Raypak 42-180 User Manual

Raypak Residential Products

Raypak’s Residential Boiler Product Family

Raypak revolutionized the boiler market in 1948 with the first
innovative high recovery boilers that utilized superior finned

opper tube material. Our successful designs became the bench-

c
mark by which all other boiler designs were judged for efficient,
reliable and durable hydronic heat.

At that time, Raypak was the first American manufacturer to
provide an innovative family of heating products that used supe­rior copper and bronze materials in the construction of their
heat exchangers. Up until that time, all manufacturers used
energy wasteful high mass cast iron and steel in the construc­tion of heat exchangers.

We direct our Engineers to consider innovation of a new func­tion or feature into the boiler’s basic design to be a requirement
of every new product. Additionally, the innovative feature pro­vided to the end user in a manner that is apparent and benefi­cial to the user, rather than as an unfathomable abstraction.

For over half a century, Raypak has led the trade with innovative
boilers that utilized finned copper tubes as the primary material of
choice for heat exchangers. Raypak has found the necessity to
increase choices in materials, so that copper, as well as aluminum
alloys are available for the construction of heat exchangers that
are suitable for any application or environment.

Recent legislative activity throughout the Unites States, where
Municipal, State and Federal Governments have created various
incentive and rebate programs in order to lower non-renewable
energy consumption at the consumer level. In the process, these
incentives have enhanced the marketplace for higher efficiency
boilers.

Raypak’s family of Hydronic boilers allows every homeowner’s
possible needs to be satisfied. Raypak provides easy, reliable sin­gle source provision of modern, Energy Star listed designs made
in the USA or Europe that are backed up with the best service
and support network in the trade.

This brochure features three Raypak families of residential boil­ers, ranging in size from 42,000 to 300,000 Btu. The specific con­struction varies. However, all product lines are at the cutting
edge of operating efficiency feasible for their particular design.
This ranges from 83% AFUE for the reliable and time proven
Raytherms, to the mid 90's for the condensing versions in which­ever size fits your needs. Choose a hydronic system to maximize
your family's comfort, and select whichever Raypak model best
meets your individual preferences from this complete array.

Raytherm

Hi Delta ss

XPak

Extruded Aluminum Heat Exchanger

®

he XPak utilizes an extruded, single tube design made of 6063-

T
T1 aluminum alloy for the heat exchanger. The pressure vessel is
rated for 45PSIG and is ASME stamped and National Board regis­tered. With over 250,000 units sold through-out Europe, you can
depend on many years of trouble free operation. That’s what
makes this boiler a Raypak!

Up to 4.4:1 Modulation

Infinitely modulating condensing design meets or exceeds Energy
Star requirements. Zero governor gas valve with negative pressure
gas regulator allows for greater installation flexibility in areas
with low gas pressures. Burner is made from high grade, perforat­ed stainless steel.

3-Speed Non-Ferrous Pump

Factory installed circulator with bypass and condensate siphon.
Thermostatically controlled circulator maintains proper flow
through the boiler.

Models 85 and 120

Electronic Direct Spark Ignition

Software controlled and monitored ignition device allows for up
to 5 tries to ignite before lock-out condition is authorized.

Natural Gas or Propane

Propane conversion kit is shipped with every unit.

Easy to Install

Inlet and outlet water connections, gas and electrical connec­tions and condensate drain are located on the bottom. Venting
on the top allows this compact and lightweight boiler to mount
easily onto walls without heavy bracing.

3” Venting - Flexible Options

•

AL29-4C Stainless steel

• Polypropylene plastic

• CPVC plastic vent

• Concentric vent or twin penetrations

• Horizontal or vertical vent

• Direct vent ready

• Common vent with multiple units when used with ULC 636

listed vent systems and in accordance with the installation
and operating manual

The XPak boiler qualifies for the 2010 IRS Federal tax credit,
and may also qualify for your State's credits and rebates.
visit www.raypak.com. Click on the "utility rebates"
page. There are several tables and charts for each program
by state. There are links to each state's energy website. The
information posted should help verify and identify the pro­grams that are available in your area.

5-1/2”

(140 mm)

8-5/8”

(

219 mm)

30-3/4”(781 mm)

Gas 6-13/16”(173 mm)

Water 4-7/8”(124 mm)

1

4-1/8”(359 mm)

XPak 85 = 15-3/4” (400 mm)

XPak 120 = 17-3/4” (451 mm)

30-3/4” (781 mm)

1” (25 mm)

XPak 85 = 3-15/16” (97mm)

XPak 120 = 4-1/2” (114 mm)

1

” (25 mm)

XPak Technical Data

Dimensions and connections XPak
models 85 and 120

MBTUH Output*

XPak

Model

BO IL ER

85 87 80 68,000 15 -3/4 3/4” 3/4” 3” 73 1.20

MBTUH

Input*

Heating Capacity

MBTUH

Net I=B=R

MBTUH

Width

Dimensions (in.)

