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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 opening shall be within 12 inches of the top,

and the other opening within 12 inches 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 Sec. 5.3.5 of the latest edition of the National

Fuel Gas Code for additional requirements.

Fig. #8198.0

NOTE:

If louvers, grills or screens are used on the

openings, obtain the net free area 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 shown in

Sec. 5.3.5 National Fuel Gas Code.

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, in square inches as
follows:

Model

Sq. In. Of Free Area

       0030 & 0042

12

0066

18

0090

24

0135

35

0180

45

Location of the openings is the same as in the

previous case - that is, within 12 inches of the top, and

within 12 inches 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 small-
est dimension be less than 3 inches.

VENTING CONNECTIONS

These boilers have built-in drafthoods.  Vent piping

the same size or larger than the draft hood 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 Part 11, Note 2 and in Appendix G of the
latest edition of the National Fuel Gas Code, 

ANSI Z

223.1. 

 As much as possible avoid 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 hori-
zontal length shall be 1-1/2 feet (18 inches) for each inch

of connector diameter as follows.

Boiler Size

Vent Connector

Max Horizontal

     Diameter

Length - FT

  30 & 42

       4"

6

  66 & 90

       5"

7.5

     135

       6"

9

     180

       7"

10.5

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.

For protections 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 Z 223.1.

The discharge opening must be a minimum of two

feet vertically from the roof surface and at least two (2)

feet higher than any part of the building within ten (10)
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 horizon-
tally 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.

12"

12"

5

Summary of Contents for 0090B 0135B

Page 1: ...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 informati...

Page 2: ...SIONS 4 3 INSTALLATION PROCEDURES 4 Code Requirements 4 Mounting Base 4 Clearance Requirements 4 Combustion Ventilation Air 5 Venting Connections 7 Vent Damper Installation 10 Gas Supply Connections 1...

Page 3: ...t in sub base for combus tible flooring Models are available with standing pilot or with intermittent ignition device I I D The boilers are equipped with the following components water circulation pum...

Page 4: ...5 Comb Alcove 6 6 6 16 6 0180 2 A front clearance of at least 24 is recommended for adequate service of burner tray and controls 3 Except for carpeted flooring boilers are certified for installation o...

Page 5: ...e shall the small est dimension be less than 3 inches VENTING CONNECTIONS These boilers have built in drafthoods Vent piping the same size or larger than the draft hood outlet is recommended however w...

Page 6: ...ng space causing serious health injury For connections to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or...

Page 7: ...or pipe to visually check spillage f After it has been determined that each appliance remaining connected to the common venting sys tem properly vents when tested as outlined above return doors windo...

Page 8: ...ion Fig 8994 DO NOT plug the hole if installing the vent damper on a continuous pilot system as this will create a hazardous condition Fig 8183 0 INSTALLING THE VENT DAMPER IN HORIZONTAL VERTICAL VENT...

Page 9: ...T 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 BOILE...

Page 10: ...em 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 thesystemhead Ft Wtr by23 inordertomaintainthe same heat transf...

Page 11: ...for wiring hook up The boiler when used in connection with a refrigeration system mustbeinstalledsothechilledmediumispipedinparallelwiththeboilerwithappropriatevalvestoprevent the chilled medium from...

Page 12: ...DIRECT 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 S...

Page 13: ...g 9000 1 HEATINGUNITS CIRCULATORS COLD WATER INLET FEED VALVE PIPEPRESSURE RELIEF VALVE TO DRAIN DIAPHRAGM EXPANSION TANK AIR SCOOP AIR VENT 12 MAX AIR VENT AIR SCOOP COLD WATER INLET FEED VALVE PIPEP...

Page 14: ...or its equivalent See wiring diagram key for 150 C wire indication ELECTRICAL WIRING The electrical power supply requirement for these boilers is 115 volts 60 Hz Field wiring connections and electric...

Page 15: ...Fig 2223e See page 14 wiring diagram key information 15 WIRING DIAGRAM STANDING PILOT 24 V 2 STAGE MODELS 90 135 180...

Page 16: ...TERMITTENT 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...

Page 17: ...NT 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 OP...

Page 18: ...lve 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 Transforme...

Page 19: ...th 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...

Page 20: ...20 WIRING DIAGRAM Primary Secondary Pumping System Honeywell Zone Valve Fig 2223 2e...

Page 21: ...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 swit...

Page 22: ...med 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 stop...

Page 23: ...ir Flush system before putting into operation to as surethatforeignmaterialdoesnotdamagepumpseals SECTION 2 Checking the Circulator Before lighting the boiler and after system is filled make sure that...

Page 24: ...iler area for gas Be sure to smell next to the floor because some gas is 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 el...

Page 25: ...0 135 180 1 Set the thermostat to the lowest setting 2 Turn off all electric power to the boiler 3 Push in and move gas control lever counter clockwise to OFF position Do not force FOR AUTOMATIC IGNIT...

Page 26: ...ll electric power to the boiler 9 Set thermostat to desired setting 10 If the boiler will not operate follow the instruction To Turn Off Gas To Boiler and call your service technician or gas supplier...

Page 27: ...ervice technician or your gas supplier d Return pilot adjustment screw counter clock wise same number of turns as in step b ROBERTSHAW7200 GASVALVE Models 90 135 180 e Replace pilot adjustment cover s...

Page 28: ...SAFE SHUTDOWN TESTS LIMIT ACTION With the burner operating lower the high limit setting to simulate an overheated boiler Normal shut down should occur Restore the normal limit setting and the burner...

Page 29: ...mpingement and this usu ally necessitates replacement of these parts 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...

Page 30: ...ating 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 strain ers for debris Expansion tank water l...

Page 31: ...rmostat and wiring circuit Replace thermostat or repair wiring connections 3 Check secondary voltage If no 24V replace transformer 4 Check relay coil or contacts Replace as required 5 Replace pump 1 L...

Page 32: ...gas line or increase gas line piping 1 Refer to installation instructions re garding combustion air require ments 2 Refer to installations instructions 3 See yellow flame section above 10 Defective i...

Page 33: ...electrical power to the boiler b Remove wiring connections to switch c Remove the screws 2 d Reverse above procedure to re install 5 Ignition Module Replacement a Shut off electrical power to the boil...

Page 34: ...everse the above procedure to re install Use new gaskets and make sure they are seated properly when tightening the nuts and bolts 12 2 Staged Controller Models 90 135 180 a Shut off electrical power...

Page 35: ...lied 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...

Page 36: ...36 BOILERSMANUFACTUREDAFTERAUGUST11 1994WITHSERIAL 9408116901ORLATER HAVEIIDIGNITIONIN LIEU OF HSI IGNITION...

Page 37: ...enwal 601129F 601129F 601129F 601129F 601129F 601129F Ignition Control IID Honeywell 004935F 004935F 004935F 004935F 004935F 004935F 6 P Pilot Mtg Bracket 306239 306239 306239 306239 306239 306239 8 P...

Page 38: ...8 889 1500FAX 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 6...

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