Raypak Raytherm 133 4001 Users Manual 6000.59 New RP2100

133-4001 to the manual 87754a62-441f-47db-ad19-25c61610373a

2015-02-02

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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 other appliance. To
do so may result in an explosion or fire.
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 phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.

CATALOG NO. 2000.50AH

Effective: 06-27-11

Replaces: 09-16-10

P/N 240035 Rev. 35

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

CONTENTS
WARNINGS
4
Pay Attention to These Terms
4
MODEL IDENTIFICATION
5
RECEIVING EQUIPMENT
6
CERTIFICATIONS
6
BOILER TYPES
6
Type H1 - Mechanical Modulating
6
Type H2 - Motorized Modulating
6
Type H3 - 2-Stage Controls
6
Type H4 - On-Off Controls
6
Type H5 - Mechanical Modulating
6
Type H9 - 4-Stage
6
INSTALLATION
6
Installation Codes
6
Installation Base
7
Clearances
7
Outdoor Boilers
8
High-Wind Conditions (Outdoor Units Only)8
Combustion and Ventilation Air
(Indoor Units Only)
8
Venting
9
Indoor Installations
10
Vent Piping
13
Vent Damper Installation
15
Plumbing
16
Gas Supply Connections
16
CONTROLS
21
Economaster Controls
21
Electronic Ignition
21
Operating Controls
21
Limit Controls
23
ELECTRICAL CONNECTIONS
24
START-UP
25
Before Start-Up
25
General
25

Filling System - Heating Boilers
Ethylene Glycol Systems Heating Boilers
Initial Start-Up - Pump And Motor
For Models with Automatic Gas Valves
After Start-Up
Standing Pilot Checkout
Procedure
Intermittent Pilot System
Checkout (S8600)
Inspections
Burners
Controls
Suggested Inspection Schedule
LOW NOx BOILERS
Models 181 to 401
Operation
Start-Up (S8600M)
Blower Adjustment
Visual Inspection
Electrical
Flame Roll-Out Safety Switch
Service
Burner Tray Removal
Gas Valve Removal
Main Burner and Orifice Removal
Pilot Removal
Combustion Fan Removal
TROUBLESHOOTING
Service
Repair Section
REPLACEMENT PARTS
WARRANTY

25
25
25
28
28
28
28
29
29
29
29
30
30
30
30
30
30
30
31
31
31
31
31
32
32
33
38
38
41
42

WARNINGS—Pay Attention to These Terms
DANGER:

Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.

WARNING:

Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.

CAUTION:

Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.

NOTE:

Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.

DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.

WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:

WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.

•

Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.

•

Heater should never be covered or have any
blockage to the flow of fresh air to the heater.

WARNING: This unit contains refractory ceramic
fiber (RCF) insulation in the combustion chamber.
RCF, as manufactured, does not contain respirable
crystalline silica. However, following sustained
exposure to very high temperatures (>2192F), the
RCF can transform into crystalline silica
(cristabolite). The International Agency for Research
on Cancer (IARC) has classified the inhalation of
crystalline silica (cristabolite) as carcinogenic to
humans.

WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.

When removing the burners or heat exchangers,
take precautions to avoid creating airborne dust and
avoid inhaling airborne fibers. When cleaning spills,
use wet sweeping or High Efficiency Particulate Air
(HEPA) filtered vacuum to minimize airborne dust.
Use feasible engineering controls such as local
exhaust ventilation or dust collecting systems to
minimize airborne dust. Wear appropriate personal
protective equipment including gloves, safety
glasses with side shields, and appropriate NIOSH
certified respiratory protection, to avoid inhalation of
airborne dust and airborne fiber particles.

CAUTION: If this heater is to be installed above
radiation level, it must be provided with a low water
cut-off device at the time of heater installation.

CAUTION: Operation of this heater in low
temperature systems requires special piping.
Harmful internal condensation will occur if the inlet
water temperature does not exceed 105°F. Warranty
claims will be denied when condensation occurs.

CAUTION: This heater requires forced water
circulation when the burner is operating. See
minimum and maximum flow rates. Severe damage
will occur if the heater is operated without proper
water flow circulation.
CAUTION: If this heater is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
4

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.

Boiler rating plate showing model number

MODEL NUMBER EXAMPLE:
H3-0514A
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 Modulation
9 4-Stage Firing
Application
H = Heating Boiler

RECEIVING EQUIPMENT BOILER TYPES
Type H1 - Mechanical
Modulating, Models 133-1826

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.

Central heating boiler with 150°-210°F mechanical
modulating gas valve(s). The number of valves varies
with the model size.

On occasion, items are shipped loose. Be sure that
you receive the number of packages indicated on the
Bill of Lading.

Type H2 - Motorized
Modulating, Models 514-4001

When ordering parts, you must specify the Model and
Serial Number of the boiler. When ordering under warranty conditions, you must also specify the date of
installation.

Central heating boiler with a motorized modulating gas
valve. Modulating controller optional.

Type H3 - 2-Stage Controls,
Models 181-4001

Raypak recommends that this manual be reviewed
thoroughly before installing your Raypak boiler. If there
are any questions which this manual does not answer,
please contact the factory or your local Raypak representative.

Central heating boiler with single 2-stage gas valve
and optional 2-stage controller.

Type H4 - On-Off Controls,
Models 181-4001

Claims for shortages and damages must be filed with
carrier by consignee. Permission to return goods must
be factory authorized and are subject to a stocking
charge.

Central heating boiler with on-off firing.

Type H5 - Mechanical
Modulating, Models 181-1826

Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defective replacement parts will not be accepted and will be
replaced in kind only per our standard warranties.

Central heating boiler with 110°-170°F mechanical
modulating gas valve(s).

CERTIFICATIONS

Type H9 - 4-Stage, Models 5144001

The Raypak hydronic boilers are design certified and
tested under the latest requirements of the American
National Standard, ANSI Z21.13. Each boiler has been
constructed and pressure tested in accordance with
the requirements of Section IV of the American Society
of Mechanical Engineers Code, and factory fire tested.

Central heating boiler with 4-stage firing. Controller
optional.

INSTALLATION

All models are National Board approved. Temperature
and pressure gauge is standard. Model 0133 has a 4pass heat exchanger, 1 tube per pass. Models
0181-1826 have 2-pass heat exchangers, 5 tubes first
pass, 4 tubes second pass. Models 2100-4001 have
2-pass heat exchangers, 9 tubes per pass. Models
926-4001 have optional single-pass heat exchangers
with cast iron headers only.

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. In Canada installations must conform with the current CAN/CSA B149 and the
Canadian Electrical Code CSA C22.1 C.E.C. Part 1
(C22.1). 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.

All units are CSA-certified for low-lead content
(<.25%).

Installation Base
The boiler should be mounted on a level, non-combustible 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 provided. 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.
NOTE: For Models 2100-4001, a factory-installed
floor shield is standard. Table B provides the floor
shield ordering information for other models.

Fig. 2: Alternate Method for Providing a NonCombustible Base

Clearances

NOTE: The boiler should be located in an area
where water leakage will not result in damage to the
area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance. The pan
must not restrict air flow.

133

In addition, the boiler shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation and service (circulator replacement, control
replacement, etc.).

001749
058313
058314
058315
058316

926*
1083*
1178*
1287*
1414*
1571*
1758*

054597
054598
054599
054600
054601
058378
058379

514
624
724
824

056199
056200
056201
056202

962
1125
1223
1336
1468
1631
1826

059233
059234
059235
059236
059237
059238
059239

MODEL
514 to 926 to 2100 to
824
1826
4001

All dimensions are in inches.
Derived from National Fuel Gas Code, Table 6.2.3(a)
*Vent includes factory-supplied drafthood and does not include fieldsupplied vent systems above the drafthood. On Models 2100-4001
drafthood is built into boiler.

