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:
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.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.

CATALOG NO. 2100.50AF

Effective: 10-09-12

Replaces: 09-21-12

P/N 240488 Rev. 33

Rev. 33 reflects the following:

Changes to: Wiring Diagram for IID On/Off on page 20, Wiring Diagram for IID 2-Stage on page 21.
Additions: None
Deletions: None
2

CONTENTS
WARNINGS
Pay Attention to These Terms
RECEIvING EqUIPMENT
GENERAL SPECIFICATIONS
INSTALLATION
Code Requirements
Mounting Base
Clearance Requirements
Combustion/Ventilation Air
Venting Connections
Vent Damper Installation Location
vENT DAMPER WIRING
DIAGRAM
Gas Supply Connections
Gas Pressure
Water Connections & System Piping
Electrical Wiring
Outdoor Air Reset Temperature
Controller
PIPING DIAGRAMS
WIRING DIAGRAMS
SERvICING PROCEDURES
General Location of Controls
SEqUENCE OF OPERATION

4
4
5
5
7
7
7
7
8
9
11

Intermittent Ignition Device (IID)

START-UP PROCEDURES
Lighting the Boiler
Filling the System
Checking the Circulator
Safety Information
Operating the Boiler
To Turn Off Gas to the Boiler
Shut-down Procedure
Testing the Ignition Safety Shut-off
Safe Shut-down Tests
Inspection Procedures
REPAIR PROCEDURES
Tube Cleaning Procedure
Heat Exchanger Removal
Heat Exchanger Re-assembly
Combustion Chamber Removal
Adjustment & Replacement of
Components
Replacement Parts
WARRANTY

14
15
15
15
16
17
18
20
26
26
26

26
27
27
27
27
27
27
28
28
29
29
29
30
30
30
31
31
32
34
35

WARNINGS
Pay Attention to These Terms
DANGER:

Indicates the presence of immediate hazards which will cause severe

personal injury, death or substantial property damage if ignored.

WARNING:

Indicates the presence of hazards or unsafe practices which could cause

severe personal injury, death or substantial property damage if ignored.

CAUTION:

Indicates the presence of hazards or unsafe practices which could cause

minor personal injury or product or property damage if ignored.

NOTE:

Indicates special instructions on installation, operation, or maintenance which

are important but not related to personal injury hazards.

DANGER: Failure to install the draft hood on indoor

installations and properly vent the heater to the
outdoors as outlined in the Venting section of this
manual can result in unsafe operation of the heater.
To avoid the risk of fire, explosion, or asphyxiation
from carbon monoxide, never operate this heater
unless it is properly vented and has an adequate air
supply for proper operation. Be sure to inspect the
vent system for proper installation at initial start-up;
and at least annually thereafter. Refer to the
Maintenance section of this manual for more
information regarding vent system inspections.

WARNING: Both natural gas and propane have an

odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.
WARNING: UL recognized fuel gas detectors are
recommended in all enclosed propane and natural
gas applications wherein there is a potential for an
explosive mixture of fuel gas to accumulate and their
installation should be in accordance with the
detector manufacturer's recommendations and/or
local laws, rules, regulations, or customs.

DANGER: Make sure the gas on which the heater

will operate is the same type as that specified on the
heater rating plate.
DANGER: When servicing or replacing components
that are in direct contact with the water, be certain
that:
There is no pressure in the heater. (Pull the release
on the relief valve. Do not depend on the pressure
gauge reading).
The heater water is not hot.
The electrical power is off.

WARNINGCALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:

WARNING: Should overheating occur or the gas

supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.

Always keep the area around the heater free of

combustible materials, gasoline, and other flammable liquids and vapors.

Heater should never be covered or have any

blockage to the flow of fresh air to the heater.

RECEIvING EqUIPMENT GENERAL

SPECIFICATIONS
On receipt of your equipment, 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 the equipment.

Raytherm hydronic boilers are design certified and

tested under the requirements of the latest edition of
the American National Standard, ANSI Z21.13/CSA
4.9. 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.

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.

These boilers are designed for indoor installation with

a built-in drafthood, and a built-in sub-base for combustible flooring. Models are equipped with an
intermittent ignition device (IID).

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.

These boilers are equipped with the following components: outdoor air reset controller, water circulation
pump, pressure relief valve, temperature/pressure
gauge, adjustable high limit switch, drain valve, fast
response temperature sensor, 40 VA transformer,
pump relay, vent thermal switch, flame roll-out switch,
and redundant combination gas valve. Two-stage gas
valve (50% firing on first stage) is standard on models
H-0090, H-0135 and H-0180.

When ordering parts, you must specify Model and

Serial Number of the boiler. When ordering under warranty conditions, you must also specify date of
installation.
Raypak recommends that this manual be reviewed
thoroughly before installing the boiler. If there are
any questions which this manual does not answer,
please contact your local Raypak representative.

All models are provided with a plug-in connector that is

compatible with the Honeywell D80D vent damper.
Similar type vent dampers made by other manufacturers, and design certified by a nationally-recognized
testing agency, under the ANSI Z21.66 standard, 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.

Piping Connections

Model
No.

Input
MBH

Heating
Capacity
MBH

AFUE

H-0042

42

35

H-0066

66

H-0090

K
Vent
Dia.

Water
NPT

Gas NPT

30

1 in.

1/2 in.

11 in.

5 3/4 in.

5 1/2 in.

4 in.

54

47

1 in.

1/2 in.

11 in.

5 3/4 in.

5 3/4 in.

5 in.

