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Raypak 5042004 Boiler User Manual

1. wNouL40 M3ONTIS Ti38 WVV O START UP NOTE The following steps must be performed by a factory trained technician Pre Start 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 Purge Domestic Hot Water Heaters Purge all air from system before heater operation This can be normally accomplished by opening a down stream valve Raypak offers an optional air vent valve for the MVB heaters which can be installed directly into the inlet side of the header to ensure that air is purged from the system This option also includes an adapter to allow the air vent to be piped in the field to a suitable drain as re quired by the jurisdiction having authority CAUTION An air vent valve should be installed at the highest point in the system for proper operation If water piping is located higher than the header the air vent valve should be relocated to the highest point in the installed system Venting System Inspection 1 Check all vent pipe connections and flue pipe ma terial
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3. POWER N SAEN enon DU WARNING Using a multi meter check the o G O16 JA following voltages at the circuit breaker panel prior to connecting any equipment Make sure proper GUGLEUGQUGUG eo polarity is followed and house ground is proven OO 0 See Fig 19 O O O O O O P N 901909 REV 2 g FACTORY WRN Check the power source REAR WIRING BOX ELECTRICAL CONNECTIONS AC 108 VAC Minimum 132 VAC MAX AB 108 VAC Minimum 132 VAC MAX BC lt 1 VAC Maximum do amp 9 amp SYSTEM SENSOR ped eed eed Scd SEO HOT JUMPERED WHEN NOT USED eee WIRING OPTIONAL OPTIONAL OPTIONAL OPTIONAL E s WIRING FRONT WIRING PANEL LOW VOLTAGE ELECTRICAL CONNECTIONS Fig 18 Wiring Electrical Connections Field Connected Controllers Fig 20 Multi meter It is strongly recommended that all individually pow Making the Electrical Connections ered control modules and the heater should be supplied from the same power source Refer to Fig 18 21 NOTE Field supplied isolation relays should be 1 Verify that circuit breaker is properly sized by installed when field connected controllers are referring to heater rating plate A dedicated circuit mounted more than 50 equivalent feet 18 AWG breaker should be provided from heater See wiring diagrams
4. A ed 7 i NS LOW VOLTAGE ELECTRICAL z CONNECTIONS Panels omitted for clarity Fig 2 Component Locations Front FLOW SWITCH COMBUSTION AIR INLET GAS SUPPLY CONNECTION PRESSURE RELIEF CONNECTION HIGH VOLTAGE ELECTRICAL CONNECTIONS WATER OUTLET WATER INLET FLUE OUTLET Fig 3 Component Locations Rear BURNER IGNITER SENSOR FRONT OF HEATER MANUAL RESET HI LIMIT Top panel blower and gas train omitted for clarity Fig 4 Component Locations Top General Information Vent Size in 1104 1100 E NES 2 1 2 1 1 4 1504 1500 1050 2 1 2 1 14 2004 1999 1400 2 1 2 H7 units only Table A Basic Data GENERAL SAFETY To 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 initial setting for the temperature control is 125 F This section applies to Hot Water Supply Boilers and Hot Water Heaters ONLY For sanitary rinse applica tions where outlet temperatures of 180 F to 19
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6. CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause im proper and dangerous operation Verify proper operation after servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is discon nected to avoid potential serious injury or damage to components HIGH VOLTAGE WIRING 7 c Fig 21 High Voltage Wiring Location f LOCATOR DIMPLES FOR OPTIONAL COMPONENTS Venting CAUTION Proper installation of flue venting is critical for the safe and efficient operation of the heater 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 A heater which operates with a non pos itive vent static pressure and with a vent gas temperature that avoids excessive condensate pro duction in the vent Category II A heater which operates with a non pos itive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent Category lll A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent Category IV A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate
7. 2 Make sure vent terminations are installed per code and are clear of all debris or blockage For Your Safety WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance has a hot surface igniter It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 42 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell near 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 electrical switch do not use any telephone in your building Immediately call your gas supplier from a neigh bors telephone 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 con trol knob Never use tools If the knob will not turn by hand do not try to repair it call a qualified serv ice technician Forced 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 Check around unit for debris and remove com bustible products i e gasol
8. KA me X B Sg THERMOSTAT OR SYSTEM SENSOR Maximum 4 times the pipe diameter or 12 whichever is less Fig 13 Dual Heaters Reverse Return with Primary Secondary Piping Three Way Valves NOTE If local codes require a vacuum relief valve acquire one locally and install per valve Three way valves intended to regulate system water manufacturer s instructions temperatures by reducing flow in the boiler should not be used Raypak heaters are high recovery low mass heaters which are not subject to thermal shock See Fig 16 and instructions on page 17 for adjusting the manual bypass Potable Water and Space Heating CAUTION When this heater is used for both potable water and space heating observe the following to ensure proper operation Domestic Hot Water 1 All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water When designing the water piping system for domestic hot water applications water hardness should be con sidered Table G indicates the suggested flow rates for soft medium and hard water Water hardness is ex pressed in grains per gallon 2 Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water used DS for space heating T SYSTEM SUPPLY 3 If the heater will be used to supply potable water it shall not be
9. 3 High p 2 F wa Table R Temperature Control Default Setpoints Pool Heater 2 2 2 Burner Delay 0 00 to 3 00 min II 2 I I A 34 Water Heater WH1 Boil Target 140 F OFF 70 to 190 F 160 F OFF 70 to 190 F Ton 2 ed 3 s Table S Modulating Temperature Control Default Setpoints Water Heater 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 the voltage varies between 1 VDC and 10 VDC the boiler target temperature varies linearly between 50 F 10 C and 220 F 104 C refer to Table O If a volt age below 0 5 VDC is received the boiler target temperature is displayed as indicating that there is no longer an internal call for heat A 0 20 mA signal can be converted to a 0 10 VDC signal by installing a 500 Q resistor on the external input signal device s terminals 2 10VDC or 4 20 mA external input signal When the 2 10VDC signal is selected an input voltage of 2 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 2 VDC and 10 VDC the boiler target
10. 800 872 9725 www raypak com START UP CHECKLIST FOR FAN ASSISTED RAYPAK PRODUCTS This start up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time All information may be used for warranty purposes and to ensure that the installation is correct Additionally this form will be used to record all equipment operation functions and required settings GAS SUPPLY DATA Regulator Model amp Size CFH Gas Line Size in room In NPT Length of Gas Line Eq Ft Low Gas Pressure Setting In WC High Gas Pressure Setting In WC Gas Shut Off Valve Type Ball Lube cock Sediment Trap Y N Port Std Full VISUAL INSPECTION OF COMPONENTS Verify inspection was done and condition of components are in good working order with a yes Wiring Harness Y N Burner s flame Y N Refractory visual Y N Remote flame sense Y N Covers in place for outdoor Y N VENTING Vent Size Stack Height Category sketch vent on reverse side Vent Material Vent Termination Type Combustion Air Openings Low in2 Ventilation air High in2 EMISSIONS SETTINGS AND TEST INFORMATION AT FULL FIRE Blower Pressure Setting In WC Supply Gas Pressure In WC Verify stable pressure static amp dynamic condition Pilot Gas Pressure Manifold Gas Pressure In WC In WC CLEARANCES Front Clearance In Right Si
11. DI MO paw L External Input i Status Field Modulation Offset Signal Displays the LM current status n 0 p of the control s fal Rae Modulating inputs outputs Control and operation Buttons Selects Item A Y Menus Items and adjusts settings Fig 37 Modulating Temperature Control Display menu name ADJUST will be displayed in the menu field The menu will automatically revert back to the view menu after 20 seconds of keyboard inactivity Then scroll to the desired item using the scroll button Fi nally use the A or W button to make the adjustment In the absence of other information the values pro vided in Tables Q R and S should be used as default settings Heater Sequence of Operation If all limits are satisfied and there is a call for heat 1 The heater pump is powered and begins circulat ing water through the heat exchanger The blower is powered and goes through a 15 sec ond prepurge beginning when air flow is proven by closure of the blower suction air pressure switch The igniter is powered and once proven heats up for 20 seconds The gas valve is then energized for a 4 second trial for ignition period Trial for ignition is fixed at 50 input The heater is allowed to modulate once flame is proven and the firing rate will adjust to match the load based on the configuration and set tings of the temperature control or external input Once the heat demand is satisfi
12. Returned Goods Receipt number will not be accepted All returned goods are subject to a restocking charge When ordering parts you must specify the model and serial number of the heater When ordering under war ranty conditions you must also specify the date of installation Purchased parts are subject to replacement only under the manufacturer s warranty Debits for defec tive replacement parts will not be accepted Parts will be replaced in kind only per Raypak s standard war ranties Model Identification The model identification number and heater serial number are found on the heater rating plate located on the upper rear jacket panel of the heater The model number will have the form H7 2004 or similar depend ing on the heater size and configuration The letter s in the first group of characters identifies the application H Hydronic Heating P Pool Heating WH Domestic Hot Water DHW WHP Water Heater for Pool Heating The number which follows identifies the firing mode 7 electronic modulation 1 On Off The second group of characters identifies the size of the heater three or four numbers representing the approximate MBTUH input and where applicable a letter indicating the manufacturing series Ratings and Certifications Standards ANSI Z21 56 CSA 4 7 latest edition Gas Fired Pool Heaters ANSI Z21 13 CSA 4 9 latest edition Gas Fired Hot Water Boilers CAN 3 1 latest
13. sl eo e e o o uo ane ms we re pao se po se en e 9 2 9 Note Basis for minimum flow is AT Basis for maximum flow is gpm Table F Heater Rates of Flow and Pressure Drops 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 must be installed so that the chilled medium is piped in parallel with the heater with appropriate valves to pre vent the chilled medium from entering the heater 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 prevent gravity circulation of the heater water during the cooling cycle It is highly recommend ed that the piping be insulated Air Separation Expansion Tank All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig 11 EXPANSION TANK U AIR SEPARATOR WITH BLEED VALVE Fig 11 Air Separation Expansion Tank 15 THERMOSTAT OR SYSTEM SENSOR Maximum 4 times the pipe diameter or 12 whichever is less Fig 12 Single Heater Low Temperature Heat Pump Application with Primary Secondary Piping at
14. structures or building finish For maximum efficiency and safety the following precautions must be observed 1 Outdoor models must be installed outdoors and must use the outdoor vent cap and air intake hood available from the manufacturer sales order option D 11 Periodically check venting system The heater s venting areas must never be obstructed in any way and minimum clearances must be observed to prevent restriction of combustion and ventilation air Keep area clear and free of combustible and flammable materials Do not locate adjacent to any window door walk way or gravity air intake The vent must be located a minimum of 4 ft horizontally from such areas Install above grade level and above normal snow levels Vent terminal must be at least 3 ft above any forced air inlet located within 10 ft Adjacent brick or masonry surfaces must be pro tected with a rust resistant sheet metal plate FLUE EXHAUST VENT CAP HEATER UNIT N SFT INTAKE VENT INSULATED EXHAUST VENTING CONDENSATION TRAP Fig 29 Outdoor Venting NOTE The vent cap and air intake hood must be furnished by the heater manufacturer in accordance with its listing sales order option D 11 NOTE Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Freeze Protection The Raypak electron
15. DE TAIL VLLLLLLLLL LEAL LO VLLLLLLLL LL A A H e Fig 7 Minimum Clearances from Vent Air Inlet Terminations Indoor and Outdoor Installations Clearance above grade veranda porch deck or balcony Canadian Installations U S Installations 1 ft 30 cm 1 ft 30 cm Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal dis tance of 2 ft 61cm from the centerline of the terminal 4 ft 1 2m below or to side of opening 1 foot 30 cm above opening 3 ft 91 cm Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line ex tended above meter regulator assembly 3 ft 91 cm within a height 15 ft above the me ter regulator assembly Clearance to service regulator vent outlet Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance Clearance to mechanical air supply inlet Clearance above paved sidewalk or paved driveway located on public property 6 ft 1 83m 4 ft 1 2m below or to side of opening 1 ft 30 cm 3 ft 91 cm above opening 3 ft 91 cm above if within 6 ft 1 83m 10 ft 3m horizontally 7 ft 2 13m t 7 ft 2 13m Clearance under veranda porch deck or balcony 12 in 30 cm TT I