Boiler Model No. Base Part No. Boiler Model No. Base Part No.
133
182/181
260/261
330/331
400/401

181 to
401

Table C: Clearances from Combustible Surfaces

NOTE 1: Combustible floor shield is required when
boiler is to be installed on a combustible surface. (See
ordering information in Table B.)
NOTE 2: Servicing Clearances: Provide at least 24"
(Models 133-1826), 48" (Models 2100-4001) in front of
unit for removal and servicing of the Controls & Burner
Tray. Provide at least 18" on side opposite water
connections for deliming of Heat Exchanger Tubes.

* Models with factory-installed floor shield as standard.
BOLD type indicates Low NOx models.

Table B: Combustible Floor Shield Ordering
Information

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)
times the total volume of the boiler.

These boilers are design 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.
The point from where the flue products exit the boiler
must be a minimum of four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top surface of the
boiler shall be at least three (3) feet above any forced
air inlet, or intake ducts located within ten (10) feet horizontally.

Fig. 3: Minimum Distances to Building Openings from
Where Flue Products Exit the Boiler
Derived from National Fuel Gas Code, Table 6.2.3(b)

High-Wind Conditions (Outdoor
Units Only)

Table D: Reduction of Clearances to Protected
Surfaces

In areas where high winds are frequent, it may be necessary to locate the boiler a minimum of 3' from high
vertical walls, or install a wind break so the boiler is not
in direct wind current.

Combustion and Ventilation Air
(Indoor Units Only)
The boiler must have both combustion and ventilation
air. Minimum requirements for net free air supply
openings are 12 inches from ceiling for ventilation and
12 inches from the floor for combustion air as outlined
in Z223.1 - latest edition or the current CAN/CSA
B149, as well as any local codes that may
have jurisdiction.
8

Venting

CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the boiler and void the warranty.

Outdoor Installations
Model 133

a. All Air From Inside The Building:
Each opening shall have a minimum net free
square inches as noted in Table E.
Model

Sq. Inches

Model

Sq. Inches

133

136

1125

182/181

181

1223

260/261

264

1336

1337

330/331

334

1468

1467

400/401

399

1631

1630

514

512

1826

624

627

2100

724

726

2500

2499

824

825

3001

3000

962

3500

4001

4000

1. Remove the front (4) screws.
2. Line up outdoor top vent opening over heater vent
opening.
3. Lower outdoor top onto unit lining up slots in the
outdoor top with screw holes in jacket top.
4. Reinstall (5) screws to secure jacket top and outdoor top to unit.

Table E: Minimum Net Free Air from Inside Building

b. All Air From Outdoors:
When air is supplied directly from outside of building, each opening shall have a minimum net free
square inches as noted in Table F.
Model

Sq. Inches

Model

Sq. Inches

133

1125

282

182/181

1223

306

260/261

1336

335

330/331

1468

367

400/401

100

1631

408

514

128

1826

457

624

157

2100

525

724

182

2500

625

824

207

3001

750

962

241

3500

875

4001

1000

Fig. 4: Installing Outdoor Top—Model 133

Models 181-401 & 182-400
Outdoor Top Installation

(Part of heater)

Table F: Minimum Net Free Air from Outside Building
Fig. 5: Installing Outdoor Top—Models 181-401 & 182400

1.
2.
3.
4.

Remove jacket top panel.
Remove and discard inner stack adapter panel.
Install jacket top panel.
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.

JACKET TOP

FASTENING
SCREW

Fig. 8: Installing Outdoor Top Detail—Models 514–824

Models 926-1758
Boilers are shipped with outdoor vent terminal factory
installed.

Indoor Installations
Detail A

Detail B

Model 133

Outdoor Top
(Shipped Loose with Heater)

1. Shut-off main electrical power switch to boiler.

Fig. 6: Installing Outdoor Top—Models 181-401 & 182400

2. Turn heater manual switch located in upper control
panel to the "OFF" position.

Models 514-824

3. Shut-off gas supply and water supply to the boiler.

1. Lower outdoor top onto unit. Position top so it is
centered on unit from side to side and front to rear.

4. 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 (see next page).
5. Remove plastic plug from left side of boiler jacket
and install the plastic grommet provided.
6. Route flue sensor wire harness through the grommet installed in Step 5.
7. Remove door and locate wire from roll-out sensor
to high limit with the male/female connector.
8. Disconnect male/female connector and attach to
the 2 wires from drafthood vent sensor harness.

Fig. 7: Installing Outdoor Top—Models 514–824

2. Tighten the (4) screws (as indicated in Fig. 8) until
they come in contact with the unit jacket top, then
evenly tighten all (4) screws to secure to unit.

Fig. 9: Indoor Installation—Model 133

Models 181-401 & 182-400

4. Turn the stack (drafthood) upside down and set it
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
pre-drilled in the stack. Make sure the brackets
are positioned with the flange near the top side
of the stack (see Fig. 10). Caution must be
taken not to over tighten and strip the screw
threads.

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.
11

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 flathead 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-off main electrical power switch to boiler.
2. Turn heater manual switch located in upper control
panel to the "OFF" position.
3. Shut-off gas supply and water supply to the boiler.
4. Mount drafthood on top of boiler as shown in Fig.
12. Drafthood should be positioned with the vent
sensor located on the front right side as shown.
5. Remove plastic plug from left side of boiler jacket
and install plastic grommet provided.

Fig. 12: Boiler After Drafthood Installation—Models
181-401 & 182-400

6. Route flue sensor wire harness through the grommet installed in Step 5.

Models 514-824

7. Remove door and locate wire from roll-out sensor
to high limit with the male/female connector.

Locate and assemble as shown in Fig. 13. Secure with
screws supplied in envelope in carton.

8. Disconnect male/female connector and attach to
the 2 wires from drafthood vent sensor harness.

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 specified in Chapter 10 of the latest edition of the National
Fuel Gas Code, ANSI Z223.1.
As much as possible, avoid long horizontal runs of
vent pipe and too many elbows. If installation requires
horizontal non-vertical runs, the vent pipe must have a
minimum of 1/4 inch per foot rise and should be supported at not more than 5 ft. intervals. Plumbers tape,
criss-crossed, will serve to space both horizontal and
vertical piping.

Fig. 13: Drafthood Installation—Models 514–824

Models 962-1826
Locate and assemble as shown in Fig. 14. Secure with
screws supplied in envelope in carton.

Gas vents supported only by the flashing and extending above the roof more than 5 ft. should be securely
guyed or braced to withstand snow and wind loads.
We recommend the use of insulated vent pipe spacers
through the roof and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which complies with the local codes or, in the absence of such
codes, to the latest edition of the National Fuel Gas
Code, ANSI Z223.1.
The discharge opening must be a minimum of 2 ft. vertically from the roof surface and at least 2 ft. higher
than any part of the building within 10 ft.
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.

Fig. 14: Drafthood Installation—Models 962–1826

The weight of the vent stack or chimney must not rest
on boiler drafthood. Support must be provided in compliance with applicable codes. The boiler top and
drafthood must be readily removable for maintenance
and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible
construction.

Models 2100-4001
These models have built-in drafthoods. For proper
operation, the drafthood outlet must be connected to
the venting system.
13

Type "B" double-wall or equivalent vent pipe is recommended. However, single-wall metal vent pipe may be
used as specified in the latest edition of the National
Fuel Gas Code ANSI Z223.1.

10' OR LESS
VENT CAP

2' MIN
2' MIN

Manifolds that connect more than one boiler to a common chimney must be sized to handle the combined
load. Consult available guides for proper sizing of the
manifold and the chimney. At no time should the area
be less than the area of the largest outlet.

5' MIN
VENT PIPE

DRAFT HOOD

HEATER

Fig. 16: Venting Clearances

hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
(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 cigarette, cigar or pipe.

Fig. 15: Common Venting

At the time of removal of an existing boiler, the following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remaining connected to the common venting system are not
in operation.

(f) After it has been determined that each appliance
remaining connected to the common venting system properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.

(a) Seal any unused openings in the common venting
system.

(g) Any improper operation of the common venting
system should be corrected so that the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1. When re-sizing any
portion of the common venting system, the common venting system should be re-sized to
approach the minimum size as determined using
the appropriate tables in Part 11 of the National
Fuel Gas Code, ANSI Z223.1.