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

Fig. 1: Dimensions

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 jurisdiction, the installation must conform to American Society
of Mechanical Engineers Safety Code for Controls and
Safety Devices for Automatically Fired Boilers, 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.
Fig. 2: Mounting Base

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.)

Clearance Requirements
1. Minimum clearances from combustible materials
are listed in Table B below.

NOTE: This 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 installed under the appliance. The pan
must not restrict air flow.

2. A front clearance of at least 24" is recommended

for adequate service of burner-tray and controls.

Model
No.

Floor

Front

Back

Right

Left

Top

Flue
Vent

0042
0066

Comb.

4 in.

6 in.

6 in.

6 in.

16 in.

6 in.

0090
0135
0180

Comb.

Alcove

6 in.

6 in.

6 in.

16 in.

6 in.

Table B: Minimum Clearances From Combustible Materials

3. Except for carpeted flooring, boilers are certified

for installation on combustible floors.

One opening shall be within 12" of the top, and the

other opening within 12" 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 the latest edition of the National Fuel Gas Code for additional
requirements.

4. For un-insulated hot water pipes, maintain a 2"

clearance, or consult local authority having jurisdiction.

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 ventilation air supply. Such
chemicals include, but are not limited to, chlorinated
and/or fluorinated hydrocarbons such as found in
refrigerants, aerosol propellants, drycleaning fluids,
degreasers, and paint removers. Other harmful
elements may come from bleaches, air fresheners,
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.

Fig. 3: Location of Openings for

Combustion/Ventilation Air

NOTE: If louvers, grills or screens are used on the

openings, obtain the net free area requirements 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 specified in the National Fuel Gas Code.

1. The boiler must be provided with adequate supply

of air for proper combustion and ventilation in
accordance with the latest edition of the National
Fuel Gas Code, ANSI Z223.1, or applicable provisions of the local building codes.

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 as shown in Table D.

2. Models 0042 and 0066 only: When the boiler is

installed in a confined space such as a utility room
or closet 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 shown in Table C.
Model No.
0042
0066

Sq. in. of Free Area

70

Table C: Minimum Net Free Area

Model No.

Sq. in. of Free Area

0042

12

0066

18

0090

24

0135

35

0180

45

Table D: Minimum Net Free Area

Location of the openings is the same as in the previous case - that is, within 12" of the top, and within 12"
of the bottom of the enclosure. If horizontal ducts are
used, the area must be doubled and the duct area
shall not be less than the area of the openings they
connect, and in no case shall the smallest dimension
be less than 3".

The discharge opening must be a minimum of two (2)

feet vertically from the roof surface and at least two (2)
feet higher than any part of the building within eight (8)
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 horizontally from, and in no case above
or below, unless a 4-foot horizontal distance is maintained, from electric meters, gas meters, regulators
and relief equipment.

venting Connections
These boilers have built-in drafthoods. Vent piping the
same size or larger than the drafthood 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 the latest edition of the National
Fuel Gas Code, ANSI Z223.1.

The weight of the vent stack or chimney must not rest

on the boiler's drafthood. Support must be provided in
compliance with applicable codes. The boiler top and
drafthood must be readily removable for maintenance
and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible
construction.

As much as possible, avoid long 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
horizontal length shall be 1-1/2 feet (18 inches) for
each inch of connector diameter as shown in Table E.

Model No.

0042

Vent
Connector
Diameter (in.)

Max.
Horizontal
Length (ft)

0066, 0090

7.5

0135

0180

10.5

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 Z223.1.

Listed Cap

Lowest Discharge
Opening

Listed Gas Vent

X
12

Roof Pitch is X/12

H - Minimum Height from

Roof to Lowest
Discharge Opening

Table E: Maximum Horizontal Length of Vent Pipe

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.

Refer to Table F for detailed information

Fig. 4: Minimum Height from Roof to Lowest Discharge

Opening

For protection 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 Z223.1.

Roof Pitch (X/12)

H (Min. ft)

Flat to 6/12

6/12 to 7/12

1.25

Over 7/12 to 8/12

1.5

Over 8/12 to 9/12

Over 9/12 to 10/12

2.5

Over 10/12 to 11/12

3.25

Over 11/12 to 12/12

Over 12/12 to 14/12

Over 14/12 to 16/12

Over 16/12 to 18/12

Over 18/12 to 20/12

7.5

Over 20/12 to 21/12

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 the Venting of
Equipment section 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.

Refer to Fig. 4 for graphical reference

Table F: Minimum Height from Roof to Lowest

Discharge Opening

Fig. 6: Common Venting

Fig. 5: Minimum Venting Measurements

10

vent Damper Installation

Location

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 remaining connected to the common venting system are not
in operation.

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.

1. Seal any unused openings in the common venting

system.

If improperly installed, a hazardous condition, such as

an explosion or carbon monoxide poisoning, 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.

2. Visually inspect the venting system for proper size

and horizontal pitch and make sure there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.

The vent damper must be installed at the appliance

drafthood, and without modification of the drafthood.

3. Insofar as is practical, close all building doors and

windows and all doors between the space in which
the appliances remaining connected to the common 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.

To connect the vent damper wiring to the boiler wiring,

connect the damper circuit plug to the boiler circuit
plug.

4. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
5. Test for spillage at the drafthood 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.
6. After it has been determined that each appliance
remaining connected to the common venting system 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.
7. Any improper operation of the common venting
system should be corrected so that the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1. When resizing any
portion of the common venting system, the common venting system should be resized to
approach the minimum size as determined using
the appropriate tables in the National Fuel Gas
Code, ANSI Z223.1 and CSA - B149.