16. Five 5 years from date of heater installation Includes cupo nickel heat exchanger with bronze and cast iron waterways Thermal Shock Warranty Twenty 20 years from date of heater installation against Thermal Shock excluded however if caused by heater operation at large changes exceeding 150 F between the water temperature at intake and heater temperature or operating at heater temperatures exceed ing 230 F ANY OTHER PART MANUFACTURED BY RAYPAK One 1 Year warranty from date of heater installation or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PROOF OF INSTALLATION DATE SUCH AS INSTALLER INVOICE IS REQUIRED THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from 1 Failure to properly install operate or maintain the heater in accordance with our printed instructions provided 2 Abuse alteration accident fire flood and the like Sediment or lime build up freezing or other conditions causing inadequate water circulation High velocity flow exceeding heater design rates Failure of connected systems devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the heater system Chemical contamination of combustion air or use of chemical additives to water Misuse or
17. NFGC U S or B149 Canada T Vertical Vent Air Inlet Certified Combustion Air Vent Vent Size Height ft Intake Pipe Max Length ft Material Category Type B Equivalent Galvanized 45 100 Steel PVC ABS CPVC 1 Vent 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 Table L Category I Vertical Venting The diameter of vent flue pipe should be sized accord ing to the NFGC U S and B149 Canada The connection from the appliance vent to the stack must be as direct as possible The horizontal breach ing of a vent must have an upward slope of not less than 1 4 inch per linear foot from the heater to the vent terminal The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent phys ical damage or separation of joints Termination The vent terminal should be vertical and should termi nate outside the building at least 2 ft above the highest point of the roof that is within 10 ft The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below unless a 4 ft hori zontal distance is maintained electric meters gas meters regulators and relief equipment The dis
18. OPE ISOLATION VALVES FULLY OPEN Fig 16 H Bypass Setting NOTE For automatic temperature adjustment a Cold Water Run CWR system can be used instead of a manual bypass See Fig 10 CAUTION Combustion air must not be contami nated by corrosive chemical fumes which can damage the heater and void the warranty Winterizing Your Heater Heaters installed outdoors as pool heaters in freezing climate areas should be shut down for the winter To shut down the heater turn off manual main gas valve and main gas shut off Close isolation valves Drain the heater using the hose bibs located on the bottom of the heat exchanger NOTE There are 2 separate drains on the MVB that must BOTH be drained to protect the heat exchanger These are both accessible by removing the lower front door from the heater Drain any piping of all water that may experience below freezing temperatures Pool Spa Water Chemistry CAUTION Corrosive water voids all warranties NOTE Chemical imbalance can cause severe damage to your heater and associated equipment 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 If the pH drops below 7 2 this will cause cor rosion of
19. Table 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 Table N on page 29 Fig 35 on page 32 Mode 8 description on page 33 minor text changes on pages 42 43 and 46 Troubleshooting chart on page 48 Additions Fig 2 on page 6 Low lead requirement on page 5 Fig 8 on page 11 note on page 12 Caution on page 20 Fig 22 on page 22 Fig 36 on page 33 air filter instructions on pages 50 and 51 CONTENTS WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information GENERAL SAFETY Time Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connection Venting Venting Installation Tips Venting Configurations Engineered Vent Systems Outdoor Installation Controls Heater Sequence of Operation WIRING DIAGRAMS START UP Pre Start up Start Up OPERATION Lighting Instructions To Turn Off Gas To Appliance UDB Fault History TROUBLESHOOTING MAINTENANCE Suggested Minimum Maintenance Schedule Preventative Maintenance Schedule Filter Maintenance Filter Replacement APPENDIX Inside Air Contamination IMPORTANT INSTRUCTIONS FOR THE COMMONWEALTH OF MASSACHUSETTS WARRANTY STA
20. an intermediate gas pressure regulator of the lockup type must be installed Model 1 in NPT 1 1 4 in NPT 1 1 2 in NPT 2 in NPT 2 1 2 in NPT Natural Gas 1 000 BTU ft3 0 60 specific gravity at 0 5 in WC pressure drop Propane Gas 2 500 BTU ft3 1 53 specific gravity at 0 6 in WC pressure drop Table I When connecting additional gas utilization equipment to the gas piping system the existing piping must be checked to determine if it has adequate capacity for the combined load The gas valve pressure regulator on the heater is nominally preset as noted in Table J During normal operation carbon dioxide should be 8 5 to 9 0 at full fire for natural gas and between 9 5 and 10 0 for propane gas Carbon monoxide should be 100ppm Manifold Gas Pressure Model High Fire Values No Natural Gas Propane Gas NOTE Manifold pressures should be 0 2 in WC Table J Manifold Gas Pressure Settings CAUTION For proper operation no more than a 30 drop in gas supply pressure from no load to full load conditions is acceptable Under no circumstances should the pressure be outside the listed operational range Electrical Power Connections Installations must follow these codes Maximum Equivalent Pipe Length 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 elec
21. be diverted away from heaters installed under overhangs The combustion air intake terminal MUST be used for outdoor installations The elbow is shipped loose to be installed on the rear of the heater at the job site Minimum Service Clearance Min Clearance from Combustible Surfaces Heater Side Rear Front Vent Table D Clearances Outdoor Installations Combustion and Ventilation Air NOTE Use of this heater in construction areas where fine particulate matter such as concrete or dry wall dust is present may result in damage to the heater that is not covered by the warranty If operated in a construction environment a clean source of combustion air must be provided directly to the heater Indoor Units This heater must be supplied with sufficient quantities of non contaminated air to support proper combustion and equipment ventilation Combustion air can be sup plied via conventional means where combustion air is drawn from the area immediately surrounding the heater or via direct vent where combustion air is drawn directly from outside All installations must com ply with the requirements of the NFGC U S and B149 Canada and all local codes CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty See the Appendix NOTE It is recommended that the intake vent be insulated to minimize sweating INSIDE CORNER
22. connected to any heating system or components previously used with a non potable water heating appliance 4 When the system requires water for space heating at temperatures higher than 140 F 60 C a means such as a mixing valve shall be installed to temper the water in order to reduce scald hazard potential Pool Heating SYSTEM RETURN When a boiler or water heater is used in a pool heat ing application ensure that all the following installation Fig 14 Single Domestic Hot Water Heater and Storage requirements are met Tank Model MBTUH Soft 0 4 grains per gallon Medium 5 15 grains per gallon Hard 16 25 grains per gallon en ee e Dm or ore om oo or e foo om fof sf ee eI be oe or ver Pros n oo oo es ava e oo we a vu s e 8 ver eve onn AT Temperature rise F AP Pressure drop through heat exchanger ft SHL System head loss ft based on heater and tank placed no more than 5 ft apart and equivalent length of 50 eq ft of tubing gpm Gallons per minute flow rate MTS Minimum tubing size Must utilize optional cupro nickel tubes If over 25 grains per gallon a water softener treatment system must be utilized Caution For scale free operation with Hard Water 16 25 grains per gallon of total hardness the operating control must NOT be set higher than 130 F For higher than 130 F operation a water softener treatment system must be utilized Table G
23. gas pressure switch automatically shuts down the burner Operation of either the High or Low Gas Pressure Switch will turn on an LED inside the switch housing Push the top of the plastic switch housing as shown in Fig 44 to reset a tripped pressure switch The white LED will go out when the switch is reset Fig 44 High Low Gas Pressure Switch Air Pressure Switch This heater is equipped with an air pressure switch to prove the operation of the blower before allowing the ignition control to begin a Call for Heat It is located on the right side of the lower flange of the blower mount ing assembly directly behind the junction box Fig 45 Air Pressure Switch Blocked Vent 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 Fig 46 Blocked Vent Switch UDB Diagnostic Board This heater is equipped with a diagnostic board which will indicate faults as they occur Refer to the Trouble shooting section for instructions on accessing reviewing and clearing these faults 0 Fig 47 UDB Diagnostic Board NOTE The wiring diagrams in this manual show all standard options Refer to the large wiring diagram provided with your heater for options installed on your specific unit s 39 WIRING DIAGRAM Models H amp WH
24. low gas pressure switches manual reset for any model with a maximum firing input greater than 1 000 000 Btu Hr in accordance with 248 CMR 7 04 11 d A gas pressure regulator field supplied is required in the gas train ahead of the heater for heaters having input rates greater than 1 000 000 Btu Hr in accordance with 248 CMR 7 04 Figure 3B requirements LIMITED PARTS WARRANTY MVB TYPES H AND WH MODELS 504 2004 SCOPE Raypak Inc Raypak warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty Labor charges and other costs for parts removal or reinstallation shipping and transportation are not covered by this Warranty but are the owner s responsibility HEAT EXCHANGER WARRANTY Domestic Hot Water Five 5 years from date of heater installation Includes copper heat exchanger with bronze waterways Ten 10 years from date of heater installation Includes only cupro nickel heat exchanger with bronze waterways Space Heating Closed Loop System Ten 10 years from date of heater installation Includes both cupro nickel and copper heat exchanger with bronze water ways Thermal Shock Warranty Twenty 20 years from date of heater installation against Thermal Shock excluded however if caused by heater operation at large changes ex
25. manual bypass valve is critical to proper operation of the heater The manual bypass valve should be adjusted to achieve a minimum inlet water temperature of 105 F 40 C for Pool Heater P and WHP versions and 120 F 49 C for Hydronic Heating H7 or Domestic Hot Water WH1 versions and a system supply water temperature below 140 F 60 C When starting with a cold pool make initial adjustments Make final adjustments when pool water approaches desired temperature The use of a bypass is required for proper operation in a pool heating application Use the following instruc tions to set the manual bypass 17 Turn on pump 2 Turn on heater and wait until heater goes to full fire 3 With the heater operating at 100 firing rate set Valve A the bypass to open position and Valve B to fully open position See Fig 16 4 Adjust Valve A until the inlet water temperature is 105 F 40 C or 120 F 49 C depending upon heater type NOTE Opening the valve will increase the temperature and closing the valve will decrease the temperature 5 If this process does not raise the inlet water tem perature to 105 F 40 C for Pool Heater P and WHP versions and 120 F 49 C for Hydronic Heating H7 or Domestic Hot Water WH1 ver sions and Valve A is fully open then slowly throttle Valve B closed to increase the inlet water temper ature to the required temperature ET ET INL FULL
26. neglect including but not limited to freeze ups operating the heater with cabinet door off having flow restrictions or obstruc tions between the heater outlet and pool spa or not maintaining proper chemical balance pH level must be between 7 2 and 7 8 and total alkalinity between 100 and 150 PPM Total Dissolved Solids TDS must be no greater than 2500 PPM PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original 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 TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of installation and description of the prob lem The installer must then notify his Raypak distributor for instructions regarding the claim If either is not available 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 replacement of any part EXCLUSIVE WARRANTY LIMITATION OF LIABILITY This is the only warranty given by Raypak No one is authoriz
27. production in the vent See Table K for appliance category requirements NOTE For additional information on appliance categorization see appropriate ANSI Z21 Standard and the NFGC U S or B149 Canada or applicable provisions of local building codes CAUTION Condensate drains for the vent piping are required for installations of the MVB Follow vent manufacturer instructions for installation and location of condensate drains in the vent Condensate drain must be primed with water to prevent gas flue leak and must be routed to an appropriate container for neutralization before disposal as required by local codes WARNING Contact the manufacturer of the vent material if there is any question about the appliance categorization and suitability of a vent material for application on a Category Ill or IV vent system Using improper venting materials can result in personal injury death or property damage Fig 22 Locator Dimples for Optional Components 22 Combustion Exhaust Heater Venting Certified Combustion Air Air Supply Configuration Category Materials Inlet Material Vertical B Vent Venting Equivalent Horizontal Through the Wall Venting From Inside Building Non Direct Venting Vertical Venting Horizontal 1 the Wall Venting From Outside Building Direct Venting Stainless Steel AL29 4C B Vent Equivalent Stainless Steel AL29 4C Galvanized Steel PVC ABS CPVC Table K Venting Cate
