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Catalog No.: 2100.50V
Effective: 04-01-04
Replaces: 01-01-03
P/N 240488
THIS MANUAL SHOULD BE MAINTAINED IN LEGIBLE CONDI-
TION AND KEPT ADJACENT TO THE BOILER OR IN A SAFE
PLACE FOR FUTURE REFERENCE.
INSTALLATION
AND OPERATING
INSTRUCTIONS
Raytherm
TM
Type H
RESIDENTIAL BOILERS
Models
0030B, 0042B, 0066B,0090B
0135B, 0180B
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.
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Strany 1 - INSTRUCTIONS

Catalog No.: 2100.50VEffective: 04-01-04Replaces: 01-01-03P/N 240488THIS MANUAL SHOULD BE MAINTAINED IN LEGIBLE CONDI-TION AND KEPT ADJACENT TO THE BO

Strany 2 - Contents

CONNECTION DIAGRAM10

Strany 3 - GENERAL SPECIFICATIONS

The gas valve is provided with pressure taps tomeasure gas pressure upstream of the gas valve anddownstream which is the same as the manifold pres-s

Strany 4 - 3. INSTALLATION PROCEDURES

Systems with multiple zones may require an additional circulator. Consult manufacturer's data for valve pressuredrops. When an indirect water h

Strany 5 - Fig. #8198.0

13ZONE HEATING WITH INDIRECT DOMESTICHOT WATER SUPPLYFig.# 8998.1ZONEVALVESHEATING UNITSFEEDVALVECOLDWATERINLETCIRCULATORPIPE PRESSURERELIEF VALVETO

Strany 6 - Fig. #9001

14MULTIPLE ZONES WITH CIRCULATORSMULTIPLE ZONES WITH ZONE VALVESAIRSCOOPAIRVENT12" MAX.AIRVENTAIRSCOOPCOLDWATERINLETFEEDVALVEPIPE PRESSURERELIEF

Strany 7 - Fig. #8642

15WIRING DIAGRAM KEYFig.# 8096.2The room thermostat should be installed in accordancewith the manufacturer's instructions. The thermostat heatant

Strany 8 - Fig. #152323

16WIRING DIAGRAM KEY

Strany 11 - Fig. # 8192.0

WIRING DIAGRAM: Single-Zone Taco ValveWIRING DIAGRAM: Dual-Zone Taco ValveWIRING DIAGRAM: Dual-Zone Honeywell ValveNOTE: Maximum three (3) zone valve

Strany 12 - Fig.# 8997.1

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California tocause cancer, birth defects or other reproducti

Strany 13 - HOT WATER SUPPLY

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. #2

Strany 14 - EXPANSION

21 WIRING DIAGRAM: Primary/Secondary Pumping SystemHoneywell Zone ValveFig. #2223.2e

Strany 15 - WIRING DIAGRAM KEY

WIRING DIAGRAM: Standing Pilot With Low Water Cut-off DeviceFig. # 2223.1eNote: Low water cut-off (LWCO) and system switch supplied by others.WIRING D

Strany 16

4. SERVICING PROCEDURESGENERAL LOCATION OF CONTROLSFast-ResponseTemperatureSensorCONTROL BOX COMPONENTLOCATIONS MODELS 135 & 1802-Stage Controlle

Strany 17

24START-UP PROCEDURESLighting the BoilerSafe-lighting and other performance criteria were metwith the gas manifold and control assembly provided onthe

Strany 18

2510. Turn on all electrical power to the boiler.11. Set the thermostat to the desired setting.TO TURN OFF GAS TO THE BOILER:(Models 90, 135 & 18

Strany 19 - Fig. # 2228e

26FOR INTERMITTENT IGNITION (IID) WITH HONEY-WELL OR ROBERTSHAW GAS VALVE (All Models)1. STOP! Read the safety information above.2. Set the thermostat

Strany 20 - Fig. #2234e

321SETPILOTONOFFPILOTADJPILOT KEYCAUTION: Should overheating occur or the gas supplyfails to shut-off, DO NOT turn off or disconnect theelectrical su

Strany 21 - Honeywell Zone Valve

Fig. #8964PILOT BURNER FLAME (STANDING PILOT UNITS)INSPECTION PROCEDURESTo be performed the first and third month after initialstart up and then on an

Strany 22 - Fig. # 2357E

LOW WATER CUT-OFF WHEN INSTALLEDThe low water cut-off automatically shuts downburner whenever water level drops below probe. 90second time delay pre

Strany 23 - 4. SERVICING PROCEDURES

Follow the installation instructions furnished with the ventdamper package. The plug-in connector can also beused with power venters. Refer to the s

Strany 24

6. Remove combustion chamber clips at the fourcorners of the heat exchanger.7. Lift heat exchanger straight up using caution not todamage refractory.H

Strany 25 - GAS INLET

TROUBLESHOOTING GUIDEIMPORTANT NOTICEThese instructions are primarily intended for the use of qualified personnel specifically trained and experienced

Strany 26 - Fig. #8199.0

10) 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 valve.

Strany 27 - Pilot Adjustment

ADJUSTMENT/REPLACEMENT OFCOMPONENTSDANGER - SHOCK HAZARDMake sure electrical power to the boiler is disconnect-ed to avoid potential serious injury or

Strany 28 - Fig. #8144

12. 2-Stage Controller (Models 90, 135 & 180)a) Shut-off electrical power to the boiler.b) Remove control cover screws and open con-trol compartme

Strany 32 - 1) Too low gas pressure

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

Strany 33 - Fig.# 8045.2 Fig.# 8102.1

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX (800) 872-9725Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Cana

Strany 34 - 6. REPLACEMENT PARTS LIST

3. INSTALLATION PROCEDURESCODE REQUIREMENTSInstallation must be in accordance with localcodes, or, in the absence of local codes, with the latestedi

Strany 35

2) When the boiler is installed in a confined spacesuch as a utility room or closet (Models 0030,0042and 0066 only), where all air is supplied from i

Strany 36

The weight of the vent stack or chimney must not reston the boiler's drafthood. Support must be provided incompliance with applicable codes. Th

Strany 37

7At the time of removal of an existing boiler, thefollowing steps shall be followed with each applianceremaining connected to the common venting syste

Strany 38

1K1K11K2D80MOTORN.C.ENDSWITCHN.O.1K3C.4321YELLOWBLUEBLACKORANGECABLE8MOUNTINGOn vertical vents, the vent damper may be mounted with the actuator in an

Strany 39 - Litho in U.S.A

SSR2SS2ESRSCR1M2341JUMPER GV24 VACTRHLLL12120 VAC 60HzTH19NOTE: To place vent damper in theopen position to allow burneroperation:Turn the power

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