Raypak 0133-4001 Installation And Operating Instructions Manual Download | Manualshive

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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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Summary of Contents for 0133-4001

Page 1: ...adjacent to the boiler or kept in a safe place for future reference FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity o...

Page 2: ...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 Boiler rating plate showing mo...

Page 3: ...5 LightingInstructions 26 AfterStart up 28 Inspections 29 LOWNOxBOILERS 30 Operation 30 Start up 30 BurnerAdjustment 30 VisualInspection 30 Electrical 30 Flame Roll out Safety Switch 30 Service 31 TRO...

Page 4: ...emove 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...

Page 5: ...r 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 su...

Page 6: ...rface See ordering infor mation 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 Provi...

Page 7: ...e boiler must have both combustion and venti lation 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...

Page 8: ...y 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...

Page 9: ...ed 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 i...

Page 10: ...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 MODELS 181 401 and 182 40...

Page 11: ...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 g...

Page 12: ...ot 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 extend...

Page 13: ...rs 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...

Page 14: ...vents do not mount the actuator either directly above or directly below the vent pipe mount the vent damper actuator to the side of the vent The vent damper is set up for a continuous pilot system If...

Page 15: ...essure testing of that system at test pressures in excess of 1 2 PSIG Dissipate test pressure in the gas supply line before reconnecting the boiler and its manual shut off valve to gas supply line FAI...

Page 16: ...ounter clockwise to decrease pressure For boilers with mechanical modulation gas valves Type H1 and H5 or two stage gas valves Type H3 the gas pressure regulator is preset and sealed and not field adj...

Page 17: ...ers 17 PUMP SELECTION In order to ensure proper hydraulics in your hydronic heating system adequate pump size must be selected We recommend that the pump be sized for 20 F Delta T Delta T is the tempe...

Page 18: ...PIPING DIAGRAMS 18 NOTE Expansion tanks supplied by others should be installed per manufacturer s instructions 7024e DIAPHRAGM TANK SYSTEM...

Page 19: ...ODELS 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 instruct...

Page 20: ...K 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 REQUIR...

Page 21: ...termittent ignition device conserves energy by automatically extinguishing the pilot when desired temperature is reached When additional heat is needed the pilot re ignites electrically eliminating th...

Page 22: ...s if abnormal pressures exist LIMIT CONTROLS HIGH LIMIT The boiler is equipped with a manual reset high limit Push the reset button and set the limit s to 30 40 F above desired operating temperature F...

Page 23: ...FLOW SWITCH CUTTING MODULATING VALVE LOW WATER CUT OFF GAS PRESSURE SWITCH Fig 8925 Fig 8995 Fig 8236 Fig 8996 23...

Page 24: ...ing diagram shipped with the boiler in the instruction packet The TH leads are for the remote tank control connection 24 Volts are supplied to this connection through the boiler transformer DO NOT att...

Page 25: ...Fill system through feed pressure Manually open air vent on the compression tank until water appears then close vent START UP Fig 8991 ETHYLENE GLYCOL SYSTEMS HEATING BOILERS Fill through filler open...

Page 26: ...r clockwise to ON 11 Replace boiler door panel 12 Turn on all electric power to the appliance 13 Set the thermostat to the desired setting PILOT THERMO BURNER COUPLE A This appliance has a pilot which...

Page 27: ...9 Replace boiler door panel 10 Turn on all electrical power to the appliance 11 Set thermostat to desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Applia...

Page 28: ...n of main burner b Make certain the pilotstat holds in and that shutdown occurs within 2 1 2 minutes after the pilot flame is extinguished c Observe operation for at least three cycles to be sure the...

Page 29: ...ht SUGGESTED INSPECTION SCHEDULE The boiler should be inspected on the first and third months after initial start up and then on an annual basis If problems are found refer to Troubleshooting Guide fo...

Page 30: ...k will turn on and pilot gas valve will open and the blower will begin running b Heater will operate until call for heat is satisfied LOW NOx BOILERS Models 181 to 401 Fig 9361 FLAME ROLL OUT SAFETY S...

Page 31: ...y and unscrew gas valve 4 Reverse above procedure to re install MAIN BURNER AND ORIFICE REMOVAL 1 Remove burner tray See Burner Tray Removal procedure 2 Remove pilot See Pilot Removal procedure 3 Remo...

Page 32: ...odule 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 line voltage p...

Page 33: ...CK 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...

Page 34: ...TYPICAL ON OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM 34 3 4 10...

Page 35: ...ight pilot Standing pilot models Check the circuit breaker outdoor con troller etc upstream of boiler If power to Leads L1 and L2 of trans former but no power on 24V side re place Jumper thermostat Re...

Page 36: ...e however to remove both RAYPAK TUBE CLEANING KIT Extension Pieces 5 Auger with Carbide Tip Wire Brush Fig 8154 headers for better visibility through the tubes and to be sure the residue does not get...

Page 37: ...REMOVAL AND CLEANING 1 Disconnect pilot tubing at pilot and sensor igniter wire Remove screws holding pilot bracket to burner tray 2 Remove pilot and bracket clean pilot of debris small bugs etc with...

Page 38: ...he call for heat The system is ready for operation 13 Within two 2 days of start up recheck all air vents and expansion tank levels COMBUSTION CHAMBER REMOVAL To remove combustion chamber you must fir...

Page 39: ...inning any wall of the tube beyond 0 015 10 Use same procedure on opposite end 11 Apply line pressure test Re roll if necessary 12 Reinstall as outlined under HEAT EXCHANGER RE ASSEMBLY CLEANING FLUE...

Page 40: ......

Page 41: ...ak 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...

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