28. tap connection D in Fig 48 This pressure should read per the values in Table X for natural and propane gas 2 Ifthe pressure reading differs by more than 0 2 in WC STOP Call the factory for directions on what to do next Air Pressure Settin 754 1704 EN Table V MVB Air Pressure Settings Tolerance 754 1504 Table W MVB Amp Draw Reference Only Manifold Gas Pressure Setting Model No ae Fire Values in WC Propane Gas Gas 9 24 95 Table X MVB Manifold Pressure Settings 44 CAUTION Special manifold and air settings may be required Finishing 1 Record all data on the Start up Checklist located at the back of this manual 2 Disconnect the manometers and reconnect the cap on the fan pressure switch tee and reinsert the sealing screws into the bleedle valves 3 Start up is complete and the heater should be operating properly 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 check all pressures on the MVB with all other equipment running 4 Check thermostats for ON OFF operation 5 Check high limits for ON OFF operation 6 While in operation check flow switch operation 7 Check the low gas pressure switch if provided For proper adjustment use the attached manometers if availa
29. temperature is 85 F 29 C minimum inlet temperature would be 130 F 54 C An injector pump arrangement may also be uti lized to keep the heater loop at or above 120 F 49 C An injector pump approach has the added value of being able to adjust to changes in the system water coming back to the heater take off HEATER INJECTOR PUMP TEMP SENSOR BOILER PUMP T amp P BER INJECTOR PUMP SYSTEM TEMP SENSOR MAIN LI SYSTEM PUMP SYSTEM RETURN Maximum 4 times the pipe diameter or 12 whichever is less Fig 10 Cold Water Run Hydronic Heating Pump Selection In order to ensure proper performance of your heater system you must install a correctly sized pump Ray pak requires designing for a AT within the range of 10 F to 40 F 5 C to 20 C See Table F for accept able flow rates for each model AT is the temperature difference between the inlet and outlet water when the heater is firing at full rate Feedwater Regulator Raypak recommends that a feedwater regulator be in stalled and set at 12 psi minimum pressure at the highest point of the system Install a check valve or back flow device upstream of the regulator with a manual shut off valve as required by local codes 40 AT nooo pa Sua ae Tes Tom omen T mm v eros em o om o omm o m oF 7 oF ot afe eeta i Liepeperpepere m pepe e ole tele fale foals wo oo am pw
30. the heat exchanger and severely damage the heater Heat exchanger damage resulting from chem ical imbalance is not covered by the warranty For your health and the protection of your pool equip ment it is essential that your water be chemically balanced The following levels must be used as a guide for balanced water Occasional chemical shock dosing of the pool or spa should not damage the heater providing the water is balanced Automatic chemical dosing devices and salt chlorina tors are usually more efficient in heater water unless controlled they can lead to excessive chlorine level which can damage your heater Calcium Hardness ppm 200 300 150 200 200 400 Salt ppm 6000 Maximum 6000 Maximum 6000 Maximum Taia os Solids 3000 Maximum 3000 Maximum 3000 Maximum Free Chlorine MUST NOT EXCEED 5 ppm Table H Water Chemistry 18 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 Automatic Chlorinators and Chemical Feeders All chemicals must be introduced and completely dilut ed into the pool or spa water before being circulated through the heater Do not place sanitizing chemicals in the skimmer High chemical concentrations will result when the pump is not running e g overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical back up into the heater when the
31. 2 NOTE Current draw noted on rating plate does not include pump current NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts 3 Turn off all power to the heater Verify that power external connections to the unit Solid conductors has been turned off by testing with a multi meter should not be used because they can cause prior to working with any electrical connections or excessive tension on contact points Install conduit components as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones onthe 4 Observe proper wire colors while making electri unit or larger cal connections Many electronic controls are polarity sensitive Components damaged by im proper electrical installation are not covered by warranty Check the Power Source 5 Provide overload protection and a disconnect BREAKER A o S means for equipment serviceability as required by MEITE local and state code GREEN 4 6 Install heater controls thermostats or building GROUND management systems in accordance with the applicable manufacturers instructions AuIB WC 7 Conduit should not be used as the earth ground Fig 19 Wiring Connections 21 NOTE A grounding electrode conductor shall be used to connect the equipment grounding conductors the equipment enclosures and the grounded service conductor to the grounding electrode Field Wiring Connection
32. 5 F are required a boiler is recommended since the 210 F limit on water heaters will NOT allow the heater to maintain these desired sanitary rinse temperatures Safety and energy conservation are factors to be con sidered when setting the water temperature on the thermostat The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs of the application Water temperature over 125 F can cause instant severe burns or death from scalds Children disabled and elderly are at highest risk of being scalded Feel water before bathing or showering Temperature limiting valves are available NOTE When this water heater is supplying general purpose hot water for use by individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further information Maximum water temperatures occur just after the heater s burner has shut off To determine the water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer A DANGER Water temperature over 125 F can cause instant severe burns or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before set ting temperature at water heater Feel wa
33. ATION TRAP TAL THROUGH THE WALL VENTING MIN DIRECT VENT HORIZO Fig 27 Horizontal Through the Wall Direct Venting CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s instructions Failure to install a condensate drain in the venting system will void all warranties on this heater Installation These installations utilize the heater mounted blower to vent the combustion products to the outdoors Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the out doors Adequate combustion and ventilation air must be supplied to the equipment room in accordance with the NFGC U S or B149 Canada The total length of the horizontal through the wall flue system should not exceed 75 equivalent ft in length If horizontal run exceeds 75 equivalent ft an appropri ately sized variable speed extractor must be used Each elbow used is equal to 10 ft of straight pipe This will allow installation in one of the four following arrangements 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 ens
34. Domestic Water Heater Flow Rate Requirements 16 The MVB must be equipped with a field supplied ex ternal pump and bypass arrangement This arrangement blends outlet water with the inlet water to 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 Water 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 system piping CAUTION Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation Improper flow control can damage the heater Uncontrolled flow too high or restricted flow too low can seriously damage the heater Follow these instructions to make sure your heater is properly installed To complete the installation of the pool heater the pool thermostat must be installed in the main return water line upstream of the heater This will ensure that the heater will be energized at the right time e E SEES E E Bee lc S AJC Eg IIO Q SSR A THERMOSTAT a i3 FROM is N FILTER po U uer S x BE a Z9 TO POOL A lss BSa ES y N Ip di CHEMICAL Ss FEED Maximum 4 times the pipe diameter or 12 whichever is less Fig 15 Single Pool Heater Application Adjustment of the
35. INSTALLATION amp OPERATING INSTRUCTIONS Models 504 2004 Types H WH P amp WHP CERTIFIED WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury exposure to hazardous materials or loss of life Review the information in this manual carefully This unit contains materials that have been identified as carcinogenic or possibly carcinogenic to humans 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 E m A Rheem Company CATALOG NO 3400 54E Effective 03 25 10 Replaces 03 19 09 P N 241317 Rev 6 Rev 5 reflects the following Changes to Air Filter instructions on page 11 minor text changes on pages 13 and 14 Figs 10 and 11 on page 15 Fig 12 and
36. P SYSTEM RETURN d L Maximum 4 times the pipe diameter or 12 whichever is less Fig 32 Mode 2 Primary Secondary Piping Mode 3 Dedicated DHW operation using UniTemp 80 piping A call for heat is determined by the DHW sensor and the DHW boiler target The heater outlet water is also controlled to the boiler target temperature factory default WH1 water heaters See Fig 33 RAYPAK ELECTRONIC TEMP CONTROL BOILER OUTLET SENSOR IN HEADER BOILER INLET SENSOR IN HEADER DHW TANK SENSOR Fig 33 Mode 3 Dedicated DHW Mode 4 Not supported Outdoor reset using pri mary piping The heater is operated as in Mode 1 However the target temperature is based on outdoor reset 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 34 RAYPAK ELECTRONIC TEMP CONTROL HEATER BOILER OUTLET SENSOR IN HEADER BOILER INLET SENSOR IN HEADER OUTDOOR AIR JZ SENSOR SYSTEM TEMP MAIN NNNM UMEN SENSOR SYSTEM PUMP o SYSTEM RETURN d Maximum 4 times the pipe diameter or 12 whichever is less Fig 34 Mode 5 Primary Secondary Piping with Outdoor Reset Mode 6 Not supported Designed for an external input signal with primary piping The external input sig nal can be provided from a BMS an EMS or a sequencing control
37. PA 70 latest edition NEC e Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 CSD 1 when required e For Canada only CAN CSA B149 Natural Gas and Propane Installation Code and CSA C22 1 C E C Part 1 C22 1 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 CAUTION This heater should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the structure When such locations cannot be avoided it is recommended that a suitable catch pan adequately drained be installed under the appliance The pan must not restrict air flow In addition the heater shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation or service circulator replacement control replacement etc If the heater needs to be secured to the ground use the brackets that were used to bolt the heater to the shipping pallet Clearances Indoor Installations Heater Minimum Clearance Side from Combustible Surfaces Rear 12 Rear 127 Minimum Service Clearance 24 Omm DO NOT install on ca
38. RT UP CHECKLIST WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe personal injury death or substantial property damage if ignored Indicates the presence of hazards or unsafe practices which could cause severe personal injury death or substantial property damage if ignored Indicates special instructions on installation operation or maintenance which Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored are important but not related to personal injury hazards 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 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 WARNING To minimize the possibility of improper operation serious personal injury fire or damage to the heater 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 a
39. SYSTEM SYSTEM RETURN PUMP Maximum 4 times the pipe diameter or 12 whichever is less Fig 36 Mode 8 Primary Secondary Piping with External Direct Drive BOIL ON Accumulated runtime of heater up to 999 hours then resets to 0 BOIL OUT Actual heater outlet water temperature BOIL START Starting boiler water temperature BOIL SUP Actual system supply water temperature BOIL TARGET Target temperature that the heater is trying to maintain BURNER DELAY Holds control output at ignition setting from the start of the ignition sequence to the specified burner delay time 0 to 3 00 min DEM 1 Indicates 24 VDC signal has been supplied to the H D terminal DEM 2 ent Indicates 24 VDC Flame Proof signal is pres DIFF The operating differential of the heater The heater outlet water temperature is allowed to rise above the BOIL TARGET temperature by 7 of this dif ferential before the heater shuts off For example if the heater target temperature is set to 160 F 71 C and the differential is set to 10 F 5 C on temperature rise the heater will shut off at 165 F 74 C Once the heater shuts off it will not come on again until the tem perature falls to 155 F 68 C em odes beta Soting Rano Hos 2 We 3 5 F 2 to 10 F 3 Table Q Temperature Control Default Setpoints Boiler 1 Boil Start 135 F 35 to 150 F Boil Target Diff F Boil Mass 1 Low 1 Low 2 Med
40. The external input signal changes the boiler target according to a linear scale The con 32 trol operates the boiler burner to maintain the boiler target at the boiler outlet sensor Mode 7 Designed for an external input signal with primary secondary piping The external input signal can be provided from a BMS an EMS or an external control The external input signal changes the boiler target according to a linear scale see Tables O amp P The control operates the boiler burner to maintain the boiler target at the system sensor See Fig 35 EXTERNAL CONTROL RAYPAK i ELECTRONIC HEATER TEMP CONTROL PEN p r 4d ha BOILER INLET HEADER SENSOR IN HEADER od d A I l d l SYSTEM TEMP MAIN t E SENSOR SYSTEM PUMP SYSTEM RETURN do LO8R Maximum 4 times the pipe diameter or 12 whichever is less Fig 35 Mode 7 Primary Secondary Piping with External Target Temp 0 10 VDC 0 20 mA Boiler Target L9 9 om SS 68 9 F 87 8 F 106 7 F 125 6 F 144 1 F 163 3 F 182 2 F 201 1 F 220 F Requires a 5000 resistor Table O 0 10 VDC or 0 20 mA External Input Signal 2 10 VDC 4 20 mA Boiler Target ee ee OFF 50 F 13 F 92 5 F 113 8 F 135 F 156 3 F 177 5 F 198 8 F 220 F Requires a 5000 resistor Table P 2 10 VDC or 4 20 mA External Input Signal Mode 8 This mode is for remote firing control of the heat
