1. Manuals
  2. Brands
  3. Raytherm Manuals
  4. Boiler
  5. 181
  6. Installation & operating instructions manual

Raytherm 181 Installation & Operating Instructions Manual

Heating boilers
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
INSTALLATION & OPERATING
Raytherm™
Heating
Boilers
Models 181–4001
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. 2000.50AI
INSTRUCTIONS
Effective: 09-28-12
Replaces: 06-27-11
P/N 240035 Rev. 36

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 181 and is the answer not in the manual?

Questions and answers

Related Manuals for Raytherm 181

Summary of Contents for Raytherm 181

  • Page 1 INSTRUCTIONS Raytherm™ Heating Boilers Models 181–4001 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. 36 reflects the following: Changes to: ASME Mark on page 1, Model Identification on page 5, Boiler Types on page 6, Tables B and C on page 7, Table D on page 8, Tables E and F on page 9, Fig. 10 on page 11, Vent Piping on page 12, Fig. 14 on page 13, Vent Damper Installation on page 14, Vent Damper Note on page 15, Gas Supply Connections on page 15, Table G on page 16, Table H on page 17, Piping instructions on page 17, Fig.

  • Page 3: Table Of Contents

    Installation Codes Burners Installation Base Controls Clearances Suggested Inspection Schedule LOW NOx BOILERS Outdoor Boilers High-Wind Conditions Models 181 to 401 (Outdoor Units Only) Operation Combustion and Ventilation Air Start-Up (S8600M) (Indoor Units Only) Blower Adjustment Venting Visual Inspection Indoor Installations...

  • 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. Boiler rating plate showing model number MODEL NUMBER EXAMPLE: H 3 - 0 5 1 4 A Series Model Size...

  • Page 6: Receiving Equipment

    Central heating boiler with on-off firing. Outdoor Air charge. Reset controller standard on models 181-261. Purchased parts are subject to replacement only Type H5 - Mechanical under the manufacturer's warranty. Debits for defec-...

  • Page 7: Installation Base

    NOTE 2: Servicing Clearances: Provide at least 24" * Models with factory-installed floor shield as standard. (Models 181-1826), 48" (Models 2100-4001) in front of BOLD type indicates Low NOx models. unit for removal and servicing of the Controls & Burner Tray.

  • Page 8: Outdoor Boilers

    (3) sides must be open in the area under the over- hang. Roof water drainage must be diverted away Boiler Size from the boilers with the use of gutters. 926 to 2100 to 181 to 401 514 to 824 Description Location 1826 4001 3-1/2 in. thick masonry walls...

  • Page 9: Venting

    3500 3500 4001 4000 Fig. 4: Installing Outdoor Top—Models 181-401 & 182- Table E: Minimum Net Free Air from Inside Building b. All Air From Outdoors: 1. Remove jacket top panel. When air is supplied directly from outside of build- 2.

  • Page 10: Indoor Installations

    Reinstall the four (4) #10 flat- head screws removed in step 1 above. JACKET TOP FASTENING SCREW Fig. 7: Installing Outdoor Top Detail—Models 514–824 Models 926-1758 Boilers are shipped with outdoor vent terminal factory installed. Fig. 8: Indoor Installation—Models 181-401 & 182-400...
  • Page 11 6. Route flue sensor wire harness through the grom- Fig. 10: Boiler After Drafthood Installation—Models met installed in Step 5 (Models 181-261). 181-401 & 182-400 7. Remove door and locate wire from roll-out sensor Models 514-824 to high limit with the male/female connector.

  • Page 12: Vent Piping

    Models 962-1826 As much as possible, avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontal non-vertical runs, the vent pipe must have a Locate and assemble as shown in Fig. 12. Secure with minimum of 1/4 inch per foot rise and should be sup- screws supplied in envelope in carton.
  • Page 13 LESS THAN 12” DIA VENT - WITHIN 8’ Manifolds that connect more than one boiler to a com- 12” OR LARGER DIA VENT - WITHIN 10’ mon chimney must be sized to handle the combined *(SEE VENT PIPING INSTRUCTIONS) load. Consult available guides for proper sizing of the manifold and the chimney.

