Raypak RAYTHERM 133-4001 manual

$%  %   !# % $%# &% $ CA T ALOG NO. 2000.50AH Effective: 06-27-1 1 Replaces: 09-16-10 P/N 240035 Rev . 35 This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference. :/07> G % D;0 [...]

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[...]

(#$  Pay Attention to These T erms 4   % %   #' "&!%  #% % $   # %*!$  T ype H1 - Mechanical Modulating 6 T ype H2 - Motorized Modulating 6 T ype H3 - 2-Stage Controls 6 T yp[...]

4  # Indicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. (# Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored.  &% ?[...]

5   % %  T he 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. MOD EL NU MB ER EXA MP LE : H 3 - 0 5 1 4 A Series M od el Si ze R e p r e s e n t a t i v e o f a p p r o x i m a t[...]

$%  %  9>?,77,?4:9:/0> The installation must conform with these instructions and the latest editio ns of the National Fuel Gas Code ANSI Z223.1, the Na tional Electric Code ANSI/NFP A 70 and local codes. In Canada installations must con- fo r m w i th t h e c u rr e n t C AN / C S A B 1 4 9 a nd t h e Canadian[...]

9>?,77,?4:9,>0 The boiler should be mounted on a level, non-com- bustible surface. Boiler must not be in stalled on carpeting. The boiler can be installed on a combustible surface only when a suitable floor shield base is pro- v ided. Raypak offers an optional floor shield base which can be factory installed on all indoor models exce[...]

8  % The boiler shall be installed in a space large i n comparison to the size of the boi ler . Large space is defined as having a volume at least sixteen (16) times the total volume of the boiler . T able D: Reduction of Clearances to Protected Surfaces Derived from National Fuel Gas Code, T able 6.2.3(b) @?/::= :470= > These boi[...]

9 a. All Air From Inside The Building: Each opening shall have a minimum net free square inches as noted in T able E. b. All Air From Outdoors: When air is supplied directly from outside of build- ing, each opening shall have a minimum net free square inches as noted in T able F .  &%    Co m bu s t i o n ai r mu s t no t be c on[...]

10 1. Remove jacket top panel. 2. Remove and discard inner stack adapter pan el. 3. Install jacket top panel. 4. Insert tabs of outdoor top into keyholes located on 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. See Detail B. :/07> [...]

11 Fig. 9: Indoor Installation—Model 133 :/07>    9/::= $?,.69>?,77,?4:9 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[...]

12 7. T urn 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. Reinstall the four (4) #10 flat- head screws removed in step 1 above. [...]

13 Fig. 13: Drafthood Installation—Models 514–824 :/07>  Locate and assemble as shown in Fig. 14. Secure with screws supplied in envelope in carton. :/07>  These models have built-in drafthoods. For proper operation, the drafthood outlet must be connected to the venting system[...]

14 T ype "B" double-wall or equivalent vent pipe is recom- mended. However , single-wall metal vent pipe may be used as specified in the latest edition of the National Fuel Gas Code ANSI Z223.1. Manifolds that connect more than one boiler to a com- mon chimney must be sized to handle the combined load. Consult available guides for proper [...]

15 ' 09? ,8;0= 9>?,77,?4:9 :/07>  % 3=:@23  ( 30= 0 #0<@4=0/ :.,?4:9 The vent damper must be located in the vent so that it serves only the appliance for which it is intended. If improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could r[...]

16  &%  Install the vent damper to service only t he single appliance for which it is intended. if improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could result. ' 09? ,8;0= := 8,7 ;0=,?4:9 $@88,= D For safe, ef ficient operation, the vent damper and all flue prod[...]

17 T able G: Maximum Equivalent Pipe Length A minimum of 7" W .C. and a maximum of 10.5" W .C. upstream pressure, under load and no-load condi- tions, must be provided for natural gas, or a minimum of 12" W .C. and a maximum of 13" for propane. ,> != 0>>@=0 #02@7,?:= The gas pressure regulator is preset nominal[...]

18 R D H R D H L E D O M SIZE GPM T P FT GPM T P FT CONN GPM T P FT GPM T P FT CONN 133* 22 10 14.7 10 22 3.3 1-1/4" 182/ 181 45 7 9.2 20 15 1.8 1-1/2" 2 60/ 261 45 10 9.4 20 22 1 .9 1-1/2" 330/ 331 45 12 9.6 20 28 1 .9 1-1/2" 400/ 401 45 15 9.8 20 33 2 .0 1-1/2" 5 14 90 9 9 40 21 1.8 2" 624 90 12 9.5 40 26 1 .9 2"[...]