41. a window or door which can be opened in any building any non mechani cal air supply inlet to any building or the combustion air inlet of any other appliance 8 Underneath a verandah porch or deck unless the verandah porch or deck is fully open on a mini mum of two sides beneath the floor and the distance between the top of the vent termination and the underside of the verandah porch or deck is greater than 1 ft 305 mm Venting Installation Tips Support piping horizontal runs at least every 5 ft e vertical runs use braces under or near elbows WARNING Examine the venting system at least once a year Check all joints and vent pipe connections for tightness corrosion or deterioration Venting Configurations 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 Natural Draft Vertical Venting Category I Installation Natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue The nega tive draft must be within the range of 01 to 08 in WC as measured 12 in above the appliance flue out let to ensure proper operation Vent material must be listed by a nationally recognized test agency The maximum and minimum venting length for Cate gory appliances shall be determined per the
42. aight up and out of the slot in the filter box J uU j Fig 51 Remove the Air Filter 3 Reverse steps 1 and 2 to install the new filter Use Raypak replacement filters kit number 012552F 12 X12 for models 504 1104 and kit number 012553F 16 X16 for models 1504 2004 APPENDIX Inside Air Contamination All heaters experience some condensation during start up The condensate from flue gas is acidic Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate Higher acidity levels attack many materials including 51 stainless steel which is commonly used in high effi ciency systems The heater can be supplied with corrosion resistant non metallic intake air vent materi al You may however choose to use outside combustion air for one or more of these reasons 1 Installation is in an area containing contaminants listed below which will induce acidic condensation 2 You want to reduce infiltration into your building through openings around windows and doors 3 You are using AL29 4C stainless steel vent pipe which is more corrosion resistant than standard metallic vent pipe In extremely contaminated ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners chlorine based swimming pool chemicals calcium chloride used for thawing sodi
43. all be provided with TWO per manent openings communicating directly with an additional room s of sufficient volume so that the com bined volume of all spaces meets the criteria for a room large in comparison NFGC The total input of all gas utilization equipment installed in the combined space shall be considered in making this determina tion Each opening shall have a minimum free area of 1 in per 1 000 BTUH 2 225 mm per kW of the total input rating of all gas utilization equipment in the con fined space but not less than 100 in 2 645 cm2 One opening shall commence within 12 in 305 mm of the top and one opening shall commence within 12 in 305 mm of the bottom of the enclosure The mini mum dimension of air openings shall be not less than 3 in 76 mm in any direction All Air from Outdoors The confined space shall communicate with the out doors in accordance with one of the methods below The minimum dimension of air openings shall not be less than 3 in 76 mm in any direction Where ducts are used they shall be of the same cross sectional area as the net free area of the openings to which they connect 1 Two permanent openings one commencing within 12 in 305 mm of the top and one com mencing within 12 in 305 mm of the bottom of the enclosure shall be provided The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely com municate with the outdoo
44. an area where condensate or vapor could create a nuisance or hazard or could be detrimen tal to the operation of regulators relief valves or other equipment Where local experience indi cates that condensate is a problem with Category and IIl appliances this provision shall also apply Locate and guard vent termination to prevent acci dental contact by people or pets DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area 10 DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations 11 Locate or guard vent to prevent condensate from damaging exterior finishes Use a rust resistant sheet metal backing plate against brick or mason ry surfaces 12 DO NOT extend exposed vent pipe outside of building beyond the minimum distance required for the vent termination Condensate could freeze and block the vent pipe U S Installations Refer to the latest edition of the National Fuel Gas Code Vent termination requirements are as follows 1 Vent must terminate at least 4 ft below 4 ft hori zontally from or 1 ft above any door window or gravity air inlet to the building 2 The vent must not be less than 7 ft above grade when located adjacent to public walkways 3 Terminate vent at least 3 ft above any forced air inlet located within 10 ft 4 Vent must terminate at least 4 ft horizontally and in no case above or below unless 4 ft
45. an prov ing switch Pull black cap from air pressure switch tee and connect the manometer NOTE Retain caps for reinstallation later GAS Fig 48 Gas Pressure Measurement Locations Check Gas Supply Pressure 1 Slowly turn on main gas shut off valve 2 Read the gas supply pressure from the manome ter minimum supply pressure for natural gas is 4 0 in WC recommended supply is 7 0 in WC mini mum supply pressure for propane gas is 4 0 in WC recommended supply is 11 0 in WC dynam ic readings full fire input 3 If the gas pressure is greater than 14 0 in WC turn off the main gas shut off valve upstream of the heater Start Up NOTE The values in Tables V W and X represent the conditions when the heater is at full firing rate at sea level NOTE Pressure and combustion data are provided with the heater 1 Turn power on 2 Turnon the heater wait approximately 15 seconds after the blower starts and the igniter should start to glow observable through the observation port located at the front bottom of the heater Look into the sight glass located at the bottom of the front panel to check igniter operation Gas valve should open in 45 60 seconds 3 The heater ignites at 50 of full rate as indicated on the LCD display of the temperature control located in the upper right of the front panel 4 Ifthe burner fails to light on the first trial it will try for ignition up to three tim
46. as equipment provides a venting system design or venting system components with the equipment the instruc tions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting sys tem design or the venting system components and 2 A complete parts list for the venting system design or vent ing system d MANUFACTURER REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting sys tems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equip ment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation GAS PRESSURE SUPERVISION The Commonwealth of Massachusetts requires listed high and
47. ayed on the LCD 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 amp and W shown at the bottom of Fig 37 All items displayed by the control are organized into two menus the view menu and the adjust menu The active menu is displayed in the upper right hand side of the display in the menu field The default menu is the view menu When the temperature control is powered up the con trol turns on all segments in the display for 2 seconds then the software version is displayed for 2 seconds At the end of that 4 second period the control enters the normal operating mode and VIEW is displayed Pressing the scroll button scrolls through the dis played values in the VIEW menu To make an adjustment to a setting in the control begin by selecting the ADJUST menu To change from the view menu to the adjust menu simultaneous ly press and hold all three buttons for 1 second The Ficia Menu Field em Fie Displays the current menu Displays an Ww adero cae aia abbreviated name of the selected item i jhe C _ Number Field STARTMINMAX e Displays the am o am min TARGETMASSAT 855 98 9 9997 77 45 current value of f Boil Dem pLYMopEPooL P DHW U 1212 the selected _OPENCLSSTG M BY W wwsp D item
48. 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 other flammable vapors and liquids 2 Check for and remove any obstruction to the flow of combustion or ventilation air to heater Monthly 1 Check for piping leaks around pumps mixing valves relief valves and other fittings If found repair at once DO NOT use petroleum based stop leak compounds 2 Visually inspect burner flame 3 Visually inspect venting system for proper func tion deterioration or leakage 4 Visually inspect for proper operation of the con densate drain in the venting If leaks are observed repair at once 5 Check air vents for leakage Yearly Beginning Of Each Heating Season Schedule annual service call by qualified service agency 1 Visually check top of vent for soot Call service person to clean Some sediment at bottom of vent is normal Visually inspect venting system for proper func tion deterioration or leakage Ensure that condensate drain is inspected and ensure that condensate is being directed to appropriate con densate management system or drain as required 49 by local codes 3 Check that area is free from combustible materi als gasoline and other flammable vapors and liquids 4 Check air filter and replace as necessary 5 Follow
49. ble to set pressure The scales on the switch are approximate only Low gas pressure switch if provided must be set at 3 0 in WC for natural gas and propane gas 8 Make sure that the high gas pressure switch op tional is set to 3 0 in WC for both natural gas and propane gas Follow Up Safety checks must be recorded as performed Turn heater on After main burner ignition 1 Check manometer for proper readings 2 Cycle heater several times and re check readings 3 Remove all manometers and replace caps and Screws 4 Check for gas leaks one more time Leak Test Procedure Dual Seat Gas Valve 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 Test point Ais a blee dle valve located upstream of the combination gas valve on the supply manifold Test point B is a bleedle valve located between the two automatic gas valve seats Test point C is a bleedle valve located downstream of both automatic gas valve seats and upstream of the manual valve Refer to Fig 49 These tests are to be conducted with the electrical power to the heater turned OFF 1 Manually close the downstream leak test valve 2 Open the bleedle valve at test point A and connect a manometer to it Verify that there is gas pressure and that it is within the proper range NOTE must not exceed 14 0 in WC Open test point B and
50. ceeding 150 F between the water temperature at intake and heater temperature or operating at heater temperatures exceed ing 230 F ANY OTHER PART MANUFACTURED BY RAYPAK One 1 year warranty from date of heater installation or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PROOF OF INSTALLATION DATE SUCH AS INSTALLER INVOICE IS REQUIRED THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from 1 Failure to properly install operate or maintain the heater in accordance with our printed instructions provided 2 Abuse alteration accident fire flood and the like Sediment or lime build up freezing or other conditions causing inadequate water circulation High velocity flow exceeding heater design rates Failure of connected systems devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the heater system Failing to eliminate air from or replenish water in the connected water system Chemical contamination of combustion air or use of chemical additives to water PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicabl
51. connect a rubber tube to it Connect the other end of the tube to a manometer and look for a build up of pressure Increasing pressure indicates a leaking gas valve which must be replaced Next close the upstream manual gas valve field supplied and remove the manometers from the bleedle valves in test point A and test point B Connect a rubber tube from the test point A blee dle valve to the test point B bleedle valve and open the upstream manual gas valve Make sure that test point A amp B bleedle valves have been opened so as to allow gas to flow This will bring gas pressure to the second valve seat Open the bleedle valve at test point C and connect a second rubber tube to it Connect the other end of the tube to a manometer and look for a build up of pressure Increasing pressure indicates a leak ing gas valve which must be replaced Remove rubber tube and manometers Close each test point bleedle valve as the tubes are removed 45 After no leakage has been verified at all valve seats and test valves open downstream leak test valve and restore electrical power to the heater MANUAL VALVE T TO BURNER Fig 49 Leak Test Procedure Post Start Up Check Check off steps as completed 1 Verify that the heater and heat distribution units or storage tank are filled with water 2 Confirm that the automatic air vent if used was opened two full turns during the venting proce dure 3 Verify that a
52. d of temperature sens ing where no action occurs All temperature controllers have a deadband and the purpose is to prevent short cycling of the heater The on board temperature controller has a deadband of 2 F around the differen tial Differential A heat source must be operated with a temperature differential in order to prevent short cycling The temperature differential is divided around the target temperature or set point The Call For Heat CFH contact will close in the controller when the water temperature is below the target temperature by 1 2 of the differential setting and will open when the water temperature is above the target temperature by 1 2 of the differential setting See Fig 30 Target temperature Differential 10 F 5 C 160 F 71 C 165 F 74 C f fy o o 160 F 71 C SA i d erui Eccc Time Water Temperature Fig 30 Differential Graph For systems with less than 4 1 turndown the control should be placed in the system return upstream of the inlet piping to the heater as shown in Figs 32 34 and 35 This placement will avoid short cycling the heat source Raypak recommends using a smaller differen tial setting when controlling the water temperature on the return side As a starting point set the return differ ential to 10 F and this will allow the system return temperature to vary 5 F above and 5 F belo