Gas
NPT

Water

NPT

Vent

Diameter

Operating

Weight

120 120 111 94,000 17 - 3/4 3/4” 3/4” 3” 80 1.25

* Ratings for models natural or propane gas and for elevations up to 2,000 ft. above sea level . For higher elevations, consult the factory.

(PSI)

Full Load

(Lbs/Hr)

Flue Gas Mass

Flow Rate

Partial Load

(Lbs/Hr)

Condensate Flow Rate

86°F Return

Full Fire GPH

Firing

Flow Rates

Xpak

Model

BO ILER

** Minimum flow rate may vary. See manual for details on pump performance settings, and residential head.

AFUE

%

Min.

GPM

85 91.8 3.0** 5.7 .85 25,600 87,000 6.5 45 90.4 26.6 0.37 0.13
120 92.6 3.5** 6.2 1.0 27,300 119,500 6.5 45 123.2 28.5 0.41 0.16

Max.
GPM

Content

Gallons

Water

Min.

(BTU/Hr)

Rate

Max.

(BTU/Hr)

Operating

Pressure

Min.
(PSI)

Max.

Amps

(lbs.)

86°F Return

Min Fire GPH

Models: HD101R thru HD301R

®

SSSS

Raypak’s Hi Delta ss

Decades of expertise and technological innovations went into
creating the Hi Delta ss boiler, a product that incorporates fea­tures sought after by engineers, installers and end-users alike.

In 1948, Raypak introduced the first straight copper finned tube
boiler designed with reliability and serviceability in mind. The
tradition continues with Raypak’s Hi Delta ss model. It’s patented
burner “security blanket,” an ingenious enhancement that pro­vides a perfected air-gas pathway for complete combustion,
makes the Hi Delta ss the most adaptable sealed-combustion boil­er on the market today.

While many manufacturers claim simple, convenient heat
exchanger removal, servicing the Hi Delta ss couldn’t be more
straightforward. Just remove the top cover and flue collector and
it lefts right out.

When installed indoors, the Hi Delta’s versatility is revealed in
smaller vent diameters, direct-venting and the convenience of
stacking without an increased footprint.

Raypak’s focus on customer satisfaction goes beyond product
design. Like all Raypak boilers, every Hi Delta ss is factory-fire
tested, assuring reliable start-up upon installation.

For over 60 years, Raypak professionals have earned their reputa­tion as The Hot Water Management Experts. From system design
through installation and start-up, you can count on your local
Raypak Representative and the backing of the industry’s best
sales staff, applications engineers and service department.

Options

• A-6 – Right hand water connection

• S-1 S-2 High and low gas pressure switches

• Digital controller

䡲 Outdoor reset

䡲 DHW boost function

Key Features

• 5 models from 100,000 to 299,000 BTUH

• All models indoor/outdoor certified

• Efficiency:

䡲 85% AFUE HD101-HD301

• Patented burner “security blanket” enhances

combustion, minimizes installation and start-up issues,
and protects burners from metal fatigue

• 105ºF minimum inlet water capability

• Copper finned tube heat exchanger; Cupro-nickel available

• Sidewall venting ready; No extractor needed for

most applications

• Ducted combustion air ready; TruSeal

direct-vent ready

TM

CSA-certified

• Meets all current and pending NOx air quality regulations

• Integral combustion air filter

®

SSSS

P

OWER

ON

CALL FOR

HEAT

BURNER

FIRING

S

ERVICE

REQUIRED

OFF

P

/N 901927 REV 1

MODELS HD101-HD301

MANUAL SHUT-OFF
& DIAGNOSTIC LIGHTS

H WATER IN

G G

AS CONNECTION

LOW VOLTAGE CONNECTIONS

H WATER OUT

8-7/8

O

PTIONAL PUMP

A

B

K FLUE CONNECTION DIA.

T CO MBUS TIO N AIR DI A.

L

INE VOLTAGE CONNECTIONS

26-3/8

1

9-7/16

1

6-9/16

1-1/4

5-1/16

18-1/4

8-1/2

19-3/8

22-1/8

2

3-1/2

2

6

4-9/16

SEE

PUMP

CHART

1

°

SLO

P

E

O

N

J

A

C

K

E

T

T

O

P

4-15/16

13-1/2

Hi Delta ss Technical Data

Hi Delta

Model

HD101 100 85 18-9/16 9-1/4 3/4 1-1/2 44150 4.7

BO IL ER

HD151 150 128 21-7/8 10-7/8 3/4 1-1/2 44175 4.7
HD201 199 169 25-1/16 12-1/2 3/4 1-1/2 54200 4.7
HD251 250 213 28-5/16 14-1/8 3/4 1-1/2 54225 4.7
HD301 299 254 31-9/16 15-3/4 3/4 1-1/2 54250 4.7

* Ratings for models HD101-HD301 for natural or propane gas and for elevations up to 2,000 ft. above sea level . For higher elevations, consult the factory.
‡ Current draw is for heater only. (Supply breaker must have a delayed trip.)