(b) Visually inspect the venting system for proper size
and horizontal pitch and make sure there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.
(c) As much as possible, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range

For special venting applications that require reduced
vent sizes and through-the-wall venting, the Type D
Induced Draft Assembly can be used. Consult the factory or your local Raypak representative.
14

Vent Damper Installation

On vertical vents, the vent damper may be mounted
with the actuator in any position. On horizontal vents,
do not mount the actuator either directly above or
directly below the vent pipe; mount the vent damper
actuator to the side of the vent.

(Models 133 Through 261)
Where Required
Location

The vent damper is set up for a continuous pilot system. If the vent damper is installed on an Intermittent
Pilot or Direct Spark Ignition equipped system, the
energy savings of the vent damper can be improved
by plugging the hole in the vent damper blade using
the knockout plug, Part No. 105612R, provided in the
parts envelope.

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.

DO NOT plug the hole if installing the vent damper on
a continuous pilot system as this will create a hazard.
HORIZONTAL INSTALLATION

The vent damper must be installed after the appliance
drafthood, as close to the drafthood as practicable,
and without modification of the drafthood.

FLOW >

YES

YES
D80B

TO BOILER

TO CHIMNEY
NO

VERTICAL
INSTALLATION

INSTALL VENT DAMPER
WITH ACTUATOR TO
SIDES OF VENT ONLY.
DO NOT MOUNT ABOVE
OR BELOW VENT.

TO CHIMNEY

VENT DAMPER
ACTUATOR MAY BE
INSTALLED IN ANY
POSITION ON VERTICAL
PIPE

TO BOILER

Fig. 18: Horizontal/Vertical Vent Damper Installation

D80B
N. O.

N. C.

END
SWITCH
C.

1K2
1K1
R

1K3
1R

BLACK

1
ORANGE

RED

4
YELLOW

5
BLUE
LIMIT

OPTIONAL LIMIT
LOCATION

THERMOSTAT OR
CONTROLLER

L1
(HOT)

DUAL VALVE
COMBINATION
GAS CONTROL OR
IGNITION SYSTEM

Fig. 17: Vent Damper Installation (Model 133 Drafthood
Shown)
1

WARNING: Do not use thermally actuated vent
dampers on a modulating boiler. To do so may result
in asphyxiation. Use only a mechanically actuated
vent damper device that is electrically interlocked
with the modulating boiler operation.

L2
TRANSFORMER

????? ??????
???????
??????????DISCONNECT
??
??? ??AND
????????
??????????PROTECTION
?? ????
?????
POWER
SUPPLY
PROVIDE
MEANS
OVERLOAD
AS REQUIRED

Fig. 19: Vent Damper General Wiring Diagram

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 follows:
1. When the boiler is off, check that the vent damper
position indicator points to the closed position. (See
figure below.)
2. Turn the thermostat or controller up to call for heat
and check that the vent damper indicator points to the
open position. (See figure below.)

Fig. 21: Connection Diagram for Effikal® Vent Damper

Plumbing

3. Turn the thermostat or controller down again and
check that the vent damper position indicator returns
to the closed position.
NOTE: The vent damper must be inspected at least
once a year by a trained, experienced service
technician. The name of the person who originally
installed your vent damper is shown on the
installation label. Damper must be in open position
when boiler main burners are operating.
Damper Position Indicator

Fig. 22: Plumbing

Gas Supply Connections
Damper Open

Gas piping must have a sediment trap ahead of the
boiler gas controls, and a manual shut-off valve located outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.

Damper Closed

Fig. 20: Vent Damper Position Indicator

NOTE: Do not use teflon tape on gas line pipe
thread. A flexible sealant approved for the fuel being
used is recommended.
16

*Low NOx units not available for propane.

Table G: Maximum Equivalent Pipe Length

Venting of Diaphragm Gas
Components

CAUTION: The boiler and its manual shut-off valve
must be disconnected from the gas supply during
any pressure testing of that system at test pressures
in excess of 1/2 PSIG. Dissipate test pressure in
the gas supply line before reconnecting the boiler
and its manual shut-off valve to gas supply line.
FAILURE TO FOLLOW THIS PROCEDURE MAY
DAMAGE THE GAS VALVE. OVER PRESSURED
GAS VALVES ARE NOT COVERED BY
WARRANTY. The boiler and its gas connections
shall be leak tested before placing the appliance in
operation. Use soapy water for leak test do NOT use
open flame.

Gas valves that are equipped with a gas bleed must be
vented to the outdoors as required by the National
Fuel Gas Code. Under NO circumstances shall bleed
lines terminate in the gas utilization equipment flue or
exhaust system.

Bleed Line
Connection

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.

Vent Line
Connection

Gas Pressure Regulator
Fig. 23: Bleed Line Connection Location

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. for natural gas and
10.5" W.C. for propane. Low NOx models should be
3.9" W.C., natural gas only. If an adjustment is needed, turn adjustment screw clockwise to increase
pressure, or counter-clockwise to decrease pressure.

General
Boiler should be located so that any water leaks will
not cause damage to any adjacent areas or structures.
See piping diagrams for proper water connections for
the type of boiler and system.

Pump Selection

For boilers with mechanical modulation gas valves
(Type H1 and H5) or two-stage gas valves (Type H3),
the gas pressure regulator is preset and sealed, and
not field adjustable. Pressure tap is provided on the
outlet side of the gas valve for measurement of gas
pressure in the manifold.

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 whenever possible. (Delta T is the temperature
17

MAXIMUM AND MINIMUM FLOW RATES
2-PASS HEAT EXCANGER
MODEL
SIZE
133*

182/181
260/261
330/331
400/401
514
624
724
824
926
962
1083
1125
1178
1223
1287
1336
1414
1468
1571
1631
1758
1826
2100
2500
3001
3500
4001

GPM
22

MAX
T
10

P FT
14.7

GPM
10

MI N
T
22

45
45
45
45
90
90
90
90
90
90
90
90
90
90
90
90
90
90
90
90
90
90
200
200
200
200
200

7
10
12
15
9
12
13
15
17
18
20
21
22
22
24
24
26
27
29
30
32
34
17
21
25
29
33

9.2
9.4
9.6
9.8
9
9.5
10
10.5
11
11
12
12
12.5
12.5
13.2
13.2
14
14
14.5
14.5
15.4
15.4
14.8
15.8
16.7
17.5
18.7

20
20
20
20
40
40
40
40
40
40
45
47
49
51
53
55
58
61
65
68
73
76
90
103
124
145
166

15
22
28
33
21
26
30
34
38
40
40
40
40
40
40
40
40
40
40
40
40
40
39
40
40
40
40

P FT
3.3
1.8
1.9
1.9
2.0
1.8
1.9
2.0
2.1
2.2
2.2
3.1
3.3
3.8
4.0
4.5
4.9
5.8
6.4
7.5
8.3
10.0
10.8
3.2
4.4
6.7
9.5
13.0

1-PASS HEAT EXCHANGER
HDR
CONN
1-1/4"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
2"
2"
2"
2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
3"
3"
3"
3"
3"

GPM

MA X
T

200
200
200
200
200
200
200
200
200
200
200
200
200
200
400
400
400
400
400

8
8
9
9
10
10
11
11
12
12
13
13
14
15
9
10
12
14
16

P FT

GPM

MIN
T

9.7
9.7
10.3
10.3
11
11
11.7
11.7
12.2
12.2
13
13
14.7
14.7
18
18.8
19.5
20.5
21.5

90
90
90
90
90
90
90
90
90
90
90
90
90
90
180
180
180
180

17
18
20
20
21
22
23
24
26
27
29
30
32
33
19
23
27
32

2.1
2.1
2.3
2.3
2.4
2.4
2.5
2.5
2.7
2.7
2.8
2.8
3
3
4
4.1
4.3
4.5

3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
4"
4"
4"
4"

180

4.7

P FT

HDR
CONN

GPM Flow rates limited by maximum acceptable velocity through heat exchanger tubes. May be increased by 10% for closed heating
systems.
* 4 Pass Heat Exchanger
BOLD TYPE indicates Low NOx models.

