Lading
when signing for the equipment.

Remove the boiler from the carton, and if it is dam­aged, report the damage to the carrier immediately. Be
sure that you receive the number of packages indicat­ed on the Bill of Lading. Claims for shortages and
damages must be filed with carrier by consignee.

Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defec­tive replacement parts will not be accepted and
defective parts will be replaced in kind only per our
standard warranties.

When ordering parts, you must specify Model and
Serial Number of the boiler. When ordering under war­ranty 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.

SPECIFICATIONS

Raytherm hydronic boilers are design certified and

ested under the requirements of the latest edition of

t
the American National Standard, ANSI Z21.13/CSA

4.9. Each boiler has been constructed and pressure
tested in accordance with the requirements of Section
IV of the American Society of Mechanical Engineers
Code, and factory fire tested.

These boilers are designed for indoor installation with
a built-in drafthood, and a built-in sub-base for com­bustible flooring. Models are available with standing
pilot, or with an intermittent ignition device (IID).

These boilers are equipped with the following compo­nents: water circulation pump, pressure relief valve,
temperature/pressure gauge, adjustable high limit
switch, drain valve, fast response temperature sensor,
40 VA transformer, pump relay, vent thermal switch,
flame roll-out switch, and redundant combination gas
valve. Two-stage gas valve (50% firing on first stage)
is standard on models H-0090, H-0135 and H-0180.

The automatic ignition models and some standing pilot
models are provided with a plug-in connector that is
compatible with the Honeywell D80D vent damper.
Similar type vent dampers made by other manufactur­ers, and design certified by a nationally-recognized
testing agency, under the ANSI Z21.66 standard, may
also be used.

Follow the installation instructions furnished with the
vent damper package. The plug-in connector can also
be used with power venters. Refer to the specific
installation instructions supplied by the power vent
manufacturer.

5

16

33

1

/

4

22

1

/

8

12

1

/

2

5

18

3

1

/

4

2

THERMOSTAT CONN

(ELECTRICAL CONN
ON OTHER SIDE)

GAS
CONN

3/4 NPT PIPE
TO DRAIN

26

1

/

4

1

/

2

C

11

7

/

8

6

INLET

OUTLET

3

1

/

8

MIN

19

K

AUTOMATIC
VENT DAMPER

(FIELD INSTALLED)

B

A

Model

No.

Input

MBH

Heating

Capacity

BH

M

Net

I=B=R

ating

R

Piping Connections

Water

NPT

Gas NPT

A B C

K

Vent

ia.

D

-0042

H

2

4

5

3

0

3

in.

1

/2 in.

1

1 in.

1

3/4 in.

5

1/2 in.

5

in.

4

H-0066 66 54 47 1 in. 1/2 in. 11 in. 5 3/4 in. 5 3/4 in. 5 in.

H-0090 90 74 64 1 in. 1/2 in. 11 in. 5 3/4 in. 5 3/4 in. 5 in.

H-0135 135 109 95 1 1/4 in. 1/2 in. 18 in. 6 1/4 in. 6 1/4 in. 6 in.

H-0180 180 148 129 1 1/4 in. 1/2 in. 18 in. 6 1/4 in. 8 in. 7 in.

Table A: Specifications

Fig. 1: Dimensions

6

INSTALLATION

Code Requirements

nstallation must be in accordance with local codes, or

I
in the absence of local codes, with the latest editions

f the National Fuel Gas Code, ANSI Z223.1, and the

o
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. Where required by the authority having jurisdic­tion, the installation must conform to American Society
of Mechanical Engineers Safety Code for Controls and
Safety Devices for Automatically Fired Boilers, CSD-1.

Mounting Base

Boiler should be mounted on a level surface. Each
boiler is designed with a built-in sub-base approved for
mounting the boiler on combustible flooring. 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.)

NOTE: This boiler should be located in an area
where water leakage will not result in damage to the
area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance. The pan
must not restrict air flow.

Model

No.

0042
0066

0090
0135
0180

Floor Front Back Right Left Top

Comb. 4 in. 6 in. 6 in. 6 in. 16 in. 6 in.

Comb. Alcove 6 in. 6 in. 6 in. 16 in. 6 in.

