Raypak 504-2004 manual

INST ALLA TION AND OPERA TING INSTR UCTIONS CA T ALOG NO. 3400.54 Effective: 06-01-07 Replaces: NEW P/N 241317 Rev . 1 This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference. Models 504–2004 Types H, WH, P & WHP L W[...]

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WARNINGS 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 6 GENERAL SAFETY 7 T ime/T emperature Relationships in Scalds 7 INST ALLA TION 8 Installation Codes 8 Equipment Base 8 Clearances 8 Combustion and V entilation Air 9 Conventi[...]

4 D ANGER: 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. CA UTION: Indicates the presence of hazards or un[...]

5 BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your MVB heater . Please review the General Safety information before installing the heater . Factory warranty does not apply to heaters that have been improperly installed or oper- ated. (Refer to the warranty at the back of this manual.)[...]

General Infor ma tion T able A: Basic Data 6[...]

7 GENERAL SAFETY T o meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F . However , water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water , the rec- ommended initial setting for the temperature control is 125°F . T[...]

Equipment Base The heater should be mounted on a level, structurally sound surface. The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed in enclosed parking garages must be located at least 18 in. above the floor . In addition, the heater shall be installed such th[...]

9 Fig. 5: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations Three sides must be open in the area under the over- hang. Roof water drainage must be diverted away from heaters installed under overhangs. The combustion air intake terminal MUST be used for outdoor installations. The hood is shipped loose and installed on[...]

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11 Optional Constr uction Air Filter An optional construction air filter is available for use. The filter should be removed after construction is fin- ished to allow for unrestricted air flow to the heater . Direct V ent If outside air is drawn through the intake pipe directly to the unit for combustion: 1. Install combustion air direct vent in acc[...]

b. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in. 2 per 2,000 BTUH (1,100 mm 2 per kW) of total input rat- ing of all equipment in the enclosure. 2. One permanent opening , commencing within 12 in. (305 mm) of the top of the enclosure, shall be permitted where the equipment has c[...]

R elief V alve Piping Hydrostatic T est Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in operation. The heat exchanger has already been fac- tory-tested and is rated for 160 psi operating pressure. However , Raypak does recommend hydrostatic test- ing of the piping connections to the heater a[...]

14 longer needed and the bypass can be shut off. If the bypass is not shut off as the system heats up, the out- let temperature may continue to climb and trip the high limit, thereby shutting down the heater . Thus an auto- matic valve system, such as a three-way proportional valve or a modulating two-way valve to control the bypass, should be util[...]

15 T able F: Heater Rates of Flow and Pressure Drops Note: Basis for minimum flow is ΔT . Basis for maximum flow is gpm. The piping system of a hot water heater connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air , must be equipped with flow control valves or other automatic means to p[...]

16 Domestic Hot Wa ter When designing the water piping system for domestic hot water applications, water hardness should be con- sidered. T able G indicates the suggested flow rates for soft, medium and hard water . Water hardness is ex- pressed in grains per gallon. P ota ble W ater and Space Heating 1. All piping materials and components connecte[...]

17 increase the inlet water temperature to a minimum of 105°F (40°C) for Pool Heater (P and WHP) versions and 120°F (49°C) for Hydronic Heating (H7) or Domestic Hot W ater (WH1) versions, thereby reducing the likelihood of condensation forming on the heat exchanger . The pump also serves to circulate water through the heater from the main syste[...]

18 P ool/Spa Water Chemistr y Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water chemistry according to the chart below . If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchang- er tubes, reducing heater efficiency and damaging the heater . I[...]

19 Further advice should be obtained from your pool or spa builder , accredited pool shop, or chemical suppli- er for the correct levels for your water . Automa tic Chlorinator s and Chemical F eeder s All chemicals must be introduced and completely dilut- ed into the pool or spa water before being circulated through the heater . Do not place sanit[...]

20 The MVB 504-1504 heaters are wired for 120 V AC, 12 amps while the MVB 2004 heaters are wired for 120 V AC, 18 amps. Consult the wiring diagram shipped with the heater . Before starting the heater , check to ensure proper voltage to the heater and pump. Boiler mounted pumps (up to 3 ⁄ 4 hp) get their power supply directly from the boiler power[...]

21 Field-Connected Controller s It is strongly recommended that all individually-pow- ered control modules and the heater should be supplied from the same power source. Check the P ower Source NO TE: Field-supplied isolation relays should be installed when field-connected controllers are mounted more than 50 equivalent feet (18 Ga) from heater . WA[...]

22 Field W iring Connection V enting General Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Category I – A heater which operates with a non-pos- itive vent static pressure and with a vent gas temperature that avoids excessive cond[...]