Table H: Maximum and Minimum Flow Rates

Recommended Purge Manifolds for
Typical Hydronic System Hookups

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.

The boiler piping system of a hot water heating boiler
connected to heating coils located in air handling units
where they may be exposed to refrigerated air circulating, must be equipped with flow control valves or other
automatic means to prevent gravity circulation of the
boiler water during the cooling cycle.

Feedwater Regulator
We recommend that a feedwater regulator be installed
and set at 12 PSIG minimum pressure. Install a check
valve or back flow device upstream of the regulator,
with a manual shut-off valve. Leave the valve open.

Temperature & Pressure Gauge

Piping—Heating Boilers

The temperature & pressure gauge is standard equipment on all hydronic heating and hot water supply
boilers. All temperature & pressure gauges are factory
mounted in the in/out header except for residential
boilers, Models 133 and 181-401. On these models
the temperature & pressure gauge is shipped loose for
field installation, and located in the outlet water connection. All fittings required to mount gauge to piping
system are supplied by others.

We recommend that all high points be vented and that
purge valves and a bypass valve be installed. A boiler
installed above radiation level must be provided with a
low water cut-off device. The boiler, when used in conjunction with a refrigeration system, must be installed
so that the chilled medium is piped in parallel with the
boiler with appropriate valves to prevent the chilled
medium from entering the boiler.
18

CONTROLLER SENSOR
(LESS THAN 4-STAGE)
5’ MAX

5’ MAX

CONTROLLER SENSOR
(4-STAGE OR MODULATION)

Note: Expansion tanks (supplied by others) should be installed per manufacturer's instructions.

Fig. 24: Single Boiler Primary/Secondary Piping—Models 133–4001

MAXIMUM OF 12”OR
4 PIPE DIAMETERS
5’ MAX

CONTROLLER
SENSOR

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

CONTROLS

Operating Controls

Economaster Controls

Modes H1 and H5 - Mechanical Modulation
Models 133-1826 with mechanical modulating controls
have one or more Robertshaw (Invensys) Unitrol 7000
Series hydraulic snap-on thermostatic combination
gas valves. These dual-seat combination 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.

The Economaster II is an electronic device that allows
the operator to set the desired time for the pump to run
after the boiler shuts off. The time is factory-set at 7
minutes and it can be re-adjusted in the field anywhere
from 3 to 10 minutes.
In a conventional system, when the aquastat is satisfied, the main gas valve closes, but the pump
continues operating. With the energy-conserving
Economaster II the boiler pump is programmed to continue running for an optimum period of time in order to
absorb the residual heat from the combustion chamber
and use it in the system. The pump then shuts off until
the next call for heat is received from the aquastat.

The valve has a remote capillary bulb immersed in a
well, at the header outlet, to maintain a constant outlet
water temperature. When multiple valves are furnished, they can be staged to give greater flexibility of
control. Standard factory setting is at position 5.
Consult the dial setting tag attached to the control for
your desired temperature. See sample tag drawings
below.

NOTE: Pump will come on when power is first
applied to boiler.

NOTE: No external control of the valve position is
possible.

INVENSYS

Low Temp. Range

High Temp. Range

Fig. 26: Economaster PCB

Electronic Ignition
The intermittent ignition device conserves energy by
automatically extinguishing the pilot when desired
temperature is reached. When additional heat is needed, the pilot re-ignites electrically, eliminating the fuel
costs of maintaining a constant pilot. To ensure safe
operation, the gas valve cannot open until the pilot
relights and is proven.
All units are shipped with lockout ignition module as
standard.

Fig. 27: Sample Tags

Mode H3 - 2-Stage Firing

MODULATING VALVES
W/ BUILT-IN REGULATOR

The boiler will fire at low fire when there is closure
across the stage 1 contacts. Thereafter, it will fire at
high fire when there is closure across the stage 2
contacts. Numerous staged controllers are available.
Mode H4 - On/Off Firing
The boiler will fire at full fire when there is closure
across the TH contacts. Numerous mechanical
staged controllers are available (see Fig. 37), as well
as digital controllers offering additional features. A
typical wiring diagram for a mid-size H4 unit is shown
on page 35; this basic layout applies to most other
firing modes as well.
Mode H9 - 4-Stage Firing

Fig. 28: Mechanical Modulating Valve Location

The boiler will fire at lowest setting when there is closure across the stage 1 contacts. Thereafter, it will
fire at increasing rates when there is closure across
the contacts for additional stages. Loss of closure
across stage 1 will shut down the entire boiler immediately. Numerous digital controllers are available.
WH Modes
Connections for Tankstats in WH modes are shown in
Figs. 30 and 31.

Fig. 29: Mechanical Modulating Valve

Mode H2 - Motorized Modulation
The design uses a motorized valve which varies position based upon an external controller that
communicates with the gas valve actuator, through a
3-wire 0-135 ohm wiper circuit. Minimum fire is 20%
of rate. The actuator runs on 120V power, and takes
26 seconds to go from fully closed to fully open.
Raypak offers a single-boiler digital controller which
drives the actuator; see controller options B-40 and
B-41 (includes outdoor reset). For systems with multiple boilers, see controller options B-45 through
B-47. For a field-supplied controller with a 4-20 mA
signal, see option B-35.

Fig. 30: Single Stage Tankstat

Flow Switch
This dual purpose control shuts off the boiler in the
case of a pump failure or low water condition. It is
mounted and wired in series to the main gas valve.
Standard on all models except the 133.
NOTE: Flow switch will not operate if flow is less
than 12 gpm.

Fig. 31: 2-Stage Tankstat

Limit Controls
Manual-Reset High Limit
All models except 133 are equipped with a manual
reset high limit. Set the manual limit to its maximum
set point.
Fig. 33: Flow Switch

100% Pilot Safety
All standard boiler models 181-4001 employ electronic devices which close the main gas valve within 8/10
of a second 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.

Fig. 32: Manual Reset High Limit

Auto-Reset High Limit
Set the auto limit(s) to 30-40 °F above the desired
operating temperature and 5-10°F below the Manual
High Limit setting.

Fig. 34: Safety Control

ELECTRICAL
CONNECTIONS

Low Water Cut-Off (Optional)
The probe-type low water cut-off automatically shuts
down burner whenever water level drops below the
probe for more than 2 seconds. A 30-second time
delay prevents premature lockout due to temporary
conditions such as power failure or air pockets.

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.
This boiler is normally wired for 120 Volts. The voltage
is indicated on the tie-in leads. Consult the wiring diagram shipped with the boiler in the instruction packet.
The "TH" leads are for the remote tank control connection. 24 Volts are supplied to this connection through
the boiler transformer.
DO NOT attach line voltage to the "TH" leads on models 133-1826. Before starting boiler check to ensure
proper voltage to boiler and pump.

Fig. 35: Low Water Cut-Off

The boiler must be electrically grounded in accordance
with National Electrical Code ANSI/NFPA No 70, or
with CSA C22.1 C.E.C. Part 1 in Canada.

High and Low Gas Pressure
Switches (Optional)
NOTE: The High Gas Pressure Switch is standard
on Models 3001-4001

NOTES:
1. Field install ground to inside of junction box.

These switches sense either high or low gas pressures and automatically shut down burners if abnormal
pressures exist.

2. If any of the original wire as supplied with the boiler must be replaced, it must be replaced with
105°C wire or its equivalent.

Fig. 36: Gas Pressure Switch

T & P GAUGE
(NOT SHOWN)
MECHANICAL
MODULATING
GAS VALVES WITH
REGULATOR

INLET

HI-LIMIT

Fig. 37: General Location of Controls

START-UP

Ethylene Glycol Systems Heating Boilers

Before Start-Up

Fill through filler opening on the top on the Air-X Tank
to solution desired. Always maintain solution level in
sight glass.

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.

NOTE: Raypak recommends the use of Ethylene
Glycol solution only.