Fig. 7: Vent Damper Location

WARNING:
Carefully read and follow the
installation instructions furnished with the vent
damper package. Failure to follow these instructions
can cause asphyxiation, explosion or fire.

11

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 ships set up for a continuous pilot
system. Since the Raytherm Residential is equipped
with an Intermittent Pilot, the hole in the vent damper
blade must be plugged using the knockout plug provided in the parts envelope.
Hole in Vent Damper Blade
Closed Position

Fig. 10: 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.
DO NOT plug the hole if installing the vent damper on
a continuous pilot system as this will create a hazardous condition.

vent Damper Operation

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.

Fig. 8: Vent Damper

Check vent damper operation as follows:

1. When the boiler is off, check that the vent damper
position indicator points to the closed position (see
Fig. 11).
Damper Position Indicator

Fig. 9: Installing The Vent Damper in Horizontal

& Vertical Vents

Damper Open

Damper Closed

Fig. 11: Vent Damper Position Indicator

12

NOTE: To place vent damper in the open position to

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.

24

2. Turn the thermostat or controller up to call for heat

and check that the vent damper indicator points to
the open position, as shown in Fig. 11.

4
3

SS

J
SS

SC

Fig. 13: Ladder Diagram

SS2 ES

SS 1
R1

Description

Damper Motor

Relay

ES

End Switch

SS1

N/C Safety Switch

SS2

N/O Safety Switch

TR

Transformer, 120/24V

HL

High Limit

GV

24V Gas Valve

TH

Thermostat, Heating, Low Voltage

JUMPER

HL

R1

Abbreviation

SC

Flair Damper

R2

Jumper
Table G: Legend for Figures 12 & 13

HL

TR
120 VAC
60Hz L
L
1
2

GV

ES

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.

GV
24 VAC

AC

TH

3. Turn the thermostat or controller down again and

check that the vent damper position indicator
returns to the closed position.

TH

Note: Circuit shown with damper in closed position, no call for

heat.

Fig. 12: System Schematic

13

VENT DAMPER

14

Model 1/2 in. Pipe

No.
Nat. Pro.

3/4 in. Pipe

1 in. Pipe

Nat.

Nat. Pro.

Pro.

0042

125

350

500

0066

60

160

175

460

0090

30

80

125

300

400

0135

15

40

60

150

200

450

20

35

90

115

300

0180

1 1/4 in. Pipe

Nat.

Pro.

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 gas piping supply line no smaller
than 1/2", according to Table H above.

These boilers are also certified to operate on propane

gas, when equipped with the combination gas valve
and orifices (pilot and main burners) sized for propane
gas.

Gas piping must have a sediment trap ahead of the

boiler gas controls, and a manual shut-off valve located outside the jacket. All gas piping should be tested
after installation in accordance with local codes.

Manual
Valve

Gas Pressure
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 pressure.

Union

Gas Valve
Sediment Trap
(min. length 3)
Must be supplied
by installer

Gas Type

Inches
WC Min.

Inches
WC Max.

Regulator
Setting

Natural

7.0

10.5

3.5

Propane

12.0

13.0

11.0

Table I: Minimum and Maximum Gas Pressure

Fig. 14: Sediment Trap

CAUTION: The boiler and its manual shut-off valve

must be disconnected from the gas supply during
any pressure testing of that system at test pressures
in excess of 1/2 psi (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.

Water Connections & System

Piping
The pipe size for water connections is shown on page
6. Typical piping systems are shown on page 17.
This boiler is supplied with a circulator and built-in
bypass as standard to ensure the required minimum
water flow in the boiler. The bypass 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
15

shipped loose. The full open position is appropriate for

most systems, and ensures adequate flow through the
boiler.

ball valves at inlet and outlet connections at the boiler

to facilitate servicing.
The pressure relief valve is mounted on the boiler and
must be piped to a drain. We recommend that all high
points be vented and that purge valves be installed. A
boiler installed above radiation level must be provided
with a low water cutoff device.

If system flow is inadequate, (indicated by excessive

temperature drop through the system) the bypass
valve can be throttled slightly. Care must be taken
against over-throttling which may lead to inadequate
flow through the boiler and boiler harmonics (a humming sound from the heat exchanger).

The boiler, when used in connection with a refrigeration system, must be installed so that the chilled
medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from
entering the boiler.

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 20F temperature
drop, and system pressure drop or head not exceeding that which is shown in Table J.
Model No.

System Flow
(gpm)

Max. System
Head (ft/WC)

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

The boiler piping system of a hot water heating boiler,

that is connected to heating coils located in air handling units where they may be exposed to refrigerated
air circulation, must be equipped with flow control
valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.
A diaphragm expansion tank should be installed in the
return line. A typical 8"-diameter expansion tank can
be used on models H-0042, and H-0066, and an 11"diameter expansion tank can be used on models
H-0090, H-0135 and H-0180. Consult tank manufacturer for correct sizing.

Table J: System Pressure Drop

Electrical Wiring

When the total system head exceeds the available

head pressures, a primary/secondary pumping system
is recommended.

The electrical power supply requirement for these boilers is 120 VAC, single-phase, 60 Hz. Field wiring
connections and electrical grounding must comply with
the local codes, or in the absence of local codes, with
the latest edition of the National Electrical Code,
ANSI/NFPA 70.

The minimum boiler operating temperature to avoid

condensation must be 105F. When operating at low
temperature applications, T (temperature rise) must
be 20F or less.

