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Raypak 133-4001 - page 1
$% % !# % $%# &% $ CA T ALOG NO. 2000.50AH Effective: 06-27-1 1 Replaces: 09-16-10 P/N 240035 Rev . 35 This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference. :/07> G % D;0 ...
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Raypak 133-4001 - page 2
2 Rev . 35 reflects the following: Changes to: Certifications on page 6, Flow chart on page 34 Additions: Canadian Installation Code references on pages 6, 8 and 24 , adjustment procedure for two-stage Robertshaw gas valve (including Fig. 47) on pages 31-32. Deletions: None ...
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Raypak 133-4001 - page 3
(#$ Pay Attention to These T erms 4 % % #' "&!% #% % $ # %*!$ T ype H1 - Mechanical Modulating 6 T ype H2 - Motorized Modulating 6 T ype H3 - 2-Stage Controls 6 T yp ...
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Raypak 133-4001 - page 4
4 # Indicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. (# Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored. &% ? ...
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Raypak 133-4001 - page 5
5 % % T he 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 num- ber represent. MOD EL NU MB ER EXA MP LE : H 3 - 0 5 1 4 A Series M od el Si ze R e p r e s e n t a t i v e o f a p p r o x i m a t ...
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Raypak 133-4001 - page 6
$% % 9>?,77,?4:9:/0> The installation must conform with these instructions and the latest editio ns of the National Fuel Gas Code ANSI Z223.1, the Na tional Electric Code ANSI/NFP A 70 and local codes. In Canada installations must con- fo r m w i th t h e c u rr e n t C AN / C S A B 1 4 9 a nd t h e Canadian ...
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Raypak 133-4001 - page 7
9>?,77,?4:9,>0 The boiler should be mounted on a level, non-com- bustible surface. Boiler must not be in stalled on carpeting. The boiler can be installed on a combustible surface only when a suitable floor shield base is pro- v ided. Raypak offers an optional floor shield base which can be factory installed on all indoor models exce ...
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Raypak 133-4001 - page 8
8 % The boiler shall be installed in a space large i n comparison to the size of the boi ler . Large space is defined as having a volume at least sixteen (16) times the total volume of the boiler . T able D: Reduction of Clearances to Protected Surfaces Derived from National Fuel Gas Code, T able 6.2.3(b) @?/::= :470= > These boi ...
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Raypak 133-4001 - page 9
9 a. All Air From Inside The Building: Each opening shall have a minimum net free square inches as noted in T able E. b. All Air From Outdoors: When air is supplied directly from outside of build- ing, each opening shall have a minimum net free square inches as noted in T able F . &% Co m bu s t i o n ai r mu s t no t be c on ...
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Raypak 133-4001 - page 10
10 1. Remove jacket top panel. 2. Remove and discard inner stack adapter pan el. 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. See Detail B. :/07> ...
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Raypak 133-4001 - page 11
11 Fig. 9: Indoor Installation—Model 133 :/07> 9/::= $?,.69>?,77,?4:9 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 ...
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Raypak 133-4001 - page 12
12 7. T urn 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 flat- head screws removed in step 1 above. ...
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Raypak 133-4001 - page 13
13 Fig. 13: Drafthood Installation—Models 514–824 :/07> Locate and assemble as shown in Fig. 14. Secure with screws supplied in envelope in carton. :/07> These models have built-in drafthoods. For proper operation, the drafthood outlet must be connected to the venting system ...
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Raypak 133-4001 - page 14
14 T ype "B" double-wall or equivalent vent pipe is recom- mended. However , single-wall metal vent pipe may be used as specified in the latest edition of the National Fuel Gas Code ANSI Z223.1. Manifolds that connect more than one boiler to a com- mon chimney must be sized to handle the combined load. Consult available guides for proper ...
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Raypak 133-4001 - page 15
15 ' 09? ,8;0= 9>?,77,?4:9 :/07> % 3=:@23 ( 30= 0 #0<@4=0/ :.,?4:9 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 r ...
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Raypak 133-4001 - page 16
16 &% Install the vent damper to service only t he single appliance for which it is intended. if improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could result. ' 09? ,8;0= := 8,7 ;0=,?4:9 $@88,= D For safe, ef ficient operation, the vent damper and all flue prod ...
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Raypak 133-4001 - page 17
17 T able 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 minimum of 12" W .C. and a maximum of 13" for propane. ,> != 0>>@=0 #02@7,?:= The gas pressure regulator is preset nominal ...
