Raypak 0133-4001 User Manual
INSTALLATION
AND OPERATING
INSTRUCTIONS
RAYTHERM™
HEATING BOILERS
Type H
Models 0133-4001
CATALOG NO. 2000.50Z
Effective: 03-15-04
Replaces: 06-15-03
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.
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
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.
This manual should be maintained in legible
condition and kept adjacent to the boiler or kept
in a safe place for future reference.
P/N 240035
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 number represent.
Boiler rating plate showing model number
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
Application
H = Heating Boiler
TABLE OF CONTENTS
MODEL IDENTIFICATION........................................................................................2
RECEIVING EQUIPMENT........................................................................................ 4
CERTIFICATIONS.................................................................................................... 4
BOILER TYPES........................................................................................................ 4
CALIFORNIA PROPOSITION 65 WARNING.......................................................... 4
INSTALLATION........................................................................................................ 5
Installation Codes............................................................................................... 5
Installation Base................................................................................................. 5
Clearances......................................................................................................... 6
Combustion and Ventilation Air..........................................................................7
Venting................................................................................................................8
Plumbing.............................................................................................................15
CONTROLS.............................................................................................................. 21
Economaster Controls........................................................................................21
Electronic Ignition............................................................................................... 21
Operating Controls............................................................................................. 21
Limit Controls......................................................................................................22
ELECTRICAL CONNECTIONS................................................................................ 24
START-UP................................................................................................................ 25
Before Start-up................................................................................................... 25
Lighting Instructions........................................................................................... 26
After Start-up...................................................................................................... 28
Inspections......................................................................................................... 29
LOW NOx BOILERS.................................................................................................30
Operation............................................................................................................30
Start-up...............................................................................................................30
Burner Adjustment............................................................................................. 30
Visual Inspection................................................................................................ 30
Electrical............................................................................................................. 30
Flame Roll-out Safety Switch.............................................................................30
Service................................................................................................................31
TROUBLESHOOTING..............................................................................................32
Electrical............................................................................................................. 32
Mechanical......................................................................................................... 35
SERVICE.................................................................................................................. 36
Tube Cleaning Procedure..................................................................................36
Burner Tray Removal......................................................................................... 37
Gas Valve Removal........................................................................................... 37
Main Burner and Orifice Removal..................................................................... 37
Pilot Removal and Cleaning.............................................................................. 37
High Limit or Tankstat Removal........................................................................ 37
Heat Exchanger Removal..................................................................................37
Combustion Chamber Removal........................................................................ 38
Control Well Replacement.................................................................................39
Tube Replacement Procedure...........................................................................39
Cleaning Flue Gas Passageways......................................................................39
REPLACEMENT PARTS..........................................................................................3 9
WARRANTY............................................................................................................. 40
3
RECEIVING EQUIPMENT
BOILER TYPES
On receipt of the equipment, visually check for
external damage to the carton or the shipping crate. If
either is damaged, make a note on the Bill of Lading
and report the damage to the Carrier immediately.
Remove the boiler from the carton or the shipping
crate.
On occasion, items are shipped loose. Be sure
that you receive the number of packages indicated on
the Bill of Lading.
When ordering parts, you must specify the Model
and Serial Number of the boiler. When ordering under
warranty conditions, you must also specify the date of
installation.
Raypak recommends that this manual be
reviewed thoroughly before installing your Raypak
boiler. If there are any questions which this manual
does not answer, please contact the factory or your
local Raypak representative.
Claims for shortages and damages must be filed
with carrier by consignee. Permission to return goods
must be factory authorized and are subject to a
stocking charge.
Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for
defective replacement parts will not be accepted and
will be replaced in kind only per our standard
warranties.
CERTIFICATIONS
The Raypak hydronic boilers are design certified
and tested under the latest requirements of the
American National Standard, ANSI Z21.13 - latest
edition. Each boiler has been constructed and
pressure tested in accordance with the requirements
of Setion IV of the American Society of Mechanical
Engineers Code, and factory fire tested.
All models are National Board approved.
Temperature and pressure gauge is standard.
Model 0133 has a 4-pass heat exchanger, 1 tube
per pass.
Models 0181-1826 have 2-pass heat exchangers,
5 tubes first pass, 4 tubes second pass.
Models 2100-4001 have 2-pass heat exchangers,
9 tubes per pass.
Models 926-4001 have optional single-pass heat
exchangers with cast iron headers only.
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 - MOTORIZED MODULATING
Central heating boiler with a motorized
modulating gas valve. Standard on models 2100-
4001. Available as option on models 514-1826.
Modulating controller provided.
TYPE H3 - 2-STAGE CONTROLS
Central heating boiler with single two-stage gas
valve . Available as option on Models 183-4001. Twostage controller provided. Available with Y-1
sequencing option.
TYPE H4 - ON-OFF CONTROLS
Central heating boiler with on-off firing. Available
as option on Models 181-4001.
TYPE H5 - MECHANICAL MODULATING
Central heating boiler with 110°-170°F
mechanical modulating gas valves and pressure relief
valve. Standard on Models 133-1826.