Provide a separate fused circuit from the main electrical panel to the boiler, and a disconnecting means
within sight of the boiler.

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/WC) by 23% in order to
maintain the same heat transfer load.

Remove the control box cover and make the power

supply connections in the field wiring compartment.
(See general location of controls drawing on page 26).
The pump is supplied and factory-wired to operate
with the boiler. The "TH" wire leads are for the room
thermostat or zone valve connections.

Systems with multiple zones may require an additional circulator. Consult manufacturer's 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.

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 on the ampere load in the thermostat circuit.

We recommend that the make-up water from the cold

water line have a check valve, gate valve, and feedwater regulator set at 12 psi. Install unions and gate or
16

The primary functions of the controller are set using

the Operating Temperature dial and the DIP switches.
See Table K. The controller has 4 LEDs to indicate the
its condition:

NOTE: If it is necessary to replace any of the

original wiring, it must be replaced with 105C wire or
its equivalent, except 150C black wire must be
replaced with 150C wire or its equivalent.

Power -

Outdoor Air Reset

Temperature Controller

On Solid - Turns on when 24 Vac Power is

present.

Heat Call - On Solid - Turns on when Heat Call (short

or 0-32 Vac) is present.

The standard configuration of the temperature controller provides for outdoor air reset of the system
target water temperature based on a user defined
reset ratio. The controller will reset between 120F
system water temperature and allow for a maximum
boiler outlet of 210F. The controller will provide two
stage firing of the heater. The controller is also
equipped with a connection for an external thermostat
input for use with an indirect load such as an indirect
DHW tank for hot water production.

Flashing - Boiler outlet sensor error. While

present, operation ceases.
IND Call - On Solid - Turns on when IND Call (short
or 0-32 Vac) is present.
Flashing - System supply sensor error.
While present, operation continues using
boiler outlet sensor.
WWSD -

ADJUSTMENT
WHEEL

On Solid - Turns on when in Outdoor

Reset AND WWSD Active AND control in
WWSD.
Flashing - Outdoor sensor error. While
present, operation continues with Fixed
boiler target of 140 based on 32F.

Fig. 15: Temperature Controller

ITEM

FEATURE

Dial

Operating
Temperature

Reset Ratio 0.4 to 3.6 / Setpoint Target 120F to 200F

SETTING / DESCRIPTION

Reset Ratio
0.4 to 3.6

DEFAULT

DIP #1

Firing Mode

Single Stage (On) / Two Stage (Off)

Single Stage
(On)

DIP #2

Configuration

Outdoor Reset (On) / Setpoint (Off)

Outdoor
Reset (On)

DIP #3

Warm Weather
Shut Down

Active 70F (On) / Inactive (Off)

Active 70F
(On)

DIP #4

Boiler Max
Outlet Setting

DIP #5

Space Heating
or Direct
Domestic Hot
Water

Boiler Maximum (dependent on DIP #5) - Default: On

o If DIP #5 set to Hydronic (On): 210F (Off) / 190F(On)
o If DIP #5 set to Direct DHW (Off): 180F (Off) / 160F(On)
Direct DHW (Off) / Hydronic (On) - Default: Hydronic (On)
Note: If DIP #5 is set to Direct DHW (Off), the operation is
based on Setpoint regardless of DIP #2 setting.

Table K: Outdoor Air Reset Temperature Controller Settings

17

190F(On)

Hydronic
(On)

Hydronic with Outdoor Air Reset

Hydronic, Outdoor Air Reset with

Indirect DHW

For hydronic operation with outdoor air reset, the

System Supply Sensor (S2) is used as the operating
sensor. Boiler Outlet Sensor (S1) is used for boiler outlet maximum limiting. Boiler Pump (P1) is controlled by
the boiler and is cycled off using a 5 minute fixed purge
delay after burner operation has ceased.

For hydronic operation with outdoor air reset and

Indirect DHW, the System Supply Sensor (S2) is used
as the operating sensor. Boiler Outlet Sensor (S1) is
used for boiler outlet maximum limiting. Contact closure from an aquastat located on an indirect DHW
tank will cause the controller to operate to a boost temperature to satisfy the indirect call for heat. Once the
aquastat opens the controller will return to normal
operation. The indirect pump is operated by an external relay (by others). The Boiler Pump (P1) is
controlled by the boiler and is cycled off using a 5
minute fixed purge delay after burner operation has
ceased.

The DIP switch settings are as follows:

DIP 1
DIP 2
DIP 3
DIP 4
DIP 5

ON
ON
ON
ON
ON

(ON/OFF) OFF (2-STAGE)

(OUTDOOR RESET)
(WWSD 70F)
(190F BOIL MAX)
(HYDRONIC)

The DIP switch settings are as follows:

DIP 1
DIP 2
DIP 3
DIP 4
DIP 5

ON
ON
ON
ON
ON

Piping Diagrams

Fig. 16: Single-Zone Piping

18

(ON/OFF) OFF (2-STAGE)

(OUTDOOR RESET)
(WWSD 70F)
(190F BOIL MAX)
(HYDRONIC)

Fig. 17: Multiple Zones with Circulators

Fig. 18: Multiple Zones with Circulators and Indirect DHW Tank

19

Wiring Diagrams

20

21

(PROVIDED BY OTHERS)

Fig. 19: Single-Zone Taco Valve

(PROVIDED BY OTHERS)

NOTE: Maximum three (3) zone valves per one (1) 40 VA transformer.

Fig. 20: Dual-Zone Taco Valve

22

(PROVIDED BY OTHERS)

NOTE: Maximum five (5) zone valves per one (1) 40 VA Transformer.