  • Page 14: Vent Damper Installation

    Location The vent damper ships set up for a continuous pilot system. Since the Raytherm is equipped with an The vent damper must be located in the vent so that it Intermittent Pilot, the hole in the vent damper blade serves only the appliance for which it is intended.

  • Page 15: Plumbing

    Plumbing Vent Damper Normal Operation Summary 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. Check vent damper operation as follows: 1.
  • Page 16 .60 SPECIFIC GRAVITY @ 05" WC. PRESSURE DROP PROPANE GAS 2500 BTU/FT 1.53 SPECIFIC GRAVITY @ 0.6" WC. PRESSURE DROP 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" *182/181 *260/261 *330/331 *400/401 926/962 1083/1125 1178/1223 1287/1336 1414/1468 1571/1631 1758/1826 2100...
  • Page 17 Models 181-401. On these models the temper- system design. The system should always include ature & pressure gauge is shipped loose for field adequate system flow in excess of the connected boil- installation, and located in the outlet water connection.
  • Page 18 Note: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. Fig. 22: Single Boiler Primary/Secondary Piping—Models 181–4001...
  • Page 19 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. 23: Multiple-Boiler– Reverse Return Hook-Up—Models 181–4001...

  • Page 20: Controls

    CONTROLS Models 181-401, when built to operate on natural gas, are equipped with a continuous retry pilot ignition mod- ule as standard. Propane units, as well as all Economaster Controls 514-4001 units regardless of fuel type, are equipped with a 90 second trial for pilot ignition - lockout ignition module as standard.
  • Page 21 ITEM FEATURE SETTING / DESCRIPTION DEFAULT Operating Reset Ratio Dial Reset Ratio 0.4 to 3.6 / Setpoint Target 120°F to 200°F Temperature 0.4 to 3.6 Single Stage DIP #1 Firing Mode Single Stage (On) / Two Stage (Off) (On) Outdoor DIP #2 Configuration Outdoor Reset (On) / Setpoint (Off)

  • Page 22: Operating Controls

    Operating Controls Direct Domestic Hot Water In this configuration the controller will operate to main- Modes H1 and H5 - Mechanical Modulation tain a set temperature in the storage tank. The differential is fixed at 5F below target. The System Models 514-1826 with mechanical modulating controls Supply Sensor (S2) is used as the operating sensor.
  • Page 23 Mode H3 - 2-Stage Firing MODULATING VALVES W/ BUILT-IN REGULATOR The boiler will fire at low fire when there is closure across the stage 1 contacts. Thereafter, it will fire at high fire when there is closure across the stage 2 contacts.

  • Page 24: Limit Controls

    Set the manual limit to its maximum set point. Fig. 34: Flow Switch 100% Pilot Safety All standard boiler models 181-4001 employ electron- ic devices which close the main gas valve within 8/10 of a second whenever the pilot flame is interrupted.

  • Page 25: Electrical Connections

    DO NOT attach line voltage to the "TH" leads on mod- els 133-1826. Before starting boiler check to ensure proper voltage to boiler and pump. Fig. 37: Low Water Cut-Off Board for Models 181-401 The boiler must be electrically grounded in accordance with National Electrical Code ANSI/NFPA No 70, or High and Low Gas Pressure with CSA C22.1 C.E.C.

  • Page 26: Start-Up

    T & P GAUGE (NOT SHOWN) MECHANICAL INLET MODULATING GAS VALVES WITH REGULATOR HI-LIMIT Fig. 39: General Location of Controls START-UP Ethylene Glycol Systems - Heating Boilers Before Start-Up Fill through filler opening on the top on the Air-X Tank to solution desired.

  • Page 27: For Your Safety Read Before Operating

    LIGHTING INSTRUCTIONS FOR BOILERS WITH ELECTRONIC IGNITION (IID) For Models with Manual Gas Valves FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. This appliance is equipped with an ignition device which If you cannot reach your gas supplier, call the fire de- automatically lights the pilot.