Fig. 2: Mounting Base

Clearance Requirements

1. Minimum clearances from combustible materials
are listed in Table B below.

2. A front clearance of at least 24" is recommended
for adequate service of burner-tray and controls.

Flue
Vent

Table B: Minimum Clearances From Combustible Materials

7

3. Except for carpeted flooring, boilers are certified
for installation on combustible floors.

4. For un-insulated hot water pipes, maintain a 2"
clearance, or consult local authority having juris­diction.

Combustion/Ventilation Air

WARNING: Air supply to the boiler room must not

be affected by mechanical exhaust vents located in
other parts of the house, such as kitchen or
bathroom fans, or attic blowers. Mechanical exhaust
vents may create a negative pressure condition in
the boiler room that can become a hazard of
asphyxiation, explosion or fire.

CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the boiler. Measures must be taken to
prevent the entry of corrosive chemical fumes to the
combustion and ventilation air supply. Such
chemicals include, but are not limited to, chlorinated
and/or fluorinated hydrocarbons such as found in
refrigerants, aerosol propellants, drycleaning fluids,
degreasers, and paint removers. Other harmful
elements may come from bleaches, air fresheners,
or mastics. Vapors from these types of products can
form corrosive acid compounds when burned in a
gas flame. The resulting acid condensate can
damage or substantially reduce the life of the heater.
It may be necessary to provide outside air directly to
the heater in order to avoid this problem.

One opening shall be within 12" of the top, and the
other opening within 12" of the floor. If additional gas
appliances are installed in the same space, the total
input of all gas appliances installed in the same space,
must be considered in the calculation. Refer to the lat­est edition of the National Fuel Gas Code for additional

equirements.

r

Fig. 3: Location of Openings for

Combustion/Ventilation Air

NOTE: If louvers, grills or screens are used on the
openings, obtain the net free area requirements from
their supplier or manufacturer. If the design free area
of a louver is not known nor available, it shall be
assumed that wood louvers will have 20-25 percent
free area and metal louvers will have 60-75 percent
free area as specified in the National Fuel Gas Code.

1. The boiler must be provided with adequate supply
of air for proper combustion and ventilation in
accordance with the latest edition of the National
Fuel Gas Code, ANSI Z223.1, or applicable provi­sions of the local building codes.

2. Models 0042 and 0066 only: When the boiler is
installed in a confined space such as a utility room
or closet where all air is supplied from inside the
building, the boiler room must be provided with
two openings, each one having a minimum net
free area, in square inches as shown in Table C.

Model No. Sq. in. of Free Area

0042
0066

Table C: Minimum Net Free Area

70

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.

Model No. Sq. in. of Free Area

0042 12

0066 18

0090 24

0135 35

0180 45

Table D: Minimum Net Free Area

8

Location of the openings is the same as in the previ-

Lowest Discharge
Opening

Listed Cap

Listed Gas Vent

X

12

Roof Pitch is X/12

H - Minimum Height from

Roof to Lowest
Discharge Opening

ous case - that is, within 12" of the top, and within 12"
of the bottom of the enclosure. If horizontal ducts are
used, the area must be doubled and the duct area
shall not be less than the area of the openings they
connect, and in no case shall the smallest dimension

e less than 3".

b

Venting Connections

These boilers have built-in drafthoods. Vent piping the
same size or larger than the drafthood outlet is recom­mended; however, when the total vent height
(drafthood outlet to vent terminal) is at least ten (10)
feet, the vent pipe size may be reduced by one size
only as specified in the latest edition of the National
Fuel Gas Code, ANSI Z223.1.

As much as possible, avoid long horizontal runs of
vent pipe and too many elbows. If installation requires
horizontal runs, the vent pipe must have a minimum of
1/4 inch per foot rise and should be supported at not
less than five foot intervals. Maximum vent connector
horizontal length shall be 1-1/2 feet (18 inches) for
each inch of connector diameter as shown in Table E.

The discharge opening must be a minimum of two (2)
feet vertically from the roof surface and at least two (2)
feet higher than any part of the building within ten (10)
feet. Vent stack shall be at least five (5) feet in vertical
height above the drafthood outlet.

he vent cap location shall have a minimum clearance

T
of four (4) feet horizontally from, and in no case above
or below, unless a 4-foot horizontal distance is main­tained, from electric meters, gas meters, regulators
and relief equipment.

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. Vent pipe should be adequately sup­ported to maintain proper clearances from combustible
construction.

Type "B" double-wall (or equivalent) vent pipe is rec­ommended. However, single-wall metal vent pipe may
be used as specified in the latest edition of the
National Flue Gas Code ANSI Z223.1.

Model No.

Vent

Connector

Diameter (in.)

