CATALOG NO. Effective: Replaces: 2000.50AB 08-14-07 11-15-05 INSTALLATION AND OPERATING INSTRUCTIONS RAYTHERM™ HEATING BOILERS Type H Models 0133-4001 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.
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.
TABLE OF CONTENTS MODEL IDENTIFICATION........................................................................................2 RECEIVING EQUIPMENT........................................................................................4 CERTIFICATIONS.................................................................................................... 4 BOILER TYPES........................................................................................................ 4 CALIFORNIA PROPOSITION 65 WARNING......
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.
INSTALLATION INSTALLATION CODES The installation must conform with these instructions and the latest editions of the National Fuel Gas Code ANSI 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.
CLEARANCES REDUCTION OF CLEARANCES TO PROTECTED SURFACES CLEARANCES FROM COMBUSTIBLE SURFACES 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. (All dimensions are in inches) 133 MODEL 181 to 514 to 926 to 2100 to 824 1826 4001 401 Derived from National Fuel Gas Code, Table 6.2.
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.
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. #RP8280.1 Detail A Detail B Outdoor Top (Shipped Loose with Heater) MODELS 514 - 824 Step 1: Lower outdoor top onto unit.
INDOOR INSTALLATIONS MODEL 133 Step 1. Step 2. Step 3. Step 4. Shut-off main electrical power switch to boiler. Turn heater manual switch located in upper control panel to the "OFF" position. Shut-off gas supply and water supply to the boiler. 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 as shown below. Step 5.
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.
MODELS 181-401 and 182-400 Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Shut-off main electrical power switch to boiler. Turn heater manual switch located in upper control panel to the "OFF" position. Shut-off gas supply and water supply to the boiler. 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. Remove plastic plug from left side of boiler jacket and install plastic grommet provided.
MODELS 514-824 MODELS 2100-4001 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.
10' or less 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.
VENT DAMPER INSTALLATION (MODELS 133 THROUGH 261) WHERE REQUIRED LOCATION 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 result. Make certain that it is mounted in an accessible location at least 6 inches from any combustible material or the heat exchanger, and that the position indicator is in a visible location.
INSTALL THE VENT DAMPER TO SERVICE ONLY THE SINGLE APPLIANCE FOR WHICH IT IS INTENDED. IF IMPROPERLY INSTALLED, A HAZARDOUS CONDITION, SUCH AS AN EXPLOSION OR CARBON MONOXIDE POISONING, COULD RESULT. VENT DAMPER NORMAL OPERATION SUMMARY For safe, efficient operation, the vent damper and all flue product carrying areas of the appliance must be checked annually, with particular attention given to deterioration from corrosion or other sources. Check vent damper operation as follows: 1.
A minimum of 7" W.C. and a maximum of 10.5" W.C. upstream pressure, under load and no-load conditions, must be provided for natural gas, or a minimum of 12" W.C. and a maximum of 13" for propane. *Low NOx units not available for propane. GAS PRESSURE REGULATOR The gas pressure regulator is preset nominally at 4" W.C. for natural gas, and 11" W.C. for propane. Between the gas valve and the burners is a 1/8" pipe plug. The pressure at this point, taken with a manometer, should be about 3.7" W.C.
EXCHANGER 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 temperature 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.
PIPING DIAGRAMS DIAPHRAGM TANK SYSTEM 7024e NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions.
MULTI-ZONE HEATING SYSTEMS MODELS 133 TO 4001 Fig.# 7027.1e NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. Fig.# 7024.1e NOTE: Expansion tanks (supplied by others) should be installed per manufacturer's instructions.
MULTIPLE-BOILER– REVERSE RETURN HOOK-UP MODELS 133 TO 4001 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.
CONTROLS OPERATING CONTROLS ECONOMASTER CONTROLS Models 133-1826 with mechanical modulating controls have one or more Robertshaw Unitrol 7000 Series hydraulic snap-on thermostatic combination gas valves. These valves have the pressure regulator and 24 volt operator built-in. The hydraulic actuator will throttle the boiler input to adjust the firing rate and meet the required load. This, in effect, prevents costly fuel consumption, as compared to an on-off cycling boiler.
MODULATING VALVES W/ BUILT-IN REGULATOR Fig. #8643 MODULATING VALVE LOCATION THERMOSTAT CONTROL LIMIT CONTROLS HIGH LIMIT The boiler is equipped with a manual reset high limit. Push the reset button and set the limit(s) to 3040 °F above desired operating temperature. rupted. Pilot flame is automatically lit when the device is powered. Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit.
MODULATING VALVE Fig. #8995 LOW WATER CUT-OFF GAS PRESSURE SWITCH Fig. #8996 Fig.
ELECTRICAL CONNECTIONS Boiler must be electrically grounded in accordance with National Electrical Code ANSI/NFPA No 70. 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. The boiler is normally wired for 120 Volts.
