Raypak 5042004 manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 3400.54E Effective: 03-25-10 Replaces: 03-19-09 P/N 241317 Rev . 6 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 T ypes H, WH, P & WHP L W WHA T T O DO IF Y OU SMELL GAS: • Do not try t[...]

2 Rev . 5 reflects the following: Changes to: Air Filter instructions on page 1 1, minor text changes on pages 13 and 14, Figs. 10 and 1 1 on page 15,. Fig 12 and T able G on page 16, Fig 13 on page 17, minor text changes on page 20, Fig. 21 on page 22, Figs. 22-28 on pages 25- 30, T able N on page 29, Fig. 35 on page 32, Mode 8 description on page[...]

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: I ndicates 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 u[...]

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 HIGH VOL TAGE ELECTRICAL CONNECTIONS Component Locations Panels omitted for clarity Fig. 1: Component Locations – Side T op panel, blower and gas train omitted for clarity Fig. 4: Component Locations – T op Fig. 3: Component Locations – Rear Model No. MBTUH Input* W ater Conn. (NPT) Gas Conn. (NPT)[...]

7 GENERAL SAFETY T o meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 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 initia[...]

Equipment Base The heater should be mounted on a level, structurally s ound surface. The heater is approved for installation on a combustible surface but must NEVER be i nstalled 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 [...]

9 Fig. 6: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations c odes and the requirments of the gas supplier . Three sides must be open in the area under the overhang. Roof water drainage must be diverted away from heaters installed under overhangs. The combustion air intake terminal MUST be used for o utdoor installat[...]

10 U. S. Ins tallations 1 Canad ia n Insta llati ons 2 A Clear ance above gr ade, veranda, p orc h, deck, or balcony 1 ft (30 c m) 1 ft (30 c m) B Clear ance to window or do or that may b e o pened 4 ft (1.2 m) below or to side of openin g; 1 foot (30 c m) a bove op ening 3 ft (91 cm) C Clearance to perma nen tly clos ed wind ow ** D V ertical clea[...]

11 Air Filter An air filter is supplied standard with the heater . This filter is shipped loose for field installation. Refer to the Air Filter Kit Installation Instructions (Part No. 241338) for details. 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 accord[...]

the enclosure, shall be provided. The openings shall communicate directly , or by ducts, with the o utdoors or spaces (crawl or attic) that freely com- municate with the outdoors. a. Where directly communicating with the out- d oors or where communicating to the outdoors through vertical ducts, each open- ing shall have a minimum free area of 1 in.[...]

R elief V alve Piping T emperature & Pr essur e Gauge The temperature and pressure gauge is shipped loose for field installation and must be installed within 12 inches of the boiler outlet (if possible) in an easily readable location. Installation must comply with ASME Section IV as well as all applicable national, state and local codes. Hydros[...]

14 longer than 7 minutes or where cold water operation is continuous, provisions must be made to mix higher t emperature outlet water with the colder inlet water and thereby raise the inlet temperature to at least 120°F (49°C) within the 7-minute time limit. Cold Wa ter Star ts Cold water starts, where the inlet water temperature remains below 12[...]

15 T able F: Heater Rates of Flow and Pressure Drops Note: Basis for minimum flow is ∆T . Basis for maximum flow is gpm. Piping All high points should be vented. A heater installed above radiation level must be provided with a low wa- ter cut-off device (sales order option F-10). This heater , when used in connection with a refrigeration system, [...]

16 P ota ble Wa ter and Space Heating 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water . 2. T oxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating. 3. If the heater will be used to su[...]

17 The MVB must be equipped with a field-supplied ex- te r n al pu m p a n d b y p as s ar ra n g em e n t. T h i s arrangement blends outlet water with the inlet water to i ncrease the inlet water temperature to a minimum of 105°F (40°C) for Pool Heater (P and WHP) versions a nd 120°F (49°C) for Hydronic Heating (H7) or Domestic Hot W ater (WH[...]