53. de Clearance In Left Side Clearance In Rear Clearance In Overhead Clearance In ELECTRICAL Voltage Supply VAC No Load Load Voltage 24 VAC Voltage Com to Ground Hot Surface Igniter Auto High Limit Setting Manual Reset High Limit Setting Operating Control Setting VAC VAC Ohms deg F deg F deg F Sketch plumbing on reverse side WATER SUPPLY Flow Rate in GPM or Delta T Measure flow rate at full fire Pump Economaster setting Low Water Cutoff Number of Tanks and Size Plumbing Size Pump Size Impeller trim Pump Model Louvers Screens If Avail Minutes Test Gallons Qty boiler Pump HP Nominal Factory Recommended Settings See manual or card tag See manual or card tag See manual or card tag See manual or card tag The following measurements must be obtained with a Combustion Analyzer NOX PPM Free Oxygen CO PPM CO2 Model Number Note draw venting with details such as extractors barometric dampers blast dampers or draft inducers Job Name Less than 20 PPM If required by Certifying Agency See manual Less than 150 PPM See manual Serial Number Site Altitude Above Sea Level Ft Address Physical Location of Boiler Indoors Outdoors Mechanical Contractor Installer Ground Level Roof Below Grade Date and Time of Start up Print Name and Signature of Start up Technic
54. detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a min imum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspec tor observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 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 To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for res idential purposes c MANUFACTURER REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented g
55. 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 You may also have other rights which may vary from state to state We suggest that you complete the information below and retain this certificate in the event warranty service is needed Reasonable proof of the effective date of the warranty date of installation must be presented otherwise the effective date will be based on the rate of manufacture plus thirty 30 days Original Owner Model Number Mailing Address Serial Number Date of Installation City Zip Code Installation Site Daytime Telephone Number Contractor Installer RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 9786 805 278 5300 Fax 800 872 9725 www raypak com LIMITED PARTS WARRANTY MVB TYPES P amp WHP MODELS 504 2004 SCOPE Raypak Inc Raypak warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty Labor charges and other costs for parts removal or reinstallation shipping and transportation are not covered by this Warranty but are the owner s responsibility HEAT EXCHANGER WARRANTY
56. e rest of the system making sure to eliminate any entrapped air by using high point vents Close 13 feed valve Test at standard operating pressure for at least 24 hours 2 Make sure constant gauge pressure has been maintained throughout test 3 Check for leaks Repair if found Cold Water Operation CAUTION Damage due to internal condensation may occur if the heater inlet water temperature does not exceed 120 F 49 C within 7 minutes of start up This heater is equipped with a proprietary condensate evaporation system which will evaporate any conden sate that may begin to accumulate inside the primary heat exchanger with water temperatures as low as 120 F 49 C Heaters operated with an inlet temperature of less than 120 F 49 C MUST have a manual bypass see Fig 16 or an approved low temperature operation system Figs 9 and 10 to prevent problems with con densation This piping is similar to a primary secondary boiler installation with a bypass acting as the secondary boiler piping Raypak strong ly recommends that thermometer s be placed into the heater piping next to the in out header to facilitate tem perature adjustment Inlet water temperatures below 120 F 49 C can excessively cool the products of combustion resulting in collection of condensate in the heat exchanger area beyond the capacity of the con densate evaporation system Failure to reach or exceed 120 F 49 C within 7 min
57. e warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original 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 TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of installation and description of the prob lem The installer must then notify his Raypak distributor for instructions regarding the claim If either is not available 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 replacement of any part EXCLUSIVE WARRANTY LIMITATION OF LIABILITY This is the only warranty given by Raypak No one is authorized to make any other warranties on Raypak s behalf THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS WARRANTY OR IN CONTRACT TORT NEGLIGENCE OR OTHERWISE FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGE INCLUDING DAMAGE FROM WATER LEAKAGE Some states
58. ed the gas valve will close and the blower will run a 30 second post purge The heater pump will continue to circulate water for 0 to 10 minutes depending on the pump delay setting on the Raypak modulating tempera ture control Ignition Module When additional heat is needed the combustion air blower starts to purge air from the combustion cham ber for 15 seconds On proof of air flow the air proving switch closes and the igniter is energized To ensure safe operation the gas valve cannot open until the igniter is verified The main burner is automat ically lit when the device is powered and pre purged The heater performs its own safety check and opens the main valve only after the igniter is proven to be capable of ignition The standard ignition module will attempt to light three times before locking out To reset it turn off power to the heater wait 30 seconds and re apply power ZA P Fig 38 Ignition Module 37 The optional single try ignition module will lock out after failing to light one time To reset it press and release the small recessed black push button located inside of the cut out on the lower right hand corner of the ignition module case Turning off the power to the heater WILL NOT reset the ignition module On System OK No faults present Possible control fault Check power Flame in combustion chamber 2 Flashes No call for heat 3 Flashes Ignition lockout 4 Flashes Low HSI cur
59. ed to make any other warranties on Raypak s behalf THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS WARRANTY OR IN CONTRACT TORT NEGLIGENCE OR OTHERWISE FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGE INCLUDING DAMAGE FROM WATER LEAKAGE 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 You may also have other rights which may vary from state to state We suggest that you complete the information below and retain this certificate in the event warranty service is needed Reasonable proof of the effective date of the warranty date of installation must be presented otherwise the effective date will be based on the rate of manufacture plus thirty 30 days Original Owner Model Number Mailing Address Serial Number Date of Installation City Zip Code Installation Site Daytime Telephone Number Contractor Installer RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 9786 805 278 5300 Fax
60. edition Industrial Commercial Gas Fired Package Boilers ANSI Z21 10 3 CSA 4 3 latest edition Gas Wa ter Heaters SCAQMD Rule 1146 2 Low lead content lt 25 CSA verified and All Raypak heaters are National Board Approved and design certified and tested by the Canadian Standards Association CSA for the U S and Canada Each heater is constructed in accordance with Section IV of the American Society of Mechanical Engineers ASME Heater Pressure Vessel Code and bears the ASME stamp This heater also complies with the latest edition of the ASHRAE 90 1 Standard WARNING Altering any Raypak pressure vessel by installing replacement heat exchangers tube bundle headers or any ASME parts not manufactured and or approved by Raypak will instantly void the ASME and CSA ratings of the vessel and any Raypak warranty on the vessel Altering the ASME or CSA ratings of the vessel also violates national state and local approval codes Installations at Elevation Rated inputs are suitable for up to 4 500 ft elevation without de rating Consult your local representative or the factory for installations at altitudes over 4 500 ft above sea level No hardware changes are required to the heaters for installations up to 10 000 ft adjust ments may be required Component Locations FRONT OF HEATER HEAT EXCHANGE ASSEMBLY BURNER FLAME VIEWING PORT Panels omitted for clarity Fig 1 Component Locations Side
61. either button to scroll through the recorded faults in history The most recent fault recorded will be the first fault displayed the last 16 faults are stored in the his tory on a rolling basis There is no time or date stamp associated with these faults When the history of faults has been exhausted pushing the UP or DOWN buttons again will roll the fault history over and it will start again To exit the fault history wait for 10 seconds and the board will automatically exit the history mode To clear the fault history press and hold both the UP and DOWN buttons for 5 seconds while the power is on NOTE Once the history has been cleared it cannot be recovered Diagnostic information is provided any time a fault is recorded This information is intended to assist in locating the problem with the heater but is not exhaus tive If multiple fault conditions occur at the same time only the fault that caused the heater to shut down will be recorded in the history TROUBLESHOOTING NO Step 1 YES 6779 Correct the shutter Step 4 setting or blower amp draw Replace air pressure switch Is 24VAC at PS on ignition module Step 5 Is connecting plug secure NO YES NO YES Step 7 NO Is gas pressure correct NO YES Step 8 NO Correct the gas pressure Step 9 48 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must
62. er via an external sequencer such as the Raypak TempTracker 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 0 10 VDC signal from the external sequencer A control signal of 20 5 VDC equates to minimum fire and a signal of 10 VDC equates to 100 firing rate NOTE For Modes 7 and 8 connect to pins 13 and 14 on the low voltage panel See page 21 Use these modes for systems using an external signal Definitions NOTE The defined terms are not active in all modes of control operation 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 MAX Highest outlet water temperature that the control is allowed to use as a target temperature BOIL MIN Lowest outlet water temperature that the control is allowed to use as a target temperature 33 EXTERNAL _____ CONTROL RAYPAK MODULATING TEMP CONTROL OUTDOOR AIR SENSOR BOILER OUTLE BOILER INLET SENSOR ud SENSOR IN HEADER SYSTEM TEMP SENSOR X MAIN
63. es before going into lock out with the standard ignition module If the heater is equipped with the optional single try ignition module it will go into lockout 5 Wait until the controller indicates 100 on the fir ing rate display screen approximately 30 seconds Blower Check 1 Check blower suction using the manometer attached to the fan pressure switch tee with the heater firing at 10096 input The reading should be as noted in Table V for both natural and propane gas 2 FOR REFERENCE ONLY Measure the blower amp draw with the heater firing at 10096 input and compare the measured value to the values in Table U The amp draw is measured with a clamp on type amp probe clamped to the 14 AWG black power wire going into the blower 3 When firing at 10095 the desired heater combus tion CO2 is between 8 5 and 9 0 for natural gas and 9 5 and 10 096 for propane with CO less than 100 ppm If this combustion cannot be achieved with the blower suction within the tolerances spec ified in Table 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 is required NOTE Most commercially available amp probes are not accurate enough and or are not shielded well enough to read accurately in the heater environment Blower amp draw readings are for reference only Manifold Check 1 Check manifold gas pressure at the gas valve out let pressure
64. et to 120 F 49 C or higher Once the system is heated up and has return water temperatures of 120 F 49 C or higher the mixing of outlet water with inlet water is no 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 utilized HEATER COLD WATER TEMP SENSOR LOCATED IN H INLET HEADER T amp P ed BYPASS SYSTEM AB SYSTEM TEMP SENSOR H 8 SYSTEM SYSTEM SUPPLY RETURN Maximum 4 times the pipe diameter or 12 whichever is less Fig 9 Cold Water Start Cold Water Run Cold water run differs from cold water start in that the system water entering the heater remains below 120 F 49 C continuously Typically this is the case in swimming pool heating If the system water is kept in a narrow temperature range of no more than 10 F 5 C a permanent manual bypass can be employed 14 and manually adjusted to achieve an inlet temperature of 120 F 49 C or higher as adjusted at the minimum temperature in this narrow temperature range i e Range 75 F to 85 F adjust bypass with temperature at 75 F 24 C so that when
65. gory Requirements Support of Vent 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 walls Vent Terminal Location NOTE During winter months check the vent cap and make sure no blockage occurs from build up of snow or ice Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Give special attention to the location of the vent termination to avoid possibility of property dam age or personal injury Gases may form a white vapor plume in winter The plume could obstruct a window view if the ter mination is installed near windows Prevailing winds in combination with below freez ing temperatures can cause freezing of condensate and water ice build up on buildings plants or roofs The bottom of the vent terminal and the air intake shall be located at least 12 in above grade includ ing normal snow line 23 6 Un insulated single wall metal vent pipe shall not be used outdoors in cold climates for venting gas fired equipment Through the wall vents for Category Il and IV appliances and non categorized condensing appli ances shall not terminate over public walkways or over
