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Raytherm 133–4001 Installation & Operating Instructions Manual

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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. 2000.50AF
INSTRUCTIONS
Effective: 01-06-10
Replaces: 02-24-09
P/N 240035 Rev. 33
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Summary of Contents for 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. 33 reflects the following: Changes to: Model Identification on page 5, Boiler Types on page 6, floor shield information on page 7, Single Boiler Primary/Secondary Piping diagram on page 19, Multiple Boiler - Reverse Return Hook-Up diagram on page 20, Low Water Cut-Off and High and Low Gas Pressure Switch instructions on page 23.

  • Page 3: Table Of Contents

    CONTENTS Filling System - Heating Boilers WARNINGS Pay Attention to These Terms Ethylene Glycol Systems - Heating Boilers MODEL IDENTIFICATION Initial Start-Up - Pump And Motor RECEIVING EQUIPMENT For Models with Automatic Gas Valves CERTIFICATIONS After Start-Up BOILER TYPES Type H1 - Mechanical Modulating Standing Pilot Checkout Type H2 - Motorized Modulating Procedure...

  • 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

    RECEIVING EQUIPMENT BOILER TYPES Type H1 - Mechanical On receipt of the equipment, visually check for exter- nal damage to the carton or the shipping crate. If either Modulating, Models 133-1826 is damaged, make a note on the Bill of Lading and report the damage to the Carrier immediately.

  • Page 7: Installation

    INSTALLATION Boiler Model No. Base Part No. Boiler Model No. Base Part No. 001749 926* 054597 Installation Codes 182/181 058313 1083* 054598 260/261 058314 1178* 054599 330/331 058315 1287* 054600 The installation must conform with these instructions 400/401 058316 1414* 054601 and the latest editions of the National Fuel Gas Code 1571*...

  • Page 8: Outdoor Boilers

    Outdoor Boilers NOTE: Combustible floor shield is required when boiler is to be installed on a combustible surface. (See ordering information in Table B) These boilers are design certified for outdoor installa- tion. Boilers must not be installed under an overhang within three (3) feet from the top on the boiler.

  • Page 9: Venting

    Venting Combustion must CAUTION: contaminated by corrosive chemical fumes which can damage the boiler and void the warranty. Outdoor Installations Model 133 a. All Air From Inside The Building: Each opening shall have a minimum net free square inches as noted in Table E. 1.

  • Page 10: Indoor Installations

    1. Remove jacket top panel. 2. Remove and discard inner stack adapter panel. 3. Install jacket top panel. 4. Insert tabs of outdoor top into keyholes located on JACKET TOP jacket top panel (4 places). See Detail A. 5. Snap tabs on outdoor top into the locked position of the keyhole so the top will not pull out.
  • Page 11 Fig. 9: Indoor Installation—Model 133 Models 181-401 & 182-400 4. Turn the stack (drafthood) upside down and set it down bottom side up. Indoor Stack Installation 5. Turn the jacket top panel (removed in step 1) upside down and place it over the stack. 1.
  • Page 12 7. Turn the assembled stack and jacket top, rightside up. The jacket top will be trapped between the brackets and the top of the stack. Place the stack over the inner stack adapter panel flanged hole and lower the louvered jacket top panel back into its original position.

  • Page 13: Vent Piping

    Vent Piping WARNING: Indoor boilers require a drafthood that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning. Vent piping the same size or larger than the drafthood outlet is recommended, however, when the total vent height is at least 10 ft.
  • Page 14 Type "B" double-wall or equivalent vent pipe is recom- mended. However, single-wall metal vent pipe may be 10' OR LESS VENT CAP used as specified in the latest edition of the National Fuel Gas Code ANSI Z223.1. 2' MIN Manifolds that connect more than one boiler to a com- 2' MIN mon chimney must be sized to handle the combined load.

  • Page 15: Vent Damper Installation

    Vent Damper Installation On vertical vents, the vent damper may be mounted with the actuator in any position. On horizontal vents, do not mount the actuator either directly above or (Models 133 Through 261) directly below the vent pipe; mount the vent damper Where Required actuator to the side of the vent.

  • Page 16: Plumbing

    EFFIKAL® RVGP CAUTION: Install the vent damper to service only the single appliance for which it is intended. if improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could result. 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.
  • Page 17 *Low NOx units not available for propane. Table G: Maximum Equivalent Pipe Length Venting of Diaphragm Gas CAUTION: The boiler and its manual shut-off valve Components must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1/2 PSIG.
  • Page 18 MAXIMUM AND MINIMUM FLOW RATES 2-PASS HEAT EXCANGER 1-PASS HEAT EXCHANGER SIZE P FT P FT CONN P FT P FT CONN 133* 14.7 1-1/4" 182/181 1-1/2" 260/261 1-1/2" 330/331 1-1/2" 400/401 1-1/2" 2" 2" 2" 2" 10.5 2 1/2" 3"...
  • 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...

