Raypak 241275 manual

This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference. Catalog No: 1000.57A Effective: 02-28-07 Replaces: 02-24-06 P/N 241275 Rev . 2 INST ALLA TION AND OPERA TING INSTR UCTIONS COLD W A TER ST AR T & COLD W A TER RUN F or Hi Delta & MVB Hea ter s & Boiler s[...]

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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 . Saf[...]

4 COLD WA TER ST AR T Before arriving at the job site to begin the installation, it's important to first inspect the system and determine what materials you will need. Some parts are includ- ed with the controller while others you will need to provide. 1 Control Box 1 T emperature Sensor 1 V alve assembly with actuator (Shipped separately) Wir[...]

5 Connecting P ow er to the Controller Supply power from the 120 V AC power input from the heater to the controller power inputs T erminal Block (TB1). This is accomplished by connecting wiring from the control box to the heater TB1 board 120 V AC power input connections. Refer to wiring diagrams. Fig. 3: Component Locations — Hi Delta Fig. 4: Lo[...]

6 Cold Star t Sequence of Operation 1) 120V AC to heater sends 120V AC to Cold Start control on terminal block 1. 2) 120/24V AC transformer and 120V AC-12VDC con- verter are powered. 3) 120/24V AC transformer outputs 24V AC to pin 2 of terminal block 2 4) 24V AC leaves pin 2 of terminal block 2 and goes to the modulating three way valve on the 20- [...]

7 NO TE: Elodrive actuator is Nema 4 rated. TR OUBLESHOO TING Check your power source using a V olt-Ohm meter; check the following voltages at TB1 terminal block: TB1-1 to TB1-2 = 108 V AC Minimum, 132 V AC Maximum TB1-1 to TB1-3 = 108 V AC Minimum, 132 V AC Maximum TB1-2 to TB1-3 = Must be less than .6 V AC IF CALL FOR HEA T LED does not illuminat[...]

8 Cold Wa ter Star t T r oubleshooting Guide[...]

9 W iring Dia gr am[...]

10 COLD WA TER R UN Pur pose The Cold W ater Run system utilizes a variable-speed pump to inject the proper amount of water from the main system loop into the boiler to maintain the opti- mum inlet temperature. This approach allows the full capacity of the boiler to be utilized to meet the system load, while at the same time continuously maintainin[...]

11 Injection & Heater Pump Comparison — Hi Delta Heater Pump Injection Pump Heater Model Flow T emp. Rise Press. Drop Flow T emp. Rise Injection Pump Heater Pump 302 32 16 2 13 40 191 1- 1 ⁄ 4 hp 11 2 402 34 20 2 17 40 191 1- 1 ⁄ 4 hp 11 2 502 42 20 2.3 22 40 191 1- 1 ⁄ 4 hp 1630 4.0 652 55 20 4.1 28 40 191 1- 1 ⁄ 4 hp 1630 4.0 752 63[...]

12 Fig. 13: Remove the pump body Fig. 14: Be sure not to damage the seal when removing or replacing the pump body Injection Pump Co v er Installation Before Star ting 1) T urn off power to the unit at the circuit breaker . 2) T urn off gas supply . 3) Shut off the water supply to the heater and, if nec- essary , drain water from the system. 4) Allo[...]

13 3. Insert and tighten all eight (8) wrench bolts, secur- ing the pump body in place. 4. Y ou will now be able to install the pump cover . See Fig. 18 and 19. Fig 15: Reposition the pump body so that the electrical box points downward Fig. 16: Place the cover on the pump Fig 17: Pump cover - angle view[...]

14 Typical Boiler Piping (Hi Delta sho wn)[...]

15 ST AR T -UP PROCEDURE • Run full system flow for two minutes. • Initiate PID pump control to achieve target inlet temperature by slowing injector pump. • Boiler ΔT will not increase during bypass operation. • If target temperature is not achieved after seven minutes from “call for heat”, the system will shut down. Sequence of Operat[...]

16 W iring Dia gr am[...]

17 Cold Wa ter Run T roubleshooting Guide Ste p 9 Ste p 8 Ste p 10 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Is th ere a C all F or Heat at t he heat er? Is th e 220 VAC inver ter in t he cold r u n co ntroll er power ed ? Re place i nverte r or in stall j umper and c orr ect s witc h s ettin gs Does the col d run inv ert er o utpu t 12VDC f[...]

18 ILL USTRA TED P ARTS LISTS Cold Wa ter Star t[...]

19 1-M 4-M 2-M 3-M CALL OUT DESCRIPTION HI DEL T A MVB F 7 1 7 1 1 0 F 7 1 7 1 1 0 L O R T N O C - Y S S A D R A O B C P C - 1 F 8 1 7 1 1 0 F 8 1 7 1 1 0 R E M R O F S N A R T C - 2 3-C POWER SUPPL Y 120V AC/12VDC 01 1719F 01 1719F F 0 2 7 1 1 0 F 0 2 7 1 1 0 V 4 2 T D P D - Y A L E R C - 4 F 9 3 0 9 0 0 F 9 3 0 9 0 0 V 4 2 T D P S - Y A L E R C -[...]

20 Cold Wa ter Run[...]

21 CALL OUT B V M A T L E D I H N O I T P I R C S E D F 7 1 7 1 1 0 F 7 1 7 1 1 0 L O R T N O C - Y S S A D R A O B C P C - 1 F 0 2 7 1 1 0 F 0 2 7 1 1 0 C A V 4 2 T D P D - Y A L E R C - 2 F 9 3 0 9 0 0 F 9 3 0 9 0 0 C A V 4 2 T D P S - Y A L E R C - 3 F 5 3 8 1 1 0 F 5 3 8 1 1 0 P H 2 / 1 - R E T R E V N I C - 4 F 6 3 8 1 1 0 F 6 3 8 1 1 0 P H 1 [...]

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.[...]