Raypak 0090B, 0135B User Manual

INSTALLATION
AND OPERATING
INSTRUCTIONS

Catalog No.: 2100.50V
Effective: 04-01-04
Replaces: 01-01-03

Raytherm

TM

Type H

RESIDENTIAL BOILERS

Models
0030B, 0042B, 0066B,0090B
0135B, 0180B

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.

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause
property damage, personal injury or loss of life. Refer to the user's information manual provided
with this boiler. Installation and service must be performed by a qualified installer, service agency
or the gas supplier.

FOR YOUR SAFETY

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.

THIS MANUAL SHOULD BE MAINTAINED IN LEGIBLE CONDI­TION AND KEPT ADJACENT TO THE BOILER OR IN A SAFE
PLACE FOR FUTURE REFERENCE.

P/N 240488

Contents

RECEIVING EQUIPMENT................................................................................. 3

GENERAL SPECIFICATIONS........................................................................... 3

INSTALLATION PROCEDURES........................................................................ 4

SERVICING PROCECURES.............................................................................. 23

Code Requirements..................................................................................... 4

Mounting Base...........................................................................................4

ClearanceRequirments.................................................................................4

Combustion/Ventilation Air........................................................................... 4

Venting Connections................................................................................... 5

Vent Damper Installation.............................................................................. 7

Gas Supply Connections............................................................................. 11

Water Connections & System Piping............................................................ 11

Piping Diagrams..........................................................................................12

Electrical Wiring..........................................................................................15

Wiring Diagrams......................................................................................... 16

General Locations of Controls.......................................................................23

Sequence of Operation................................................................................ 23

Start-Up Procedures.................................................................................... 24

Shut-Down Procedure.................................................................................. 26

Safe Shutdown Test.................................................................................... 28

Inspection Procedures................................................................................. 28

Repair Procedures.......................................................................................29

TROUBLE SHOOTING GUIDE........................................................................... 31

Adjustments/Replacements of Components...................................................33

REPLACEMENT PARTS LIST........................................................................... 34

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to

cause cancer, birth defects or other reproductive harm.

These instructions are provided to assure 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.

2

RECEIVING EQUIPMENT

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 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.

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.

SPECIFICATIONS AND DIMENSIONS

GENERAL SPECIFICATIONS

Raytherm hydronic boilers are design certified and
tested under the requirements of the American National
Standard, ANSI Z21.13. Each boiler has been con-
structed and pressure tested in accordance with the
requirements of Section IV of the American Society of
Mechanical Engineers Code, and factory fire tested.

The 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 intermittent ignition device (I.I.D.). The 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 standards, may also be
used.

Fig. #8978.1

3

3. INSTALLATION PROCEDURES

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

CAN/CGA B149.1 or .2 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, No. 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 flooring.

CLEARANCE REQUIREMENTS

1) Minimum Clearances From Combustible Materials

Model Floor Front Back Right Left Top Flue
No. Vent
0030
0042 Comb. 4" 6" 6" 6" 16" 6"
0066
0090
0135 Comb. Alcove 6" 6" 6" 16" 6"
0180

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

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

Fig.# 8196

NOTE: The 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.

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.)

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.

1) The boiler must be provided with adequate supply of
air for proper combustion and ventilation in accor­dance with Sec. 5.3, of the latest edition of the
National Fuel Gas Code, ANSI Z223.1, or appli­cable provisions of the local building codes.

4

2) When the boiler is installed in a confined space
such as a utility room or closet (Models 0030,0042
and 0066 only), 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 follows:

Model Sq. In. of Free Area

0030, 0042 & 0066 100

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 Sec. 5.3.5 of the
latest edition of the National Fuel Gas Code for additional
requirements.

Location of the openings is the same as in the
previous 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 be less than
3".

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 Chapter 10 of the latest edition of the
National Fuel Gas Code, ANSI Z 223.1. 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 follows.

Fig. #8198.0

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 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 follows:

Model (Sq. In.) Net Free Area

0030 & 0042 12

0066 18
0090 24
0135 35
0180 45

Model Vent Connector Max Horizontal

Diameter Length - FT

30 & 42 4" 6'
66 & 90 5" 7.5'
135 6" 9'
180 7" 10.5'

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 Z 223.1.

The discharge opening must be a minimum of two
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. The vent cap location
shall have a minimum clearance 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.

5

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 Z 223.1.