TYPE H6 - B6000 SYSTEM CONTROL
Central heating boiler for use with the B6000
boiler management system. Available for Models
514-4001.
TYPE H9 - 4-STAGE
Central heating boiler for use with 4-stage firing.
Controller optional. Available option on Models 514-
4001.
CALIFORNIA PROPOSITION 65
WARNING:
This product contains chemicals known to the State
of California to cause cancer, birth defects or other
reproductive harm.
4
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 as
required by code.
INSTALLATION BASE
The boiler should be mounted on a level, non-combustible surface. Boiler must not be installed on carpeting.
The boiler can be installed on a combustible surface only when a suitable floor shield base is provided. Raypak
offers an optional floor shield base which can be factory installed on all indoor models except Model 133; the
Model 133 floor shield base is shipped loose and must be installed by the contractor.
Do NOT use the shipping crate base as an installation base.
NOTE: The boiler should be located in an area where water leakage will not result in damage to the area adjacent
to the appliance or to the structure. When such locations cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the appliance. The pan must not restrict air flow.
In addition, the boiler shall be installed such that the gas ignition system components are protected from water
(dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control
replacement, etc.).
Combustible Floor Shield ordering information:
Boiler Model No. Base Part No. Boiler Model No. Base Part No.
133
182/181
260/261
330/331
400/401
514
624
724
824
* Models with factory-installed floor shield as standard.
BOLD type indicates Low NOx models.
ALTERNATE METHOD FOR PROVIDING A NON-COMBUSTIBLE BASE
001749
058313
058314
058315
058316
056199
056200
056201
056202
926*
1083*
1178*
1287*
1414*
1571*
1758*
962
1125
1223
1336
1468
1631
1826
054597
054598
054599
054600
054601
058378
058379
059233
059234
059235
059236
059237
059238
059239
Fig. #8148.1
5
CLEARANCES
REDUCTION OF CLEARANCES TO PROTECTED
SURFACES
CLEARANCES FROM COMBUSTIBLE SURFACES
(All dimensions are in inches)
MODEL
181 to
133
401
Derived from National Fuel Gas Code, Table 6.2.3(a)
514 to
824
926 to
1826
2100 to
4001
Note 1:
Combustible floor shield is required when boiler is to be
installed on a combustible surface. (See ordering information on pg. 4.)
Note 2:
Servicing Clearances: Provide at least 24" (Models
133-1826), 48" (Models 2100-4001) in front of unit for
removal and servicing of the Controls & Burner Tray.
Provide at least 18" on side opposite water connections
for deliming of Heat Exchanger Tubes.
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.
*Vent includes factory-supplied drafthood and does not
include field-supplied vent systems above the drafthood. On Models 2100-4001 drafthood is built into
boiler.
Derived from National Fuel Gas Code, Table 6.2.3(b)
6
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 flue products exit the boiler must be a minimum of four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top surface of the boiler
shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10) feet horizontally.
HIGH-WIND CONDITIONS (Outdoor Units Only)
In areas where high winds are frequent, it may be
necessary to locate the boiler a minimum of 3' from
high vertical walls, or install a wind break so the boiler
is not in direct wind current.
COMBUSTION AND VENTILATION AIR
(Indoor Units Only)
The boiler must have both combustion and ventilation air. Minimum requirements for net free air supply
openings are 12 inches from ceiling for ventilation and
12 inches from the floor for combustion air as outlined
in Z223.1 - latest edition and any local codes that may
have jurisdiction.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
boiler and void the warranty.
a. All Air From Inside The Building:
Each opening shall have a minimum net free
square inches as noted:
Fig. #8245
Model Square Inches Model Square Inches
133 136 1125 1125
182/181 181 1223 1223
260/261 264 1336 1337
330/331 334 1468 1467
400/401 399 1631 1630
514 512 1826 1826
624 627 2100 2100
724 726 2500 2499
824 825 3001 3000
962 962 3500 3500
4001 4000
b. All Air From Outdoors:
When air is supplied directly from outside of building, each opening shall have a minimum net free
square inches as noted:
Model Square Inches Model Square Inches
133 34 1125 282
182/181 46 1223 306
260/261 66 1336 335
330/331 84 1468 367
400/401 100 1631 408
514 128 1826 457
624 157 2100 525
724 182 2500 625
824 207 3001 750
962 241 3500 875
4001 1000
7
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
Fig. #RP8280.1
Detail A Detail B
Outdoor Top
(Shipped Loose with Heater)
MODELS 514 - 824
Step 1: Lower outdoor top onto unit. Position top so it
is centered on unit from side to side and front
to rear.
MODELS 181-401 and 182-400
Outdoor Top Installation
(Part of heater)
Fig. # 9389
Step 1: Remove jacket top panel.
Step 2: Remove and discard inner stack adapter
panel.
Step 3: Install jacket top panel.
