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INSTALLATION & OPERATING
Raytherm™
Heating
Boilers
Models 133–4001
Type H
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: 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 a safe place for future
reference.
CATALOG NO. 2000.50AH
INSTRUCTIONS
Effective: 06-27-11
Replaces: 09-16-10
P/N 240035 Rev. 35
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Related Manuals for Raypak RAYTHERM 133-4001
Summary of Contents for Raypak RAYTHERM 133-4001
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS Raytherm™ Heating Boilers Models 133–4001 Type H 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.
- Page 2 Rev. 35 reflects the following: Changes to: Certifications on page 6, Flow chart on page 34 Additions: Canadian Installation Code references on pages 6, 8 and 24, adjustment procedure for two-stage Robertshaw gas valve (including Fig. 47) on pages 31-32. Deletions: None...
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Page 3: Table Of Contents
WARNINGS Pay Attention to These Terms MODEL IDENTIFICATION RECEIVING EQUIPMENT CERTIFICATIONS BOILER TYPES Type H1 - Mechanical Modulating Type H2 - Motorized Modulating Type H3 - 2-Stage Controls Type H4 - On-Off Controls Type H5 - Mechanical Modulating Type H9 - 4-Stage... -
Page 4: Warnings
WARNINGS— Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. -
Page 5: 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 num- ber represent. MODEL NUMBER EXAMPLE: H 3 - 0 5 1 4 A... -
Page 6: Receiving Equipment
Raypak recommends that this manual be reviewed thoroughly before installing your Raypak boiler. If there are any questions which this manual does not answer, please contact the factory or your local Raypak repre- sentative. Claims for shortages and damages must be filed with carrier by consignee. -
Page 7: Installation Base
The boiler can be installed on a combustible surface only when a suitable floor shield base is pro- vided. 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 8: Outdoor Boilers
In areas where high winds are frequent, it may be nec- essary to locate the boiler a minimum of 3' from high vertical walls, or install a wind break so the boiler is not in direct wind current. Combustion and Ventilation Air... -
Page 9: Venting
CAUTION: Combustion contaminated by corrosive chemical fumes which can damage the boiler and void the warranty. a. All Air From Inside The Building: Each opening shall have a minimum net free square inches as noted in Table E. Model Sq. Inches... -
Page 10: Indoor Installations
2. Turn heater manual switch located in upper control panel to the "OFF" position. 3. Shut-off gas supply and water supply to the boiler. 4. Mount drafthood on boiler and attach with the sheet metal screws provided. Drafthood should be positioned with the vent sensor located on the front left side (see next page). - Page 11 Models 181-401 & 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 12 "OFF" position. 3. Shut-off gas supply and water supply to the boiler. 4. Mount drafthood on top of boiler as shown in Fig. 12. Drafthood should be positioned with the vent sensor located on the front right side as shown.
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Page 13: Vent Piping
The weight of the vent stack or chimney must not rest on boiler drafthood. Support must be provided in com- pliance with applicable codes. The boiler top and drafthood must be readily removable for maintenance and inspection. - Page 14 At no time should the area be less than the area of the largest outlet. Fig. 15: Common Venting At the time of removal of an existing boiler, the follow- ing steps shall be followed with each appliance remaining connected to the common venting system...
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Page 15: Vent Damper Installation
Fig. 17: Vent Damper Installation (Model 133 Drafthood Shown) 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 16: 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 17 Connection Fig. 23: Bleed Line Connection Location 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.
- Page 18 * 4 Pass Heat Exchanger BOLD TYPE indicates Low NOx models. 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 19 Note: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. Fig. 24: Single Boiler Primary/Secondary Piping—Models 133–4001...
- Page 20 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. Fig. 25: Multiple-Boiler– Reverse Return Hook-Up—Models 133–4001...
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Page 21: Controls
The Economaster II is an electronic device 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 The actuator runs on 120V power, and takes 26 seconds to go from fully closed to fully open. Raypak offers a single-boiler digital controller which drives the actuator; see controller options B-40 and B-41 (includes outdoor reset). For systems with mul- tiple boilers, see controller options B-45 through B-47.
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Page 23: Limit Controls
5-10°F below the Manual High Limit setting. 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 24: Electrical Connections
This boiler is normally wired for 120 Volts. The voltage is indicated on the tie-in leads. Consult the wiring dia- gram shipped with the boiler in the instruction packet. -
Page 25: Start-Up
Heating Boilers Fill through filler opening on the top on the Air-X Tank to solution desired. Always maintain solution level in sight glass. NOTE: Raypak recommends the use of Ethylene Glycol solution only. Initial Start-Up - Pump and Motor Many pumps are now direct-drive. They have no cou- pler or bearing assembly. -
Page 26: To Turn Off Gas To Appliance
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: For Models With Automatic Gas Valves
For Models with Automatic Gas Valves Lighting Instructions 1. Close all gas valves. Turn off electrical power sup- ply. 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
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
Start-Up (S8600H) 1. Turn on power to the boiler with gas supply off. 2. Check ignition module as follows: a. Set the thermostat or controller to call for heat. b. Watch for continuous spark at the pilot burner. -
Page 31: Flame Roll-Out Safety Switch
Flame Roll-Out Safety Switch The boiler is equipped with a cut-off device to prevent flame roll-out in the event the heat exchanger becomes blocked. This is a "manual reset" type roll- out switch, that must be reset by a service technician after any over temperature conditions have been fixed. -
Page 32: Pilot Removal
7. Using an Allen wrench, turn the screw clockwise to increase or counterclockwise to decrease high fire manifold pressure –see Fig. 47. 8. Install the spring, weight and aluminum cap –tight- en the cap using same # of turns as was used in removing the cap. -
Page 33: Troubleshooting
TROUBLESHOOTING Electrical—Electronic Ignition IID Intermittent Pilot System 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? SYSTEM RUNS UNTIL... - Page 34 IF NO 24 V CHECK TRANSFORMER OUPUT IF NO 24V: REPLACE TRANSFORMER WARNING—HIGH VOLTAGE: For qualified technicians ONLY. For Service Technicians START BOILER IF 24 V: REPLACE IF 24 V: PROBLEM IN LIMIT CIRCUITS IF O.K. IF DEFECTIVE GAS VALVE...
- Page 35 TYPICAL ON-OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM...
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Page 36: Corrective Action
MECHANICAL PROBLEM 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 37 Pumps Failure To Pump 1. Pump not properly primed. 2. Wrong direction of rotation. 3. Speed too low. 4. Total head too high. Reduced Capacity And/Or Head 1. Air pockets or leaks in suction line. 2. Clogged impeller. 3. Foot valve strainer too small or clogged. 4.
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Page 38: Service
RAYPAK TUBE CLEANING KIT Auger with Carbide Tip Fig. 51: Raypak Tube Cleaning Kit 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. -
Page 39: Pilot Removal And Cleaning
4. Loosen bolts and disconnect flange nuts on in/out header, loosen union(s) at gas pipe, and slide boil- er away from piping until studs clear the heater. SEDIMENT TRAP Fig. 53: Model 2100–4001 Boiler Illustration ELECTRICAL JUNCTION BOX REDUNDANT SAFETY... -
Page 40: 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 41: Replacement Parts
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. -
Page 42: Warranty
REPAIR OR REPLACEMENT At its option, Raypak will repair or replace a defective part(s) in accordance with the terms of this Limited Warranty, if it fails in normal use and service during its specified warranty period. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. - Page 44 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.