Lowest Discharge

Listed Cap

Listed Gas Vent

Opening

12

Roof Pitch is X/12

H - Minimum Height from

Roof to Lowest
Discharge Opening

Roof Pitch H (Min. Ft.)

Flat to 6/12 1.0

6/12 to 7/12 1.25
Over 7/12 to 8/12 1.5
Over 8/12 to 9/12 2.0
Over 9/12 to 10/12 2.5
Over 10/12 to 11/12 3.25
Over 11/12 to 12/12 4.0
Over 12/12 to 14/12 5.0
Over 14/12 to 16/12 6.0
Over 16/12 to 18/12 7.0
Over 18/12 to 20/12 7.5
Over 20/12 to 21/12 8.0

X

Fig.# 8191

WARNING: These boilers must not be connected into
any portion of mechanical draft systems operating
under positive pressure. To do so may cause the flue
products to be discharged into the living space causing
serious health injury.

For connections to gas vents or chimneys, vent
installations shall be in accordance with Part 7, Venting
of Equipment, 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. #9001

6

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.

(a) Seal any unused openings in the common venting

system.
(b) 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.
(c) Insofar as is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the com-

mon 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.
(d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat

so appliance will operate continuously.
e) 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.
(f) After it has been determined that each appliance

remaining connected to the common venting sys-

tem 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.
(g) 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 Z 223.1. When resizing any

portion of the common venting system, the com-

mon venting system should be resized to approach

the minimum size as determined using the

appropriate tables in Chapter 10 and in Appendix
G of the National Fuel Gas Code, ANSI Z 223.1
and CAN/CGA - B149.1 - B149.2.

VENT DAMPER INSTALLATION

LOCATION

The vent damper supplied with each boiler must be
located in the vent so that it serves only the appliance for
which it is intended.

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 appli-
ance drafthood, and without modification of the
drafthood.
To connect the vent damper wiring to the boiler wiring,
remove the jumper from the circuit plug. (See wiring
diagram) Connect the damper circuit plug to the boiler
circuit plug.

Fig. #8642

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

7

MOUNTING

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 directly below the vent pipe; mount the vent damper 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 or Hot Surface Ignition the energy savings of the vent damper can be improved by plugging the hole
in the vent damper blade using the knockout plug, Part No. 105612R, provided in the parts envelope.

Hole in Vent Damper Blade

Closed Position

Fig. #8994

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

1K

1K1

D80
MOTOR

N.C.

N.O.

C.

1K3

32

BLUE

BLACK

1K2

1

ORANGE

Fig. #8183.0

INSTALLING THE VENT DAMPER IN HORIZONTAL

END
SWITCH

4

YELLOW

& VERTICAL VENT.

CABLE

Fig. #152323

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.

8

R

2

4

3

J

SS

HL

GV

1

ES

R

2

SC

M

24 V AC

R

1

SS

2

TH

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, below.

DAMPER POSITION
INDICATOR

DAMPER POSITION
INDICATOR

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.

DAMPER OPEN DAMPER CLOSED

Fig. # 8181.0

VENT DAMPER POSITION INDICATOR

2. Turn the thermostat or controller up to call for heat and check that the vent damper indicator points to the
open position, below.

3. Turn the thermostat or controller down again and check that the vent damper position indicator returns to
the closed position.
THE VENT DAMPER MUST BE INSPECTED AT LEAST ONCE A YEAR BY A TRAINED, EXPERIENCED

SERVICE TECHNICIAN. THE NAME OF THE PERSON WHO ORIGINALLY INSTALLED YOUR VENT
DAMPER IS SHOWN ON THE INSTALLATION LABEL. DAMPER MUST BE IN OPEN POSITION WHEN
BOILER MAIN BURNERS ARE OPERATING.

FLAIR DAMPER

SYSTEM SCHEMATIC LEGEND LADDER DIAGRAM

M - Damper motor

R - Relay

R

R

SS

2

SC

R

1

GV
24 VAC

120 VAC
60Hz

M

2

HL

TR

L

L

12

ES

2

SS

1

JUMPER

3

TH

41

Fig. #9002 Fig. #9003

ES - End switch

SS1 - N/C Safety switch
SS2 - N/O Safety switch

contacts
TR - Transformer 120/24V
HL - High limit
GV - 24V gas valve*

TH - Thermostat, heating,
low voltage
J - Jumper
Note: Circuit shown with
damper in closed
position, no call
for heat.