Fig. 21: Dual-Zone Honeywell Valve

(PROVIDED BY OTHERS)

NOTE: Check VA rating of each relay coil. Total load must not exceed VA rating of transformer.

Fig. 22: System with Three (3) Zone Pumps

23

Fig. 23: Power Vent System with Zone Valve (Taco)

24

Fig. 23: Power Vent System with Zone Valve (Honeywell)

25

SERvICING
PROCEDURES

SEqUENCE OF
OPERATION

General Location of Controls

Intermittent Ignition Device

(IID)

Relay

Boilers equipped with the IID system will automatically light the pilot burner first and then the main burner,
each time there is a call for heat from the room thermostat. Whenever the room thermostat is calling for
heat, the circulator supplied with the boiler will be
energized and should be running.
The ignition control module will also be energized to
initiate the pilot ignition by opening the first main valve
(pilot). At the same time, the electronic spark generator in the module produces a high-voltage spark output
that lights the pilot burner. If the pilot burner does not
light, the module will not energize the second main
valve and the burners will not light.

FastIgnition Module
Response
Temperature (Auto Ignition Only)
Sensor

Ignition spark continues only until the timed trial for

ignition period ends. Then, the module goes into safety shutdown or lockout. Lockout de-energizes the first
main valve operator and closes the first main (pilot)
valve in the gas control, stopping pilot gas flow. The
ignition control system must be reset by setting the
thermostat below room temperature for one minute or
by turning off power to the module for one minute.

Fig. 25: Control Box Component Locations

Models 0135 & 0180

When the pilot flame is established, flame rectification

circuit is completed between the sensor and burner
ground. The flame sensing circuit in the module
detects the flame current, shuts off the spark generator and energizes the second main valve operator
which opens the second main valve. This allows gas to
flow to the burners where it is ignited by the pilot burner flame.
When the thermostat is satisfied, the valve operators
are de-energized shutting off the pilot and main burners, and also the circulator.

Fig. 26: Component Locations

26

START-UP
PROCEDURES

Safety Information
Please read carefully and understand the following
safety information before operating the boiler.

Lighting the Boiler

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.

Safe-lighting and other performance criteria were met

with the gas manifold and control assembly provided
on the boiler when the boiler underwent tests specified
in the latest edition of the ANSI Z21.13/CSA 4.9
Standard.
CAUTION: Propane gas is heavier than air and
sinks to the ground. Exercise extreme care in lighting
boiler in confined areas.

A. This boiler is equipped with an ignition device

which automatically lights the pilot. Do not try to
light the pilot by hand; or this boiler may not have
a pilot and is equipped with a hot surface ignition
device which automatically lights the burners. Do
not try to light the burners by hand.

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.

B. BEFORE OPERATING smell all around the boiler

area for gas. Be sure to smell next to the floor
because some gases are heavier than air and will
settle on the floor.
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.

Filling the System

Flush system before putting into operation to ensure
that foreign material does not damage pump seals. 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 appears, then
close vent.

C. Use only your hand to push in, move or turn the

gas control knob or lever. Never use tools. If the
knob or lever will not push in, move or turn by
hand don't try to repair it, call a qualified service

On multiple-zone systems, purge each zone separately. Isolate the other zones while one zone is being
purged of air.

technician. Force or attempted repair may result in

a fire or explosion.

Checking the Circulator

D. Do not use this boiler if any part has been under

water. Immediately call a qualified service technician to inspect the boiler and to replace any part of
the control system and any gas control which has
been under water.

Before lighting the boiler and after system is filled,

make sure that circulator is operating properly. Manual
gas valve should be off. By adjusting the wall thermostat to the maximum setting, circulator should run
immediately and allow water to flow through the boiler
and the entire system.

Operating the Boiler

1.
2.
3.
4.

CAUTION: In case of a prolonged power failure

during freezing weather conditions, boiler and piping
system must be drained completely to avoid possible
damage to the heating system.
NOTE: Circulator motor supplied with the boiler
does not require lubrication.
27

STOP! Read the previous safety information.

Set the thermostat to the lowest setting.
Turn off all electrical power to the appliance.
This boiler is equipped with an ignition device
whichautomatically lights the pilot. Do not try to
light the pilot by hand.

To Turn Off Gas to the Boiler

GAS CONTROL
KNOB SHOWN
IN "OFF"
POSITION

1. Set the thermostat at the lowest setting.

2. Turn off all electrical power to the boiler if service
is to be performed.
3. For Honeywell valve:
Turn gas control knob clockwise
to
"Off". Make sure knob rest against stop.
For Robertshaw valve:
Push in and move gas control lever to "Off"
position.

GAS INLET
HONEYWELL
(Models 0042 - 0090)
Fig. 27: Honeywell Gas Valve

5. For Honeywell valve: Turn gas control knob

clockwise
to "Off".
For Robertshaw valve: Push in and move gas
control lever to "Off" position.
6. Wait 5 minutes to clear out any gas. Then smell for
gas, including near the floor. If you smell gas,
STOP! Follow "B" in the safety information on the
label affixed to the front of the unit. If you don't smell
gas, go to the next step.
7. For Honeywell valve: turn gas control counterclockwise
to "On".
For Robertshaw valve: Move gas control lever
to "On" position.

HONEYWELL PILOT
Fig. 29: Honeywell Pilot

Shut-down Procedure
To prevent freeze damage to the heating system, it is
recommended that the following system shut-down
procedure be performed.