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Raypak 133-4001 - page 18
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" 2 60/ 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" 5 14 90 9 9 40 21 1.8 2" 624 90 12 9.5 40 26 1 .9 2" ...
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Raypak 133-4001 - page 19
19 CONTROLLER SENSOR (LE SS TH AN 4-S TA G E) CONTROLLER SENSOR (4-ST A GE OR MODULA TION) 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. ...
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Raypak 133-4001 - page 20
20 MAXIMUM OF 12”OR 4 PIPE DIAMETERS CONTROLLER SENSOR 5’ MAX Reverse return piping is a proper method of manifolding multiple boiler hook-ups to ensure balanced flow through each boiler . V alves on supply and return are needed to isolate any boiler , as required. Fig. 25: Multiple-Boiler– Reverse Return Hook-Up—Models 133–4001 ...
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Raypak 133-4001 - page 21
21 %# $ .:9:8,>?0= :9?= :7> T he Economaster II is an electronic device that allows the operator to set the desired time for the pump to run after the boiler shuts of f. The time is factory-set at 7 minutes and it can be re-adjusted i n the field anywhere from 3 to 10 minutes. In a conve ntional system, when the aquastat is ...
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Raypak 133-4001 - page 22
22 Fig. 29: Mechanical Modulating V alve M O D U LA T IN G VA LV E S W / B U IL T -I N R EG U L AT O R Fig. 28: Mechanical Modulating V alve Location :/0 :?:=4E0/ :/@7,?4:9 The design uses a motorized valve which varies posi- tion based upon an external controller that communicates with the gas valve actuator , throu ...
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Raypak 133-4001 - page 23
23 484? :9?= :7> ,9@,7# 0>0? 423 484? All models except 133 are equipped with a manual reset high limit. Set the manual limit to its maximum set point. @?:# 0>0? 423 484? Set the auto limit(s) to 30-40 °F above the desired operating temperature and 5-10°F below the Manual High Limit setting. F ...
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Raypak 133-4001 - page 24
24 %# % $ This boiler is normally wired for 120 V olts. The voltage is 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 V olts are supplied to thi s connection throu ...
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Raypak 133-4001 - page 25
25 $% #% &! 01:=0 $?,= ?&; Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in the latest edition of ANSI Z21.13 Standard. 090=,7 Before lighting up a new installation, water should be flowing through the boiler ...
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Raypak 133-4001 - page 26
26 1. Se t t he th er mo st at to lo we st se tt in g. 2 . T ur n o ff a ll el e ct ri c p o we r t o th e a pp l ia nc e. 3 . R e m o v e b o i l e r d o o r . 4 . Pu sh in ga s c on tr ol kn ob sl ig ht ly an d t ur n c lo ck - wise to “O F F”. Do not force. 5 . R e p l a c e b o i l e r d o o r panel. 1 . S TO P! Re a d t he s af et y i n fo ...
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Raypak 133-4001 - page 27
27 L I GH TI NG IN S TR UC T IO NS FO R B OI LE RS W IT H E LE CT R ON IC I GN IT IO N ( I ID ) F or Mo de ls wit h M an ua l Ga s V al ve s FO R Y O U R S A F E T Y RE A D B E F O R E O P E RA T I N G WARN ING: If you do not fol low the se inst ructio ns exac tly, a f ire or e xplosi on may r esult c ausin g prop erty dam age, per sonal i njury or ...
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Raypak 133-4001 - page 28
28 := :/07> B4?3 @?:8, ?4. ,> ' ,7A 0> 423?492 9>?= @.?4:9> 1. Close all gas valves. T urn off electrical power sup- ply . W ait five (5) minutes. 2. Open manual pilot valve. T urn on electrical power . Pilot is automatically lighted. 3. Open main gas valve. 4. Set temperature controls to desire ...
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Raypak 133-4001 - page 29
29 at once. Pilot burner should ignite after gas reaches 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 burner port. 9>;0.?4:9> @= 90= > Clean main burners and air louvers of dust, lint and debris. Keep boiler area ...
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Raypak 133-4001 - page 30
30 Replace any parts showing wear . c. Check pump coupler for wear and vibration. 7. Check flow switch paddle. 8. Clean room air intake openi ngs to ensure ade- quate flow of combustion and ventilation air . 9. Keep boiler area clear and free from combustible materials, gasoline, and other flammable vapors and liquids. *Should be checked monthly . ...