General

Initial Start-Up - Pump and
Motor

Before lighting up a new installation, water should be
flowing through the boiler. Regulator should be set to
minimum 12 PSI.

Many pumps are now direct-drive. They have no coupler or bearing assembly. These pumps do not require
lubrication. Others require SAE-30 non-detergent oil to
lubricate both the motor and the bearing assembly.
Check pump motor for type before attempting to oil.

CAUTION: Propane gas is heavier than air and
sinks to the ground. Exercise extreme care in lighting boiler in confined areas.

Filling System - Heating
Boilers

Clean dust and lint from pump and motor. Check pump
coupler and tighten if necessary. Flush system before
putting into operation to ensure that foreign material
does not damage pump seals.

Fill system with water. Purge all air from the system
using purge valve sequence. After system is purged of
air, lower system pressure. Open valves for normal
system operation. Fill system through feed pressure.
Manually open air vent on the compression tank until
water appears, then close vent.

CAUTION: Pump must be off to check oil in bearing
assembly. Do not run pump without water in system.

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.
B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and
will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.

If you cannot reach your gas supplier, call
the fire department.

C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, don’t try to repair it,
call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
service technician to inspect the appliance and
to replace any part of the control system and
any gas control which has been under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above on
this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. Remove boiler door panel.
5. Push in gas control knob slightly and turn
clockwise
to “OFF”.
GAS CONTROL
KNOB SHOWN
IN "OFF"
POSITION

GAS INLET

GAS CONTROL
KNOB SHOWN
IN "OFF"
POSITION

PILOT
BURNER

7. Locate pilot mounted
on the right side of the
burner tray, and right
of first burner.
8. Turn knob on gas control
counter-clockwise
to "PILOT"
9. Push in control knob all the way and hold in .

GAS INLET

NOTE: Knob cannot be turned from “PILOT” to “OFF”
unless knob is pushed in slightly. Do not force.
6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you
smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell
gas, go to next step.

THERMOCOUPLE

10.
11
12.
13

Immediately light the pilot with a match. Continue
to hold the control knob in for about one (1) minute
after the pilot is lit. Release knob and it will pop
back up. Pilot should remain lit. If it goes out, repeat steps 5 through 9.
• If knob does not pop up when released, stop
and immediately call your service technician
or gas supplier.
• If the pilot will not stay lit after several tries,
turn the gas control knob to “OFF” and call
your service technician or gas supplier.
Stand to the side of the boiler and turn the gas
control knob counter-clockwise
to "ON".
Replace boiler door panel.
Turn on all electric power to the appliance.
Set the thermostat to the desired setting.

TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance.
3. Remove boiler door.

4. Push in gas control knob slightly and turn clockwise
to “OFF”. Do not force.
5. Replace boiler door panel.

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.

BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch; do not use any phone
in your building.
Immediately call your gas supplier from your neighbor’s
phone. Follow the gas supplier’s instructions.

*
*
*

If you cannot reach your gas supplier, call the fire department.

Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or turn
by hand, do not try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.

Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.

OPERATING INSTRUCTIONS
1.
2.
3.
4.
5.
6.

STOP! Read the safety information above.
Set the thermostat on the lowest setting.
Turn off all electrical power to the appliance.
This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot
by hand.
Remove boiler door panel.
For Robertshaw gas valve: Turn gas control knob
clockwise
to “OFF”.
For Honeywell gas valve (all models except 40#):
Turn gas control knob clockwise
to “OFF".
Make sure knob rest against stop.
For Honeywell gas valve (Models 40# only):
Push in gas control knob slightly and turn clockwise
to “OFF”. Knob cannot be turned to “OFF”
unless knob is pushed in slightly. Do not force.
Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas, STOP!
Follow “B” in the safety information above. If
you do not smell gas, go to the next step.
For Robertshaw gas valve: Turn gas control knob
counter-clockwise
to “ON”.
ROBERTSHAW
GAS CONTROL
KNOB SHOWN
IN "ON" POSITION

For Honeywell gas valve: Turn gas control knob
counter-clockwise
from “OFF” until it
stops. Push in gas control knob and continue
rotating counter-clockwise
to “ON”
position. Make sure knob rests against stop.
HONEYWELL
GAS CONTROL
KNOB SHOWN
IN "ON" POSITION
GAS INLET

For Honeywell gas valve (Models 40# only):
Turn gas control knob counter-clockwise
to “ON”.
GAS CONTROL KNOB
SHOWN IN "ON"
POSITION
GAS INLET

9.
10.
11.
12.

GAS INLET

Replace boiler door panel.
Turn on all electrical power to the appliance.
Set thermostat to desired setting.
If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE
1.
2.
3.
4.

Set the thermostat to the lowest setting.
Turn off all the electrical power to the appliance if service
is to be performed.
Remove door panel.
For Robertshaw gas valve: Turn gas control knob
clockwise
to “OFF”.
For Honeywell gas valve (all models except 40#):

Turn gas control knob clockwise
to “OFF”.
Make sure knob rests against stop.
For Honeywell gas valve (Models 40# only):
Push in gas control knob slightly and turn clockwise
to “OFF”.
Replace heater door panel.

For Models with Automatic
Gas Valves

soap and water solution. Bubbles indicate a gas
leak.
2. Adjust pilot to obtain a normal flame enveloping
3/8 to 1/2 inch [9.5 to 12.5 mm] of the thermocouple or generator tip.

Lighting Instructions
1. Close all gas valves. Turn off electrical power supply. Wait five (5) minutes.

3. Place system in operation, and:
a. Check for satisfactory ignition of main burner.
b. Make certain the pilotstat "holds in", and that
shutdown occurs within 2-1/2 minutes after the
pilot flame is extinguished.
c. Observe operation for at least three cycles to
be sure the system is functioning normally.

2. Open manual pilot valve. Turn on electrical power.
Pilot is automatically lighted.
PILOT
VALVE CONTROL
SHOWN IN THE
"ON" POSITION

MAIN GAS SHUT-OFF
VALVE SHOWN IN
THE "ON"
POSITION

Pilot with
Burner Flame

GAS INLET

Fig. 38: Shut Off Valve

3. Open main gas valve.

Standing Pilot

4. Set temperature controls to desired temperature.

To Shut Down

Fig. 40: Pilot Flame Should Engulf Thermocouple

Intermittent Pilot System
Checkout
(S8600)

Close all manual gas valves. Turn off electrical power.

1. Turn on power to the ignition systems and turn gas
supply off.
2. Check ignition module as follows:
a. Set the thermostat or controller above room
temperature to call for heat.
b. Watch for continuous spark at the pilot burner.
c. Time the spark operation. Time must be within the lockout timing period (15 or 90
seconds).
d. Turn thermostat down to end call for heat and
wait 60 seconds on lockout models before
beginning step 3.

Fig. 39: Ignition Module

After Start-Up

3. Turn on gas supply.

Standing Pilot Checkout
Procedure

4. Set thermostat or controller above room temperature to call for heat.

1. Turn on pilot gas supply, light pilot, and check pilot
tubing connections for leakage. With main burner
in operation, paint tubing connections with a rich

5. Systems should start as follows:
a. Spark will turn on and pilot gas valve will open
28

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.

Inspections
Burners
Clean main burners and air louvers of dust, lint and
debris. Keep boiler area clear and free from combustibles and flammable liquids. Do not obstruct the
flow of combustion and ventilation air. Make visual
check of burner and pilot flame. Yellow flame indicates
clogging of air openings. Lifting or blowing flame indicates high gas pressure. Low flame indicates low gas
pressure.

Fig. 43: Pilot Burner Flame (Standing Pilot Units)

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. Reset dial to 30°F to 40°F
above desired operating temperature, and push reset
button. Burner should light.

Suggested Inspection
Schedule

Modulating burner flame varies in height from approximately 1/4"
at low fire to approximately 4" at high fire.