66. h the out doors or through vertical duct s The total cross sectional area shall be at least 1 in of free area per 10 000 BTUH 222 mm per kW of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct s In cold climates and to mitigate potential freeze up Raypak highly recommends the installation of a motorized sealed damper to prevent the circula tion of cold air through the heater during the non operating hours TruSeal Combustion Air In addition to the 3 previous steps combustion air may be ducted directly to the heater by using PVC CPVC 11 or sealed single wall galvanized ducting The duct will attach directly to the air collar located on the rear of the heater using three or four sheet metal screws not supplied equally positioned around the circumference of the duct The screen assembly should be removed before attaching any air duct to the heater The screws and duct connection point must be sealed with RTV not supplied TruSeal is generally used when dam aging contaminants are present in the mechanical room All ducting must be self supported CAUTION Use TruSeal combustion air if damaging airborne contaminants are or may be present in the heater area See the Appendix of this manual regarding air contamination Conventional Combustion Air Supply U S Installations All Air from Inside the Building The confined space sh
67. he connection from the appliance flue to the stack must be as direct as possible and should be the same size or larger than the vent outlet Maximum Horizontal Vent Length ft Certified Vent Material Category Ill D Subtract 10 ft per elbow Max 4 elbows t Adapters supplied by others Air Inlet Combustion Air Max Length ft Intake Pipe Material Galvanized Steel PVC ABS CPVC Table N Category Ill Horizontal Vent amp Horizontal Direct Vent 3 MIN FLUE EXHAUST VENT CAP INTAKE VENT 3 3 MIN i 1 MIN 1 INSULATED EXHAUST d VENTING HEATER UNIT N 7 ALTERNATE COMBUSTION Le AIR INTAKE LOCATION DIRECT VENT VERTICAL Fig 28 Direct Vent Vertical CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s instructions Failure to install a condensate drain in the venting system will void all warranties on this heater See Table L for Category venting guidelines It is recommended that the intake vent be insulated in colder climates Termination The flue terminal should be vertical and should termi nate outside the building at least 2 ft above the highest point of the roof within 10 ft The vent cap should have 29 a minimum clearance of 4 ft horizontally from and in no case above or bel
68. horizontal distance is maintained from electric meters gas meters regulators and relief equipment 5 Terminate vent at least 6 ft away from adjacent walls 6 DO NOT terminate vent closer than 5 ft below roof overhang 7 The vent terminal requires a 12 in vent terminal clearance from the wall 8 Terminate 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 WARNING The Commonwealth of Massachusetts requires that sidewall vented heaters installed in every dwelling building or structure used in whole or in part for residential purposes be installed using special provisions as outlined on page 53 of this manual Canadian Installations Refer to latest edition of the B149 Installation code A vent shall not terminate 1 Directly above a paved sidewalk or driveway which is located between two single family dwell ings and serves both dwellings 2 Less than 7 ft 2 13 m above a paved sidewalk or paved driveway located on public property 3 Within 6 ft 1 8 m of a mechanical air supply inlet to any building 4 Above a meter regulator assembly within 3 ft 915 mm horizontally of the vertical centre line of the regulator 5 Within 6 ft 1 8 m of any gas service regulator vent outlet 6 Less than 1 ft 305 mm above grade level 7 Within the 3 ft 915 mm of
69. ian Information must be faxed to 805 278 5471 in order to ensure warranty consideration Attn Service Manager 55 Registered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A
70. ic 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 WARNING Installation adjustment and service of heater controls including timing of various operating functions must be performed by a qualified installer service agency or the gas supplier Failure to do so may result in control damage heater malfunction property damage personal injury or death WARNING Turn off the power to the heater before installation adjustment or service of any heater controls Failure to do so may result in board damage heater malfunction property damage personal injury or death CAUTION This appliance has provisions to be connected to more than one supply source To reduce the risk of electric shock disconnect all such connections before servicing CAUTION Risk of electric shock More than one disconnect switch may be required to de energize the equipment before servicing 30 The Raypak electronic temperature control is pro vided to maintain the desired system water temperature The control has various modes of opera tion which are described on the following pages To minimize short cycling locate the system target sensor as follows Setpoint The intended system supply temperature Deadband Deadband is a ban
71. ine etc Pre Start up Check 1 Verify the heater is filled with water 2 Check system piping for leaks If found repair immediately 3 Vent air from system Air in system can interfere with water circulation 4 Purge air from gas line to heater Initial Start up Required tools 1 12 0 12 24 scale U tube manometer 2 6 0 6 12 scale U tube manometer Screwdrivers assorted sizes and shapes 1 Crescent wrench 8 or 10 1 Multi meter 1 Amp probe Metric Allen wrenches will be required for servicing the gas valve but not during start up NOTE Digital manometers are not recommended Preparation WARNING Do not turn on gas at this time Check Power Supply With multi meter at incoming power check voltage between Hot Common 120 VAC Hot Ground 120 VAC Common Ground lt 1 VAC WARNING If Common Ground is gt 1 VAC STOP Contact electrician to correct ground failure Failure to do this may burn out 120V 24V transformer or may cause other safety control damage or failure Attach Manometers to Measure Pressures 1 Turn off main gas valve 2 Attach 1 12 scale manometer to an upstream bleedle valve on the gas supply pipe to the heater Measure point A in Fig 48 3 Attach 1 24 scale manometer to the manifold pressure tap located on the elbow downstream of the valve Measure point D in Fig 48 4 Attach 1 12 scale manometer near the f
72. ir has been purged from the system 4 Verify that air has been purged from the gas pip ing and that the piping has been checked for leaks 5 Confirm that the proper start up procedures were followed 6 Inspect burner to verify flame 7 Test safety controls If heater is equipped with a low water cut off or additional safety controls test 10 11 12 13 14 15 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 Test limit control While burner is operating move indicator on high limit control below actual water temperature Burner should go off while blower and circulator continue to operate Raise setting on limit control above water temperature and burner should re ignite after pre purge time delay NOTE Ignition control may have to be reset after this portion of the test Test ignition system safety device a Open manual gas valve Turn power on b Setthermostat to call for heat c When the heater is in operation pull hose off the air switch The burner should go off almost immediately d Reattach hoses Burner should re ignite after pre purge time delay NOTE Ignition control may have to be reset after this portion of the test To restart system follow lighting instructions in the Operation section Check to see that the high limit c
73. lue Products Vent Size NOTE Data for 100 firing rate Table M Typical Volume of Flue Products Horizontal Through the Wall Direct Venting Category III INSULATED EXHAUST VENTING HEATER UNIT ES m 12 MIN EIEMEREX amp S eB FLUE EXHAUST a VENT CAP TEST PORT 12 MIN LU 7 id CONDENSATION TRAP HORIZONTAL THROUGH THE WALL VENTING CATEGORY IV Fig 25 Horizontal Through the Wall Venting INSULATED EXHAUST VENTING HEATER UNIT i TEST 12 MIN PORT FLUE EXHAUST VENT CAP 222 i b 12 MIN i CONDENSATION TRAP OPTIONAL HORIZONTAL THROUGH THE WALL VENTING CATEGORY IV Fig 26 Alt Horizontal Through the Wall Venting NOTE While a drain connection is required in the vent of all Cat III horizontal MVB installations the drain can be accomplished in several different ways The figures in this manual show the drain in a vent tee however this can also be accomplished using an inline collector for condensing stacks or an inline vertical or horizontal collector available from several of the listed vent manufacturers 77 ALTERNATE COMBUSTION N AIR INTAKE LOCATION i ee INSULATED EXHAUST VENTING FLUE EXHAUST an VENT CAP TEST PORT CONDENS
74. n accordance with manufacturer s instructions Turn 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 Required 1 Recondition or replace low water cut off device if equipped 2 Check drip leg and gas strainers 3 Check flame failure detection system See Post Start Up Check page 45 4 Check igniter Resistance reading should be 42 70 ohms at ambient temperature 5 Check flame signal strength Flame signal should be greater than 1 microampere as measured at the 2 pins on the upper left corner of the ignition control 6 Check firing rate control by checking the manifold pressure See Manifold Check on page 44 7 Test safety safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV Filter Maintenance NOTE Use Raypak replacement filters kit number 012552F 12 X12 for models 504 1104 and kit number 012553F 16 X16 for models 1504 2004 50 Inspect quarterly Replace when tracking pressure exceeds 0 5 in WC at 10096 fan speed except for models 1104 and 2004 which need to be replaced when track ing pressure exceeds 0 7 in WC at 100 fan speed Filter Replacement Remove the filter box cover by loosening and removing the two wing nuts holding it in place Fig 50 Remove the Air Filter Box Cover 2 Remove the filter by lifting it str
75. n accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code In accordance with the current CAN CGA B149 Installation Codes Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves both dwellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and underside of veranda porch deck or balcony is greater than 1 ft 30cm Clearances in accordance with local installation codes and the requirements of the gas supplier Table E Vent Air Inlet Termination Clearances 10 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 Vent If outside air is drawn through the intake pipe directly to the unit for combustion 1 Install combustion air direct vent in accordance with Fig 27 horizontal or Fig 28 vertical of this manual pages 28 and 29 respectively Provide adequate ventilation of the space occu pied by the heater s by an opening s for ventilation air at the highest practical point com municating with the outdoors The total cross sectional area shall be at least 1 in of free area per 20 000 BTUH 111 mm per kW of total input rating of all equipment in the room when the opening is communicating directly wit
76. ning s shall be either located at or ducted to a point not more than 18 in 450 mm nor less than 6 in 152 mm above the floor level The duct can also goose neck through the roof The duct is preferred to be straight down and terminated 18 in 450 mm from the floor but not near piping This air supply opening require ment shall be in addition to the air opening for ventilation air required in 1 above WARNING Care must be taken to ensure that the equipment room is not under negative pressure conditions 3 For heaters not using a barometric damper in the vent system and when air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator drafthood or similar flue gas dilution device installed in the same space in addition to the opening for ventilation air required in 1 there shall be a permanent air sup ply opening s having a total cross sectional area of not less than 1 in 2 for each 30 000 BTUH 74 mm per kW of total rated input of the burner s and the location of the opening s shall not inter fere with the intended purpose of the opening s for ventilation air referred to in 1 This opening s can be ducted to a point not more than 18 in 450 mm nor less than 6 in 152 mm above the floor level The duct can also goose neck through the WARNING Do not use the one permanent roof The duct is preferred to be straight down 18 opening method if the equipment
77. ny blockage to the flow of fresh air to the heater WARNING Risk of electrical shock More than one disconnect switch may be required to de energize the equipment before servicing WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 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 120 F Warranty claims will be denied when condensation occurs 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 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 NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts external connections to the unit Solid conductors should not be used because they can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the one
