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size, and connections which comply with all applicable

codes.

Flame Roll-Out Safety Switch

The boiler is equipped with a cut-off device to prevent

flame roll-out in the event the heat exchanger

becomes blocked. This is a "manual reset" type roll-

out switch, that must be reset by a service technician

after any over temperature conditions have been fixed.

Excessive restriction in the heat exchanger flue pas-

sage may cause the switch to disable the boiler.

Service
Burner Tray Removal

Fig. 45: Flame Roll-Out Safety Switch

1. Shut-off main electrical power switch to heater.

2. Shut-off gas upstream of heater.

3. Remove front door.

4. Disconnect gas line from gas valve.

5. Remove (2) screws that mount burner tray to the

base of the unit, and (2) screws that secure gas

valve to jacket.

6. Disconnect wires that terminate at gas valve.

7. Unscrew (4) screws that secure the control box.

8. Disconnect pilot wire from the ignition module.

9. Disconnect wire harness from the combustion

blower.

10. Carefully slide out the burner tray assembly.

11. Reverse above procedure to re-install.

Gas Valve Removal

1. Remove burner tray. See Burner Tray Removal

procedure.

2. Disconnect, pilot tubing from gas valve.

3. Turn vertical gas pipe from manifold slightly 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. Remove (8) total screws from the hold-down

brackets, front and rear of tray.

4. Remove (8) total screws from the left and right

sides of the manifold assembly. Detach the mani-

fold assembly from the burner tray assembly.

5. Remove burners by raising the bracket on the

back end of the burners up and out of their slots.

BURNER

BURNER

HOLD-

DOWN

BRACKET

GAS

VALVE

COMBUSTION

AIR BLOWER

AIR SHUTTER

ADJUSTMENT

Fig. 46: Low NOx Burner Tray Assembly

Summary of Contents for 133-4001

Page 1: ...pplier s instructions If you cannot reach your gas supplier call the fire department 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 Do not store or use gasoline or other flam...

Page 2: ...on page 19 Multiple Boiler Reverse Return Hook Up diagram on page 20 Low Water Cut Off and High and Low Gas Pressure Switch instructions on page 23 Additions Expanded Operating Controls section on pages 21 23 to cover all modes Manual and Auto Reset High Limit instructions on page 23 Deletions Diaphragm Tank System diagram on page 19 Multi zone Heating Systems diagram on page 20 ...

Page 3: ...c Ignition 21 Operating Controls 21 Limit Controls 23 ELECTRICAL CONNECTIONS 24 START UP 25 Before Start Up 25 General 25 CONTENTS 3 Filling System Heating Boilers 25 Ethylene Glycol Systems Heating Boilers 25 Initial Start Up Pump And Motor 25 For Models with Automatic Gas Valves 28 After Start Up 28 Standing Pilot Checkout Procedure 28 Intermittent Pilot System Checkout S8600 28 Inspections 29 B...

Page 4: ... be required to de energize the equipment before servicing CAUTION This heater requires forced water circulation when the burner is operating See minimum and maximum flow rates Severe damage will occur if the heater is operated without proper water flow circulation CAUTION Operation of this heater in low temperature systems requires special piping Harmful internal condensation will occur if the in...

Page 5: ...odel num ber represent 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 On Off Firing 5 Low Temperature Mechanical Modulation 9 4 Stage Firing Application H Heating Boiler Boiler rating plate showing model number ...

Page 6: ...rs are design certified and tested under the latest requirements of the American National Standard ANSI Z21 13 Each boiler has been constructed and pressure tested in accordance with the requirements of Section 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 hea...

Page 7: ...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 Boiler Model No Base Part No Boiler Model No Base Part No 926 1083 1178 1287 1414 1571 1758 962 1125 1223...

Page 8: ...under the over hang 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 win dow 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 l...

Page 9: ... 3000 962 962 3500 3500 4001 4000 Model Sq Inches Model Sq 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 Table E Minimum Net Free Air from Inside Building Table F Minimum Net Free Air from Outside Building Venting Outdoor Installations Model 133 1...

Page 10: ...wer switch to boiler 2 Turn heater manual switch located in upper control panel to the OFF position 3 Shut off gas supply and water supply to the boiler 4 Mount drafthood on boiler and attach with the sheet metal screws provided Drafthood should be positioned with the vent sensor located on the front left side see next page 5 Remove plastic plug from left side of boiler jacket and install the plas...

Page 11: ...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 over 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...

