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Raypak 0090B 0135B - page 1
Catalog No.: 2100.50P Effective: 11-01-99 Replaces: 6-01-99 P/N 240488 THIS MANUAL SHOULD BE MAINTAINED IN LEGIBLE CONDITION AND KEPT ADJACENT TO THE BOILER OR KEPT IN A SAFE PLACE FOR FUTURE REFERENCE. ® OPERA TING AND INST ALLA TION INSTRUCTIONS Models 0030B, 0042B, 0066B, 0090B 0135B, 0180B T ype H RESIDENTIAL BOILERS FOR YOUR SAFETY Do not sto ...
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Raypak 0090B 0135B - page 2
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 DIMENS ...
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Raypak 0090B 0135B - page 3
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 th ...
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Raypak 0090B 0135B - page 4
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 Elec ...
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Raypak 0090B 0135B - page 5
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 ...
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Raypak 0090B 0135B - page 6
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" d ...
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Raypak 0090B 0135B - page 7
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 in ...
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Raypak 0090B 0135B - page 8
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 I ...
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Raypak 0090B 0135B - page 9
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 ...
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Raypak 0090B 0135B - page 10
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 circul ...
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Raypak 0090B 0135B - page 11
Systems with multiple zones may require an additional circulator. Consult manufacturers 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 ...
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Raypak 0090B 0135B - page 12
12 ZONE HEATING WITH INDIRECT DOMESTIC HOT WATER SUPPLY Fig.# 8998.1 ZONE VALVES HEATING UNITS FEED VALVE COLD WATER INLET CIRCULATOR PIPE PRESSURE RELIEF VALVE TO DRAIN DIAPHRAGM EXPANSION TANK AIR SCOOP AIR VENT HOT WATER SUPPLY COLD WATER SUPPLY ...
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Raypak 0090B 0135B - page 13
13 MULTIPLE ZONES WITH CIRCULATORS Fig. #8999.1 MULTIPLE ZONES WITH ZONE VALVES Fig. #9000.1 HEATING UNITS CIRCULATORS COLD WATER INLET FEED VALVE PIPE PRESSURE RELIEF VALVE TO DRAIN DIAPHRAGM EXPANSION TANK AIR SCOOP AIR VENT 12" MAX. AIR VENT AIR SCOOP COLD WATER INLET FEED VALVE PIPE PRESSURE RELIEF VALVE TO DRAIN DIAPHRAGM EXPANSION TANK H ...
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Raypak 0090B 0135B - page 14
14 WIRING DIAGRAM KEY Fig.# 8096.2 The room thermostat should be installed in accordance with the manufacturer's instructions. The thermostat heat anticipator should be set at 1.0 ampere (automatic ignition) and 0.60 ampere (standing pilot) for single zone installations. For multi-zone applications, the heat anticipator setting should be based ...
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Raypak 0090B 0135B - page 15
Fig. # 2223e See page 14 wiring diagram key information. 15 WIRING DIAGRAM: STANDING PILOT 24 V 2 STAGE MODELS 90, 135 & 180 ...
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Raypak 0090B 0135B - page 16
16 WIRING DIAGRAM:INTERMITTENT IGNITION DEVICE (IID) MODELS 30, 42, & 66 See page 14 wiring diagram key information. *REFER TO INSTALLATION/OPERATING INSTRUCTIONS AND WIRING DIAGRAM SUPPLIED WITH VENT DAMPER. VENT DAMPER OPTIONAL ON CANADIAN MODELS. ...
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Raypak 0090B 0135B - page 17
WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID) MODELS 90, 135 & 180 Fig. #2358 See page 14 wiring diagram key information. 17 *REFER TO INSTALLATION/OPERATING INSTRUCTIONS AND WIRING DIAGRAM SUPPLIED WITH VENT DAMPER. VENT DAMPER OPTIONAL ON CANADIAN MODELS. ...