78. ontrol Refer to information starting on page 30 for information on the setting and use of this control poe Fig 42 Modulating Temperature Control Low Water Cut Off Optional The optional low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe A 5 second time delay pre vents premature lockout due to temporary conditions such as power fluctuations or air pockets VAN 25 Fig 43 Low Water Cut Off High amp Low Gas Pressure Switches Optional The optional low gas pressure switch connection mounts upstream of the gas valve on the inlet flange to the gas valve and is accessible through the remov able access panels on the rear of the heater to reset the gas pressure switch as necessary It is used to ensure that sufficient gas pressure is present for prop 38 er valve regulator performance The low gas pressure switch automatically shuts down the heater if gas sup ply drops below the factory setting of 3 0 in WC for natural gas or propane gas The optional high gas pressure switch connection mounts down stream of the gas valve Special ports are located on the backside of the gas valve and accessible from the front of the heater to reset the gas pressure switch or through the removable access panels on the rear of the heater to reset the gas pres sure switch as necessary If the gas pressure regulator in the valve fails the high
79. ontrol is set above the design temperature requirements of the system For multiple zones Check to make sure the flow is adjusted as required in each zone Check that the heater is cycled with the thermo stat Raise the setting on the thermostat to the highest setting and verify that the heater goes through the normal start up cycle Reduce to the lowest setting and verify that the heater goes off Observe several operating cycles for proper oper ation Set the heater thermostat to desired temperature Review all instructions shipped with this heater with owner or maintenance person return to enve lope and give to owner or place the instructions inside front panel on heater 46 OPERATION Lighting Instructions 1 10 11 12 Before operation make sure you have read all of the safety information in this manual Remove upper front panel Set the thermostat to the lowest setting Turn off all electrical power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn on main manual gas valve field installed near gas inlet connection on back of heater Wait 5 minutes to clear out any gas Then smell for gas especially near the floor If you then smell gas STOP Follow the steps in the safety informa tion on the front cover of this manual If you do not smell gas go to next step Turn on all electrical power
80. other appliances remaining connected to the common venting system are not in operation 1 Seal any unused opening in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and verify there is no block age restriction leakage corrosion or other unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the com mon venting system are located and other spaces of the building Turn on clothes dryers and any ap pliance not connected to the common vent system Turn on any exhaust fans such as range hoods and bathroom exhausts at maximum speed Do not operate summer exhaust fan Close fireplace dampers VARIABLE SPEED EXTRACTOR ALT LOCATION COMMON VENT PIPE VARIABLE SPEED EXTRACTOR S CAT 1 EXTRACTOR PRESSURE SET POINT nS fi P d SS lt i Sgil Ss y 1 1 P S L CONDENSATION TRAP ADJUSTABLE VEN A A T T DAMPER BAFFLE VENT PIPE SAME La DIAMETER AS BOILER VENT CAT IV v TEST PORT ELBOW Fig 24 Typical Common Venting 26 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 the pressu
81. ow unless a 4 ft horizontal distance is maintained electric meters gas meters regulators and relief equipment The distance of the vent terminal from adjacent public walkways adjacent buildings open windows and building openings must be consis tent with the NFGC U S or B149 Canada Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that might ob struct combustion air flow This dimension is critical to the correct operation of the heater and venting system and reduces the chance of blockage from snow The vent cap must have a minimum 3 ft vertical clearance from the air inlet opening WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants Outdoor Installation Outdoor models must be vented with listed vent mate rial per the following instructions and installed with the optional factory supplied outdoor vent kit A special vent cap and air intake hood are provided in accor dance with CSA requirements These must be installed as illustrated in Fig 29 Care must be taken when locating the heater out doors because the flue gases discharged from the vent cap can condense as they leave the cap Improper location can result in damage to adjacent
82. pre start up check in the Start up section 6 Visually inspect burner flame It should be light blue at full input Remove and visually inspect hot surface igniter and sensor for damage cracking or debris build up 7 Check operation of safety devices Refer to manu facturers instructions 8 Follow oil lubricating instructions on pump if re quired Over oiling will damage pump Water lubricated circulators do not need oiling 9 To avoid potential of severe burn DO NOT REST HANDS ON OR GRASP PIPES Use a light touch return piping will heat up quickly 10 Check blower and blower motor 11 Check for piping leaks around pumps relief valves and other fittings Repair if found DO NOT use petroleum based stop leak Periodically 1 Check relief valve Refer to manufacturer s instructions on valve 2 Testlow water cut off if equipped Refer to manu facturer s instructions Preventive Maintenance Schedule The following procedures are recommended and are good practice for all MVB installations Daily 1 Check gauges monitors and indicators 2 Check instrument and equipment settings See Post Start Up Check on page 45 3 Check burner flame Should see light blue flame at full input rate Weekly For low pressure heaters test low water cut off device With heater in pre purge depress the low water cut off test button Appliance should shut off and ignition fault light should come on Depres
83. pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi 3 45 kPa Relieve test pressure in the gas supply line prior to reconnecting the heater and its manual shut off valve to the gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE Over pressurized gas valves are not covered by warranty The heater and its gas con nections shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use an open flame MUST BE SUPPLIED BY INSTALLER WRENCHING NIPPLE STREET ELBOW 1 MANUAL SHUTOFF VALVE SEDIMENT TRAP JACKET ZERO GOVERNOR ON OFF COMBO VALVE Fig 17 Gas Supply Connection CAUTION Do not use Teflon tape on gas line pipe thread A pipe compound rated for use with natural and propane gases is recommended Apply sparingly only on male pipe ends leaving the two end threads bare CAUTION Support gas supply piping with hangers not by the heater or its accessories Make sure the gas piping is protected from physical damage and freezing where required Gas Supply Pressure A minimum of 4 0 in WC and a maximum of 10 5 in WC upstream gas pressure is required under load and no load conditions for natural gas A minimum of 4 0 in WC and a maximum of 13 0 in WC is required for propane gas The gas pressure regulator s supplied on the heater is for low pressure service If upstream pressure exceeds these values
84. pump is shut off NOTE High chemical concentrates from feeders and chlorinators that are out of adjustment will cause rapid corrosion to the heat exchanger Such damage is not covered under the warranty NOTE Failure of a heat exchanger due to lime scale build up on the heating surface low pH or other chemical imbalance is non warrantable Gas Supply DANGER Make sure the gas on which the heater will operate is the same type as specified on the heater s rating plate Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve lo cated outside the heater jacket It is recommended that a union be installed in the gas supply piping adja cent to the heater for servicing The gas supply pressure to the heater must not exceed 10 5 in WC for natural gas or 13 0 in WC for propane gas A pounds to inches regulator must be installed to reduce the gas supply pressure if it is higher than noted above This regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the heater gas controls Refer to Table for maximum equivalent pipe lengths Gas Supply Connection CAUTION The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1 2 psi 3 45 kPa 19 The heater must be isolated from the gas supply pip ing system by closing the upstream manual shut off valve during any
85. quirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vent ed gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide
86. re 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 in WC 6 After it has been determined that each appliance remaining connected to the common venting sys tem properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use 7 Any improper operation of the common venting system should be corrected so that the installation conforms with the NFGC U S or B149 Canada 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 Ap pendix G in the NFGC U S or B149 Canada Engineered Vent Systems Table M provides boiler discharge vent volumes of flue products at full fire for the calculation of appropriate vent sizing for common venting WARNING Vent connectors serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure If an MVB heater is installed to replace an existing heater the vent system MUST be verified to be of the correct size and Category If it is NOT it MUST be replaced NOTE For extractor sizing typical CO levels are 8 5 for natural gas and 9 5 for LP gas and flue temperature of 350 F 27 Volume of F
87. rent 5 Flashes Low 24 VAC 6 Flashes Internal fault Replace control Table U Ignition Module Diagnostic LED Flash Codes High Limit Manual Reset This heater is equipped with a fixed setting manual re set high limit temperature device as standard or it may have an optional adjustable setting manual reset high temperature device The fixed setting manual reset high limit is located on the In Out header of the heat exchanger on the right side of the heater accessible through the front door for reset as necessary The optional adjustable manual reset high limit is lo cated inside the heater junction box Push the reset button and adjust the setting to approx 40 F 20 C above desired outlet temperature Fig 39 High Limit Manual Reset High Limit Auto Reset Optional This heater may be equipped with an optional adjust able auto reset high limit temperature device The optional adjustable auto reset high limit is located inside the heater junction box Adjust the setting to approx 20 F 10 C above desired outlet temperature lee T L Ne Fig 40 Adjustable High Limit Auto Reset Flow Switch This standard dual purpose control mounted and wired in series with the main gas valve shuts off heater in case of pump failure or low water flow Fig 41 Flow Switch Modulating Temperature Control This heater is equipped with a Raypak modulating temperature c
88. room is under in 450 mm from the floor but not near piping negative pressure conditions 4 Refer to the B149 Installation Code for additional Canadian Installations REIT CAUTION All combustion air must be drawn from Pre outside of the building the mechanical equipment Water Piping room must communicate directly with the outdoors 1 Ventilation of the space occupied by the heater General shall be provided by an opening s for ventilation air at the highest practical point communicating The heater should be located so that any water leaks with the outdoors The total cross sectional area of will not cause damage to the adjacent area or struc such an opening s shall be at least 10 of the tures area required in 2 and 3 below but in no case shall the cross sectional area be less than 10 in NOTE In lieu of installing the System Temp Sensor 65 cm in the system return loop an alternate system using a buffer tank see Fig 31 can be used for better sys tem temperature control 12 CAUTION This heater requires forced water circulation when the burner is operating See Table F and Table G for minimum and maximum flow rates and water pump selection The pump must be interlocked with the heater to prevent heater operation without water circulation NOTE Minimum pipe size for in out connections is 2 in NPT for 504 and 754 models and 2 Z in NPT for 1104 2004 models Verify proper flow rates and AT as in
89. rpeting Table C Clearances Indoor Installations When installed according to the listed minimum clear ances from combustible construction these heaters can still be serviced without removing permanent structural construction around the heater However for ease of servicing a clearance of at least 24 in in front at least 24 in on the rear and 10 in above the top of the heater is required This will allow the heater to be TOP VIEW 24 SERVICE CLEARANCE REAR EXHAUST INSTALLATION FRONT VIEW 10 SERVICE CLEARANCE VERTICAL CLEARANCE ALL INSTALLATIONS Venting not shown for clarity Heater must be vented per instruc tions in this manual Fig 6 Minimum Clearances from Combustible Surfaces Indoor and Outdoor Installations serviced in its installed location without movement or removal of the heater Service clearances less than the minimum may require removal of the heater to service either the heat exchanger or the burner components In either case the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater Outdoor Installations These heaters are design certified for outdoor installa tion Heaters must not be installed under an overhang unless they are in accordance with local installation codes and the requirments of the gas supplier Three sides must be open in the area under the overhang Roof water drainage must
90. rs a Where directly communicating with the out doors or where communicating to the outdoors through vertical ducts each open ing shall have a minimum free area of 1 in per 4 000 BTUH 550 mm per kW of total input rating of all equipment in the enclosure b Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in per 2 000 BTUH 1 100 mm per kW of total input rat ing of all equipment in the enclosure One permanent opening commencing within 12 in 305 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 25 mm from the sides and back and 6 in 152 mm from the front of the appliance The opening shall directly communicate with the out doors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of a 1 in per 3 000 BTUH 740 mm per kW of the total input rating of all equipment located in the enclosure and b Notless than the sum of the areas of all vent connectors in the confined space 2 For heaters using a barometric damper in the vent system there shall be a permanent air supply opening s having a cross section area of not less than 1 in 2 per 7 000 BTUH 320 mm per kW up to and including 1 million BTUH plus 1 in per 14 000 BTUH 160 mm per kW in excess of 1 million BTUH This ope