Fig. 41: Typical Main Burner Flame

The boiler should be inspected on the first and third
months after initial start-up and then on an annual
basis. If problems are found, refer to Troubleshooting
Guide for additional directions.
1. Remove top of heater and inspect heat exchanger
for soot and examine venting system.
2. Remove rear header and inspect for scale
deposits, and/or accelerated erosion.
*3. Inspect pilot and main burner flame and firing rate.
*4. Inspect and operate all controls and gas valve.
*5. Visually inspect system for water leaks.

Fig. 42: Pilot Burner Flame (IID Units)

*6. a. Oil pump motor and bearing assembly, if oil
cups are provided.
b. Disconnect pump from header and check condition of pump impeller. Check condition of bearing
by attempting to move impeller from side to side.
29

Operation

Replace any parts showing wear.
c. Check pump coupler for wear and vibration.

On call for heat, the ignition system, consisting of an
electronic spark module, and gas pilot system is energized. Providing pilot is proven, blower will start
running, the main gas valve will open and the boiler
will operate. When the operating control is satisfied the
boiler will shut down.

7. Check flow switch paddle.
8. Clean room air intake openings to ensure adequate flow of combustion and ventilation air.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the boiler and void the warranty.

Start-Up (S8600H)
1. Turn on power to the boiler with gas supply off.

9. Keep boiler area clear and free from combustible
materials, gasoline, and other flammable vapors
and liquids.

2. Check ignition module as follows:
a. Set the thermostat or controller to call for heat.
b. Watch for continuous spark at the pilot burner.
c. Check the ignition spark operation. Time must
be within the lockout timing period (90 seconds).
d. Turn control down to end call for heat and wait
60 seconds before beginning step 3.

*Should be checked monthly. (Takes approximately
15 minutes).

LOW NOx BOILERS—
Models 181 to 401

3. Turn on gas supply.

The boilers are certified and tested under the latest
edition of the ANSI Z21.13 standards for hot water
boilers.

4. Set controller to call for heat.
5. System should start as follows:
a. Spark will turn on and pilot gas valve will open.
b. Main valve and blower will be powered after
pilot flame signal is proven.
c. Heater will operate until call for heat is satisfied.

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.

Blower Adjustment
The blower is set for optimal operation. If adjustment is
needed, see Fig. 46.

Visual Inspection
Flame can be observed through the slot opening
above the plenum. Flame color is blue and evenly
spread on the top surface of the burner. At least every
three months a visual inspection should be made of
the burners. In case flame lifting is observed, check
gas pressure on manifold and static pressure in
plenum. Gas pressure in manifold should be 3.9" W.C.
and static pressure in plenum should be greater than
0.5" W.C.

DETAIL A
SEE DETAIL VIEW A

Electrical
Be sure that electrical service to the boiler has proper
overload fuse or circuit breaker protection and wire
Fig. 44: Burner Detail

size, and connections which comply with all applicable
codes.

1.
2.
3.
4.
5.

Flame Roll-Out Safety Switch
The boiler is equipped with a cut-off device to prevent
flame roll-out in the event the heat exchanger
becomes blocked. This is a "manual reset" type rollout switch, that must be reset by a service technician
after any over temperature conditions have been fixed.
Excessive restriction in the heat exchanger flue passage may cause the switch to disable the boiler.

6.
7.
8.
9.
10.
11.

Shut-off main electrical power switch to heater.
Shut-off gas upstream of heater.
Remove front door.
Disconnect gas line from gas valve.
Remove (2) screws that mount burner tray to the
base of the unit, and (2) screws that secure gas
valve to jacket.
Disconnect wires that terminate at gas valve.
Unscrew (4) screws that secure the control box.
Disconnect pilot wire from the ignition module.
Disconnect wire harness from the combustion
blower.
Carefully slide out the burner tray assembly.
Reverse above procedure to re-install.

Gas Valve Adjustment - Robertshaw
(Invensys) 7000 Series 2-Stage Gas
Valve with Solenoid Valve
NOTE: Attach a manometer and check the manifold
pressures –both high fire and low fire– before
making any adjustments.
1. Turn the heater off.
2. Remove the 3/8” nut or the #10 Torx screw.
3. Lift solenoid valve up, keeping the wires connected to the solenoid valve.
4. If only low fire adjustment is needed, go to Step 9.
5. Using a 3/8” wrench, carefully remove the aluminum cap that was under the solenoid
valve-count # of turns when removing the cap.
Be careful not to drop the cylinder (weight) or the
small spring that is under the cap –see Fig. 47.
6. Remove the spring and store in a safe place.

Fig. 45: Flame Roll-Out Safety Switch

Service
Burner Tray Removal
COMBUSTION
AIR BLOWER
AIR SHUTTER
ADJUSTMENT
GAS
VALVE
BURNER

BURNER
HOLDDOWN
BRACKET

Fig. 46: Low NOx Burner Tray Assembly
Fig. 47: 2-Stage Gas Valve Adjustment (Invensys)

7. Using an Allen wrench, turn the screw clockwise to
increase or counterclockwise to decrease high fire
manifold pressure –see Fig. 47.
8. Install the spring, weight and aluminum cap –tighten the cap using same # of turns as was used in
removing the cap.
9. For low fire adjustment, tighten the aluminum cap
to increase and loosen to decrease low fire manifold pressure.
10. Install 2-stage solenoid valve and turn heater on,
check manifold pressures.
11. Repeat steps 3 to 10 until correct manifold pressures are obtained.
12. Secure 2-stage solenoid valve by tightening the
3/8” nut or #10 Torx screw.

Fig. 48: IID Pilot

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.

Gas Valve Removal
1. Remove burner tray. See Burner Tray Removal
procedure.
2. Disconnect, pilot tubing from gas valve.
3. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.
4. Reverse above procedure to re-install.

Main Burner and Orifice
Removal
1. Remove burner tray. See Burner Tray Removal
procedure.
2. Remove pilot. See Pilot Removal procedure.
3. Remove (8) total screws from the hold-down
brackets, front and rear of tray.
4. Remove (8) total screws from the left and right
sides of the manifold assembly. Detach the manifold assembly from the burner tray assembly.
5. Remove burners by raising the bracket on the
back end of the burners up and out of their slots.
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.

FOR HEATERS
MADE IN OR AFTER
AUGUST 2001

Fig. 49: Pilot Removal

Combustion Fan Removal

Pilot Removal

1. Remove burner tray. See Burner Tray Removal
procedure.
2. Remove (4) screws that mount the combustion
blower to the manifold assembly.
3. Reverse above procedure to re-install.

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. Remove (2) screws that mount the pilot bracket to
the air manifold assembly.

TROUBLESHOOTING

WARNING—HIGH VOLTAGE: For qualified
technicians ONLY.

Electrical—Electronic Ignition IID

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.

Intermittent Pilot System
Honeywell S8600
START
TURN GAS SUPPLY OFF.
TURN THERMOSTAT
(CONTROLLER) TO CALL
FOR HEAT
POWER TO MODULE
(24 V NOMINAL)
YES
SPARK ACROSS
IGNITER/SENSOR GAP
YES

TURN GAS SUPPLY ON
PILOT BURNER LIGHTS?
YES

NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout
procedure.

Pull ignition lead and check spark at module.

SPARK STOPS WHEN
PILOT IS LIT?
YES

MAIN BURNER LIGHTS?
YES

SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES

Check line voltage power, low voltage transformer, limit controller, thermostat
(controller) and wiring.

If spark Okay:
• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
• Check boot of the ignition cable for signs of melting or buckling. Take protective
action to shield cable and boot from excessive temperatures.
If not, replace module.

• Check that all manual gas valves are open, supply tubing and pressures are
good, and pilot burner orifice is not blocked.
• Check electrical connections between module and pilot operator on gas control.
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is
okay, replace gas control; if not, replace module.
NOTE: If S8600H goes into lockout, reset system. Lockout is used on propane
models.
• Check continuity of ignition cable and ground wire.
• Clean flame rod.
• Check electrical connections between flame rod and module.
• Check for cracked ceramic flame rod insulator.
• Check that pilot flame covers flame rod and is steady and blue.
• Adjust pilot flame.
• If problem persists, replace module.
• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.
• Check electrical connections between module and gas control. If okay, replace
gas valve or gas control operator, i.e. pilot gas valve, flow switch, etc.
NOTE: IF S8600H goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though
operation is normal at the time of checkout.
• Check that pilot flame covers flame rod and is steady and blue.
• If checks are okay, replace module.