  • Page 28: For Models With Automatic Gas Valves

    For Models with Automatic 2. Check ignition module as follows: a. Set the thermostat or controller above room Gas Valves temperature to call for heat. b. Watch for continuous spark at the pilot burner. Lighting Instructions c. Time the spark operation. Time must be with- in the lockout timing period (15 or 90 1.

  • Page 29: Controls

    Controls Check all controls to see that they are operational. To check electronic safety (IID Models), turn off main burner. Observe pilot burner when shutting off pilot gas. Ignition spark should go on. Main gas valve will also drop out. To check high limit switch, turn dial setting down to a point slightly below the temperature of the water leav- ing the heater.

  • Page 30: Low Nox Boilers

    LOW NOx BOILERS Operation — Models 181 to 401 On call for heat, the ignition system, consisting of an electronic spark module, and gas pilot system is ener- The boilers are certified and tested under the latest gized. Providing pilot is proven, blower will start edition of the ANSI Z21.13 standards for hot water...

  • Page 31: Flame Roll-Out Safety Switch

    size, and connections which comply with all applicable 1. Shut-off main electrical power switch to heater. codes. 2. Shut-off gas upstream of heater. 3. Remove front door. Flame Roll-Out Safety Switch 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 The boiler is equipped with a cut-off device to prevent valve to jacket.

  • Page 32: Gas Valve 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 WARNING—HIGH VOLTAGE: For qualified technicians ONLY. Electrical—Electronic Ignition IID NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to Intermittent Pilot System light. To reset, interrupt power to heater. Honeywell S8600 START NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout TURN GAS SUPPLY OFF.
  • Page 34 TYPICAL ON-OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM...

  • Page 35: Corrective Action

    POSSIBLE CAUSE MECHANICAL PROBLEM CORRECTIVE ACTION Check the circuit breaker, outdoor con- When boiler is turned on nothing No power to the boiler…………………... happens. troller, etc., upstream of boiler. If power to Leads L1 and L2 of trans- Bad transformer…………………………. former, but no power on 24V side, re- place.
  • Page 36 Pumps Pump Loses Prime Failure To Pump 1. Air leaks in suction line. 2. Excessive amount of air in water. 1. Pump not properly primed. 3. Water seal in stuffing box not functioning. 2. Wrong direction of rotation. 4. Excessive suction lift and pump operating too 3.

  • Page 37: Service

    RAYPAK TUBE CLEANING KIT Extension Pieces (5) Auger with Carbide Tip Wire Brush P/N 052871F - 5/8 DIA. P/N 052870F - 7/8 DIA. Fig. 51: Raypak Tube Cleaning Kit Service Burner Tray Removal Repair Section 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 38: Pilot Removal And Cleaning

    2. Remove front inspection panel. NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become 3. Remove wires to high limit and loosen screws distorted from direct flame impingement and this holding high limit to cabinet. usually necessitates replacement of these parts.

  • Page 39: Combustion Chamber Removal

    5. Remove heat exchanger corner brackets. 10. If gas piping was disconnected, reconnect gas pip- ing system and check for leakage using a soapy 6. Remove combustion chamber clips at the four cor- solution. ners of the heat exchanger. 11. Check for correct water pressure and water level 7.

  • Page 40: Cleaning Flue Gas Passageways

    Cleaning Flue Gas Passageways 5. Insert replacement tube by inserting the end with the most fins removed in the opening of one tube sheet. Slide tube until the opposite end clears the Soot will clog areas behind fins and cause eventual other tube sheet and fit the tube into the hole.

  • Page 41: Replacement Parts

    REPLACEMENT PARTS See separate parts sheet in instruction envelope. 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.

  • Page 42: Warranty

    Catalog Number: 1900.10H Effective 08/01/10 LIMITED WARRANTY RAYTHERM - TYPES H AND WH Models: 133 - 4001 SCOPE Raypak, Inc. (Raypak) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from defects in materials and workmanship under normal use and service for the specified warranty periods and subject to the conditions set forth in this Limited Warranty.
  • Page 44 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

This manual is also suitable for:

4001

Table of Contents