18 P ool/Spa Water Chemistr y Chemical imbalance can cause severe damage to the pool heater and associated equipment. Maintain the 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 [...]

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 • National Electrical Code and any other national, state, provincial or local codes or regulations hav- ing jurisdiction. • Safety wiring must be NEC Class 1. • Heater must be electrically grounded as required by the NEC. • In Canada, CSA C22. 1 C.E.C. Part 1. The MVB 504-1504 heaters are wired for 120 V AC, 12 amps while the MVB 2004 he[...]

Check the power source: AC = 108 V AC Minimum, 132 V AC MAX AB = 108 V AC Minimum, 132 V AC MAX BC = <1 V AC Maximum Making the Electrical Connections Refer to Fig. 18-21. 1. V erify that circuit breaker is properly sized by referring to heater rating plate. A dedicated circuit breaker should be provided. 2. NOTE: Current draw noted on rating pl[...]

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- it i v e ve n t s ta t i c pr e s su r e a n d wi t h a v en t g a s temperature that[...]

Suppor t of V ent Stack The weight of the vent stack or chimney must not rest on the heater vent connection. Support must be pro- vided in compliance with applicable codes. The vent should also be installed to maintain proper clearances from combustible materials. Use insulated vent pipe spacers where the vent passes through combustible roofs and w[...]

V enting Installation Tips Support piping: • horizontal runs—at least every 5 ft • vertical runs—use braces • under or near elbows V enting Configur a tions For heaters connected to gas vents or chimneys, vent installations shall be in accordance with the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes. Nat[...]

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. ** Adapters supplied by others. Fig. 23: V ertical V enting Model No. Ce[...]

26 C ommon V enting M anifolds 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 o f the common vent be less than the area of the largest heater exhaust outlet. Common venting systems may be too la[...]

4. Place in operation the appliances being inspected. Follow the manufacturer ’s instructions for lighting each appliance. Adjust thermostat so appliance w ill operate continuously . 5 . Check the pressure at a pressure tap located 12 in. above the bottom joint of the first vertical vent pipe. Pressure should be anywhere between -0.01 and -0.08 i[...]

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 ** Subtract 10 ft per elbow . Max. 4 elbows. t Adapters supplied by others. 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 climates. T er mina tion The flue terminal should be vertical and should termi- nate outsid[...]

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 sen- sors, 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 Deadband: Deadband is a band of temperature sens- ing where no action occurs. All temperature controllers h ave a deadband and the purpose is to prevent short- cyc ling of t he h eate r . The on- boar d t emp erat ure controller has a deadband of 2ºF around the differen- tial. Differential: A heat source must be operated with a temperature diff[...]

t rol operates the boiler burner to maintain the boiler target at the boiler outlet sensor . Mode 7 – Designed for an external input signal with p rimary/secondary piping. The external input signal can be provided from a BMS, an EMS or an external c ontrol. The external input signal changes the boiler target according to a linear scale (see T abl[...]

Mode 8 – This mode is for remote firing control of the heater via an external sequencer such as the Raypak T empT racker MOD+. The Boil Max setting is the heater shutdown temperature (max temperature). The heater is enabled via dry contact at the Enable/Disable connection at the low voltage terminal strip, and the fir- ing rate is controlled by a[...]

34 T able Q: T emperature Control Default Setpoints—Boiler Boiler (H7) Item Modes Default Setting Range B oil T arget 2 1 40°F O FF , 70 to 220°F 3 1 60°F O FF , 70 to 190°F 5, 7 180°F OFF , 70 to 220°F Boil Max 2, 5, 7, 8 200°F OFF , 120 to 225°F 3 180°F OFF , 120 to 190°F Boil Min 2, 3, 5, 7 135°F OFF , 80 to 180°F ‘Burner ’ Del[...]

35 EXTERNAL INPUT SIGNAL – Selects external input signal range (0-10VDC or 2-10VDC): 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 t[...]