GAS CONTROL
KNOB SHOWN
IN "OFF"
POSITION

1. Set the room thermostat to "OFF" or the lowest

setting.
2. Turn off all electrical switches to the boiler.
3. 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 boiler piping system loop.
5. Open drain valve on the boiler to remove water
from the boiler and the piping circuits.

GAS INLET

ROBERTSHAW
(All Models)
Fig. 28: Robertshaw Gas Valve

NOTE: It may be necessary to open the purge

valves and/ or manual air vents to facilitate complete
drainage of water from the heating system.

8. Turn on all electrical power to the boiler.

9. Set thermostat to desired setting.
10. If the boiler will not operate, follow the instructions
"To Turn Off Gas To Boiler" and call your service
technician or gas supplier.

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
possible damage to the boiler and injury to the user.

28

Testing the Ignition Safety

Shut-off

debris. Keep boiler area clear and free from combustibles and flammable liquids. Do not obstruct the
flow of combustion and ventilation air. Make visual
check of burner and pilot flame. Yellow flame indicates
clogging of air openings. Lifting or blowing flame indicates high gas pressure. Low flame indicates low gas
pressure.

The ignition system safety shut-off must be tested by

conducting the following tests:
1. Turn on power to the ignition systems and turn gas
supply off at the gas valve.
2. Check ignition module as follows:
a. Set the thermostat or controller above room
temperature to call for heat.
b. Watch for continuous spark at the pilot burner.
c. Time the spark operation. Time must be within the lockout timing period (15 or 90
seconds).
d. Turn thermostat down to end call for heat and
wait 60 seconds on lockout models before
beginning step 3.
3. Turn on gas supply.
4. Set thermostat or controller above room temperature to call for heat.
5. Systems should start as follows:
a. Spark will turn on and pilot gas valve will open
at once. Pilot burner should ignite after gas
reaches the pilot burner.
b. Spark ignition should cut-off when pilot flame
is established.
c. Main gas valve should open and main burner
should ignite after gas reaches the burner
port.

NOTE: Modulating burner flame varies in height from approximately

1/4" at low fire to approximately 4" in high fire.

Fig. 30: Main Burner Flame

Inspection Schedule
To be performed the first and third month after initial
start up and then on an annual basis. If problems are
found, refer to Troubleshooting Guide for additional
directions.
1. Remove top of boiler and inspect heat exchanger
for soot and examine venting system.
2. Remove rear header and inspect for scale
deposits.
*3. Inspect pilot and main burner flame and firing rate.
*4. Inspect and operate all controls and gas valve.
*5. Visually inspect system for water leaks.
*6. Inspect oil pump motor and bearing assembly, if oil
cups are provided.
7. Check flow switch paddle.
8. Clean room air intake openings to ensure adequate flow of combustion and ventilation air.
9. Keep boiler area clear and free from combustible
materials, gasoline, and other flammable vapors
and liquids.

Safe Shut-down Tests

Limit Action
With the burner operating, lower the high limit setting
to simulate an overheated boiler. Normal shutdown
should occur. Restore the normal limit setting, and the
burner should restart.

Flame Failure
With burner operating, close the manual fuel valves to
simulate a flame failure. System should lock out after
safety switch timing (15 seconds). After the safety
switch has cooled, open the manual valves (relight
standing pilots) and reset the safety switch; the burner should restart.

*Should be checked monthly. (Takes approximately 15

minutes).

Procedure for Cleaning Flue Gas

Passageways

Inspection Procedures

Soot will clog areas behind fins and eventually cause

tube failure. Any sign of soot at base of burners or
around outer jacket indicates a need for cleaning.

Burners

1. Lift off drafthood and flue collector by removing

bolts and screws.

Clean main burners and air louvers of dust, lint and

29

REPAIR PROCEDURES

2. Remove "V" baffles from heat exchanger.

3. Remove burner tray, see Burner Tray Removal.
4. Take garden hose and wash heat exchanger, making sure soot is removed from between fins. (Avoid
excessive water against refractory).
5. Reassemble; when boiler is fired, some steam will
form from wet refractory. This is normal.

Tube Cleaning Procedure

(Typical)
Establish a regular inspection schedule, the frequency
of which depends on the local water condition and
severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness.

NOTE: In extreme cases it may be necessary to

remove the heat exchanger completely for cleaning.
The simplest method is steam cleaning at a local car
wash. DO NOT WIRE BRUSH!

To clean the tubes, remove the heat exchanger, ream

tubes and immerse heat exchanger in non-inhibited
de-scale solvent.

CAUTION: Soot is combustible, so exercise

extreme care.

Heat Exchanger Removal

Burner Tray Removal

1. Shut water, gas and electricity off, close valves,

relieve pressure and remove relief valve. Remove
front inspection panel.

1. Shut-off power and gas supply to the boiler.

Disconnect union(s) and pilot tubing when present; then loosen and remove burner hold-down
screws.
2. Disconnect wires at gas valve and slide burner
tray out.

2. Remove top holding screws.

3. Remove draft diverter, lift and remove top and flue
collector on stack type models.

Main Burner and Orifice Removal

4. Loosen bolts and disconnect flange nuts on

inlet/outlet header, loosen union(s) at gas pipe,
and slide boiler away from piping until studs clear
the heater.

1. Remove screws and burner hold-down bracket.

NOTE: If the heat exchanger is sooted badly, the
burner hold-down bracket and spacer can become
distorted from direct flame impingement and this
usually necessitates replacement of these parts.

5. Lift heat exchanger straight up using caution not to

damage refractory.