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Raypak 133-4001 - page 31
31 size, and connections which comply with all applicable codes. 7,80 # :77 @? $,10?D $B4?.3 The boiler is equipped with a cut-off device to prevent f la m e r o l l- o u t i n t h e e ve n t t h e h ea t e x c h an g e r becomes blocked. This is a "manual reset" type roll- out switch, that must be reset by a service techni ...
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Raypak 133-4001 - page 32
32 5. Pull the pilot bracket slightly , then drop and pull downwards and outwards. 6. Reverse above procedure to re-install. Make sure the pilot bracket is all the way up on the pilot side, see drawing below . :8-@>?4:9 ,9 # 08: A,7 1. Remove burner tray . See Burner Tray Removal procedure. 2. Remove (4) screws that mount the combust ...
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Raypak 133-4001 - page 33
33 NO TE : Be fo re t ro ub le shoot i ng , f amiliar i ze y ours el f w ith th e s tar t-u p a nd c heckout procedure. C he ck li ne v ol ta ge p ow er, lo w v olt age t ransforme r , l imi t c ontrolle r, t hermostat ( c on tr ol le r ) a nd wi ri n g. Pu ll ig ni ti on le ad an d c h ec k s pa rk a t m odu le. If sp ark Oka y: • C he ck i gni ...
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Raypak 133-4001 - page 34
34 F o r S e r v i c e T e c h n i c i a n s S T A R T B O I L ER 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 G AS VA LV E IF NO 24 V IF 24 V: IF O.K. IF DE FE C TI V E CHECK T RANSFORMER O UPUT REPLA CE E C A ...
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Raypak 133-4001 - page 35
35 T Y P I C A L O N - O F F IN T E R M I T T E N T I G N I T I O N C O N T R O L W I R I N G D I A G R A M ...
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Raypak 133-4001 - page 36
36 M EC HA N IC AL P RO BL E M W he n b oi le r is t ur ne d on n ot h in g happens. Th er m os ta t i n " ON " p os it io n c au se s re la y an d pu mp to o pe rat e, but boi le r do es no t fi re . Co nt inu ou s sh ut do wn o f m anu al res et h i gh l im i t. Sooting CA UTI ON-S oot may be c omb usti ble . We t d ow n a nd ex er ci s ...
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Raypak 133-4001 - page 37
37 !@8;> ,47@= 0 % : !@8; 1. Pump not properly primed. 2. W rong direction of rotation. 3. Speed too low . 4. T otal head too high. # 0/@.0/ ,;,.4?D 9/ = 0,/ 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. Insuf ...
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Raypak 133-4001 - page 38
38 RAY PAK TU BE CLE ANING K IT E x t e n s i o n P i e c e s ( 5 ) A u g e r w i t h C a r b i d e T i p W i r e B r ush P/ N 05 28 71F - 5/ 8 DI A. P/ N 05 28 70F - 7/ 8 DI A. $0= A4.0 # 0;,4= $0.?4:9 % @-0 70,9492 != :.0/@= 0 Establish a regular inspection schedule, the frequency depending on the local water condition and severity of ...
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Raypak 133-4001 - page 39
39 2 . Lift burners from slotted spacer and slide from ori- fices. Clean with a wire brush. 3. Clean orifice(s) as necessary . !47:? #08: A,7 ,9/ 70,9492 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 pilot of debris, small bugs, etc. ...
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Raypak 133-4001 - page 40
40 5. Remove heat exchanger corner brackets. 6. Remove combustion chamber clips at the four cor- ners of the heat exchanger . 7. Lift heat exchanger straight up using caution not to damage refractory . 0,?C.3,920=#0>>08-7D 1. Heat exchanger water header O-rings should be replaced with new ones. 2. Install in/out and return w ...
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Raypak 133-4001 - page 41
41 5. Insert replacement tube by inserting the end with the most fins removed in the opening of one tube sheet. Slide tube until the opposite end clears the other 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 projects beyond the tube sheet. 7. Attach drill to ...
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Raypak 133-4001 - page 42
42 Catalo g Nu mber: 19 00.1 0H Ef fe ctiv e 0 8/0 1/10 LIMITED WAR RAN TY RAYTHER M - TYP ES H AND WH Mo dels : 1 33 - 4 001 SCOPE Raypak, Inc. (Ray pak ) w arrants t o the orig inal owner th at al l parts of this hea ter w hich are act ually ma nufactu re d by R ayp ak will be fre e fro m def ects in mater ials and w orkm ans hip u nder norm al u ...
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Raypak 133-4001 - page 43
43 ...
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Raypak 133-4001 - page 44
ww w .r ay p ak.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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