START-UP HIGH LIMIT Fig. #8991 ETHYLENE GLYCOL SYSTEMS HEATING BOILERS Fill through filler opening on the top on the Air-X Tank to solution desired. Always maintain solution level in sight glass. BEFORE START-UP 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. INITIAL START-UP - PUMP AND MOTOR Many pumps are now direct-drive.
START-UP LIGHTING INSTRUCTIONS FOR BOILERS WITH STANDING PILOT. For Models 133, 182, 260, 330 & 400 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. • If you cannot reach your gas supplier, call the fire department. C.
LIGHTING INSTRUCTIONS FOR BOILERS WITH ELECTRONIC IGNITION (IID) For Models with Manual Gas Valves FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
FOR MODELS WITH AUTOMATIC GAS VALVES LIGHTING INSTRUCTIONS 3. Open main gas valve. 4. Set temperature controls to desired temperature. 1. Close all gas valves. Turn off electrical power supply. Wait five (5) minutes. 2. Open manual pilot valve. Turn on electrical power. Pilot is automatically lighted. PILOT VALVE CONTROL SHOWN IN THE "ON" POSITION TO SHUT DOWN Close all manual gas valves. Turn off electrical power. MAIN GAS SHUT-OFF VALVE SHOWN IN THE "ON" POSITION IGNITION MODULE GAS INLET Fig.
CONTROLS Check all controls to see that they are operational. To check electronic safety (IID Models), turn off 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 leaving the heater. The reset button should snap out and the burner should shut-off.
LOW NOx BOILERS Models 181 to 401 The boilers are certified and tested under the latest edition of the ANSI Z21.13 standards for hot water boilers. BURNER ADJUSTMENT This burner assembly does not require any primary air adjustments. The boiler should be installed to meet the latest edition of all local codes, the National Fuel Gas Code Z223.1 and the National Electrical Code, ANSI/NFPA 70. VISUAL INSPECTION Flame can be observed through the slot opening above the plenum.
SERVICE 6. Use a long ½” socket wrench to remove orifices from the gas manifold. 7. Remove burners by raising the bracket on the back end of the burners up and out of their slots. 8. Reverse above procedure to re-install. Fig # 9363 Fig # 9362 IID PILOT LOW NOx BURNER TRAY ASSEMBLY 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.
TROUBLESHOOTING ELECTRICAL ELECTRONIC IGNITION IID Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START TURN GAS SUPPLY OFF.
ELECTRICAL STANDING PILOT For Service Technicians START BOILER IF PILOT BURNER LIGHTS BUT MAIN BURNERS DO NOT IF PILOT BURNER DOES NOT LIGHT CHECK FOR 24 V AT GAS VALVE CHECK THERMOCOUPLE IF NOT 24 V: IF 24 V: CHECK TRANSFORMER OUPUT FOR 24 V IF NO 24V: IF O.K.
10 3/4 TYPICAL ON-OFF INTERMITTENT IGNITION CONTROL WIRING DIAGRAM 34
MECHANICAL PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION When boiler is turned on nothing happens. Pilot is not lit……………………………… No power to the boiler…………………... Light pilot. (Standing pilot models) Check the circuit breaker, outdoor controller, etc., upstream of boiler. If power to Leads L1 and L2 of transformer, but no power on 24V side, replace. 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.
PUMPS FAILURE TO PUMP 1. Pump not properly primed. 2. Wrong direction of rotation. 3. Speed too low. 4. Total head too high. 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. REDUCED CAPACITY AND/OR HEAD 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.
COMBINATION FLAME SENSOR/ IGNITER AND PILOT BURNER TYPICAL BURNER TRAY ILLUSTRATED BURNER TRAY REMOVAL PILOT REMOVAL AND CLEANING 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 valve and slide burner tray out. 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.
MODEL 2100-4001 BOILER ILLUSTRATED IN/OUT HEADER ELECTRICAL JUNCTION BOX REDUNDANT SAFETY SHUT-OFF VALVE MANUAL GAS VALVE HIGH LIMIT MAIN GAS VALVE SEDIMENT TRAP Fig. # 8184 8. Shut down entire system and vent all radiation units and high points in system piping. Check all strainers for debris. Expansion tank water level should be at the 1/4 mark and the balance of the tank filled with air. 9. Install flue collector, jacket top and inspection panels. Install top holding screws.
CONTROL WELL REPLACEMENT CLEANING FLUE GAS PASSAGEWAYS Remove top, sensing bulb and clip. Collapse well tube at the opening with a chisel, push through into header and remove the well through header. Insert a new well and roll into place. If a roller is not available, solder the well in place with silver solder. Soot will clog areas behind fins and cause eventual tube failure. Any sign of soot at base of burners or around outer jacket indicates a need for cleaning. 1.
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