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Raypak RAYTHERM 0133-4001 - page 1
CATALOG NO. 2000.50Z Effective: 03-15-04 Replaces: 06-15-03 FOR YOUR SAFETY 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 yo ...
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Raypak RAYTHERM 0133-4001 - page 2
MODEL NUMBER EXAMPLE: H 3 - 0 5 1 4 A Series Model Size Representative of approximate MBTUH input (Model 0514 has input of 511,500 BTUH) Firing Mode 1 Mechanical Modulation 2 Motorized Modulation 3 2-Stage Firing / 4-Stage Firing Option 4 On-Off Firing 5 Low Temperature Mechanical Modulation 6 Motorized Modulation w/Electronic Outdoor Reset B6000 A ...
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Raypak RAYTHERM 0133-4001 - page 3
3 TABLE OF CONTENTS MODEL IDENTIFICATION........................................................................................2 RECEIVING EQUIPMENT........................................................................................ 4 CERTIFICATIONS................................................................................................ ...
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Raypak RAYTHERM 0133-4001 - page 4
4 CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. BOILER TYPES TYPE H1 - MECHANICAL MODULATING Central heating boiler with 150°-210°F mechanical modulating gas valves and pressure relief valve. Standard on models 133-1826. TYPE H2 - MOTO ...
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Raypak RAYTHERM 0133-4001 - page 5
INSTALLATION INSTALLATION CODES The installation must conform with these instructions and the latest editions of the ANSI National Fuel Gas Code Z223.1, the National Electric Code ANSI/NFPA 70 and local codes. All boiler installations must conform to ASME boiler code. Hot water pipes must be installed with minimum clearances to combustible material ...
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Raypak RAYTHERM 0133-4001 - page 6
REDUCTION OF CLEARANCES TO PROTECTED SURFACES CLEARANCES CLEARANCES FROM COMBUSTIBLE SURFACES (All dimensions are in inches) Note: The boiler shall be installed in a space large in comparison to the size of the boiler. Large space is defined as having a volume at least sixteen (16) times the total volume of the boiler. Note 1: Combustible floor shi ...
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Raypak RAYTHERM 0133-4001 - page 7
OUTDOOR BOILERS These boilers are designed certified for outdoor installation. Boilers must not be installed under an overhang within three (3) feet from the top on the boiler. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from the boilers with the use of gutters. The point from where the flu ...
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Raypak RAYTHERM 0133-4001 - page 8
VENTING OUTDOOR INSTALLATIONS MODEL 133 Step 1: Remove the front (4) screws. Step 2: Line up outdoor top vent opening over heater vent opening. Step 3: Lower outdoor top onto unit lining up slots in the outdoor top with screws holes in jacket top. Step 4: Reinstall (5) screws to secure jacket top and outdoor top to unit. Fig. #8114 MODELS 514 - 824 ...
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Raypak RAYTHERM 0133-4001 - page 9
INDOOR INSTALLATIONS MODEL 133 Step 1. Shut-off main electrical power switch to boiler. Step 2. Turn heater manual switch located in upper control panel to the "OFF" position. Step 3. Shut-off gas supply and water supply to the boiler. Step 4. Mount drafthood on boiler and attach with the 4 sheet metal screws provided. Drafthood should be ...
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Raypak RAYTHERM 0133-4001 - page 10
Fig. #8246.5 6. Attach the three (3) mounting brackets to the stack using the screws provided and the holes that are pre-drilled in the stack. Make sure the brackets are positioned with the flange near the top side of the stack (see illustration). Caution must be taken not to over tighten and strip the screw threads. 7. Turn the assembled stack and ...
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Raypak RAYTHERM 0133-4001 - page 11
MODELS 181-401 and 182-400 Step 1. Shut-off main electrical power switch to boiler. Step 2. Turn heater manual switch located in upper control panel to the "OFF" position. Step 3. Shut-off gas supply and water supply to the boiler. Step 4. Mount drafthood on top of boiler as shown on page 8. Drafthood should be positioned with the vent se ...
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Raypak RAYTHERM 0133-4001 - page 12
MODELS 962-1826 Locate and assemble as shown below. Secure with screws supplied in envelope in carton. Fig. # 8165.0 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 sam ...