19 CONTROLLER SENSOR (LE SS TH AN 4-S TA G E) CONTROLLER SENSOR (4-ST A GE OR MODULA TION) 5’ MAX 5’ MAX Fig. 24: Single Boiler Primary/Secondary Piping—Models 133–4001 Note: Expansion tanks (supplied by others) should be installed per manufacturer's instructions.[...]

20 MAXIMUM OF 12”OR 4 PIPE DIAMETERS CONTROLLER SENSOR 5’ MAX Reverse return piping is a proper method of manifolding multiple boiler hook-ups to ensure balanced flow through each boiler . V alves on supply and return are needed to isolate any boiler , as required. Fig. 25: Multiple-Boiler– Reverse Return Hook-Up—Models 133–4001[...]

21  %# $ .:9:8,>?0= :9?= :7> T he Economaster II is an electronic device that allows the operator to set the desired time for the pump to run after the boiler shuts of f. The time is factory-set at 7 minutes and it can be re-adjusted i n the field anywhere from 3 to 10 minutes. In a conve ntional system, when the aquastat is[...]

22 Fig. 29: Mechanical Modulating V alve M O D U LA T IN G VA LV E S W / B U IL T -I N R EG U L AT O R Fig. 28: Mechanical Modulating V alve Location :/0   :?:=4E0/ :/@7,?4:9 The design uses a motorized valve which varies posi- tion based upon an external controller that communicates with the gas valve actuator , throu[...]

23 484? :9?= :7> ,9@,7# 0>0? 423 484? All models except 133 are equipped with a manual reset high limit. Set the manual limit to its maximum set point. @?:# 0>0? 423 484? Set the auto limit(s) to 30-40 °F above the desired operating temperature and 5-10°F below the Manual High Limit setting. F[...]

24 %#  % $ This boiler is normally wired for 120 V olts. The voltage is indicated on the tie-in leads. Consult the wiring dia- gram shipped with the boiler in the instruction packet. The "TH" leads are for the remote tank control connec- tion. 24 V olts are supplied to thi s connection throu[...]

25 $% #% &! 01:=0 $?,= ?&; Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in the latest edition of ANSI Z21.13 Standard. 090=,7 Before lighting up a new installation, water should be flowing through the boiler[...]

26 1. Se t t he th er mo st at to lo we st se tt in g. 2 . T ur n o ff a ll el e ct ri c p o we r t o th e a pp l ia nc e. 3 . R e m o v e b o i l e r d o o r . 4 . Pu sh in ga s c on tr ol kn ob sl ig ht ly an d t ur n c lo ck - wise to “O F F”. Do not force. 5 . R e p l a c e b o i l e r d o o r panel. 1 . S TO P! Re a d t he s af et y i n fo[...]

27 L I GH TI NG IN S TR UC T IO NS FO R B OI LE RS W IT H E LE CT R ON IC I GN IT IO N ( I ID ) F or Mo de ls wit h M an ua l Ga s V al ve s FO R Y O U R S A F E T Y RE A D B E F O R E O P E RA T I N G WARN ING: If you do not fol low the se inst ructio ns exac tly, a f ire or e xplosi on may r esult c ausin g prop erty dam age, per sonal i njury or[...]

28  := :/07> B4?3 @?:8, ?4. ,> ' ,7A 0> 423?492 9>?= @.?4:9> 1. Close all gas valves. T urn off electrical power sup- ply . W ait five (5) minutes. 2. Open manual pilot valve. T urn on electrical power . Pilot is automatically lighted. 3. Open main gas valve. 4. Set temperature controls to desire[...]

29 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. 9>;0.?4:9> @= 90= > Clean main burners and air louvers of dust, lint and debris. Keep boiler area [...]

30 Replace any parts showing wear . c. Check pump coupler for wear and vibration. 7. Check flow switch paddle. 8. Clean room air intake openi ngs to ensure ade- quate flow of combustion and ventilation air . 9. Keep boiler area clear and free from combustible materials, gasoline, and other flammable vapors and liquids. *Should be checked monthly . [...]

31 size, and connections which comply with all applicable codes. 7,80 # :77 @? $,10?D $B4?.3 The boiler is equipped with a cut-off device to prevent f la m e r o l l- o u t i n t h e e ve n t t h e h ea t e x c h an g e r becomes blocked. This is a "manual reset" type roll- out switch, that must be reset by a service techni[...]