2. Lift burners from slotted spacer and slide from orifices. Clean with a wire brush.
3. Orifices usually do not need to be replaced. To
clean, run either copper wire or wood through orifice. Do not enlarge hole. To remove orifice, use a
socket wrench and remove the manifold. DO NOT
over-tighten when reinstalling.

RAYPAK TUBE CLEANING KIT

Extension Pieces (5)

Auger with Carbide Tip

5/8" - PN 052871F

Fig. 31: Raypak Tube Cleaning Kit

30

Wire Brush

Heat Exchanger Re-assembly

9. Install flue collector, jacket top and inspection panels. Install top holding screws. Install draft diverter
and vent piping if so equipped.

1. Heat exchanger water header O-rings should be

replaced with new ones.

10. If gas piping was disconnected, reconnect gas piping system and check for leakage using a soap
solution.

2. Install in/out and return water headers and install

header retainer nuts and torque nuts evenly.

4. Install thermostat sensing bulbs in header wells

and replace bulb retaining clips.

11. Check for correct water pressure and water level

in the system. Make sure that system pump operates immediately on the call for heat. The system
is ready for operation.

5. Install inlet and return pipes in water headers

using pipe thread sealant.

12. Within two (2) days of start-up, recheck all air

vents and expansion tank levels.

3. Replace "V" baffles.

Combustion Chamber Removal

6. Install water pressure relief valve, flow switch, and

low water cut-off devices if so equipped.

To remove combustion chamber panels, you must first

remove the heat exchanger. Remove combustion
chamber panels individually.

7. Open water supply and return shut-off valves. Fill

boiler and water piping system with water. Check
boiler and piping system for leaks at full line pressure. Run system circulating pump for a minimum
of 1/2 hour with boiler shut off.
8. Shut down entire system and vent all radiation
units and high points in system piping. Check all
strainers for debris. Expansion tank water level
should be at the 1/4 mark and the balance of the
tank filled with air (when using Air-X-Tank).

Fig. 32: Combustion Chamber PanelsTop View

31

Adjustment & Replacement of

Components
DANGERSHOCK HAZARD: Make sure
electrical power to the boiler is disconnected to avoid
potential serious injury or damage to components.

Gas valve Replacement

1. Shut-off electrical power and gas supply to the
boiler.
2. Remove gas piping to gas valve inlet.
3. Disconnect wiring connections, pilot tubing (when
present).
4. Remove screws (2) holding the burner tray.
5. Slide burner tray out.
6. Remove gas valve bracket screws and bracket.
7. Unscrew gas valve from gas pipe.
8. Reverse above procedure to re-install.

Gas valve Adjustment - Robertshaw

(Invensys) 7000 Series 2-Stage Gas
valve with Solenoid valve

Fig. 33: 2-Stage Gas Valve Adjustment (Invensys)

Flame Roll-out Switch Replacement

1.
2.
3.
4.

NOTE: Attach a manometer and check the manifold

pressures both high fire and low fire before
making any adjustments.
1. Turn the heater off.
2. Remove the 3/8 nut or the #10 Torx screw.
3. Lift solenoid valve up, keeping the wires connected to the solenoid valve.
4. If only low fire adjustment is needed, go to Step 9.
5. Using a 3/8 wrench, carefully remove the aluminum cap that was under the solenoid
valve-count # of turns when removing the cap.
Be careful not to drop the cylinder (weight) or the
small spring that is under the cap see Fig. 33.
6. Remove the spring and store in a safe place.
7. Using an Allen wrench, turn the screw clockwise to
increase or counterclockwise to decrease high fire
manifold pressure see Fig. 33.
8. Install the spring, weight and aluminum cap tighten the cap using same # of turns as was used in
removing the cap.
9. For low fire adjustment, tighten the aluminum cap
to increase and loosen to decrease low fire manifold pressure.
10. Install 2-stage solenoid valve and turn heater on,
check manifold pressures.
11. Repeat steps 3 to 10 until correct manifold pressures are obtained.
12. Secure 2-stage solenoid valve by tightening the
3/8 nut or #10 Torx screw.

Shut-off electrical power to the boiler.

Remove wiring connections to switch.
Remove screws (2) holding the switch.
Reverse above procedure to re-install.

vent Thermal Switch Replacement

1.
2.
3.
4.

Shut-off electrical power to the boiler.

Remove wiring connections to switch.
Remove the screws (2).
Reverse above procedure to re-install.

Ignition Module Replacement

1. Shut-off electrical power to the boiler.
2. Remove control cover screws and open control
compartment.
3. Disconnect wiring connections to module.
4. Remove screws (2) holding module.
5. Reverse above procedure to re-install.

Transformer Replacement
1. Shut-off electrical power to the boiler.
2. Remove control cover screws and open control
compartment.
3. Disconnect wiring connections from transformer
leads.
4. Remove screws (2) holding transformer.
5. Reverse above procedure to re-install.
32

Pump Relay Replacement

Circulator Replacement

1. Shut-off electrical power to the boiler.

2. Remove control cover screws and open control
compartment.
3. Disconnect wiring to the relay.
4. Remove screws (2) holding relay.
5. Reverse above procedure to re-install.

1. Shut-off electrical power to the boiler.

2. Shut-off water supply and open drain valve to
remove water in the piping at the pump level.
CAUTION: To avoid damage to electrical
components, keep water from getting into the control
compartments and gas valve.

High Limit Control

3. Disconnect wiring and conduit connections to the

pump.
4. Disconnect the bypass tube connections to the
inlet flange.
5. Remove the nuts and bolts at the inlet and outlet
flanges. Remove old gaskets.
6. Remove the pump.
7. Reverse the above procedure to re-install. Use
new gaskets and make sure they are seated properly when tightening the nuts and bolts.