Max.
Horizontal
Length (ft)

0042 4 6

0066, 0090 5 7.5

0135 6 9

0180 7 10.5

Table E: Maximum Horizontal Length of Vent Pipe

Gas vents supported only by the flashing and extend­ing above the roof more than five feet should be
securely guyed or braced to withstand snow and wind
loads. We recommend use of insulated vent pipe
spacer through the roofs and walls.

For protection against rain or blockage by snow, the
vent pipe must terminate with a listed vent cap which
complies with the local codes or, in the absence of
such codes, to the latest edition of the National Fuel
Gas Code, ANSI Z223.1.

Refer to Table F for detailed information

Fig. 4: Minimum Height from Roof to Lowest Discharge

Opening

9

Roof Pitch (X/12) H (Min. ft)

Flat to 6/12 1

6/12 to 7/12 1.25

Over 7/12 to 8/12 1.5

WARNING: These boilers must not be connected

nto any portion of mechanical draft systems

i
operating under positive pressure. To do so may
cause the flue products to be discharged into the
living space causing serious health injury.

Over 8/12 to 9/12 2

Over 9/12 to 10/12 2.5

Over 10/12 to 11/12 3.25

Over 11/12 to 12/12 4

Over 12/12 to 14/12 5

Over 14/12 to 16/12 6

Over 16/12 to 18/12 7

Over 18/12 to 20/12 7.5

Over 20/12 to 21/12 8

Refer to Fig. 4 for graphical reference

Table F: Minimum Height from Roof to Lowest

Discharge Opening

For connections to gas vents or chimneys, vent instal­lations shall be in accordance with the Venting of
Equipment section of the National Fuel Gas Code,
ANSI Z223.1, or applicable provisions of the local
building codes.

Common Vents

Manifolds that connect more than one boiler to a com­mon 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.

Fig. 5: Minimum Venting Measurements

Fig. 6: Common Venting

10

At the time of removal of an existing boiler, the follow­ing steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remain­ing connected to the common venting system are not
in operation.

1. Seal any unused openings in the common venting
system.

2. Visually inspect the venting system for proper size
and horizontal pitch and make sure there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.

3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the com­mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will oper­ate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.

Vent Damper Installation
Location

he vent damper supplied with each boiler must be

T
located in the vent so that it serves only the appliance

or which it is intended.

f

If improperly installed, a hazardous condition, such as
an explosion or carbon monoxide poisoning, could
result. Make certain that it is mounted in an accessible
location at least 6 in. (152.4 mm) from any combustible
material or the heat exchanger and that the position
indicator is in a visible location.

The vent damper must be installed at the appliance
drafthood, and without modification of the drafthood.

To connect the vent damper wiring to the boiler wiring,
connect the damper circuit plug to the boiler circuit
plug.

4. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.

5. Test for spillage at the drafthood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a ciga­rette, cigar or pipe to visually check spillage.

6. After it has been determined that each appliance
remaining connected to the common venting sys­tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.

7. Any improper operation of the common venting
system should be corrected so that the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1. When resizing any
portion of the common venting system, the com­mon venting system should be resized to
approach the minimum size as determined using
the appropriate tables in the National Fuel Gas
Code, ANSI Z 223.1 and CSA - B149.

Fig. 7: Vent Damper Location

WARNING: Carefully read and follow the
installation instructions furnished with the vent
damper package. Failure to follow these instructions
can cause asphyxiation, explosion or fire.

11

Mounting

Damper Position Indicator

Damper Open Damper Closed

On vertical vents, the vent damper may be mounted
with the actuator in any position. On horizontal vents,
do not mount the actuator either directly above or

irectly below the vent pipe; mount the vent damper

d
actuator to the side of the vent.

The vent damper is set up for a continuous pilot sys­tem. If the vent damper is installed on a system with an
Intermittent Pilot, the energy savings of the vent
damper can be improved by plugging the hole in the
vent damper blade using the knockout plug provided in
the parts envelope.

Hole in Vent Damper Blade

Closed Position

Fig. 10: D80D General Wiring Diagram

Install the vent damper to service only the single
appliance for which it is intended. If improperly
installed, a hazardous condition, such as an explo­sion or carbon monoxide poisoning, could result.

DO NOT plug the hole if installing the vent damper on
a continuous pilot system as this will create a haz­ardous condition.

Fig. 9: Installing The Vent Damper in Horizontal

Fig. 8: Vent Damper

& Vertical Vents

Vent Damper Operation

For safe, efficient operation, the vent damper and all
flue-product-carrying areas of the appliance must be
checked annually, with particular attention given to
deterioration from corrosion or other sources.

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).

Fig. 11: Vent Damper Position Indicator

12