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Raypak RAYTHERM 0133-4001 - page 13
Vent stack shall be at least 5 ft. in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4 feet horizontally from, and in no case above or below, unless a 4-foot horizon- tal distance is maintained, from electric meters, gas meters regulators and relief equipment. The weight of the vent stack or chim ...
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Raypak RAYTHERM 0133-4001 - page 14
VENT DAMPER INSTALLATION (MODELS 133 THROUGH 261) WHERE REQUIRED LOCATION 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 result. Make certain that it is mounted in an accessible locatio ...
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Raypak RAYTHERM 0133-4001 - page 15
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. Fig. # 8181.0 1. When the boiler is off, check that the vent damper position indicator points to the closed position. (See figure below.) 2. Turn the ...
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Raypak RAYTHERM 0133-4001 - page 16
A minimum of 7" W.C. and a maximum of 10.5" W.C. upstream pressure, under load and no-load conditions, must be provided for natural gas, or a minimum of 12" W.C. and a maximum of 13" for propane. Bleed Line Connection GAS PRESSURE REGULATOR The gas pressure regulator is preset nominally at 4" W.C. for natural gas, and 11&qu ...
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Raypak RAYTHERM 0133-4001 - page 17
RECOMMENDED PURGE MANIFOLDS FOR TYPICAL HYDRONIC SYSTEM HOOKUPS The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulating, must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler wat ...
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Raypak RAYTHERM 0133-4001 - page 18
PIPING DIAGRAMS 18 NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. 7024e DIAPHRAGM TANK SYSTEM ...
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Raypak RAYTHERM 0133-4001 - page 19
MULTI-ZONE HEATING SYSTEMS MODELS 133 TO 4001 19 NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. Fig.# 7027.1e Fig.# 7024.1e ...
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Raypak RAYTHERM 0133-4001 - page 20
MULTIPLE-BOILER– REVERSE RETURN HOOK-UP 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. 20 MODELS 133 TO 4001 Fig. #9495 ...
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Raypak RAYTHERM 0133-4001 - page 21
OPERATING CONTROLS Models 133-1826 with mechanical modulating controls have one or more Robertshaw Unitrol 7000 Series hydraulic snap-on thermostatic combination gas valves. These valves have the pressure regulator and 24 volt operator built-in. The hydraulic actuator will throttle the boiler input to adjust the firing rate and meet the required lo ...
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Raypak RAYTHERM 0133-4001 - page 22
rupted. Pilot flame is automatically lit when the device is powered. Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit. LOW WATER CUT-OFF (OPTIONAL) The low water cut-off automatically shuts down burner whenever water level drops below probe. 90- second time delay prevents premature lockout due to ...
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Raypak RAYTHERM 0133-4001 - page 23
FLOW SWITCH CUTTING MODULATING VALVE LOW WATER CUT-OFF GAS PRESSURE SWITCH Fig. #8925 Fig. #8995 Fig. #8236 Fig. #8996 23 ...
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Raypak RAYTHERM 0133-4001 - page 24
ELECTRICAL CONNECTIONS CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. DANGER - SHOCK HAZARD Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. The boiler is n ...
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Raypak RAYTHERM 0133-4001 - page 25
BEFORE START-UP Safe lighting and other performance criteria were met with the gas manifold and control assembly pro- vided on the boiler when the boiler underwent tests specified in the latest edition of ANSI-Z21.13 Standard. GENERAL Before lighting up a new installation, water should be flowing through the boiler. Regulator should be set to minim ...
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Raypak RAYTHERM 0133-4001 - page 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 thermostat to lowest setting. 3. Turn off all electr ...
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Raypak RAYTHERM 0133-4001 - page 27
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. A. This appliance is equipped with an ignition device which automa ...
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Raypak RAYTHERM 0133-4001 - page 28
FOR MODELS WITH AUTOMATIC GAS VALVES LIGHTING INSTRUCTIONS 1. Close all gas valves. Turn off electrical power supply. Wait five (5) minutes. 2. Open manual pilot valve. Turn on electrical power. Pilot is automatically lighted. PILOT VALVE CONTROL SHOWN IN THE MAIN GAS SHUT-OFF "ON" POSITION VALVE SHOWN IN THE "ON" POSITION GAS I ...