1. Shut-off electrical power to the boiler.

2. Remove control cover screws and open control
compartment.
3. The control is factory set at 180F. To adjust setting, use a small screw driver and turn dial
clockwise to lower the temperature or counterclockwise to raise the setting.
4. To replace the limit control, disconnect the wiring
connections.
5. Remove screws (2) holding the limit control.
6. Remove upper access panel.
7. Remove the wedge or retaining clip holding the
sensing bulb in the control well in the in/out header.
8. Pull out the sensing bulb carefully from the control
well.
9. Remove the limit control with capillary from unit.
10. Reverse above procedure to re-install.

Fast-Response Temperature Sensor

Module Replacement
1. Shut-off electrical power to the boiler.
2. Remove control cover screws and open control
compartment.
3. Disconnect wiring to the board.
4. Carefully pull out the control board from the nylon
pin supports.
Reverse above procedure to re-install.

Fast-Response Temperature Sensor

Probe Replacement
1. Shut-off electrical power to the boiler.
2. Shut-off water supply to the boiler and open drain
valve to remove water to the sensor probe level.
3. Remove control cover screws and open control
compartment.
4. Disconnect wire leads from control board.
5. Remove upper access panel.
6. Remove sensor probe from in/out header.
7. Reverse above procedure to re-install.

33

Replacement Parts List

(see Raypak Catalog No. 9300.9.1,
located in the Document Library at
www.raypak.com)
NOTE: To supply the correct part it is important that
you supply the model number, serial number and
type of gas when applicable.
Any part returned for replacement under standard
company warranties must be properly tagged with
Raypak return parts tag, completely filled in with the
heater serial number, model number etc., and shipped
to Raypak freight prepaid.
If determined defective by Raypak and within warranty, the part will be returned in kind or equal
substitution, freight collect. Credit will not be issued.
RAYPAK, INC.
2151 Eastman Avenue
Oxnard, CA 93030

34

Catalog No.: 1910.10 I

Effective: 10-01-08
Replaces: 01-01-04
LIMITED PARTS WARRANTY
RESIDENTIAL HEATING BOILERS
MODELS 0042 TO 0180
SCOPE:
Raypak, Inc. (Raypak) warrants to the original owner that all parts of this boiler which are actually manufactured by
Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the
conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and
transportation are not covered by this Warranty but are the owners responsibility.
ANY PART MANUFACTURED BY RAYPAK:
One (1) year warranty from date of boiler installation, or eighteen (18) months from date of factory shipment based on
Raypaks records, whichever comes first.
SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS
WARRANTY WILL BE VOID IF THE BOILER RATING PLATE IS ALTERED OR REMOVED.
HEAT EXCHNAGER WARRANTY:
Second through tenth years from date of installation, Raypak warrants that the copper and cast iron waterway are free
from defects in material and workmanship. If any of these parts are found defective Raypak will replace or repair free
of charge subject to conditions listed under Scope above.
Eleventh through twentieth years from date of installation, Raypak warrants that the copper and cast iron waterways
are free from defects in material and workmanship. If any of these parts are found defective Raypak will replace the
original parts and payment of a proportionate charge equal to 1/120th of the list price of such parts, at the time the
warranty claim is made, for each month, or portion there of, beyond the tenth year.
ADDITIONAL WARRANTY EXCLUSIONS:
This warranty does not cover failures or malfunctions resulting from:
1. Failure to properly install, operate or maintain the boiler in accordance with our printed instructions provided;
2. Abuse, alteration, accident, fire, flood and the like;
3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;
4. High velocity flow exceeding boiler design rates;
5. Failure of connected systems devices, such as pump or controller;
6. Use of non-factory authorized accessories or other components in conjunction with the boiler system;
7. Failure to eliminate air from, or replenish water in, the connected water system;
8. Chemical contamination of combustion air or use of chemical additives to water;
9. Boilers installed in buildings other that one- or two-family dwellings.
PARTS REPLACEMENT:
Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to
Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions satisfied. The
replacement part will be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty
whatsoever on parts manufactured by others, but Raypak will apply any such warranty as may be provided by the parts
manufacturer.
TO MAKE WARRANTY CLAIM:
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and
description of the problem. The installer must then notify a Raypak distributor for instructions regarding the claim. If
neither the installer nor the distributor is available, contact Service Manager, Raypak, Inc., 2151 Eastman Avenue,
Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be received from Raypak before
replacement of any part.
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY:
This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypaks behalf.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
RAYPAKS SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE
PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO
LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE,
FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL, DAMAGE, INCLUDING DAMAGE FROM WATER
LEAKAGE. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of
incidental or consequential damages. So the above limitation or exclusion may not apply to you.
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to
state. We suggest that you complete the information below and retain this certificate in the event warranty service is
needed. Reasonable proof of the effective date of the warranty (date of installation) must be presented, otherwise, the
effective date will be based on the date of manufacture plus thirty (30) days.
______________________________________________
Name of Owner
______________________________________________
Address
______________________________________________

______________________________________________
Name of Installer
______________________________________________
Address
______________________________________________

______________________________________________
Model No.

______________________________________________
Serial No.

Date of Installation______________________________

Date of Initial Operation___________________________

RAYPAK, INC. 2151 Eastman Avenue Oxnard, CA 93030 (805) 278-5300 Fax (800) 872-9725 www.raypak.com
P/N: 240419

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

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