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Raypak 0090B 0135B - page 18
WIRING DIAGRAM: Single Zone Taco Valve WIRING DIAGRAM: Dual Zone Taco Valve WIRING DIAGRAM: Dual Zone Honeywell Valve NOTE: Maximum three (3) zone valves per one (1) 40 VA transformer. NOTE: Maximum five (5) zone valves per one (1) 40 VA Transformer. Fig. # 2230e Fig. # 2229e Fig. # 2228e 18 ...
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Raypak 0090B 0135B - page 19
WIRING DIAGRAM: System with (3) Zone Pumps NOTE: Check VA rating of each relay coil. Total load must not exceed VA rating of transformer. Fig. #2232e Fig. #2233e Fig. #2234e WIRING DIAGRAM: Power Vent System w/ Zone Valve Taco Zone Valve Honeywell Zone Valve 19 ...
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Raypak 0090B 0135B - page 20
20 WIRING DIAGRAM: Primary/Secondary Pumping System Honeywell Zone Valve Fig. #2223.2e ...
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Raypak 0090B 0135B - page 21
WIRING DIAGRAM: Standing Pilot With Low Water Cut Off Device Fig. # 2223.1e Note : Low water cut off (LWCO) and system switch supplied by others. WIRING DIAGRAM: IID Units With Low Water Cut Off Device Note : Low water cut off (LWCO) and system switch supplied by others. 21 Fig. # 2357E ...
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Raypak 0090B 0135B - page 22
4. SERVICING PROCEDURES GENERAL LOCATION OF CONTROLS Fast Response Temperature Sensor CONTROL BOX COMPONENT LOCATIONS MODELS 135 & 180 2-Staged Controller Relay Fig.# 8195.1 Ignition Module (Auto Ignition Only) 22 Fig.# 8195.4 SEQUENCE OF OPERATION INTERMITTENT IGNITION DEVICE (IID) Boilers equipped with the IID system will automatically light ...
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Raypak 0090B 0135B - page 23
START-UP PROCEDURES SECTION 1 . Filling the System Fill system with water. Purge all air from the system using purge valve sequence. After system is purged of air, lower system pressure. Open valves for normal system operation, fill system through feed pressure regulator to minimum 12 PSI. Manually open air vent on the compression tank until water ...
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Raypak 0090B 0135B - page 24
24 SECTION 3. Lighting the Boiler Safe lighting and other performance criteria were met with the gas manifold and control assembly pro- vided on the boiler when the boiler underwent tests specified in ANSI-Z21.13a 1983 Standard. CAUTION: Liquefied petroleum gas is heavier than air and sinks to the ground. Exercise extreme care in lighting boiler in ...
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Raypak 0090B 0135B - page 25
25 FOR STANDING PILOT MODELS WITH ROBERT- SHAW GAS VALVE, 2 STAGE OPERATION (Models 90, 135 & 180) 1. STOP! Read the safety information. 2. Set the thermostat to the lowest setting. 3. Turn off all electric power to the boiler. 4. Push in and move gas control lever counter- clockwise to "OFF" position. GAS CONTROL LEVER SHOWN IN " ...
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Raypak 0090B 0135B - page 26
26 FOR INTERMITTENT IGNITION (IID) WITH HONEY- WELL OR ROBERTSHAW GAS VALVE (For All Mod- els) 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 pilo ...
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Raypak 0090B 0135B - page 27
3 2 1 S E T P I L O T O N O F F PILOT ADJ PILOT KEY CAUTION: Should overheating occur or the gas supply fails 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 boiler. Failure to observe this precaution may aggravate the overheated condition resulting in poss ...
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Raypak 0090B 0135B - page 28
Fig. #8964 PILOT BURNER FLAME (STG PILOT UNITS) NORMAL INSPECTION PROCEDURES First and third month after initial start up and then on an annual basis. If problems are found, refer to Trouble Shooting Guide for additional directions. 1. Remove top of boiler and inspect heat exchanger for soot and examine venting system. 2. Remove rear header and ins ...
