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Manual Raypak RAYTHERM 133-4001

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  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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.  &% ? ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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>  ...

  • Raypak RAYTHERM 133-4001 - page 11

    11 Fig. 9: Indoor Installation—Model 133 :/07>    9/::= $?,.69>?,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 ...

  • Raypak RAYTHERM 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.  ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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" ...

  • Raypak RAYTHERM 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. ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 . ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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. ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 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 ...

  • Raypak RAYTHERM 133-4001 - page 43

    43 ...

  • Raypak RAYTHERM 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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Documents that we receive from a manufacturer of a Raypak RAYTHERM 133-4001 can be divided into several groups. They are, among others:
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All of them are important, but the most important information from the point of view of use of the device are in the user manual Raypak RAYTHERM 133-4001.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Raypak RAYTHERM 133-4001, service manual, brief instructions and user manuals Raypak RAYTHERM 133-4001. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Raypak RAYTHERM 133-4001.

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A complete Raypak manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

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