Raypak 0090B 0135B User manual

Catalog No.: 2100.50P
Effective: 11-01-99
Replaces: 6-01-99
P/N 240488
THISMANUALSHOULDBEMAINTAINEDINLEGIBLECONDITION
ANDKEPTADJACENTTOTHEBOILER ORKEPTINA SAFEPLACE
FORFUTUREREFERENCE.
®
OPERATING AND
INSTALLATION
INSTRUCTIONS
Models
0030B, 0042B, 0066B, 0090B
0135B, 0180B
Type H
RESIDENTIAL BOILERS
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.

These instructions are provided to assure the proper
installation and operation of Raypak boilers. Should
questions arise regarding the specifications, installa-
tion, operation or servicing of these boilers, we suggest
that the local Sales representative or the factory be
consulted.
2
3 1. RECEIVING EQUIPMENT
3 2. GENERAL SPECIFICATIONS AND DIMENSIONS
4 3. INSTALLATION PROCEDURES
4 - Code Requirements
4 - Mounting Base
4 - Clearance Requirements
4 - Combustion/Ventilation Air
5 - Venting Connections
7 - Vent Damper Installation
10 - Gas Supply Connections
10 - Water Connections & System Piping
14 - Electrical Wiring
22 4. SERVICING PROCECURES
22 - General Locations of Controls
22 - Sequence of Operation
23 - Start Up Procedures
28 - Safe Shutdown Test
28 - Normal Inspection Procedures
29 - Repair Section
31 5. TROUBLE SHOOTING GUIDE
33 - Adjustments/Replacements of Components
34 6. REPLACEMENT PARTS LIST
Contents

1. RECEIVING EQUIPMENT
On receipt of your equipment it is suggested that
you 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 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 re-
viewed thoroughly before installing your Raypak
Boiler. If there are any questions which this manual
does not answer, please contact your local Raypak
representative.
2. GENERAL SPECIFICATIONS
The Raypak hydronic boilers are design certified by
the American Gas Association, and tested under the
requirements of the American National Standard, ANSI
Z21.13. 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.
The boilers are designed for indoor installation with
a built-in drafthood, and a built-in sub-base for combus-
tible 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 trans-
former, pump relay, vent thermal switch, flame roll-out
switch, and redundant combination gas valve for use
with either natural or propane gases. Two-staged gas
valve (50% firing on 1st 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 manufactur-
ers, and design certified by a nationally-recognized
testing Agency, under the ANSI Z21.66 standards, 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.
SPECIFICATIONS AND DIMENSIONS
3
K
16
4
1
/
2
33
1
/
4
22
1
/
8
12
1
/
2
5
18
3
1
/
4
26
1
/
2
C
THERMOSTAT CONN
(ELECTRICAL CONN
ON OTHER SIDE) GAS
CONN
3/4 NPT PIPE
TO DRAIN
A
11
7
/
8
6
INLET
OUTLET
3
1
/
8
MIN
19
AUTOMATIC
VENT DAMPER
(FIELD INSTALLED)
B
HEATING NET K
INPUT CAPACITY I=B=R WATER GAS VENT
MODE
L
MBH MBH RATING NPT. NPT. A B C DIA.
H-0030 30 25 22 1" 1/2" 11" 5 3/4 5 1/2 4"
H-0042 42 35 30 1" 1/2" 11" 5 3/4 5 1/2 4"
H-0066 66 54 47 1" 1/2" 11" 5 3/4 5 3/4 5"
H-0090 90 74 64 1" 1/2" 11" 5 3/4 5 3/4 5"
H-0135 135 109 95 1 1/4" 1/2" 18" 6 1/4 6 1/4 6"
H-0180 180 148 129 1 1/4" 1/2" 18" 6 1/4 8.0 7"
CONNECTIONS
PIPING
Fig. #8978.1

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 NationalFuel GasCode, ANSIZ223.1,
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 con-
form to American Society of Mechanical Engineers
Safety Code for Controls and Safety Devices for Auto-
matically 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.
CARPET
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 in-
stalled 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.)
4
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 jurisdic-
tion.
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 ven-
tilation air supply. Such chemicals include, but are not
limited to, chlorinated and/or fluorinated hydrocarbons
such as found in refrigerants, aerosol propellants, dry-
cleaning fluids, degreasers, and paint removers. Other
harmful elements may come from bleaches, air fresh-
eners, 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 accor-
dance with Sec. 5.3, of the latest edition of the
National Fuel Gas Code, ANSI Z223.1, or appli-
cable provisions of the local building codes.
CARPET Fig.# 8196.0p

