Raypak 133-4001 - Manuals - manualsarea.com

Page 3 - CONTENTS

WARNINGS 4 Pay Attention to These Terms 4 MODEL IDENTIFICATION 5 RECEIVING EQUIPMENT 6 CERTIFICATIONS 6 BOILER TYPES 6 Type H1 - Mechanical Modulating 6 Type H2 - Motorized Modulating 6 Type H3 - 2-Stage Controls 6 Type H4 - On-Off Controls 6 Type H5 - Mechanical Modulating 6 Type H9 - 4-Stage 6 INS...

Page 4 - WARNING - CALIFORNIA PROPOSITION; WARNINGS—; Pay Attention to These Terms

4 DANGER: Indicates the presence of immediate hazards which will cause severepersonal injury, death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could causesevere personal injury, death or substantial property damage if ignored. CAUT...

Page 5 - MODEL NUMBER EXAMPLE:; Series; Mechanical Modulation; Application; Boiler rating plate showing model number

5 MODEL IDENTIFICATION The model number of a boiler can be found on theSales Order and the boiler's rating plate. The examplebelow identifies what the characters of the model num-ber represent. MODEL NUMBER EXAMPLE: H 3 - 0 5 1 4 A Series Model Size Representative of approximate MBTUH input(Model 05...

Page 6 - INSTALLATION; Installation Codes; RECEIVING EQUIPMENT

INSTALLATION Installation Codes The installation must conform with these instructionsand the latest editions of the National Fuel Gas CodeANSI Z223.1, the National Electric Code ANSI/NFPA70 and local codes. In Canada installations must con-form with the current CAN/CSA B149 and theCanadian Electrica...

Page 7 - The boiler should be located in an area; Table B: Combustible Floor Shield Ordering; Combustible Base; Combustible floor shield is required when

Installation Base The boiler should be mounted on a level, non-com-bustible surface. Boiler must not be installed oncarpeting. The boiler can be installed on a combustiblesurface only when a suitable floor shield base is pro-vided. Raypak offers an optional floor shield basewhich can be factory inst...

Page 8 - The boiler shall be installed in a space large; Table D: Reduction of Clearances to Protected; Outdoor Boilers; In areas where high winds are frequent, it may be nec-; Combustion and Ventilation Air; Fig. 3: Minimum Distances to Building Openings from

8 NOTE: The boiler shall be installed in a space large in comparison to the size of the boiler. Large spaceis defined as having a volume at least sixteen (16)times the total volume of the boiler. Table D: Reduction of Clearances to Protected Surfaces Derived from National Fuel Gas Code, Table 6.2.3(...

Page 9 - Combustion air must not be; Model; Table E: Minimum Net Free Air from Inside Building; Venting; Outdoor Installations; Lower outdoor top onto unit lining up slots in the

9 a. All Air From Inside The Building: Each opening shall have a minimum net freesquare inches as noted in Table E. b. All Air From Outdoors: When air is supplied directly from outside of build-ing, each opening shall have a minimum net freesquare inches as noted in Table F. CAUTION: Combustion air ...

Page 10 - Indoor Installations; Detail A; Fig. 8: Installing Outdoor Top Detail—Models 514–824

10 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 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 - Make sure the brackets

11 Fig. 9: Indoor Installation—Model 133 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 flu...

Page 13 - Vent Piping; Indoor boilers require a drafthood

13 Fig. 13: Drafthood Installation—Models 514–824 Models 962-1826 Locate and assemble as shown in Fig. 14. Secure withscrews supplied in envelope in carton. Models 2100-4001 These models have built-in drafthoods. For properoperation, the drafthood outlet must be connected tothe venting system. Vent ...

Page 15 - Vent Damper Installation; Where Required; Do not use thermally actuated vent; HORIZONTAL INSTALLATION; Fig. 19: Vent Damper General Wiring Diagram

15 Vent Damper Installation (Models 133 Through 261) Where Required Location The vent damper must be located in the vent so that itserves only the appliance for which it is intended. If improperly installed, a hazardous condition, such asan explosion or carbon monoxide poisoning, couldresult. Make c...

Page 16 - Vent Damper; Normal Operation Summary; Fig. 21: Connection Diagram for Effikal® Vent Damper; Plumbing

16 CAUTION: Install the vent damper to service only the single appliance for which it is intended. ifimproperly installed, a hazardous condition, such asan explosion or carbon monoxide poisoning, couldresult. Vent Damper Normal Operation Summary For safe, efficient operation, the vent damper and all...

Page 17 - Table G: Maximum Equivalent Pipe Length; Gas Pressure Regulator; The boiler and its manual shut-off valve

17 Table 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 minimumof 12" W.C. and a maximum of 13" for propane. Gas Pressure Regulator The gas pressure regula...

Page 18 - MAXIMUM AND MINIMUM FLOW RATES; -PASS HEAT EXCHANGER; Feedwater Regulator; Table H: Maximum and Minimum Flow Rates

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" 260/ 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" 514 90 9 9 40 21 1.8...

Page 19 - Fig. 24: Single Boiler Primary/Secondary Piping—Models 133–4001

19 C O N T R O LL E R S E N S O R (L E S S T H A N 4 -S TA G E ) C O N T R O LL E R S E N S O R (4 -S TA G E O R M O D U LA T IO N ) 5’ M A X 5’ M A X Fig. 24: Single Boiler Primary/Secondary Piping—Models 133–4001 Note: Expansion tanks (supplied by others) should be installed per manufacturer's ins...