Hi Delta

Model

GPM

HD101 13 0.7 14 44 8.8 4 17 1.4
HD151 13 0.7 20 44 8.8 6 26 3.1 13 1.0
HD201 13 3.4 27 44 8.9 8 34 5.4 17 1.3
HD251 13 0.7 34 44 9.2 10 43 8.5 21 2.1 14 0.9

85 % A FU E

HD301 13 0.7 41 44 9.4 12 25 3.1 17 1.4 13 0.7

MBTUH

Output*

Input*

Minimum Flow

⌬P Ft ⌬T °F

MBTUH

Type H

(Cat. I)

Flow Rates

A

Width

Maximum Flow

GPM

⌬P Ft ⌬T °F

Dimensions (in.)

B

G

NPT

10°F ⌬T

GPM

⌬P Ft

NPT

20°F ⌬T

GPM

H

Pressure Drops

⌬P Ft

K

Flue Ø

GPM

T

Ø

⌬P Ft

Operating

Weight

(lbs.)

40°F ⌬T30°F ⌬T

GPM

Amps

⌬P Ft

‡

Less than Minimum Flow

Exceeds Maximum Flow

Firing Mode

®

Models 42 & 66 – Single-stage firing
Models 90-180 – 2-stage firing

Non-Condensing

Operates at 105 °F return water temperature without condensing
perfect for the low-temperature needs of radiant floor and snow

melting systems

Built-In Pump and Bypass

Offers maximum application flexibility

Honeywell IID Ignition

Standard S8600 IID eliminates off-cycle fuel consumption;
Standing pilot available on Models 90-180 only

Models 42 – 180

“Spark-To-Hood” Pilot

Eliminates erratic pilot ignition and lockout

Motorized Vent Damper

Prevents heat loss during off-cycles

Built-in low profile draft hood

Fits into tight spaces

Non-Ferrous Waterways Option

All stainless steel pump, brass fittings and glass-lined headers
eliminate boiler oxygen permeation problems associated with non­barrier radiant tubing

Outstanding Warranty

One-year parts and service warranty against defects

The Raytherm Residentials

With five sizes to choose from, there is a copper fin tube
Residential for every home, apartment or condominium. Small
enough to fit in almost any space and fuel efficient for utility sav­ings. Easy to install and service because it’s complete right out of
the box. Reliable because it’s a Raypak.

• Radiant Heating

• Hydronic Space Heating

Safe

• Over-temperature protection device with LED

• Instantly shuts down boiler in a no-flow

condition.

• Safety features shut boiler down in the event of

a blocked flue or heat exchanger.

• ASME heat exchanger is inspected and stamped

for 160 psi operating pressure.

• 30 psi pressure relief valve.

• Available with or without pump.

Easy to Install

• Lightweight; All sizes transportable by one

person.

• Weight of the largest model is 140 lbs.,

compared to an equivalent cast iron boiler at
over 300 lbs.

• One carton contains all components.

• Piping and wiring located at front

A line of boilers that are perfect for residential and light com­mercial applications. Crafted with Raypak’s proven copper
finned tube and cast iron headers, ASME heat exchanger and
stainless steel burners, backed up with Raypak’s unmatched
warranty.

• Snow Melting

• Light Commercial

• Multiple Boilers

• Indirect Fired Water Heating

(with indirect storage tank)

Raytherm Technical Data

AFUE Ratings

Tested with IID igni­tion and vent damper.

Model AFUE

H-0042 84.0
H-0066 83.0
H-0090 83.0
H-0135 83.0
H-0180 83.0

Results for standing
pilot models available

0135 thru 0180

Dimensions (in.)

Water

NPT

Operating

Vent Diameter

Raytherm

Model

0042 thru 0090

MBTUH

Input*

MBTUH Output*

Heating Capacity

MBTUH

Net I=B=R

Raiting MBTUH

Gas
NPT

H-0042 42 35 30 1/2” 1” 4” 99 <3

BO IL ER

H-0066 66 54 47 1/2” 1” 5” 109 <3
H-0090 90 74 64 1/2” 1” 5” 109 <3
H-0135 135 109 95 1/2” 1 - 1/4” 6” 139 <3
H-0180 180 148 129 1/2” 1 - 1/4” 7” 144 <3

* Ratings for models natural or propane gas and for elevations up to 2,000 ft. above sea level . For higher elevations, consult the factory.

Operating

Pressure

Min.
(PSI)

Max.

(PSI)

Raytherm

Model

AFUE

(%)

Water

Content

Gallons

Min.

(BTU/Hr)

Firing

Rate

Max.

(BTU/Hr)

Weight

(lbs.)

Amps

‡

H-0042 84 0.5 42,000 42,000 12 160

BO ILER

H-0066 83 0.7 66,000 66,000 12 160
H-0090 83 0.7 45,000 90,000 12 160
H-0135 83 1.0 67,500 135,000 12 160
H-0180 83 1.0 90,000 180,000 12 160

Visit our website at www.raypak.com to find the Raypak representative in your area. Cat. 1100.13 09-15-10 Replaces New