Page 12: ... of boiler as shown in Fig 12 Drafthood should be positioned with the vent sensor located on the front right side as shown 5 Remove plastic plug from left side of boiler jacket and install plastic grommet provided 6 Route flue sensor wire harness through the grom met installed in Step 5 7 Remove door and locate wire from roll out sensor to high limit with the male female connector 8 Disconnect mal...

Page 13: ...e 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 com plies 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 ver tically from the roof surface and at least 2 ft higher than an...

Page 14: ...stem Turn on any exhaust fans such as range Fig 15 Common Venting hoods and bathroom exhausts so they will oper ate 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 minute...

Page 15: ...energy savings of the vent damper can be improved by plugging the hole in the vent damper blade using the knockout plug Part No 105612R provided in the parts envelope DO NOT plug the hole if installing the vent damper on a continuous pilot system as this will create a hazard Fig 17 Vent Damper Installation Model 133 Drafthood Shown WARNING Do not use thermally actuated vent dampers on a modulating...

Page 16: ...elow 3 Turn the thermostat or controller down again and check that the vent damper position indicator returns to the closed position NOTE The vent damper must be inspected at least once a year by a trained experienced service technician The name of the person who originally installed your vent damper is shown on the installation label Damper must be in open position when boiler main burners are op...

Page 17: ...ed to the outdoors as required by the National Fuel Gas Code Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system General Boiler should be located so that any water leaks will not cause damage to any adjacent areas or structures See piping diagrams for proper water connections for the type of boiler and system Pump Selection In order to ensure ...

Page 18: ...heating systems 4 Pass Heat Exchanger BOLD TYPE indicates Low NOx models difference between the inlet and outlet water when the boiler is firing at full rate For some boilers the Delta T is more than 20 F 22 33 F at the recommended flow rates Feedwater Regulator We recommend that a feedwater regulator be installed and set at 12 PSIG minimum pressure Install a check valve or back flow device upstre...

Page 19: ...LESS THAN 4 STAGE CONTROLLER SENSOR 4 STAGE OR MODULATION 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 ...

Page 20: ...X 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 Fig 25 Multiple Boiler Reverse Return Hook Up Models 133 4001 ...

Page 21: ...nnot open until the pilot relights and is proven All units are shipped with lockout ignition module as standard NOTE Pump will come on when power is first applied to boiler Fig 26 Economaster PCB Operating Controls Modes H1 and H5 Mechanical Modulation Models 133 1826 with mechanical modulating controls have one or more Robertshaw Invensys Unitrol 7000 Series hydraulic snap on thermostatic combina...

Page 22: ...The boiler will fire at low fire when there is closure across the stage 1 contacts Thereafter it will fire at high fire when there is closure across the stage 2 contacts Numerous staged controllers are available Mode H4 On Off Firing The boiler will fire at full fire when there is closure across the TH contacts Numerous mechanical staged controllers are available see fig 37 as well as digital cont...

Page 23: ...of a pump failure or low water condition It is mounted and wired in series to the main gas valve Standard on all models except the 133 NOTE Flow switch will not operate if flow is less than 12 gpm Fig 33 Flow Switch 100 Pilot Safety All standard boiler models 181 4001 employ electron ic devices which close the main gas valve within 8 10 of a second whenever the pilot flame is interrupted Pilot fla...

Page 24: ... replaced with 105 C wire or its equivalent 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 disconnected to avoid potential serious injury or damage to components Low Water Cut Off Optional The probe type low water c...

Page 25: ...eme care in light ing boiler in confined areas CAUTION Pump must be off to check oil in bearing assembly Do not run pump without water in system MECHANICAL MODULATING GAS VALVES WITH REGULATOR T P GAUGE NOT SHOWN INLET HI LIMIT Fig 37 General Location of Controls Ethylene Glycol Systems Heating Boilers Fill through filler opening on the top on the Air X Tank to solution desired Always maintain sol...

Page 26: ...rol knob counter 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 must be lighted by hand When lighting the pilot follow these instructions exactly B BEFORE LIGHTING smell all around the appli ance area for gas Be sure to smell next to the floor beca...

Page 27: ... clockwise to ON 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 Appliance and call your service technician or gas supplier HONEYWELL GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET ROBERTSHAW GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET TO TURN OFF G...

Page 28: ...e thermocou ple or generator tip 3 Place system in operation and a Check for satisfactory ignition 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 system is functioning normally Intermittent Pilot System Checkout S8600 1 Turn on power to the ignition...