CALL FOR HEAT ENDS
SYSTEM SHUTS OFF?
YES

• Check for proper thermostat (controller) operation.
• Remove MV lead at module; if valve closes, re-check temperature
controller and wiring; if not, replace gas valve.

TROUBLESHOOTING
ENDS

Electrical—Standing Pilot

WARNING—HIGH VOLTAGE: For qualified
technicians ONLY.

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 NO 24 V

IF 24 V:

CHECK TRANSFORMER OUPUT
FOR 24 V

IF NO
24V:

REPLACE
TRANSFORMER

IF O.K.

REPLACE
GAS VALVE

IF 24 V:

PROBLEM IN
LIMIT
CIRCUITS

REPLACE
GAS VALVE

IF DEFECTIVE

REPLACE
THERMOCOUPLE

TYPICAL ON-OFF INTERMITTENT IGNITION
CONTROL WIRING DIAGRAM
35

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.

Bad transformer………………………….
Inoperative thermostat…………………..
Inoperative toggle switch………………..
Inoperative relay………………………….

Thermostat in "ON" position causes
relay and pump to operate, but boiler
does not fire.

Main gas valve is closed……………….
Plugged bleed line on gas valve or
gas pressure regulator…………………..
Broken pump coupler……………………
Shutdown by low water cut-off,
caused by air……………………………..
Gas valve defective………………………

Continuous shut down of manual reset Temperature setting too low…………….
Low water flow……………………………
high limit.
Interrupted pump operation……………..
Modulating control set too high………..
Mechanical modulating control…………
Sooting
CAUTION-Soot may be combustible.
Wet down and exercise caution when
cleaning.

Air starvation……………………………..
Condensation……………………………..
Toxic fumes which cause a chemical
reaction with copper tubes or destroy
combustion……………………………….
Improper venting…………………………

Continuous shut down of low water cut- Insufficient system flow………………….
Low water due to leaking………………..
off or flow switch.
Air in system………………………………
Line strainer dirty…………………………
Lime in heat exchanger…………………
Low flame.

Gas supply………………………………..

Insects or debris clogging burners..........
Burner intake ports low gas pressure….
Venting or combustion air……………….
Outer jacket very hot (blistered paint). Broken refractory…..…………………….

Open valve.
Loosen bleed line and clean.
Replace coupler. Inspect bearing assembly, and if frozen, lubricate or replace.
Bleed air from system.
Check for power to gas valve. If valve
has power but will not open, check vent
tube for blockage. If clear, replace
valve.
Reset high limit to higher temperature.
Check system water pumps.
Check pump oil if necessary.
Reset modulator to a lower setting.
Check and replace if necessary.
Refer to installation instructions regarding combustion air requirements.
Set bypass valve to prevent boiler inlet
temperature from dropping below
105 °F.
Remove all sources of fumes, such as
freon, chloride, or isolate the boiler.
Follow recommended vent installation
instructions.
Check pumps and piping.
Inspect for leakage and repair.
Inspect for leakage and repair. Install
an automatic air vent.
Clean.
Ream tubes.
Debris in gas line (pipe dope, rocks,
etc.). Gas line too small.
Improperly sized gas meter.
Gas regulator adjustment.
Clean burners.
Adjust gas pressure.
Refer to installation instructions regarding combustion air requirement.
Replace refractory panels.

Pumps

Pump Loses Prime

Failure To Pump

1. Air leaks in suction line.

1. Pump not properly primed.

2. Excessive amount of air in water.

2. Wrong direction of rotation.

3. Water seal in stuffing box not functioning.

3. Speed too low.

4. Excessive suction lift and pump operating too
near shut-off point.

4. Total head too high.

Overloaded Driving Unit

Reduced Capacity And/Or Head
1. Air pockets or leaks in suction line.

1. Head much lower than that for which pump is
designed.

2. Clogged impeller.

2. Speed too high or higher than that contemplated.

3. Foot valve strainer too small or clogged.

Mechanical Troubles and Noise

4. Excessive suction lift (over 15 ft.).

1. Misalignment.

5. Insufficient positive suction head (for hot water).

2. Excessive suction lift or vapor binding (hot
water).

6. Total head more than that for which pump is
intended.

3. Bent shaft and/or damaged bearings.

7. Excessively worn impeller and wearing rings.

4. Suction and discharge piping not properly supported and anchored.

Rapid Wear Of Coupling
1. Misalignment or a bent shaft.
2. Sagging motor mounts (over-oiling).

Fig. 50: Tube Cleaning Procedure

RAYPAK TUBE CLEANING KIT
Extension Pieces (5)

Auger with Carbide Tip

P/N 052871F - 5/8 DIA.

Wire Brush

P/N 052870F - 7/8 DIA.
Fig. 51: Raypak Tube Cleaning Kit

Service

Burner Tray Removal

Repair Section

1. Shut-off power and gas supply to the boiler.
Disconnect union(s) and pilot tubing, then loosen
and remove burner hold-down screws.

Tube Cleaning Procedure

2. Disconnect wires at gas valve and slide burner
tray out.

Establish a regular inspection schedule, the frequency
depending on the local water condition and severity of
service. Do not let the tubes clog up solidly. Clean out
deposits over 1/16" in thickness.

Gas Valve Removal
1. Shut-off gas supply to the boiler. Remove gas piping to gas valve inlet.

The boiler may be cleaned from the side opposite the
water connections as shown, without breaking pipe
connections. It is preferable, however, to remove both
headers for better visibility through the tubes and to be
sure the residue does not get into the system.

2. Disconnect wires, pilot tubing and bleed line, if
required.
3. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.

Note that you do not remove the top pan or the heat
exchanger generally. After reaming with the auger,
mount the wire brush and clean out the debris remaining in the tubes. Another method is to remove the heat
exchanger, ream tubes and immerse heat exchanger
in noninhibited de-scale solvent.

4. Reverse above procedure to re-install.

Main Burner And Orifice Removal
1. Remove screws and burner hold-down bracket.

COMBINATION FLAME SENSOR/
IGNITER AND PILOT BURNER

Fig. 52: Typical Burner Tray Illustrated

NOTE: If the heat exchanger is sooted badly, the
burner hold-down bracket and spacer can become
distorted from direct flame impingement and this
usually necessitates replacement of these parts.
2. Lift burners from slotted spacer and slide from orifices. Clean with a wire brush.
3. Clean orifice(s) as necessary.

Pilot Removal and Cleaning

Remove front inspection panel.

Remove wires to high limit and loosen screws
holding high limit to cabinet.

Remove wedge clip holding sensing bulb in control well.

Remove high limit and install a new one.

Check control operation before leaving job.

Heat Exchanger Removal

1. Disconnect pilot tubing at pilot and sensor/igniter
wire. Remove screws holding pilot bracket to burner tray.

1. Shut water, gas and electricity off, close valves
and relieve pressure, remove relief valve. Remove
side inspection panels.

2. Remove pilot and bracket, clean pilot of debris,
small bugs, etc., with wire or small brush.

2. Remove top holding screws.

3. Replace pilot, pilot tubing, sensor ignition wires
and check for leaks.

3. Remove draft diverter, lift and remove top and flue
collector on stack type models. Remove inspection panels.

High Limit or Tankstat Removal
1.

4. Loosen bolts and disconnect flange nuts on in/out
header, loosen union(s) at gas pipe, and slide boiler away from piping until studs clear the heater.

Turn off electrical power.

