Raypak RAYTHERM 0133-4001 Installation And Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Raypak Manuals
  4. Boiler
  5. 0133-4001
  6. Installation and operating instructions manual

Raypak RAYTHERM 0133-4001 Installation And Operating Instructions Manual

Raypak boiler user manual
Hide thumbs Also See for RAYTHERM 0133-4001:
Table of Contents

Advertisement

Quick Links

See also: Installation Instructions and Operating Manual
INSTALLATION
AND OPERATING
INSTRUCTIONS
RAYTHERM™

HEATING BOILERS

Type H
Models 0133-4001
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 this manual. 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.
This manual should be maintained in legible
condition and kept adjacent to the boiler or kept
in a safe place for future reference.
CATALOG NO. 2000.50Z
Effective:
03-15-04
Replaces:
06-15-03
P/N 240035

Advertisement

Table of Contents
loading

Related Manuals for Raypak RAYTHERM 0133-4001

Summary of Contents for Raypak RAYTHERM 0133-4001

  • Page 1: Heating Boilers

    *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. This manual should be maintained in legible condition and kept adjacent to the boiler or kept in a safe place for future reference. CATALOG NO. 2000.50Z Effective:...

  • Page 2: Model Identification

    MODEL IDENTIFICATION The model number of a boiler can be found on the Sales Order and the boiler's rating plate. The example below identifies what the characters of the model number represent. MODEL NUMBER EXAMPLE: H 3 - 0 5 1 4 A...

  • Page 3: Table Of Contents

    MODEL IDENTIFICATION...2 RECEIVING EQUIPMENT...4 CERTIFICATIONS... 4 BOILER TYPES... 4 CALIFORNIA PROPOSITION 65 WARNING... 4 INSTALLATION... 5 Installation Codes...5 Installation Base... 5 Clearances... 6 Combustion and Ventilation Air...7 Venting...8 Plumbing...15 CONTROLS... 21 Economaster Controls...21 Electronic Ignition... 21 Operating Controls... 21 Limit Controls...22 ELECTRICAL CONNECTIONS...

  • Page 4: Receiving Equipment

    CERTIFICATIONS The Raypak hydronic boilers are design certified and tested under the latest requirements of the American National Standard, ANSI Z21.13 - latest edition. Each boiler has been constructed and...

  • Page 5: Installation

    The boiler should be mounted on a level, non-combustible surface. Boiler must not be installed on carpeting. The boiler can be installed on a combustible surface only when a suitable floor shield base is provided. Raypak offers an optional floor shield base which can be factory installed on all indoor models except Model 133; the Model 133 floor shield base is shipped loose and must be installed by the contractor.

  • Page 6: Clearances

    REDUCTION OF CLEARANCES TO PROTECTED SURFACES Note: The boiler shall be installed in a space large in comparison to the size of the boiler. Large space is defined as having a volume at least sixteen (16) times the total volume of the boiler.

  • Page 7: Combustion And Ventilation Air

    These boilers are designed certified for outdoor installation. Boilers must not be installed under an overhang within three (3) feet from the top on the boiler. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from the boilers with the use of gutters.

  • Page 8: Venting

    VENTING OUTDOOR INSTALLATIONS MODEL 133 Step 1: Remove the front (4) screws. Step 2: Line up outdoor top vent opening over heater vent opening. Step 3: Lower outdoor top onto unit lining up slots in the outdoor top with screws holes in jacket top. Step 4: Reinstall (5) screws to secure jacket top and outdoor top to unit.
  • Page 9 Step 3. Shut-off gas supply and water supply to the boiler. Step 4. Mount drafthood on boiler and attach with the 4 sheet metal screws provided. Drafthood should be positioned with the vent sensor located on the front left side as shown below.
  • Page 10 MODELS 181-401 and 182-400 INDOOR STACK INSTALLATION 1. Remove the louvered jacket top by removing four (4) #10 flathead screws. 2. If originally installed, remove outdoor top from the louvered jacket top. 3. Place the inner stack adapter panel over the flue collector inside the heater.
  • Page 11 Step 3. Shut-off gas supply and water supply to the boiler. Step 4. Mount drafthood on top of boiler as shown on page 8. Drafthood should be positioned with the vent sensor located on the front right side as shown.
  • Page 12 MODELS 514-824 Locate and assemble as shown below. Secure with screws supplied in envelope in carton. MODELS 962-1826 Locate and assemble as shown below. Secure with screws supplied in envelope in carton. MODELS 2100-4001 These models have built-in drafthoods. For proper operation, the drafthood outlet must be connected to the venting system.
  • Page 13 At no time should the area be less than the area of the largest outlet. 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...
  • Page 14 WARNING: Do not use thermally actuated vent dampers on a modulating boiler. To do so, may result in asphyxiation. Use only a mechanically actuated vent damper device that is electrically interlocked with the modulating boiler operation.

  • Page 15: Plumbing

    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 figure below.) 2.
  • Page 16 Bleed Line Connection GENERAL Boiler should be located so that any water leaks will not cause damage to any adjacent areas or structures. See piping diagrams for proper water connections for the type of boiler and system. Fig. # 8185.2...
  • Page 17 We recommend that the pump be sized for 20°F Delta T. (Delta T is the temperature difference between the inlet and outlet water when the boiler is firing at full rate). For some boilers, the Delta T is more than 20°F (22°-33°F) at the recommended flow rates.
  • Page 18 PIPING DIAGRAMS DIAPHRAGM TANK SYSTEM NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. 7024e...
  • Page 19 MULTI-ZONE HEATING SYSTEMS MODELS 133 TO 4001 NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. Fig.# 7027.1e Fig.# 7024.1e...
  • Page 20 MULTIPLE-BOILER– REVERSE RETURN HOOK-UP MODELS 133 TO 4001 Fig. #9495 REVERSE RETURN PIPING IS A PROPER METHOD OF MANIFOLDING MULTIPLE BOILER HOOK-UPS TO ENSURE BALANCED FLOW THROUGH EACH BOILER. VALVES ON SUPPLY AND RETURN ARE NEEDED TO ISOLATE ANY BOILER, AS REQUIRED.