Page 21 - CONTROLS; Economaster Controls; Pump will come on when power is first; Operating Controls; Modes H1 and H5 - Mechanical Modulation; No external control of the valve position is

21 CONTROLS Economaster Controls The Economaster II is an electronic device that allowsthe operator to set the desired time for the pump to runafter the boiler shuts off. The time is factory-set at 7minutes and it can be re-adjusted in the field anywherefrom 3 to 10 minutes. In a conventional system...

Page 22 - Fig. 28: Mechanical Modulating Valve Location; Mode H2 - Motorized Modulation

22 Fig. 29: Mechanical Modulating Valve MODULATING VALVES W/ BUILT-IN REGULATOR Fig. 28: Mechanical Modulating Valve Location Mode H2 - Motorized Modulation The design uses a motorized valve which varies posi-tion based upon an external controller thatcommunicates with the gas valve actuator, throug...

Page 23 - Limit Controls; Manual-Reset High Limit; Flow switch will not operate if flow is less

23 Limit Controls Manual-Reset High Limit All models except 133 are equipped with a manualreset high limit. Set the manual limit to its maximumset point. Auto-Reset High Limit Set the auto limit(s) to 30-40 °F above the desiredoperating temperature and 5-10°F below the ManualHigh Limit setting. Fig....

Page 24 - Field install ground to inside of junction box.; High and Low Gas Pressure; The High Gas Pressure Switch is standard

24 ELECTRICAL CONNECTIONS This boiler is normally wired for 120 Volts. The voltageis 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 Volts are supplied to this connecti...

Page 25 - Raypak recommends the use of Ethylene

25 START-UP Before Start-Up Safe lighting and other performance criteria were metwith the gas manifold and control assembly providedon the boiler when the boiler underwent tests specifiedin the latest edition of ANSI Z21.13 Standard. General Before lighting up a new installation, water should beflow...

Page 26 - TO TURN OFF GAS TO APPLIANCE

26 1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance.3. Remove boiler door. 4. Push in gas control knob slightly and turn clock- wise to “OFF”. Do not force. 5. Replace boiler door panel. 1. STOP! Read the safety information above on this label. 2. Set the therm...

Page 28 - VALVE SHOWN IN; Standing Pilot; Fig. 40: Pilot Flame Should Engulf Thermocouple

28 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. 3. Open main gas valve. 4. Set temperature controls to desired tempe...

Page 29 - Inspections; Remove top of heater and inspect heat exchanger

29 at once. Pilot burner should ignite after gasreaches 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 burnerport. Inspections Burners Clean main burners and air louvers of dust, li...

Page 30 - LOW NOx BOILERS; DETAIL A; Operation

30 Replace any parts showing wear.c. Check pump coupler for wear and vibration. 7. Check flow switch paddle. 8. Clean room air intake openings to ensure ade- quate flow of combustion and ventilation air. 9. Keep boiler area clear and free from combustible materials, gasoline, and other flammable vap...

Page 31 - Gas Valve Adjustment - Robertshaw; ed to the solenoid valve.; Attach a manometer and check the manifold

31 size, and connections which comply with all applicablecodes. Flame Roll-Out Safety Switch The boiler is equipped with a cut-off device to preventflame roll-out in the event the heat exchangerbecomes blocked. This is a "manual reset" type roll-out switch, that must be reset by a service te...

Page 33 - TROUBLESHOOTING; Electrical—Electronic Ignition IID; Intermittent Pilot System

33 NOTE: Before troubleshooting, familiarize yourself with the start-up and checkoutprocedure. Check line voltage power, low voltage transformer, limit controller, thermostat(controller) and wiring. Pull ignition lead and check spark at module. If spark Okay:• Check ignition cable, ground wiring, ce...

Page 34 - Electrical—Standing Pilot; WARNING—HIGH VOLTAGE:

34 For Service Technicians START BOILER 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 GAS VALVE IF NO 24 V IF 24 V: IF O.K. IF DEFECTIVE CHECK TRANSFORMER OUPUT ...

Page 36 - CORRECTIVE ACTION

36 MECHANICAL PROBLEM When boiler is turned on nothinghappens. Thermostat in "ON" position causesrelay and pump to operate, but boilerdoes not fire. Continuous shut down of manual resethigh limit. SootingCAUTION-Soot may be combustible.Wet down and exercise caution whencleaning. Continuous s...

Page 37 - Pumps

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. Excessive suction lift (over 15 f...

Page 38 - RAYPAK TUBE CLEANING KIT; Auger with Carbide Tip; Service; Tube Cleaning Procedure; Disconnect wires at gas valve and slide burner; Gas Valve Removal; ing to gas valve inlet.; Main Burner And Orifice Removal

38 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. Service Repair Section Tube Cleaning Procedure Establish a regular inspection schedule, the frequencydepending on the local water condition and severity ofservice. Do not ...

Page 39 - HIGH LIMIT

39 2. Lift burners from slotted spacer and slide from ori- fices. Clean with a wire brush. 3. Clean orifice(s) as necessary. Pilot Removal and Cleaning 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...

Page 41 - Cleaning Flue Gas Passageways; REPLACEMENT PARTS

41 5. Insert replacement tube by inserting the end with the most fins removed in the opening of one tubesheet. Slide tube until the opposite end clears theother 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 pro...