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 inches of the top,
and the other opening within 12 inches 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.
Fig. #8198.0
NOTE: If louvers, grills or screens are used on the
openings, obtain the net free area 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, in square inches as
follows:
Model Sq. In. Of Free Area
0030 & 0042 12
0066 18
0090 24
0135 35
0180 45
Location of the openings is the same as in the
previous case - that is, within 12 inches of the top, and
within 12 inches of the bottom of the enclosure. If
horizontalducts areused, the areamust be doubled and
the duct area shall not be less than the area of the
openings they connect, and in no case shall the small-
est dimension be less than 3 inches.
VENTING CONNECTIONS
These boilers have built-in drafthoods. Vent piping
the same size or larger than the draft hood 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 Part 11, Note 2 and in Appendix G of the
latest edition of the National Fuel Gas Code, ANSI Z
223.1. As much as possible avoid 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 hori-
zontallength shallbe 1-1/2 feet (18 inches)for each inch
of connector diameter as follows.
Boiler Size 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 protections 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 horizon-
tallyfrom, andin no caseabove orbelow, unless a4-foot
horizontal distance is maintained, from electric meters,
gas meters regulators and relief equipment.
12"
12"
5

The weight of the vent stack or chimney must not
rest on boiler draft hood. Support must be provided in
compliance with applicable codes. The boiler top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported 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.
6
Fig.# 8191.0
10’
2’ MIN.
5’ MIN.
2’ MIN.
OR LESS
VENT CAP
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
Lowest Discharge
Opening
Listed Cap
Listed Gas Vent
X
12
Roof Pitch is X/12
H (Min.)-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

7
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 remain-
ing 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 determine 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 draft hood 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 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 ap-
proach the minimum size as determined using the
appropriate tables in Part 11 and in Appendix G
of the National Fuel Gas Code, ANSI Z 223.1 and
CAN/CGA - B149.1 - M91.
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 poison-
ing, 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 draft hood, and without modification of the draft
hood.
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

8
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 an Intermittent Pilot
or Hot Surface Ignition equipped system, 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.
Fig. #8183.0
INSTALLING THE VENT DAMPER IN HORIZONTAL
& VERTICAL VENTS.
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.
1K
1K1
1K2
D80
MOTOR
N.C.
END
SWITCH N.O. 1K3
C.
432
1
YELLOW
BLUE BLACK
ORANGE
CABLE
NO
YES
NO
YES
INSTALL VENT
DAMPER WITH
ACTUATOR TO SIDES
OF VENT ONLY. DO
NOT MOUNT ABOVE OR
BELOW VENT.
TO CHIMNEY
TO BOILER VENT DAMPER
FLOW >
HORIZONTAL INSTALLATION
TO CHIMNEY
AT BOILER
DRAFT
HOOD
VENT
DAMPER
VERTICAL
INSTALLATION
ACTUATOR MAY BE
INSTALLED IN ANY
POSITION ON VERTICAL
PIPE.

9
VENT DAMPER
NORMAL OPERATION SUMMARY
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.
Fig. # 8181.0
FIG. 4- VENT DAMPER POSITION INDICATOR SHOWING OPEN & CLOSED POSITIONS.
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
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.
Fig. #9002 Fig. #9003
NOTE: To place vent damper in
the open position to allow burner
operation do the following:
Turn the power off, turn the damper
blade to fully open position (arrow
facing same direction as vent
pipe). Turn power on.
DAMPER
POSITION
INDICATOR
DAMPER
POSITION
INDICATOR
DAMPER OPEN DAMPER CLOSED
SS
R
2
SS
2
ES
R
SC
R
1
M
2341
JUMPER
GV
24 VAC TR
HL
L
L
12
120 VAC
60Hz
TH
1
R
24
3JSS HL GV
1
ES
R
2
SC
M
24 V AC
R
1
SS
2
TH

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 pres-
sure.
WATER CONNECTIONS & SYSTEM PIPING
The pipe size for water connections is shown on
page 3. Typical piping systems are shown on pages 11
to 13.
The boiler is supplied as standard with a circulator
and a built -in by-pass to insure the required minimum
water flow in the boiler. The by-pass 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 insures adequate flow through the
boiler. If system flow is inadequate, (indicated by
excessive temperature drop through the system) the by-
pass valve can be throttled slightly. Care must be taken
against over throttling which may lead to inadequate
flowthrough the boiler and boilerharmonics (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 is shown
below.
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 tempera-
ture applications, ÐT (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.
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:
Maximum Equivalent Pipe Length (Feet)
Gas piping must have a sediment trap ahead of the
boiler gas controls, and a manual shutoff valve located
outside the jacket. All gas piping should be tested after
installation in accordance with local codes.
CAUTION:The boiler and its manualshut off valve must
be disconnected from the gas supply during any pres-
sure 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.
GAS PRESSURE-SPECIFICATIONS
Inches W.C. Regulator
Min. Max. Setting
Natural 7.0 14.0 3.5
Propane 12.0 14.0 11.0
Sediment Trap Gas Valve
Manual Union
Valve
Fig. # 8192.0
MODEL NAT PRO NAT PRO NAT PRO NAT PRO
0030 &
0042 125 350 500 - - - - -
0066 60 160 175 460 - - - -
0090 30 80 125 325 400 - - -
0135 15 40 60 155 200 500 - -
0180 - 20 35 90 115 300 425 -
1/2" Pipe 3/4" Pipe 1" Pipe 1 1/4" Pipe
System Maximum
Models Flow System Head
(GPM) (Ft/Wtr)
H-0030 2.5 9.0
H-0042 3.5 8.0
H-0066 5.3 8.5
H-0090 7.3 6.5
H-0135 11.0 10.0
H-0180 14.6 7.0