Raypak Raytherm 0090B Operations Instructions

INSTALLATION & OPERATING INSTRUCTIONSCATALOG NO. 2100.50AA Effective: 12-26-07 Replaces: 01-31-07 P/N 240488 Rev. 28WARNING: If these instruct

10Roof Pitch (X/12) H (Min. ft)Flat to 6/12 16/12 to 7/12 1.25Over 7/12 to 8/12 1.5Over 8/12 to 9/12 2Over 9/12 to 10/12 2.5Over 10/12 to 11/12 3.25Ov

11At the time of removal of an existing boiler, the follow-ing steps shall be followed with each applianceremaining connected to the common venting sy

12MountingOn vertical vents, the vent damper may be mountedwith the actuator in any position. On horizontal vents,do not mount the actuator either dir

132. Turn the thermostat or controller up to call for heatand check that the vent damper indicator points tothe open position, as shown in Fig. 11.3.

14VENT DAMPER

15Gas Supply ConnectionsThe inlet gas connection of the boiler gas valve is 1/2".Provide an adequate gas piping supply line no smallerthan 1/2&qu

16shipped loose. The full open position is appropriate formost systems, and ensures adequate flow through theboiler.If system flow is inadequate, (ind

17AirScoopAir VentDiaphragmExpansion TankFeed ValvePipe Pressure Relief Valveto Drain Cold WaterInletHeating UnitsFig. 15: Single-Zone PipingAirScoopA

18Electrical WiringThe electrical power supply requirement for these boil-ers is 120 VAC, 60 Hz. Field wiring connections andelectrical grounding must

19Wiring Diagrams

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22Fig. 17: Single-Zone Taco ValveFig. 18: Dual-Zone Taco ValveFig. 19: Dual-Zone Honeywell ValveNOTE: Maximum three (3) zone valves per one (1) 40 VA

23Fig. 20: System with Three (3) Zone PumpsNOTE: Check VA rating of each relay coil. Total load must not exceed VA rating of transformer.Fig. 21: Powe

24Fig. 22: Primary/Secondary Pumping System Honeywell Zone ValveFig. 23: Standing Pilot with Low Water Cut-off DeviceNote: Low water cut-off (LWCO) an

25Fig. 24: IID Units with Low Water Cut-off DeviceNote: Low water cut-off (LWCO) and system switch supplied by others.

26SERVICING PROCEDURESGeneral Location of ControlsFast-ResponseTemperatureSensor2-Stage ControllerRelayIgnition Module(Auto Ignition Only)Fig. 25: Con

27START-UP PROCEDURESLighting the BoilerSafe-lighting and other performance criteria were metwith the gas manifold and control assembly providedon the

28For Standing Pilot Models withRobertshaw Gas Valve, 2-stage Operation(Models 90, 135 & 180)10. Turn on all electrical power to the boiler.11. Se

29technician. Force or attempted repair may result ina fire or explosion.D. Do not use this boiler if any part has been underwater. Immediately call

WARNINGS 4Pay Attention to These Terms 4RECEIVING EQUIPMENT 5GENERAL SPECIFICATIONS 5INSTALLATION 7Code Requirements 7Mounting Base 7Clearance Require

303. Turn off all gas valves supplying gas to the boiler.Refer to operating instruction label on the boiler.4. Shut-off the water supply to the boil

31Inspection ProceduresBurnersClean main burners and air louvers of dust, lint anddebris. Keep boiler area clear and free from com-bustibles and flamm

32Burner Tray Removal1. Shut-off power and gas supply to the boiler.Disconnect union(s) and pilot tubing when pres-ent; then loosen and remove burner

9. Install flue collector, jacket top and inspection pan-els. Install top holding screws. Install draft diverterand vent piping if so equipped.10. I

34TROUBLESHOOTINGThese instructions are primarily intended for the use of qualified personnel specifically trained and experiencedin the installation

3510) Before module goes into a lock-out,check voltage across MV and MV/PV. If no 24V is present, replacemodule. If 24V is present, replacegas valv

36Adjustment & Replacement ofComponentsGas Valve Replacement1. Shut-off electrical power and gas supply to theboiler.2. Remove gas piping to gas

377. Remove the wedge or retaining clip holding thesensing bulb in the control well in the in/out head-er.8. Pull out the sensing bulb carefully fro

38LIMITED PARTS WARRANTYRESIDENTIAL HEATING BOILERSMODELS 42 TO 180SCOPE:Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this

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DANGER: Indicates the presence of immediate hazards which will cause severepersonal injury, death or substantial property damage if ignored.WARNING:In

www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468Litho in U.S.A.

RECEIVING EQUIPMENTOn receipt of your equipment, visually check for exter-nal damage to the carton. If the carton is damaged, itis suggested that a no

616331/4221/8121/251831/42THERMOSTAT CONN(ELECTRICAL CONNON OTHER SIDE)GASCONN3/4 NPT PIPETO DRAIN261/41/2C117/86INLETOUTLET31/8MIN19KAUTOMATIC VENT D

7INSTALLATIONCode RequirementsInstallation must be in accordance with local codes, orin the absence of local codes, with the latest editionsof the Nat

83. Except for carpeted flooring, boilers are certifiedfor installation on combustible floors.4. For un-insulated hot water pipes, maintain a 2"

9Location of the openings is the same as in the previ-ous case - that is, within 12" of the top, and within 12"of the bottom of the enclosur