9

CONNECTION DIAGRAM

10

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 the chart below:

The gas valve is provided with pressure taps to
measure gas pressure upstream of the gas valve and
downstream which is the same as the manifold pres­sure.

Maximum Equivalent Pipe Length (Feet)

Gas piping must have a sediment trap ahead of the
boiler gas controls, and a manual shut-off valve located
outside the jacket. All gas piping should be tested after
installation in accordance with local codes.

Manual Union
Valve

Sediment Trap Gas Valve

Fig. # 8192.0

WATER CONNECTIONS & SYSTEM PIPING

The pipe size for water connections is shown on
page 3. Typical piping systems are shown on pages 12
to 14.

The boiler is supplied with a circulator and built in
bypass as standard to ensure the required minimum
water flow in the boiler. The bypass on models H-0135
and H-0180 is provided with an adjustable valve that is
factory-set in the full open position. The handle is shipped
loose. The full open position is appropriate for most
systems, and ensures adequate flow through the boiler.
If system flow is inadequate, (indicated by excessive
temperature drop through the system) the bypass valve
can be throttled slightly. Care must be taken against over

-throttling which may lead to inadequate flow through the
boiler and boiler harmonics (a humming sound from the
heat exchanger). If adequate system flow cannot be
obtained without causing harmonics, an additional pump
is required. The factory-mounted circulator will provide
adequate water flow for systems designed at a 20°F
temperature drop, and system pressure drop or head not
exceeding that which is shown below.

CAUTION: The boiler and its manual shut-off valve must be

disconnected from the gas supply during any pressure
testing of that system at test pressures in excess of 1/2 psig
(3.45 KPA). Dissipate test pressure in the gas supply line
before reconnecting the boiler and its manual shut-off valve
to gas supply line. FAILURE TO FOLLOW THIS PROCE­DURE MAY DAMAGE THE GAS VALVE. OVER PRES­SURED GAS VALVES ARE NOT COVERED BY WAR­RANTY. The boiler and its gas connections shall be leak
tested before placing the appliance in operation. Use soapy
water for leak test. DO NOT use open flame.

NOTE: Do not use teflon tape on gas line pipe thread.
A flexible sealant suitable for use with Natural and
Propane gases is recommended.

These boilers are also certified to operate on propane
gas, when equipped with the combination gas valve and
orifices (pilot and main burners) sized for propane gas.

GAS PRESSURE

Inches W.C. Regulator

Min. Max. Setting
Natural 7.0 14.0 3.5
Propane 12.0 14.0 11.0

When the total system head exceeds the available
head pressures, a primary/secondary pumping system
is recommended.

The minimum boiler operating temperature
should be 105°F. When operating at low tempera­ture applications, T (temperature rise) must be
20°F or less.

Propylene glycol solution is commonly used in the
heating system when freeze protection is required. This
will affect the system design and pump performance. As
a rule of thumb, 50% solution of propylene glycol will
require the system flow (GPM) to increase by 14%, and
the system head (Ft/Wtr) by 23% in order to maintain the
same heat transfer load.

11

Systems with multiple zones may require an additional circulator. Consult manufacturer's data for valve pressure
drops. When an indirect water heating system is used, it is recommended that a separate circulator be installed
to meet the required flow and pressure drop conditions of the indirect water heater.

We recommend that the make-up water from the cold water line have a check valve, gate valve, and feedwater
regulator set at 12 psig. 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. We recommend that all high
points be vented and that purge valves be installed. A boiler installed above radiation level must be provided with
a low water cut-off device. See page 22 for wiring hook-up. The boiler, when used in connection with a refrigeration
system, must be installed so that the chilled medium is piped in parallel with the boiler with appropriate valves to
prevent the chilled medium from entering the boiler.

The boiler piping system of a hot water heating boiler, that is connected to heating coils located in air handling
units where they may be exposed to refrigerated air circulation, must be equipped with flow control valves or other
automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

A diaphragm expansion tank should be installed in the return line. A typical 8" -diameter expansion tank can
be used on models H-0030, H-0042, and H-0066, and an 11"-diameter expansion tank can be used on models H­0090, H-0135 and H-0180. Consult tank manufacturer for correct sizing.

PIPING DIAGRAMS

HEATING UNITS

AIR

VENT

AIR

SCOOP

DIAPHRAGM

EXPANSION TANK

FEED

VALVE

PIPE PRESSURE

RELIEF VALVE

TO DRAIN

COLD

WATER

INLET

SINGLE-ZONE PIPING

12

Fig.# 8997.1