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Raypak 0090B 0135B - page 29
LOW WATER CUT OFF WHEN INSTALLED The low water cut off automatically shuts down burner whenever water level drops below probe. 90 second time delay prevents premature lockout due to temporary conditions such as power failure or air pock- ets. Flush float type devices at beginning of each heating season. PROCEDURE FOR CLEANING FLUE GAS PASSAGE-WAYS ...
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Raypak 0090B 0135B - page 30
6. Remove combustion chamber clips at the four corners of the heat exchanger. 7. Lift heat exchanger straight up using caution not to damage refractory. HEAT EXCHANGER RE-ASSEMBLY 1. Heat exchanger water header O-rings should be replaced with new ones. 2. Install inlet-outlet and return water headers and install header retainer nuts and torque nuts ...
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Raypak 0090B 0135B - page 31
5. TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shal ...
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Raypak 0090B 0135B - page 32
10) Before module goes into a lock-out, check voltage across MV and MV/ PV. If no 24V is present, replace module. If 24V is present, replace gas valve. 1) Adjust inlet gas pressure as shown on rating plate. 2) Clean pilot orifice. 3) Replace thermocouple. 1 ) Adjust manifold pressure as shown on rating plate. 2) Clean burners free of debris or in- ...
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Raypak 0090B 0135B - page 33
ADJUSTMENTS/REPLACEMENTS OF COMPONENTS DANGER - SHOCK HAZARD Make sure electrical power to the boiler is disconnect- ed to avoid potential serious injury or damage to com- ponents. 1. Gas Valve Replacement a) Shut off electrical power and gas supply to the boiler. b) Remove gas piping to gas valve inlet. c) Disconnect wiring connections, pilot tubi ...
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Raypak 0090B 0135B - page 34
j) Reverse above procedure to re-install. 9. Fast Response Temperature Sensor Module Replacement a) Shut-off electrical power to the boiler. b) Remove control cover screws and open control compartment. c) Disconnect wiring connections to the board. d) Carefully pull out the control board from the nylon pin supports. e) Reverse above procedure to re ...
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Raypak 0090B 0135B - page 35
35 HONEYWELL STANDING PILOT HONEYWELL IID ROBERTSHAW STANDING PILOT *Bypass valve supplied on sizes H-0135 and H-0180 only. Fig. # 8190.0 3-P 1-P 2-P 6-P 8-P 3-P 1-P 2-P 6-P 8-P Fig. # 8189.3 1-P 2-P 9-P 6-P 8-P Fig. # 9112 4-C 5-M 3-H 3-M 6-H 1-M 9-H 2-H 1-H 7-H 1-V 2-V 2-S 1-R (30 & 42) 1-S 6-H 4-M 3-C 4-H 3-S 1-R 5-H 8-H 3-J 1-J 1-R 1-C 4-S ...
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Raypak 0090B 0135B - page 36
36 BOILERS MANUFACTURED AFTER AUGUST 11, 1994 WITH SERIAL #9408116901 OR LATER, HAVE IID IGNITION IN LIEU OF HSI IGNITION. ...
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Raypak 0090B 0135B - page 37
BOILERS MANUFACTURED AFTER AUGUST 11, 1994 WITH SERIAL #9408116901 OR LATER, HAVE IID IGNITION IN LIEU OF HSI IGNITION. 37 CALL OU T DESCRI PTION 30B 42B 66B 90B 135B 180 B M MISCELLANEOUS 1-M PRV 30 P SI 50141 0 501410 501410 5014 10 501410 501410 2-M Deliming Kit 052871F 052871F 052 871 F 052871F 05287 1F 052871 F 3-M T & P G auge 600671 6006 ...
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Raypak 0090B 0135B - page 38
Raypak, Inc. , 31111 Agoura Road, Westlake Village, CA 91361-4699 (818) 889-1500 FAX (818) 889-4522 Raypak Canada LTD , 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036 Raypak Australia Pty. Ltd , 7 Geddes St., Mulgrave, Victoria, Australia 3170 (6139) 560 4944 FAX (6139) 560 4974 Litho in U.S.A. w w w .ray ...
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