UNITS - Selects the temperature units to be displayed (°F or °C). WWSD - Selects the outdoor temperature that shuts the heater off, no matter what the demand. NOTE: The WWSD segment will be displayed on the LCD. Operation The Raypak electronic temperature control uses a Liquid Crystal Display (LCD) as a method of supply- ing information. The LCD [...]

The optional single-try ignition module will lock out after failing to light one time. T o reset it, press and release the small, recessed black push button located i nside of the cut-out on the lower right-hand corner of the ignition module case. T urning off the power to t he heater WILL NOT reset the ignition module. High Limit—Manual R eset T[...]

38 Modulating T emper ature Contr ol This heater is equipped with a Raypak modulating t emperature control. Refer to information starting on page 30 for information on the setting and use of this control. 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[...]

39 Block ed V ent Switch This heater is equipped with a blocked vent pressure s witch 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 the[...]

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

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

42 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 Wa ter Heaters) Pu[...]

43 C heck P ow er Suppl y W ith 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. Turn of f main gas valve. 2. Attach (1) 12” scale manometer to an upstream bleedle valve on the gas supply pipe to the heater (Measure[...]

44 w ith the blower suction within the tolerances spec- ified in T able T , contact the factory . The reference amp draw reading may help to indicate if there is a problem with the system or if blower adjustment i s required. Manifold Chec k 1. Check manifold gas pressure at the gas valve out- let pressure tap (connection “D” in Fig. 48) . This[...]

45 Leak T est Procedur e: Dual-Seat Gas V alve P roper 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 l[...]

46 f or 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 d elay . 8 . T est limit control: While burner is operating, move indicator on high limit control below actual water temperature. Burner should go of[...]

47 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 Appliance 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[...]

48 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 conn ection int act? Does the combustion air blower come on? Is 4-20mA present at the quick disconne ct s on the black and blue wir es of the tem p erature controlle r ? Is 24VAC at the NC side of the air pressure switch? Doe[...]

49 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency . Maintenance as outlined below may be performed by the owner . Daily 1. Check that the area where the heater is installed is free from combustible materials, gasoline, and othe[...]

50 6 . Perform leakage test on gas valves (See Fig. 49.) and procedure on page 45. 7. T est air switch in accordance with manufacturer ’ s i nstructions. (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 lo[...]

51 Filter R eplacement 1. Remove the filter box cover by loosening and removing the two wing nuts holding it in place. 2. Remove the filter by lifting it straight up and out of the slot in the filter box. 3. Reverse steps 1 and 2 to install the new filter . Use Raypak replacement filters, kit number 012552F (12”X12”) for models 504-1 104 and ki[...]

52 (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 [...]

53 LIMITED PARTS WARRANTY MVB – TYPES H AND WH MODELS 504-2004 SCOP E R aypak , Inc . (“Ray pak”) w arr ants to t he o rig in al ow ner th at all par ts o f th is h ea ter w hic h ar e ac tu al ly m an uf actur ed by R ay pak w il l be fre e f ro m fai lur e un der n ormal us e and s ervic e for th e sp ec if ied w ar ra nty per io ds and s u[...]

54 LIMITED PARTS WARRANTY MVB – TYPES P & WHP MOD ELS 504–2004 S CO PE Ray pak, Inc . (“R ay pak ”) w arrant s to th e o rig inal ow ner th at al l par ts o f t his h eat er w hic h a re ac tu al ly m an ufac tur ed by R ay pak wil l b e fre e fro m f ailur e un der n orm al us e a nd s erv ic e for t he s p ecif ie d wa rr a nty per io[...]

55 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This s tart -u p chec klis t is to be co mplete ly filled o ut by t he service technician star ting up the Rayp ak Boiler or H eater f or the first time . A ll i n formation may be used f or w arranty p urposes an d to ensure t ha t the ins tallation is corre ct. Additionally this form will be [...]

w w w .ra y pak .co m Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.[...]