1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 2. Give special attention to the location of the vent termination to avoid possibility of property dam- age or personal injury . 3. Gases may form a white vapor plume in winter . The plume could obstruct a window view if the ter- mina[...]

24 7. The vent terminal requires a 12 in. vent terminal clearance from the wall. 8. T erminate vent at least 1 ft above grade, including normal snow line. 9. Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane. Canadian Installations Refer to latest edition of the B149 Insta[...]

25 T able L: Category I V ertical V enting 1 V ent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. When vertical height exceeds 25 ft, consult factory prior to installation. * Subtract 10 ft per elbow . Max. 4 elbows. T er mina tion The vent terminal should be vertical and should termi- na[...]

26 Common V enting Manifolds that connect more than one heater to a com- mon 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 of the common vent be less than the area of the largest heater exhaust outlet. Common venting systems may be too large[...]

system. T urn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliances being inspected. Follow the manufacturer ’s instructions for lighting each appliance. Adjust thermostat so appliance will operate continuously . 5. Check t[...]

28 • 75’ of straight flue pipe • 65’ of straight flue pipe and one elbow • 55’ of straight flue pipe and two elbows • 45’ of straight pipe and three elbows The vent cap is not considered in the overall length of the venting system. The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure t[...]

29 * V ent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. ** Subtract 10 ft per elbow . Max. 4 elbows. T able N: Category III Horizontal V ent & Horizontal Direct V ent See T able L for Category I venting guidelines. It is recommended that the intake vent be insulated in colder climat[...]

F r eeze Protection The Raypak electronic temperature control includes a freeze protection feature. In the event the temperature drops below 40° F at any of the boiler temperature sensors, the pump is turned on and will remain on until the temperature at all boiler sensors rises to 45° F . Controls The Raypak electronic temperature control is pro[...]

31 Operating Modes Mode 1 – (H7 and WH1 models) Setpoint operation using primary piping. The heater outlet water temper- ature is controlled to the boiler target setpoint. See Fig. 27. Mode 2 – Setpoint operation using primary/secondary piping. The control operates the heater to satisfy a remote system sensor . The heater is turned off based on[...]

32 Mode 5 – Outdoor reset using primary/secondary pip- ing. The heater is operated as in Mode 2. However , the target temperature is based on outdoor reset. See Fig. 31. Mode 6 – Designed for an external input signal with primary piping. The external input signal can be pro- vided from a BMS, an EMS or a sequencing control. The external input s[...]

33 T able O: T emperature Control Default Setpoints—Boiler Boiler (H7) Item Modes Default Setting Range Boil T arget 1, 2 140°F OFF , 70 to 220°F 3 160°F OFF , 70 to 190°F 4, 5, 6, 7 180°F OFF , 70 to 220°F Boil Max 1, 2, 4, 5, 6, 7, 8 200°F OFF , 120 to 225°F 3 180°F OFF , 120 to 190°F Boil Min 1, 2, 3, 4, 5, 6, 7 135°F OFF , 80 to 18[...]

34 Definitions % OUT - Current percent modulation rate of heater . BOIL DSGN - Design boiler water temperature used in heat loss calculations. BOIL MASS - This setting allows adjustment in the field for high or low thermal masses; High thermal mass (setting=3) provides slower reaction, lower ther- mal mass (setting=1) provides faster reaction. BOIL[...]

35 0-10VDC or 0-20 mA external input signal – When the 0-10VDC signal is selected, an input voltage of 1 VDC corresponds to a boiler target temperature of 50°F (10°C). An input voltage of 10 VDC corresponds to a boiler target temperature of 220°F (104°C). As the voltage varies between 1 VDC and 10 VDC, the boiler target temperature varies lin[...]

36 Operation The Raypak electronic temperature control uses a Liquid Crystal Display (LCD) as a method of supply- ing information. The LCD is used to setup and monitor system operation by means of three push buttons ( Item , L and M ) shown at the bottom of Fig. 34. All items displayed by the control are organized into two menus, the view menu and [...]

37 9. 24 V AC is sent from the NC contact of the High Gas Pressure Switch to the common terminal of the Low W ater Cut Off (if equipped). Upon loss of water in the heater , the Low Water Cut Of f (if equipped) will send a 24V AC signal to pin P3-4 of the UDB board to indicate a safety fault. 10. 24V AC is sent from the NO contact of the Low W ater [...]

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Modulating T emper a tur e Control The heater is equipped with a Raypak modulating tem- perature control. Refer to information starting on page 31 for information on the setting and use of this con- trol. Low W ater Cut-Off (Optional) The optional low water cut-off automatically shuts down the burner whenever water level drops below the level of th[...]

Block ed V ent Switch This heater is equipped with a blocked vent pressure switch to prevent the operation of the heater when too much of the vent is blocked. This switch is located on the right side of the heater near the right rear corner . UDB Diagnostic Boar d This heater is equipped with a diagnostic board which will indicate faults as they oc[...]