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Raypak RAYTHERM 0133-4001 - page 29
PILOT BURNER FLAME (IID UNITS) INSPECTIONS BURNERS Clean main burners and air louvers of dust, lint and debris. Keep boiler area clear and free from com- bustibles and flammable liquids. Do not obstruct the flow of combustion and ventilation air. Make visual check of burner and pilot flame. Yellow flame indicates clogging of air openings. Lifting o ...
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Raypak RAYTHERM 0133-4001 - page 30
30 The boilers are certified and tested under the latest edition of the ANSI Z21.13 standards for hot water boilers. The boiler should be installed to meet the latest edition of all local codes, the National Fuel Gas Code Z223.1 and the National Electrical Code, ANSI/NFPA 70. OPERATION On call for heat, the ignition system, consisting of an electro ...
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Raypak RAYTHERM 0133-4001 - page 31
31 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. Fig # 9362 Fig # 9363 IID PILOT LOW NOx BURNER TRAY ASSEMBLY BURNER TRA Y REMOV AL 1. Shut-of f main electrical power switch to he ...
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Raypak RAYTHERM 0133-4001 - page 32
TROUBLESHOOTING ELECTRICAL ELECTRONIC IGNITION IID WARNING HIGH VOLTAGE For qualified technicians ONLY NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. To reset, interrupt power to heater. NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout procedure. Check li ...
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Raypak RAYTHERM 0133-4001 - page 33
For Service Technicians START BOILER IF PILOT BURNER LIGHTS IF PILOT BURNER BUT MAIN BURNERS DO NOT DOES NOT LIGHT CHECK FOR 24 V CHECK THERMOCOUPLE AT GAS VALVE IF NOT 24 V: IF 24 V: IF O.K. IF DEFECTIVE CHECK TRANSFORMER OUPUT REPLACE FOR 24 V GAS VALVE REPLACE REPLACE GAS VALVE THERMOCOUPLE IF NO IF 24 V: 24V: REPLACE PROBLEM IN TRANSFORMER LIMI ...
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Raypak RAYTHERM 0133-4001 - page 34
TYPICAL ON-OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM 34 3/4 10 ...
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Raypak RAYTHERM 0133-4001 - page 35
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. Continuous shut down of low water cut- off or flow switc ...
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Raypak RAYTHERM 0133-4001 - page 36
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 ft.). 5. Insufficient positive suction head (for hot w ...
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Raypak RAYTHERM 0133-4001 - page 37
TYPICAL BURNER TRAY ILLUSTRATED 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. 2. Disconnect wires at gas valve and slide burner tray out. GAS VALVE REMOVAL 1. Shut-off gas supply to the boiler. Remove gas piping to gas valve inlet. 2. Disconn ...
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Raypak RAYTHERM 0133-4001 - page 38
5. Remove heat exchanger corner brackets. 6. Remove combustion chamber clips at the four corners of the heat exchanger. 7. Lift heat exchanger straight up using caution not to damage refractory. IN/OUT HEADER HIGH LIMIT ELECTRICAL JUNCTION BOX REDUNDANT SAFETY SHUT-OFF VALVE MANUAL GAS VALVE MAIN GAS VALVE SEDIMENT TRAP Fig. # 8184 REFRACTORY PANEL ...
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Raypak RAYTHERM 0133-4001 - page 39
CONTROL WELL REPLACEMENT Remove top, sensing bulb and clip. Collapse well tube at the opening with a chisel, push through into header and remove the well through header. Insert a new well and roll into place. If a roller is not available, solder the well in place with silver solder. TUBE REPLACEMENT PROCEDURE 1. Remove heat exchanger from boiler fo ...
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Raypak RAYTHERM 0133-4001 - page 40
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Raypak RAYTHERM 0133-4001 - page 41
Raypak, Inc. , 2151 Eastman Avenue, Oxnard CA 93030 (805) 278-5300 Fax (800) 872-9725 Raypak Canada LTD , 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A. www .raypak.com ...
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