Page 29: ... main burner Observe pilot burner when shutting off pilot gas Ignition spark should go on Main gas valve will also drop out To check high limit switch turn dial setting down to a point slightly below the temperature of the water leav ing the heater The reset button should snap out and the burner should shut off Reset dial to 30 F to 40 F above desired operating temperature and push reset button Bu...

Page 30: ... boiler will shut down Start Up S8600H 1 Turn on power to the boiler with gas supply off 2 Check ignition module as follows a Set the thermostat or controller to call for heat b Watch for continuous spark at the pilot burner c Check the ignition spark operation Time must be within the lockout timing period 90 sec onds d Turn control down to end call for heat and wait 60 seconds before beginning st...

Page 31: ...screw 4 screws that secure the control box 8 Disconnect pilot wire from the ignition module 9 Disconnect wire harness from the combustion blower 10 Carefully slide out the burner tray assembly 11 Reverse above procedure to re install Gas Valve Removal 1 Remove burner tray See Burner Tray Removal procedure 2 Disconnect pilot tubing from gas valve 3 Turn vertical gas pipe from manifold slightly and ...

Page 32: ... slots 8 Reverse above procedure to re install Pilot Removal 1 Disconnect pilot tubing from gas valve 2 Remove 4 screws from control box Open the control box 3 Remove the pilot wire from the ignition wire 4 Remove 2 screws that mount the pilot bracket to the air manifold assembly 5 Pull the pilot bracket slightly then drop and pull downwards and outwards 6 Reverse above procedure to re install Mak...

Page 33: ...eplace module Check for 24 Vac across MV MV PV terminals If no voltage replace module Check electrical connections between module and gas control If okay replace gas valve or gas control operator i e pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system Check continuity of ignition cable and ground wire NOTE If ground is poor or erratic shutdowns may occur occasionally even...

Page 34: ... 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 NOT 24 V IF 24 V IF O K IF DEFECTIVE CHECK TRANSFORMER OUPUT REPLACE E C A L P E R E C A L P E R E V L A V S A G V 4 2 R O F GAS VALVE THERMOCOUPLE IF NO IF 24 V 24V REPLACE PROBLEM IN TRANSFORMER LIMIT CIRCUITS Electrical Standing Pilot WARNING HIGH VOLTAGE For qualified technicians ONLY ...

Page 35: ...35 TYPICAL ON OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM ...

Page 36: ...ON Light 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 Replace with new if boiler fires If power to toggle switch but not through switch replace If power to relay but not operating replace Open valve Loosen bleed line and clean Replace coupler Inspect b...

Page 37: ...pid Wear Of Coupling 1 Misalignment or a bent shaft 2 Sagging motor mounts over oiling Pump Loses Prime 1 Air leaks in suction line 2 Excessive amount of air in water 3 Water seal in stuffing box not functioning 4 Excessive suction lift and pump operating too near shut off point Overloaded Driving Unit 1 Head much lower than that for which pump is designed 2 Speed too high or higher than that cont...

Page 38: ...erally After reaming with the auger mount the wire brush and clean out the debris remain ing in the tubes Another method is to remove the heat exchanger ream tubes and immerse heat exchanger in noninhibited de scale solvent 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 v...

Page 39: ...parts 2 Remove front inspection panel 3 Remove wires to high limit and loosen screws holding high limit to cabinet 4 Remove wedge clip holding sensing bulb in con trol well 5 Remove high limit and install a new one 6 Check control operation before leaving job Heat Exchanger Removal 1 Shut water gas and electricity off close valves and relieve pressure remove relief valve Remove side inspection pan...

Page 40: ...pection pan els Install top holding screws Install draft diverter and vent piping if so equipped 10 If gas piping was disconnected reconnect gas pip ing system and check for leakage using a soapy solution 11 Check for correct water pressure and water level in the system Make sure that system pump oper ates immediately on the call for heat The system is ready for operation 12 Within two 2 days of s...

Page 41: ...nd wash heat exchanger mak ing sure soot is removed from between fins Avoid excessive water against refractory 5 Reassemble when boiler is fired some steam will form from wet refractory This is normal 6 Correct reason for soot formation REPLACEMENT PARTS See separate parts sheet in instruction envelope Any part returned for replacement under standard company warranties must be properly tagged with...

Page 42: ... conditions satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts manufactured by others but Raypak will apply any such warranty as may be provided by the parts manufacturers TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of installa...

Page 43: ...43 ...

Page 44: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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