1. DL manuals
  2. Raypak
  3. Boiler
  4. 0133-4001
  5. Installation And Operating Instructions Manual

Raypak 0133-4001 Installation And Operating Instructions Manual

Manual is about: Raypak INSTALLATION AND OPERATING INSTRUCTIONS HOT WATER SUPPLY HEATERS 0133-4001

Summary of 0133-4001

  • Page 1

    Models 0133-4001 types wh & nh catalog no. 3000.52h effective: 07-15-06 replaces: 11-01-04 for your safety what to do if you smell gas *do not try to light any appliance. *do not touch any electrical switch; do not use any phone in your building. *immediately call your gas supplier from a neighbor's...

  • Page 2

    Table of contents 2 receiving equipment ........................................ 3 model identification ........................... 3 general specifications ....................... 3 general safety precautions .............. 4 installation instructions .............................. 5 clearances ......

  • Page 3

    3 receiving equipment on receipt of the equipment, visually check for external damage to the carton or the shipping crate. If the carton or shipping crate is damaged, make a note on the bill of lading and report the damage to the carrier immediately. Remove the heater from the carton or the shipping...

  • Page 4

    4 be sure to read and understand the entire instruction manual before attempting to install or operate this water heater. Pay particular attention to the following general safety precautions. Failure to follow these warnings could result in a fire or explosion, causing property damage, bodily injury...

  • Page 5

    Installation codes installation must be in accordance with local codes, or, in the absence of local codes, with the latest editions of the national fuel gas code, ansi z223.1/nfpa 54, and the national electrical code, ansi/nfpa 70. In canada installations must conform with the current can/csa b149.1...

  • Page 6

    Clearances to protected surfaces note 1: combustible floor shield is required when heater is to be installed on a combustible surface. (see ordering info. On pg.5.) note 2: servicing clearances: provide at least 24" (models 0133-1826), 48" (models 2100-4001) in front of unit for removal & servicing ...

  • Page 7

    Specifications and dimensions models 182-400 and 181-401 7 note: ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level. Bold type indicates low nox models. * recovery based on manufacturer's rating. Model 133 note: ra...

  • Page 8

    8 models 514-824 models 962-1826 note: ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level. *recovery based on manufacturer's rating. Note: ratings are shown for elevations up to 2,000 feet. For elevations over 2,00...

  • Page 9

    9 models 926-1758 models 2100-4000 note: ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level. *recovery based on manufacturer's rating. Note: ratings are shown for elevations up to 2,000 feet. For elevations over 2,...

  • Page 10

    Outdoor water heaters these heaters are design certified for out- door installation. Heaters must not be installed under an overhang of less than three (3) feet from the top on the heater. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from the...

  • Page 11

    11 outdoor installations step 2: tighten the (4) screws (shown below) until they come in contact with the unit jacket top, then evenly tighten all (4) screws to secure to unit. Models 926-1758 heaters are shipped with outdoor vent terminal factory installed. Models 2100-4001 these units are not cert...

  • Page 12

    Indoor installations model 133 step 1. Shut-off main electrical power switch to heater. Step 2. Turn heater manual switch, located in upper control panel, to the "off" position. Step 3. Shut-off gas supply and water supply to the heater. Step 4. Mount drafthood on heater and attach with the 8 sheet ...

  • Page 13

    Fig. # 8167 models 962-1826 locate and assemble as shown below. Secure with screws supplied in envelope in carton. Fig. # 8165 models 2100-4001 these models have built-in drafthoods. For proper operation, the drafthood outlet must be connected to the venting system. Models 514-824 locate and assembl...

  • Page 14

    Vent piping warning: indoor heaters 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 of the same size as the drafthood outlet is recommended, however, when the...

  • Page 15

    (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 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigare...

  • Page 16

    Installing the vent damper vent damper general wiring diagram fig. # 8183.0 fig. # 8615.0 no yes no yes install vent damper with actuator to sides of vent only. Do not mount above or below vent. To chimney to boiler d808 flow > horizontal installation to chimney to boiler d808 vertical installation ...

  • Page 17

    Plumbing fig. # 8090.1 general heater should be located so that any water leaks will not cause damage to any adjacent areas or struc- tures. Gas supply connections gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. Al...

  • Page 18

    18 a minimum of 7" wc and a maximum of 10.5" wc upstream pressure under load, and no load conditions must be provided for natural gas or a minimum of 11" wc and a maximum of 13" for propane. Gas pressure regulator the gas pressure regulator located in the gas valve is preset nominally at 4" wc for n...

  • Page 19

    19 flow rates.

  • Page 20

    20 the table above provides data for selecting in-line pumps for use in a uni-temp 80 system for a single heater and tank according to the following: 1. Flow rates are based on water hardness as measured in grains per gallon. Soft: 0-4 grains per gallon. Medium: 5-15 grains per gallon. Hard: 16 and ...

  • Page 21

    21 type wh - unitemp 80 system piping diagrams.

  • Page 22

    Type nh - instantaneous type nh heaters provide instant hot water without a tank and are used in applications where scaling is prevalent and where hot water demand is fairly constant throughout the day, such as apartments, hotels, motels and industrial applications. The type nh heater should not be ...

  • Page 23

    1. Estimate total length of supply and return loop. Refer to table. 2. If multiple loops are used: (a) use multiple pumps and size return pipes according to table; or (b) use one larger recirculating pump with balancing valves on each return line. 3. First fixture on supply line must be a minimum of...