  • Page 21: Controls

    The Raytemp Economaster II is an electronic de- vice that allows the operator to set the desired time for the pump to run after the boiler shuts off. The time is factory-set at 7 minutes and it can be re-adjusted in the field anywhere from 3 to 10 minutes.

  • Page 22: Limit Controls

    Push the reset button and set the limit(s) to 30- 40 °F above desired operating temperature. FLOW SWITCH This dual purpose control shuts off the boiler in the case of a pump failure or low water condition. It is mounted and wired in series to the main gas valve.
  • Page 23 FLOW SWITCH CUTTING LOW WATER CUT-OFF Fig. #8925 GAS PRESSURE SWITCH Fig. #8996 MODULATING VALVE Fig. #8995 Fig. #8236...

  • Page 24: Electrical Connections

    National Electrical Code ANSI/NFPA No 70. NOTES: 1. Field install ground to inside of junction box. 2. If any of the original wire as supplied with the boiler must be replaced, it must be replaced with 105°C wire or its equivalent.

  • Page 25: Start-Up

    BEFORE START-UP Safe lighting and other performance criteria were met with the gas manifold and control assembly pro- vided on the boiler when the boiler underwent tests specified in the latest edition of ANSI-Z21.13 Standard. GENERAL Before lighting up a new installation, water should be flowing through the boiler.

  • Page 26: Lighting Instructions

    If the pilot will not stay lit after several tries, turn the gas control knob to “OFF” and call your service technician or gas supplier. 10. Stand to the side of the boiler and turn the gas control knob counter-clockwise 11 Replace boiler door panel.

  • Page 27: For Your Safety Read Before Operating

    Turn off all electrical power to the appliance. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. Remove boiler door panel. For Robertshaw gas valve: Turn gas control knob clockwise to “OFF”.

  • Page 28: After Start-Up

    FOR MODELS WITH AUTOMATIC GAS VALVES LIGHTING INSTRUCTIONS 1. Close all gas valves. Turn off electrical power supply. Wait five (5) minutes. 2. Open manual pilot valve. Turn on electrical power. Pilot is automatically lighted. PILOT VALVE CONTROL SHOWN IN THE "ON"...

  • Page 29: Inspections

    40°F above desired operating temperature, and push reset button. Burner should light. SUGGESTED INSPECTION SCHEDULE The boiler should be inspected on the first and third months after initial start-up and then on an annual basis. If problems are found, refer to Troubleshooting Guide for additional directions.

  • Page 30: Low Nox Boilers

    Providing pilot is proven, blower will start running, the main gas valve will open and the boiler will operate. When the operating control is satisfied the boiler will shut down.

  • Page 31: Service

    SERVICE LOW NOx BURNER TRAY ASSEMBLY BURNER TRAY REMOVAL 1. Shut-off main electrical power switch to heater. 2. Shut-off gas upstream of heater. 3. Remove front door. 4. Disconnect gas line from gas valve. 5. Remove (2) screws that mount burner tray to the base of the unit, and (2) screws that secure gas valve to jacket.

  • Page 32: Troubleshooting

    TROUBLESHOOTING ELECTRICAL ELECTRONIC IGNITION IID Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24 V NOMINAL) SPARK ACROSS IGNITER/SENSOR GAP TURN GAS SUPPLY ON PILOT BURNER LIGHTS? SPARK STOPS WHEN PILOT IS LIT? MAIN BURNER LIGHTS?
  • Page 33 AT GAS VALVE IF NOT 24 V: CHECK TRANSFORMER OUPUT FOR 24 V IF NO 24V: REPLACE TRANSFORMER For Service Technicians START BOILER IF 24 V: REPLACE GAS VALVE IF 24 V: PROBLEM IN LIMIT CIRCUITS IF PILOT BURNER DOES NOT LIGHT CHECK THERMOCOUPLE IF O.K.
  • Page 34 TYPICAL ON-OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM...

  • Page 35: Mechanical

    When boiler is turned on nothing happens. Thermostat in "ON" position causes relay and pump to operate, but boiler does not fire. Continuous shut down of manual reset high limit. Sooting CAUTION-Soot may be combustible. Wet down and exercise caution when cleaning.

  • Page 36: Service

    Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness. The boiler may be cleaned from the side opposite the water connections as shown, without breaking pipe connections. It is preferable, however, to remove both PUMP LOSES PRIME 1.

  • Page 37: Burner Tray Removal

    BURNER TRAY REMOVAL 1. Shut-off power and gas supply to the boiler. Disconnect union(s) and pilot tubing, then loosen and remove burner hold-down screws. 2. Disconnect wires at gas valve and slide burner tray out. GAS VALVE REMOVAL 1. Shut-off gas supply to the boiler. Remove gas piping to gas valve inlet.

  • Page 38: Combustion Chamber Removal

    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 pres- sure. Run system circulating pump for a minimum of 1/2 hour with boiler off.

  • Page 39: Control Well Replacement

    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 war- ranty, the part will be returned in kind or equal substi- tution, freight collect.
  • Page 41 Raypak, Inc., 2151 Eastman Avenue, Oxnard CA 93030 (805) 278-5300 Fax (800) 872-9725 Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A.

This manual is also suitable for:

Raytherm h-133Raytherm h-182Raytherm h-181Raytherm h-260Raytherm h-261Raytherm h-330 ... Show all

Table of Contents