91. s on the unit or larger BEFORE INSTALLATION 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 Installation and service must be performed by a qualified installer service agency or gas supplier If after reviewing this manual you still have questions which this manual does not answer please contact your local Raypak representative or visit our website at www raypak com Thank you for purchasing a Raypak product We hope you will be satisfied with the high quality and durability of our equipment Product Receipt On receipt of your heater it is suggested that you visu ally check for external damage to the shipping crate If the crate is damaged make a note to that effect on the Bill of Lading when signing for the shipment Next remove the heater from the shipping packaging Report any damage to the carrier immediately On occasion items are shipped loose Be sure that you receive the correct number of packages as indi cated on the Bill of Lading Claims for shortages and damages must be filed with the carrier by consignee Permission to return goods must be received from the factory prior to shipping Goods returned to the factory without an authorized
92. s reset button on front of heater control panel to reset Monthly 1 Check flue vent stack or outlet dampers 2 Test blower air pressure See Blower Check on page 43 3 Test high and low gas pressure interlocks if equipped See Safety Inspection on page 44 Semi Annually 1 Recalibrate all indicating and recording gauges 2 Check flame failure detection system components 3 Check firing rate control by checking the manifold pressure See Manifold Check on page 44 4 Check piping and wiring of all interlocks and shut off valves 5 Check air filter and replace as necessary Annually 1 Test flame failure detection system and pilot turn down 2 Test high limit and operating temperature See Post Start Up Check page 45 3 Check flame sensor 4 Conduct a combustion test at full fire Carbon diox ide should be 8 5 to 9 0 at full fire for natural gas and between 9 5 to 10 096 for propane gas Carbon monoxide should be 100 ppm 5 Check valve coil for 60 cycle hum or buzz Check for leaks at all valve fittings using a soapy water solution while heater is operating Test other operating parts of all safety shut off and control valves and increase or decrease settings depending on the type of control until the safety circuit opens Reset to original setting after each device is tested 6 Perform leakage test on gas valves See Fig 49 and procedure on page 45 7 Test air switch i
93. structed in this manual Relief Valve Piping WARNING Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns Do not pipe to any area where freezing could occur Refer to local codes Temperature amp Pressure 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 Hydrostatic Test 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 and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based anti freeze Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply Leaks must be repaired at once to prevent damage to the heater NEVER use petroleum based stop leak compounds To perform hydrostatic test 1 Connect fill water supply With bleed valve open fill heater with water When water flows from bleed valve shut off water Close bleed valve Carefully fill th
94. tance of the vent terminal from adjacent public walkways adjacent buildings open windows and building open ings must be consistent with the NFGC U S or B149 Canada Gas vents supported only by flashing and extended above the roof more than 5 ft should be se curely guyed or braced to withstand snow and wind loads CAUTION A listed vent cap terminal adequately sized must be used to evacuate the flue products from the building 25 10 OR LESS 2 MIN 2 MIN CAT I VENT PIPE B HEATER UNIT Mr PORT ded Mss Fig 23 Vertical Venting Common Venting 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 WARNING Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure CAUTION Vent connectors for natural draft venting systems must be Type B or better Common venting systems may be too large once an existing unit is removed At the time of removal of an existing appliance the following steps must be fol lowed with each appliance remaining connected to the common venting system placed in operation while the
95. temperature varies linearly between 50 F 10 C and 220 F 104 C refer to Table P If a volt age below 1 5 VDC is received the boiler target temperature is displayed as indicating that there is no longer an internal call for heat A 4 20 mA signal can be converted to a 2 10 VDC signal by installing a 500 Q resistor on the external input signal device s terminals FP Flame proof warning MODE Operating mode of the heater OFFSET The Offset setting allows the boiler target temperature to be fine tuned to the external input sig nal The control reads the external input signal and converts this to a boiler target temperature The Offset setting is then added to the boiler target temperature OUTDR Outdoor air temperature OUTDR DESIGN Design outdoor air temperature used in the heat loss calculation OUTDR START Starting outdoor air temperature PUMP DLY Sets the operating time of the pump once the CFH is satisfied TANK Current DHW tank temperature Mode 3 TANK DIFF Storage tank differential Mode 3 TANK TARGET Target temperature in the DHW storage tank Mode 3 CO s ose rst senserit 8 eme S cer outeorsmerster 8 ems 9m ror tor sensorapen Table T Error Codes 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 displ
96. ter before bathing or show ering Temperature limiting valves are available see manual Time Temperature Relationships in Scalds The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications Water Time to Produce Serious Temp Burn 120 F More than 5 minutes 125 F 1 1 2 to 2 minutes 130 F About 30 seconds Table courtesy of The Shriners Burn Institute Table B Time to Produce Serious Burn The temperature of the water in the heater can be reg ulated by using the Raypak Modulating Temperature Control To comply with safety regulations the control is set at 120 F when shipped from the factory Mode 3 default setting for Tank Target To adjust the water temperature follow the instruction for the operation of the control starting on page 30 of this manual The control is shown below for identifica tion purposes only See Fig 5 E Fig 5 Modulating Temperature Control CAUTION Hotter water increases the risk of scalding There is a hot water scald potential if the thermostat is set too high INSTALLATION Installation Codes Installations must follow these codes Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition NFGC National Electrical Code ANSI NF
97. to the appliance Set thermostat to desired setting The appliance will operate The igniter will glow after the pre purge time delay 15 seconds After igniter reaches temperature 30 seconds the main valve should open System will try for ignition up to three times one time on optional single try ignition mod ule If flame is not sensed lockout will commence If the appliance will not operate follow the instruc tions To Turn Off Gas To Appliance and call your service technician or gas supplier Replace upper front panel If heater fails to start verify the following a There are no loose connections or that the service switch is off b High temperature limit switch is set above wa ter temperature or manual reset high limit is not tripped c Thermostat is set above water temperature Gas is on at the meter and the heater Incoming dynamic gas pressure to the gas valve is NOT less than 4 0 in WC for natural gas or propane gas To Turn Off Gas To 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 4 Turn off all electrical power to the appliance if serv ice is to be performed 5 Replace access panel 47 UDB Fault History To view the fault codes in the UDB history file 1 Press the UP or DOWN buttons on the membrane switch for 2 seconds to access the fault history Press
98. trically grounded as required by the NEC n Canada CSA C22 1 C E C Part 1 The MVB 504 1504 heaters are wired for 120 VAC 12 amps while the MVB 2004 heaters are wired for 120 VAC 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 hp get their power supply directly from the boiler power supply connec tions in rear wiring box Install a circuit breaker sized sufficiently for both the heater and the pump Pumps larger than 2 hp must use a separate power supply and run the power through the optional pump contac tor which is located in the rear wiring box Use appropriately sized wire as defined by NEC CSA and or local codes All primary wiring should be 125 of minimum rating If any of the original wire as supplied with the heater must be replaced it must be replaced with 105 C wire or its equivalent All high voltage wiring connections to the MVB heater are made inside the rear wiring box as shown in Fig 18 Pump power should be taken from terminals 2 Com 3 GND and 6 Hot hp and smaller ONLY Power to the MVB heater should be connected to ter minals 1 2 and 3 as noted in Fig 18 All low voltage wiring including sensors interlocks enable disable and various options are wired into terminals 1 20 on the front wiring panel as noted in Fig 18 FIELD WIRING
99. um chloride used for water softening refrigerant leaks paint or varnish removers hydrochloric acid muriatic acid cements and glues antistatic fabric softeners used in clothes dryers chloride type bleaches detergents and cleaning solvents found in household laundry rooms adhesives used to fasten building products similar products Areas where contaminated combustion air commonly exists dry cleaning laundry areas metal fabrication plants beauty shops refrigeration repair shops photo processing plants auto body shops plastic manufacturing plants furniture refinishing areas and establishments new building construction remodeling areas open pit skimmers Check for areas and products listed above before in stalling heater If found remove products permanently OR install TruSeal direct vent Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 00 and 5 00 for installation of through the wall vented gas appliances as follows a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following re
100. ure that all joints are sealed properly and are airtight The vent must be installed to prevent the potential accumulation of condensate in the vent pipes It is required that 1 The vent must be installed with a condensate drain located in proximity to the heater as directed by the vent manufacturer 2 The vent must be installed with a slight upward slope of not less than 1 4 inch per foot of horizon tal run to the vent terminal 3 The vent must be insulated through the length of the horizontal run Termination The flue direct vent cap MUST be mounted on the ex terior of the building The direct vent cap cannot be installed in a well or below grade The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels The Raypak approved stainless steel flue direct vent cap must be used sales order option D 15 The vent terminal must be located NO CLOSER than 12 off the wall WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants Direct Vent Vertical Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and force the heated flue products through the vent pipe under posi tive pressure The vent material must be in accordance with the above instructions for vent mate rials Vent material must be listed by a nationally recognized test agency T
101. utes may damage or cause failure of the heat exchanger combustion chamber or other parts within the combustion chamber It can cause operational problems bad combustion sooting flue gas leakage and reduced service life of the appliance and the vent system A bypass allows part of the heater discharge water to be mixed with the cooler water returning to the heater inlet to increase the heater inlet temperature above 120 F 49 C This precautionary measure should prevent the products of combustion from con densing beyond the ability of the condensate management system employed in this heater in most installations Warranty claims will be denied for damage or failures caused by condensation Cold water operation issues are applicable to both cold water start and cold water run applications Cold water operation for 7 minutes or less on initial daily start up is acceptable Where cold water starts will last longer than 7 minutes or where cold water operation is continuous provisions must be made to mix higher temperature 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 Water Starts Cold water starts where the inlet water temperature remains below 120 F 49 C for more than 7 minutes must have cold water start protection Known pro tection methods consist of mixing heated outlet water with the inlet water using a bypass to raise the inl
102. w the set point For systems with more than 4 1 turndown the recom mended location of the system target sensor is in the system supply loop downstream of the outlet piping from the heater When controlling systems with more than 4 1 turndown set the supply side differential to 20 F and the temperature will vary 10 F around the setpoint In lieu of installing the target sensor in the system return a properly sized buffer tank can be installed as shown in Fig 31 Consult factory for buffer tank sizing Operating Modes Mode 1 Not supported Setpoint operation using primary piping The heater outlet water temperature is controlled to the boiler target setpoint RAYPAK ELECTRONIC TEMP CONTROL HEATER BOILER OUTLET SENSOR IN RM LS HEADER J PN a qp E BOILER INLET SENSOR IN HEADER SYSTEM BUFFER TANK SENSOR SYSTEM RETURN FOR BUFFER TANK SIZING PLEASE CONSULT FACTORY Fig 31 Buffer Tank Piping 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 boiler target and boiler differential factory default H7 P and WHP boilers See Fig 32 RAYPAK ELECTRONIC TEMP CONTROL HEATER BOILER OUTLET SENSOR IN HEADER putet cnr BOILER INLET SENSOR IN HEADER SYSTEM RN CRM TEMP MAIN SENSOR SYSTEM PUM

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