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INSTALLATION & OPERATING
INSTRUCTIONS
Raytherm™
Residential
Boilers
Models 0042B, 0066B, 0090B
0135B & 0180B – Type H
WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
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.
WHAT TO DO IF YOU SMELL GAS:
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CONTENTS WARNINGS 4 Heat Exchanger Re-assembly 33 Pay Attention to These Terms 4 Combustion Chamber Removal 33 RECEIVING EQUIPMENT 5 TROUBLESHOOTING 34 GENERAL SPECIFICATIONS 5 Adjustment & Replacement of INSTALLATION 7 Components 36 Code Requirements 7 Replacement Parts 37 Mounting Base 7 WARRANTY 38 Clearance Requirements 7 Combustion/Ventilation Air 8 Venting Connections 9 Vent Damper Installation Location 11 VENT DAMPER WIRING DIAGRAM 14 Gas Supply Connections 15 Gas Pressure 15 Water Conn
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WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. Indicates special i
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RECEIVING EQUIPMENT GENERAL SPECIFICATIONS On receipt of your equipment, visually check for exter- nal damage to the carton. If the carton is damaged, it Raytherm hydronic boilers are design certified and is suggested that a note be made on the Bill of Lading tested under the requirements of the latest edition of when signing for the equipment. the American National Standard, ANSI Z21.13/CSA 4.9. Each boiler has been constructed and pressure Remove the boiler from the carton, and if it is dam-
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Piping Connections Heating Net K Model Input Capacity I=B=R A B C Vent No. MBH Water MBH Rating Dia. Gas NPT NPT H-0042 42 35 30 1 in. 1/2 in. 11 in. 5 3/4 in. 5 1/2 in. 4 in. H-0066 66 54 47 1 in. 1/2 in. 11 in. 5 3/4 in. 5 3/4 in. 5 in. H-0090 90 74 64 1 in. 1/2 in. 11 in. 5 3/4 in. 5 3/4 in. 5 in. H-0135 135 109 95 1 1/4 in. 1/2 in. 18 in. 6 1/4 in. 6 1/4 in. 6 in. H-0180 180 148 129 1 1/4 in. 1/2 in. 18 in. 6 1/4 in. 8 in. 7 in. Table A: Specifications 16 B 1 AUTOMATIC 4 K / VENT DAMPER 2
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INSTALLATION 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 CSA B149 and the Canadian Electrical Code Part 1 CSA C22.2 No.1. Where required by the authority having jurisdic- tion, the installation must conform to American Society of Mechanical Engineers Safety Code for
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3. Except for carpeted flooring, boilers are certified One opening shall be within 12" of the top, and the for installation on combustible floors. other opening within 12" of the floor. If additional gas appliances are installed in the same space, the total 4. For un-insulated hot water pipes, maintain a 2" input of all gas appliances installed in the same space, clearance, or consult local authority having juris- must be considered in the calculation. Refer to Sec. diction. 5.3.5 of the latest
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Location of the openings is the same as in the previ- The discharge opening must be a minimum of two (2) ous case - that is, within 12" of the top, and within 12" feet vertically from the roof surface and at least two (2) of the bottom of the enclosure. If horizontal ducts are feet higher than any part of the building within ten (10) used, the area must be doubled and the duct area feet. Vent stack shall be at least five (5) feet in vertical shall not be less than the area of the openings they h
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WARNING: These boilers must not be connected Roof Pitch (X/12) H (Min. ft) into any portion of mechanical draft systems Flat to 6/12 1 operating under positive pressure. To do so may cause the flue products to be discharged into the 6/12 to 7/12 1.25 living space causing serious health injury. Over 7/12 to 8/12 1.5 Over 8/12 to 9/12 2 For connections to gas vents or chimneys, vent instal- lations shall be in accordance with Part 7, Venting of Over 9/12 to 10/12 2.5 Equipment, of the National Fue
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At the time of removal of an existing boiler, the follow- Vent Damper Installation ing steps shall be followed with each appliance Location remaining connected to the common venting system placed in operation, while the other appliances remain- The vent damper supplied with each boiler must be ing connected to the common venting system are not located in the vent so that it serves only the appliance in operation. for which it is intended. 1. Seal any unused openings in the common venting If impr
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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 sys- tem. 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 plug- ging the hole in the vent damp
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NOTE: To place vent damper in the open position to 24 V AC 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. R TH 2. Turn the thermostat or controller up to call for heat 2 and check that the vent damper indicator points to 4 GV the open position, as shown in Fig. 11. SS 3 1 HL J ES 3. Turn the thermostat or controller down again and check that the vent damper position indicator SS R returns
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VENT DAMPER 14
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1/2 in. Pipe 3/4 in. Pipe 1 in. Pipe 1 1/4 in. Pipe Model No. Nat. Pro. Nat. Pro. Nat. Pro. Nat. Pro. 0042 125 350 500 0066 60 160 175 460 0090 30 80 125 300 400 0135 15 40 60 150 200 450 0180 20 35 90 115 300 425 Table H: Maximum Equivalent Pipe Length (Feet) Gas Supply Connections NOTE: Do not use teflon tape on gas line pipe thread. A flexible sealant suitable for use with Natural and Propane gases is recommended. The inlet gas connection of the boiler gas valve is 1/2". Provide an adequate g
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shipped loose. The full open position is appropriate for Systems with multiple zones may require an addition- most systems, and ensures adequate flow through the al circulator. Consult manufacturer's data for valve boiler. pressure drops. When an indirect water heating sys- tem is used, it is recommended that a separate If system flow is inadequate, (indicated by excessive circulator be installed to meet the required flow and temperature drop through the system) the bypass pressure drop conditio
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Piping Diagrams Air Vent Air Scoop Diaphragm Expansion Tank Feed Valve Pipe Pressure Relief Valve to Drain Cold Water Inlet Heating Units Fig. 15: Single-Zone Piping 12” Max. Air Scoop Diaphragm Expansion Tank Feed Valve Pipe Pressure Relief Valve to Drain Circulators Cold Water Inlet Heating Units Fig. 16: Multiple Zones with Circulators 17 Air Vent
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The room thermostat should be installed in accor- Electrical Wiring dance with the manufacturer's instructions. The thermostat heat anticipator should be set at 1.0 The electrical power supply requirement for these boil- ampere (automatic ignition) and 0.60 ampere (stand- ers is 120 VAC, 60 Hz. Field wiring connections and ing pilot) for single- zone installations. For multi-zone electrical grounding must comply with the local codes, applications, the heat anticipator setting should be or in the
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Wiring Diagrams 19
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