  • Page 21: Controls Economaster Controls

    CONTROLS Operating Controls Economaster Controls Modes H1 and H5 - Mechanical Modulation Models 133-1826 with mechanical modulating controls The Economaster II is an electronic device that allows have one or more Robertshaw (Invensys) Unitrol 7000 the operator to set the desired time for the pump to run Series hydraulic snap-on thermostatic combination after the boiler shuts off.
  • Page 22 Mode H3 - 2-Stage Firing MODULATING VALVES The boiler will fire at low fire when there is closure W/ BUILT-IN REGULATOR across the stage 1 contacts. Thereafter, it will fire at high fire when there is closure across the stage 2 contacts.

  • Page 23: Limit Controls

    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. Standard on all models except the 133. NOTE: Flow switch will not operate if flow is less than 12 gpm.

  • Page 24: Electrical Connections

    ELECTRICAL Low Water Cut-Off (Optional) CONNECTIONS The probe-type low water cut-off automatically shuts down burner whenever water level drops below the probe for more than 2 seconds. A 30-second time CAUTION: Label all wires prior to disconnection delay prevents premature lockout due to temporary when servicing controls.

  • Page 25: Start-Up Before Start-Up

    T & P GAUGE (NOT SHOWN) MECHANICAL INLET MODULATING GAS VALVES WITH REGULATOR HI-LIMIT Fig. 37: 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 26: To Turn Off Gas To Appliance

    START-UP LIGHTING INSTRUCTIONS FOR BOILERS WITH STANDING PILOT. For Models 133, 182, 260, 330 & 400 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.

  • 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 soap and water solution. Bubbles indicate a gas leak. Gas Valves 2. Adjust pilot to obtain a normal flame enveloping Lighting Instructions 3/8 to 1/2 inch [9.5 to 12.5 mm] of the thermocou- ple or generator tip. 1.

  • Page 29: Inspections

    at once. Pilot burner should ignite after gas reaches the pilot burner. b. Spark ignition should cut-off when pilot flame is established. c. Main gas valve should open and main burner should ignite after gas reaches the burner port. Inspections Burners Clean main burners and air louvers of dust, lint and debris.

  • Page 30: Low Nox Boilers Models 181 To 401

    Operation Replace any parts showing wear. Check pump coupler for wear and vibration. On call for heat, the ignition system, consisting of an 7. Check flow switch paddle. electronic spark module, and gas pilot system is ener- gized. Providing pilot is proven, blower will start 8.

  • 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. Flame Roll-Out Safety Switch 3. Remove front door. The boiler is equipped with a cut-off device to prevent 4.

  • Page 32: Pilot Removal

    6. Use a long ½” socket wrench to remove orifices from the gas manifold. 7. Remove burners by raising the bracket on the back end of the burners up and out of their slots. 8. Reverse above procedure to re-install. FOR HEATERS MADE IN OR AFTER AUGUST 2001...

  • 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 Electrical—Standing Pilot WARNING—HIGH VOLTAGE: For qualified technicians ONLY. For Service Technicians START BOILER AT GAS VALVE IF NOT 24 V: IF 24 V: IF O.K. IF DEFECTIVE CHECK TRANSFORMER OUPUT REPLACE GAS VALVE THERMOCOUPLE IF NO IF 24 V: 24V: REPLACE PROBLEM IN TRANSFORMER...
  • Page 35 TYPICAL ON-OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM...

  • Page 36: Corrective Action

    MECHANICAL PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Light pilot. (Standing pilot models) When boiler is turned on nothing Pilot is not lit……………………………… Check the circuit breaker, outdoor con- No power to the boiler…………………... happens. troller, etc., upstream of boiler. If power to Leads L1 and L2 of trans- Bad transformer………………………….
  • Page 37 Pumps Pump Loses Prime 1. Air leaks in suction line. Failure To Pump 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 38: 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. 50: 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 39: 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 40: 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 41: Replacement Parts

    5. Insert replacement tube by inserting the end with NOTE: In extreme cases it may be necessary to the most fins removed in the opening of one tube remove the heat exchanger completely for cleaning. sheet. Slide tube until the opposite end clears the The simplest method is steam cleaning at a local car other tube sheet and fit the tube into the hole.

  • Page 42: Warranty

    Effective: 12-01-06 LIMITED PARTS WARRANTY Replaces: 01-01-04 RAYTHERM™ COMMERCIAL BOILERS TYPES H & WH MODELS 133 TO 4001 SCOPE: Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this 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.

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