32 5. Pull the pilot bracket slightly , then drop and pull downwards and outwards. 6. Reverse above procedure to re-install. Make sure the pilot bracket is all the way up on the pilot side, see drawing below . :8-@>?4:9 ,9 # 08: A,7 1. Remove burner tray . See Burner Tray Removal procedure. 2. Remove (4) screws that mount the combust[...]

33 NO TE : Be fo re t ro ub le shoot i ng , f amiliar i ze y ours el f w ith th e s tar t-u p a nd c heckout procedure. C he ck li ne v ol ta ge p ow er, lo w v olt age t ransforme r , l imi t c ontrolle r, t hermostat ( c on tr ol le r ) a nd wi ri n g. Pu ll ig ni ti on le ad an d c h ec k s pa rk a t m odu le. If sp ark Oka y: • C he ck i gni [...]

34 F o r S e r v i c e T e c h n i c i a n s S T A R T B O I L ER R E N R U B T O L I P F I S T H G I L R E N R U B T O L I P F I T H G I L T O N S E O D T O N O D S R E N R U B N I A M T U B E L P U O C O M R E H T K C E H C V 4 2 R O F K C E H C AT G AS VA LV E IF NO 24 V IF 24 V: IF O.K. IF DE FE C TI V E CHECK T RANSFORMER O UPUT REPLA CE E C A[...]

35 T Y P I C A L O N - O F F IN T E R M I T T E N T I G N I T I O N C O N T R O L W I R I N G D I A G R A M[...]

36 M EC HA N IC AL P RO BL E M W he n b oi le r is t ur ne d on n ot h in g happens. Th er m os ta t i n " ON " p os it io n c au se s re la y an d pu mp to o pe rat e, but boi le r do es no t fi re . Co nt inu ou s sh ut do wn o f m anu al res et h i gh l im i t. Sooting CA UTI ON-S oot may be c omb usti ble . We t d ow n a nd ex er ci s[...]

37 !@8;>  ,47@= 0 % : !@8; 1. Pump not properly primed. 2. W rong direction of rotation. 3. Speed too low . 4. T otal head too high. # 0/@.0/ ,;,.4?D 9/ = 0,/ 1. Air pockets or leaks in suction line. 2. Clogged impeller . 3. Foot valve strainer too small or clogged. 4. Excessive suction lift (over 15 ft.). 5. Insuf [...]

38 RAY PAK TU BE CLE ANING K IT E x t e n s i o n P i e c e s ( 5 ) A u g e r w i t h C a r b i d e T i p W i r e B r ush P/ N 05 28 71F - 5/ 8 DI A. P/ N 05 28 70F - 7/ 8 DI A. $0= A4.0 # 0;,4= $0.?4:9 % @-0 70,9492 != :.0/@= 0 Establish a regular inspection schedule, the frequency depending on the local water condition and severity of[...]

39 2 . Lift burners from slotted spacer and slide from ori- fices. Clean with a wire brush. 3. Clean orifice(s) as necessary . !47:? #08: A,7 ,9/ 70,9492 1. Disconnect pilot tubing at pilot and sensor/igniter wire. Remove screws holding pilot bracket to burn- er tray . 2. Remove pilot and bracket, clean pilot of debris, small bugs, etc.[...]

40 5. Remove heat exchanger corner brackets. 6. Remove combustion chamber clips at the four cor- ners of the heat exchanger . 7. Lift heat exchanger straight up using caution not to damage refractory . 0,?C.3,920=#0>>08-7D 1. Heat exchanger water header O-rings should be replaced with new ones. 2. Install in/out and return w[...]

41 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 other tube sheet and fit the tube into the hole. 6. Insert the tube roller into tube opening up to stop, making certain that 1/8" of tube projects beyond the tube sheet. 7. Attach drill to[...]

42 Catalo g Nu mber: 19 00.1 0H Ef fe ctiv e 0 8/0 1/10 LIMITED WAR RAN TY RAYTHER M - TYP ES H AND WH Mo dels : 1 33 - 4 001 SCOPE Raypak, Inc. (Ray pak ) w arrants t o the orig inal owner th at al l parts of this hea ter w hich are act ually ma nufactu re d by R ayp ak will be fre e fro m def ects in mater ials and w orkm ans hip u nder norm al u[...]

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