Step 4: Insert tabs of outdoor top into keyholes located
on jacket top panel (4 places). See Detail A
Step 5: Snap tabs on outdoor top into the locked
postion of the keyhole so the top will not pull
out. See Detail B
Fig. # 8166.1
Step 2: Tighten the (4) screws (Shown below) until
they come in contact with the unit jacket top,
then evenly tighten all (4) screws to secure to
unit.
JACKET TOP
FASTENING
SCREW
Fig. # 8233
MODELS 926-1758
Boilers are shipped with outdoor vent terminal
factory installed.
8
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
positioned with the vent sensor located on the front left side as shown below.
Step 5. Remove plastic plug from left side of boiler jacket and install the plastic grommet provided.
Step 6. Route flue sensor wire harness through the grommet installed in Step 5.
BOILER ON/OFF
SWITCH
Fig. #8946
Step 7. Remove door and locate wire from roll-out sensor to high limit with the male/female connector.
ROLL-OUT
ROLL-OUT SENSOR
ROLL-OUT SENSOR
BEFORE
INSTALLATION
OF DRAFTHOOD
AFTER
INSTALLATION
OF DRAFTHOOD
Fig. #8947
Step 8. Disconnect male/female connector and attach to the 2 wires from drafthood vent sensor harness.
9
MODELS 181-401 and 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
flue collector inside the heater. Make sure
the flanged side of the flue opening is up.
4. Turn the stack (drafthood) upside
down and set it down bottom side up.
5. Turn the jacket top panel (removed in step 1)
upside down and place it through the stack.
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 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
flathead screws removed in step 1 above.
Fig. #8246.5
10
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
sensor located on the front right side as shown.
Step 5. Remove plastic plug from left side of boiler jacket and install plastic grommet provided.
Step 6. Route flue sensor wire harness through the grommet installed in Step 5.
Step 7. Remove door and locate wire from roll-out sensor to high limit with the male/female connector.
Step 8. Disconnect male/female connector and attach to the 2 wires from drafthood vent sensor harness.
BOILER BEFORE
DRAFTHOOD
INSTALLATION
Fig# 9349
BOILER AFTER
DRAFTHOOD
INSTALLATION
11
Fig# 9351
MODELS 514-824
MODELS 2100-4001
Locate and assemble as shown below. Secure with
screws supplied in envelope in carton.
Fig. # 8167.0
MODELS 962-1826
Locate and assemble as shown below. Secure with
screws supplied in envelope in carton.
These models have built-in drafthoods. For proper
operation, the drafthood outlet must be connected to
the venting system.
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. (drafthood relief
opening to vent terminal), the vent pipe size may be
reduced as specified in Chapter 10 of the latest edition
of the National Fuel Gas Code, ANSI Z223.1. 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 minimum
of 1/4 inch per foot rise and should be supported at not
more than 5 ft. intervals. Plumbers tape, criss-crossed,
will serve to space both horizontal and vertical piping.
Gas vents supported only by the flashing and extending above the roof more than 5 ft. should be securely
guyed or braced to withstand snow and wind loads. We
recommend the use of insulated vent pipe spacers
through the roof and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which complies with the local codes or, in the absence of such
codes, to the latest edition of the National Fuel Gas
Code, ANSI Z223.1.
The discharge opening must be a minimum of 2 ft.
vertically from the roof surface and at least 2 ft. higher
than any part of the building within 10 ft.
Fig. # 8165.0
12
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 horizontal distance is maintained, from electric meters, gas
meters regulators and relief equipment.
The weight of the vent stack or chimney must not rest
on boiler drafthood. Support must be provided in compliance with applicable codes. The boiler top and
drafthood must be readily removable for maintenance
and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible
construction.
Type "B" double-wall or equivalent vent pipe is recommended. However single-wall metal vent pipe may
be used as specified in the latest edition of the National
Flue Gas Code ANSI Z223.1.
10' or less
Vent Cap
2' min.
2' min.
5' min.
Vent Pipe
Drafthood
Heater
Manifolds that connect more than one
boiler to a common chimney must be
sized to handle the combined load. Consult available guides for proper sizing of
the manifold and the chimney. At no time
should the area be less than the area of
the largest outlet.
Fig. #7043.1
At the time of removal of an existing boiler, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while the other appliances remaining connected to the common venting system are not in
operation.
(a) Seal any unused openings in the common venting
system.
(b) Visually inspect the venting system for proper size
and horizontal pitch and make sure there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.
(c) Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common venting system are located and other spaces
of the building. Turn on clothes dryers and any
Fig. #8119.0
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
(e) Test for spillage at the drafthood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
(f) After it has been determined that each appliance
remaining connected to the common venting system properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.
(g) Any improper operation of the common venting
system should be corrected so that the installation
conforms with the latest edition of the National Fuel
Gas Code, ANSI Z223.1. When re-sizing any
portion of the common venting system, the common venting system should be re-sized to
approach the minimum size as determined using
the appropriate tables in Part 11 of the National
Fuel Gas Code, ANSI Z223.1.
For special venting applications that require reduced
vent sizes and through-the-wall venting, the Type D
Induced Draft Assembly can be used. Consult the
factory or your local Raypak representative.
13
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