  • Page 24

    Operating controls on models 514-1826, models with mechanical modulating controls have one or more robertshaw unitrol 7000 series hydraulic snap on thermostatic combination gas valves. These valves have the pres- sure regulator and 24-volt operator built-in. The hy- draulic actuator will throttle th...

  • Page 25

    Whenever the pilot flame is interrupted. 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. Low water cut-off (optional) the low water cut-off automatically shuts down burner whenever wate...

  • Page 26

    26 component identification manual reset high limit thermostat control high and/or low gas pressure switch ignition control module low water cut-off mechanical modulating valve flow switch flow switch paddle cutting guide fig# 9314 fig# 8929.1 fig# 9316 fig# 9317 fig# 8643 fig# 9312 fig# 8995 fig# 8...

  • Page 27

    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 discon- nected to avoid potential serious injury or damage to ...

  • Page 28

    Location of controls 28 400 wh1, wh2, wh3 181 (low nox) wh1 fig # 9360

  • Page 29

    29 fig. #9334 location of controls.

  • Page 30

    Before start-up safe lighting and other performance criteria were met with the gas manifold and control assembly pro- vided on the heater when the heater underwent tests specified in the latest edition of the ansi-z21.10.3/csa 4.3 standard. General before lighting up a new installation, water should...

  • Page 31

    General safety precautions maximum water temperatures occur just after burner has shut-off. To determine the water temperature being delivered, turn on the hot water only, place a thermometer in the stream, and read the thermom- eter. There is a hot water scald potential if the thermostat is set too...

  • Page 32

    To turn off gas to appliance lighting instructions for heaters 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 lo...

  • Page 33

    For models with automatic gas valves 1. Close all gas valves. Turn off electric power supply. Wait five (5) minutes. 2. Open manual pilot valve. Turn on electric power. Pilot is automatically lighted. 3. Open main gas valve. 4. Set temperature controls to desired temperature. To shut down close all ...

  • Page 34

    Pilot burner flame-iid (atmospheric units) inspect on the first and third month after initial start- up and then on an annual basis. If problems are found, refer to the troubleshooting sections of this manual for additional directions. 1. Remove top of heater and inspect heat exchanger for soot and ...

  • Page 35

    The raytherm low nox heater is offered with wh1- on-off firing (standard) or 2-stage firing (optional). The heaters are certified and tested under the latest edition of the ansi z21.10.3/csa 4.3 standard for hot water heaters. The heater should be installed to meet all local codes, the national fuel...

  • Page 36

    36 burner tray removal 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 unit, and (4) screws that secure gas valve to jacket. 6. Disconnect wires that te...

  • Page 37

    Troubleshooting - electrical (electronic ignition iid) warning high voltage for qualified technicians only note: some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. To reset, interrupt power to heater. Note: before troubleshooting, familiarize yours...

  • Page 38

    Wiring diagram - wh2 182/260 38 wiring diagrams.

  • Page 39

    Wiring diagram - wh2 330/400 39.

  • Page 40

    40 wiring diagram - wh2 514/624.

  • Page 41

    41 wiring diagram - wh2 724-1336.

  • Page 42

    42 wiring diagram - wh2 1414-1826.

  • Page 43

    43 wiring diagram - wh2 2100-2500

  • Page 44

    44 wiring diagram - wh2 3001-4001.

  • Page 45

    Wiring diagram - wh1 181/261 low nox 45.

  • Page 46

    46 wiring diagram - wh1 331/401 low nox.

  • Page 47

    Mechanical problem when heater is turned on nothing happens. Thermostat in "on" position causes relay and pump to operate, but heater does not fire. Continuous shut down of manual reset high limit. Sooting caution-soot may be combus- tible. Wet down and exercise caution when cleaning. Continuous shu...

  • Page 48

    Failure to pump 1. Pump not properly primed. 2. Wrong direction of rotation. 3. Speed too low. 4. Total head too high. 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 feet). 5. ...

  • Page 49

    Combination flame sensor/ ignitor and pilot burner location typical burner tray illustrated burner tray removal 1. Shut-off power and gas supply to the heater. Disconnect union(s) and pilot tubing, then loosen and remove burner hold-down screws. 2. Disconnect wires at gas valve and slide burner draw...

  • Page 50

    Refractory panels top view heat exchanger re-assembly 1. Heat exchanger water header o-rings should be replaced with new ones. 2. Install in/out and return water headers and install header retainer nuts and torque nuts evenly. 3. Install the four (4) corner clips between tube sheets and refractory. ...

  • Page 51

    9. Do not apply excessive torque during rolling operation and avoid thinning any wall of the tube beyond 0.015". 10. Use same procedure on opposite end. 11. Apply line pressure test. Re-roll if necessary. 12. Reinstall as outlined under heat exchanger reassembly. Cleaning flue gas passageways soot w...

  • Page 52

    52 warranty limited parts warranty raytherm™ commercial heaters types h, nh & wh models 133 to 4001 scope: raypak, inc. ("raypak") warrants to the original owner that all parts of this heater which are actually manufactured by raypak will be free from failure under normal use and service for the spe...

  • Page 53

    Raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (800) 872-9725 raypak canada ltd, 2805 slough street, mississauga, ontario, canada l4t 1g2 (905) 677-7999 fax (905) 677-8036 litho in u.S.A. Www.Raypak.Com.