IN/OUT
HEADER
ELECTRICAL
JUNCTION BOX
REDUNDANT
SAFETY
SHUT-OFF
VALVE
MANUAL GAS VALVE

HIGH LIMIT

SEDIMENT TRAP
Fig. 53: Model 2100–4001 Boiler Illustration

MAIN GAS VALVE

5. Remove heat exchanger corner brackets.

10. If gas piping was disconnected, reconnect gas piping system and check for leakage using a soapy
solution.

6. Remove combustion chamber clips at the four corners of the heat exchanger.

11. Check for correct water pressure and water level
in the system. Make sure that system pump operates immediately on the call for heat. The system
is ready for operation.

7. Lift heat exchanger straight up using caution not to
damage refractory.

12. Within two (2) days of start-up, recheck all air
vents and expansion tank levels.

Combustion Chamber Removal
To remove combustion chamber you must first remove
the heat exchanger. Unbolt metal combustion chamber retainer from top and remove combustion chamber
panels individually.

Fig. 54: Heat Exchanger

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. Replace "V" baffles.
4. Install thermostat sensing bulbs in header wells
and replace bulb retaining clips.

Fig. 55: Refractory Panels—Top View

Control Well Replacement

5. Install inlet and return pipes in water headers
using pipe thread sealant.

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.

6. Install water pressure relief valve, flow switch, and
low water cut-off devices if so equipped.
7. Open water supply and return shut-off valves. Fill
boiler and water piping system with water. Check
boiler and piping system for leaks at full line pressure. Run system circulating pump for a minimum
of 1/2 hour with boiler off.

Tube Replacement Procedure
1. Remove heat exchanger from boiler following
instructions outlined under HEAT EXCHANGER
REMOVAL above.

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.

2. Remove in/out and return headers. Remove "V"
baffle from damaged tube.
3. Remove damaged tube by cutting with a hack saw
or shearing with a chisel adjacent to each tube
sheet.

9. Install flue collector, jacket top and inspection panels. Install top holding screws. Install draft diverter
and vent piping if so equipped.

4. Collapse stub ends in tube sheets using a chisel or
screwdriver. DO NOT cut into tube sheet or mar
surface in tube hole in any way.
40

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.

NOTE: In extreme cases it may be necessary to
remove the heat exchanger completely for cleaning.
The simplest method is steam cleaning at a local car
wash. DO NOT WIRE BRUSH!

6. Insert the tube roller into tube opening up to stop,
making certain that 1/8" of tube projects beyond
the tube sheet.

CAUTION: Soot is combustible, so exercise
extreme care.

7. Attach drill to tube roller, holding it straight and
level.

REPLACEMENT PARTS

NOTE: Use a 3/8" heavy duty, reversible, electric
drill or larger. Proceed to expand tube until tool starts
to grab. Approximately 1/2 to 1" of the tool shank will
be visible.

See separate parts sheet in instruction envelope.
NOTE: To supply the correct part it is important that
you supply the model number, serial number and
type of gas when applicable.

8. Reverse drill motor and withdraw tube roller. If
necessary wrench out by hand.

Any part returned for replacement under standard
company warranties must be properly tagged with
Raypak return parts tag, completely filled in with the
heater serial number, model number, etc., and shipped
to Raypak freight prepaid. If determined defective by
Raypak and within warranty, the part will be returned in
kind or equal substitution, freight collect. Credit will not
be issued.

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
RE-ASSEMBLY.

RAYPAK, INC.
2151 Eastman Avenue
Oxnard, CA 93030

Cleaning Flue Gas Passageways
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. Lift off drafthood and flue collector by removing
bolts and screws.
2. Remove "V" baffles from heat exchanger.
3. Remove burner tray.
4. Take garden hose and wash heat exchanger, making sure soot is removed from between fins. (Avoid
excessive water against refractory).
5. Reassemble; when boiler is fired, some steam will
form from wet refractory. This is normal.
6. Correct reason for soot formation.

Catalog Number: 1900.10H
Effective 08/01/10
LIMITED WARRANTY
RAYTHERM - TYPES H AND WH
Models: 133 - 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 defects in
materials and workmanship under normal use and service for the specified warranty periods and subject to the conditions set forth in this Limited
Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Limited Warranty, but
are the owner’s responsibility.
EFFECTIVE DATE
The Effective Date of this Limited Warranty is the date of original installation if properly documented; if you are not able to provide documentary proof of
the date of original installation, the Effective Date will be the date of manufacture plus 30 days.
HEAT EXCHANGER WARRANTY PERIODS
Domestic Hot Water
Five (5) years from Effective Date. Includes copper heat exchanger with bronze or cast iron waterways.
Ten (10) years from Effective Date. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways.
Space Heating (Closed Loop System)
Ten (10) years from Effective Date. Includes both cupro-nickel and copper heat exchanger with bronze or cast iron waterways.
Thermal Shock Limited Warranty
Twenty (20) years from Effective Date against “Thermal Shock” (excluded, however, if caused by heater operation at large changes exceeding 150ºF
between the water temperature at intake and heater temperature, or operating at heater temperatures exceeding 230ºF).
ANY OTHER PART MANUFACTURED BY RAYPAK
One (1) year from Effective Date.
THIS LIMITED WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.
ADDITIONAL WARRANTY EXCLUSIONS
This Limited Warranty does NOT cover units moved from their original installation location or conditions including failures or malfunctions resulting from:
1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;
2. Abuse, misuse, alteration, accident, fire, flood and the like;
3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;
4. High velocity flow exceeding heater design rates;
5. Failure of connected systems devices, such as pump or controller;
6. Use of non-factory authorized accessories or other components in conjunction with the heater system;
7. Failing to eliminate air from, or replenish water in, the connected water system;
8. Chemical contamination of combustion air or use of chemical additives to water.
REPAIR OR REPLACEMENT
At its option, Raypak will repair or replace a defective part(s) in accordance with the terms of this Limited Warranty, if it fails in normal use and service
during its specified warranty period. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable
warranty conditions found satisfied. The repair or replacement part will be warranted for only the unexpired portion of the original Limited Warranty.
Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak will apply any such warranty as may be provided to it by the parts
manufacturer.
HOW TO MAKE A WARRANTY CLAIM
You should immediately notify the original installer, supplying the model number and serial numbers of the unit, date of installation and description of the
problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available please contact Service
Manager, Raypak, Inc. 2151 Eastman Avenue, Oxnard CA 93030 or call (805) 278-5300. In all cases proper authorization must first be received from
Raypak before repair or replacement of any part.
EXCLUSIVE WARRANTY-LIMITATION OF LIABILITY
The Limited Warranty is the only warranty for this product and its component parts given by Raypak. No one is authorized to make any other warranties
on Raypak’s behalf. ANY IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT
EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS SPECIFIED IN THIS LIMITED WARRANTY. RAYPAK’S SOLE LIABILITY WITH
RESPECT TO ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO
LIABILITY WHETHER UNDER THIS LIMITED WARRANTY OR IN CONTRACT, TORT OR NEGLIGENCE OR OTHERWISE FOR CLAIMS FOR
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING NO LIABILITY FOR DAMAGE FROM WATER LEAKAGE) WHICH ARE
EXPRESSLY EXCLUDED, NOTWITHSTANDING ANY FAILURE OF ESSENTIAL PURPOSE OF ANY LIMITED REMEDY. Some states do not allow
limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages, so the above limitation or exclusion may
not apply to you.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE
TO STATE.
We suggest you immediately record the model and serial number and date of original installation and retain this Limited Warranty Certificate along with
your original proof of purchase and date of installation/start-up in the event warranty service is needed.
DO NOT RETURN THIS DOCUMENT TO RAYPAK. KEEP IT WITH YOUR HEATER OR BUSINESS RECORDS.
Name of Ow ner

Name of Installer

Owners A ddr ess

Telephone Number of Installer

Date of Installation

Installation Site

Model N umber

Serial Number

RAYPAK, INC., 2151 Eastman Avenue, Oxnard, CA 93030 • (805) 278-5300 FAX (800) 872-9725 www.raypak.com

www.raypak.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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Raypak Raytherm 133 4001 Users Manual 6000.59 New RP2100

133-4001 to the manual 87754a62-441f-47db-ad19-25c61610373a

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