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INSTALLATION & OPERATING
INSTRUCTIONS
Raytherm™
Heating
Boilers
Models 133–4001
Type H
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 flammable vapors and
liquids or other combustible materials in the vicinity of this or any
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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 2
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CONTENTS WARNINGS 4 Filling System - Heating Boilers 25 Pay Attention to These Terms 4 Ethylene Glycol Systems - MODEL IDENTIFICATION 5 Heating Boilers 25 RECEIVING EQUIPMENT 6 Initial Start-Up - Pump And Motor 25 CERTIFICATIONS 6 For Models with Automatic Gas Valves 28 BOILER TYPES 6 After Start-Up 28 Type H1 - Mechanical Modulating 6 Standing Pilot Checkout Type H2 - Motorized Modulating 6 Procedure 28 Type H3 - 2-Stage Controls 6 Intermittent Pilot System Type H4 - On-Off Controls 6 Checkou
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WARNINGS—Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. Indicates special i
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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 num- ber represent. Boiler rating plate showing model number 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 Modula
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RECEIVING EQUIPMENT BOILER TYPES Type H1 - Mechanical On receipt of the equipment, visually check for exter- nal damage to the carton or the shipping crate. If either Modulating, Models 133-1826 is damaged, make a note on the Bill of Lading and report the damage to the Carrier immediately. Remove Central heating boiler with 150°-210°F mechanical the boiler from the carton or the shipping crate. modulating gas valve(s). The number of valves varies with the model size. On occasion, items are shi
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Installation Base The boiler should be mounted on a level, non-com- bustible surface. Boiler must not be installed on carpeting. The boiler can be installed on a combustible surface only when a suitable floor shield base is pro- vided. Raypak offers an optional floor shield base which can be factory installed on all indoor models except Model 133; the Model 133 floor shield base is shipped loose and must be installed by the contractor. Do NOT use the shipping crate base as an installation base.
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Outdoor Boilers 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) These boilers are design certified for outdoor installa- times the total volume of the boiler. tion. 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 over- hang. Roof water drainage must be diverted away from the boilers with
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Venting CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the boiler and void the warranty. Outdoor Installations a. All Air From Inside The Building: Model 133 Each opening shall have a minimum net free square inches as noted in Table E. 1. Remove the front (4) screws. 2. Line up outdoor top vent opening over heater vent opening. Model Sq. Inches Model Sq. Inches 3. Lower outdoor top onto unit lining up slots in the 133 136 1125 1125 outdoor top with
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1. Remove jacket top panel. 2. Remove and discard inner stack adapter panel. 3. Install jacket top panel. JACKET TOP 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 FASTENING Detail B. SCREW Fig. 8: Installing Outdoor Top Detail—Models 514–824 Models 926-1758 Boilers are shipped with outdoor vent terminal factory installed. Indoor Installations
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Fig. 9: Indoor Installation—Model 133 4. Turn the stack (drafthood) upside down and set it Models 181-401 & 182-400 down bottom side up. Indoor Stack Installation 5. Turn the jacket top panel (removed in step 1) upside down and place it over the stack. 1. Remove the louvered jacket top by removing four (4) #10 flathead screws. 6. Attach the three (3) mounting brackets to the stack using the screws provided and the holes that are 2. If originally installed, remove outdoor top from the pre-drilled
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7. Turn 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. Fig. 11: Boiler Before Drafthood Installation—Models 181-401 & 182-400 Fig. 10: Indoor Installation—Models 181-401 & 182-400 Models 181-401 & 182-400 1. Shut
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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. Vent piping the same size or larger than the drafthood outlet is recommended, however, when the total vent height is at least 10 ft. (drafthood relief opening to vent terminal), the vent pipe size may be reduced as spec- ified in Chapter 10 of the latest edition of the National Fu
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10' OR LESS Type "B" double-wall or equivalent vent pipe is recom- VENT CAP 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. 2' MIN 2' MIN 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 sizing of the 5' MIN manifold and the chimney. At no time should the area VENT PIPE be less than the area of the largest outlet. D
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On vertical vents, the vent damper may be mounted Vent Damper Installation with the actuator in any position. On horizontal vents, do not mount the actuator either directly above or (Models 133 Through 261) directly below the vent pipe; mount the vent damper Where Required actuator to the side of the vent. Location The vent damper is set up for a continuous pilot sys- tem. If the vent damper is installed on an Intermittent The vent damper must be located in the vent so that it Pilot or Direct Sp
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EFFIKAL® RVGP CAUTION: 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 f
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*Low NOx units not available for propane. Table G: Maximum Equivalent Pipe Length Venting of Diaphragm Gas CAUTION: The boiler and its manual shut-off valve must be disconnected from the gas supply during Components any pressure testing of that system at test pressures in excess of 1/2 PSIG. Dissipate test pressure in Gas valves that are equipped with a gas bleed must be the gas supply line before reconnecting the boiler vented to the outdoors as required by the National and its manual s
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MAXIMUM AND MINIMUM FLOW RATES 2-PASS HEAT EXCANGER 1-PASS HEAT EXCHANGER MODEL MAX MIN HDR MAX MIN HDR 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" 1-1/2" 182/181 45 7 9.2 20 15 1.8 1-1/2" 260/261 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 2.0 514 2" 90 9 9 40 21 1.8 624 2" 90 12 9.5 40 26 1.9 724 2" 90 13 10 40 30 2.0 824 2" 90 15 10.5 40 34 2.1 2 1/2" 9017 2.1 3" 926 90 17 11 40 38 2.2 200 8 9.7 2 1/2" 9
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Note: Expansion tanks (supplied by others) should be installed per manufacturer's instructions. Fig. 24: Single Boiler Primary/Secondary Piping—Models 133–4001 19 CONTROLLER SENSOR (4-STAGE OR MODULATION) 5’ MAX CONTROLLER SENSOR (LESS THAN 4-STAGE) 5’ MAX
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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 20 CONTROLLER SENSOR 5’ MAX MAXIMUM OF 12”OR 4 PIPE DIAMETERS