41 WIRING DIA GRAM - Models H & WH[...]

WIRING DIA GRAM - Models P & WHP 42[...]

43 ST ART -UP Pre Star t-up Filling System (Heating Boilers) Fill system with water . Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. Air Pur ge (Domestic Hot W ater Heaters) Pu[...]

44 Check P ower Supply With multi-meter at incoming power , check voltage between: Hot - Common (≈120 V AC) Hot - Ground (≈120 V AC) Common - Ground (< 1 V AC) Attach Manometers to Measure Pr essures 1. T urn off main gas valve. 2. Attach (1) 12” scale manometer to an upstream bleedle valve on the gas supply pipe to the heater (Measure poi[...]

45 2. If the pressure reading differs by more than ± 0.2 in. WC, STOP – Call the factory for directions on what to do next! Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record. 3. If other gas-fired appliances in the room are on the same gas main[...]

46 Leak T est Procedur e: Dual-Seat Gas V alve Proper leak testing requires three pressure test points in the gas train. Remove the access panel on the rear of the heater to access the gas valve for this test. T est point A is a blee- dle valve located upstream of the combination gas valve on the supply manifold. T est point B is a bleedle valve lo[...]

47 for operation as outlined by manufacturer . Burner should be operating and should go off when con- trols are tested. When safety devices are restored, burners should re-ignite after pre-purge time delay . 8. T est limit control: While burner is operating, move indicator on high limit control below actual water temperature. Burner should go off w[...]

48 d. Gas is on at the meter and the heater . e. Incoming dynamic gas pressure to the gas valve is NOT less than 4.0 in. WC for natural gas or propane gas. T o T ur n Of f Gas T o A ppliance 1. Shut off manual gas valve field installed near gas inlet connection on back of heater . 2. Remove upper front panel. 3. Set the thermostat to lowest setting[...]

49 TR OUBLESHOO TING Ste p 8 Ste p 7 Ste p 6 Ste p 9 Step 1 Step 2 Step 3 Step 4 Step 5 Is there a Call For Heat? Is Disable connection intact? Does the combustion air blower come on? Is 4-20mA present at the quick disconnects on the black and blue wires of the tem p erature controlle r ? Is 24VAC at the NC side of the air pressure switch? Does F2 [...]

50 UDB F ault Histor y T o view the fault codes in the UDB history file: 1. Press and hold the switch labeled “SW1” for 5 sec- onds to access the fault history . LED 17 will begin to flash when the history has been accessed. See Fig. 44 on page 40. 2. Press the switch labeled “SW2” to scroll through the recorded faults in history . 3. When [...]

51 by local codes. 3. Check that area is free from combustible materi- als, gasoline, and other flammable vapors and liquids. 4. Check for and remove any obstruction to the flow of combustion or ventilation air to heater . 5. Follow pre-start-up check in the Start-up section. 6. Visually inspect burner flame. It should be light blue at full input. [...]

52 6. Perform leakage test on gas valves (See Fig. 46.) and procedure on page 46. 7. T est air switch in accordance with manufacturer ’s instructions. (T urn panel switch to the “On” posi- tion until blower is proven, then turn the switch to “Off.” 8. Inspect and clean burner using shop air . As R equir ed 1. Recondition or replace low wa[...]

53 (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required T o Be V ented" in the most current edition of NFP A 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or s[...]

54 LIMITED PARTS WARRANTY MVB – TYPES H AND WH MODELS 504-2004 SCOP E Ray pak, Inc. (“ Ray pak ”) w arr ants to the o rig inal ow ner th at al l par ts of this hea ter w hic h a re actu al ly m anuf actur ed by R ay pak w ill b e fre e fro m fai lur e un der nor mal use and s ervic e for th e sp ec ifie d wa rra nty per iods a nd s ubjec t t [...]

55 LIMI TED P ARTS WARRANTY MVB – TYPE P & WHP MODELS 504–2004 SCOP E Ray pak, Inc. (“ Ray pak ”) w arr ants to th e orig in al ow ner th at al l parts o f this h eater w hic h a re actu al ly m anuf ac tured by R aypak w ill b e fre e fro m fai lur e un der nor mal use and s ervic e for th e s pec ifie d wa rra nty per iods a nd s ubje[...]

56 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS - M V B Thi s s ta rt-u p ch ec klis t is to b e c o mpl ete ly fill ed o u t b y t he s erv ic e tec hn ic ian s tar tin g up th e R ayp a k Boi le r or He ater for the first time. All information may be used for warra nty purposes an d to ensure that the ins tallation is corre ct. Add itio n [...]

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ww w .raypak.c om Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A.[...]