Instruction/ maintenance manual of the product 504-2004 Raypak
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INST ALLA TION AND OPERA TING INSTR UCTIONS CA T ALOG NO. 3400.54 Effective: 06-01-07 Replaces: NEW P/N 241317 Rev . 1 This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference.
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WARNINGS 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 6 GENERAL SAFETY 7 T ime.
4 D ANGER: Indicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored.
5 BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your MVB heater . Please review the General Safety information before installing the heater . Factory warranty does not apply to heaters that have been improperly installed or oper- ated.
General Infor ma tion T able A: Basic Data 6.
7 GENERAL SAFETY T o meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F . However , water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water , the rec- ommended initial setting for the temperature control is 125°F .
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.
9 Fig. 5: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations Three sides must be open in the area under the over- hang. Roof water drainage must be diverted away from heaters installed under overhangs. The combustion air intake terminal MUST be used for outdoor installations.
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11 Optional Constr uction Air Filter An optional construction air filter is available for use. The filter should be removed after construction is fin- ished to allow for unrestricted air flow to the heater . Direct V ent If outside air is drawn through the intake pipe directly to the unit for combustion: 1.
b. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in. 2 per 2,000 BTUH (1,100 mm 2 per kW) of total input rat- ing of all equipment in the enclosure. 2. One permanent opening , commencing within 12 in.
R elief V alve Piping Hydrostatic T est Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in operation. The heat exchanger has already been fac- tory-tested and is rated for 160 psi operating pressure.
14 longer needed and the bypass can be shut off. If the bypass is not shut off as the system heats up, the out- let temperature may continue to climb and trip the high limit, thereby shutting down the heater .
15 T able F: Heater Rates of Flow and Pressure Drops Note: Basis for minimum flow is ΔT . Basis for maximum flow is gpm. The piping system of a hot water heater connected to heating coils located in .
16 Domestic Hot Wa ter When designing the water piping system for domestic hot water applications, water hardness should be con- sidered. T able G indicates the suggested flow rates for soft, medium and hard water . Water hardness is ex- pressed in grains per gallon.
17 increase the inlet water temperature to a minimum of 105°F (40°C) for Pool Heater (P and WHP) versions and 120°F (49°C) for Hydronic Heating (H7) or Domestic Hot W ater (WH1) versions, thereby reducing the likelihood of condensation forming on the heat exchanger .
18 P ool/Spa Water Chemistr y Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water chemistry according to the chart below . If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchang- er tubes, reducing heater efficiency and damaging the heater .
19 Further advice should be obtained from your pool or spa builder , accredited pool shop, or chemical suppli- er for the correct levels for your water . Automa tic Chlorinator s and Chemical F eeder s All chemicals must be introduced and completely dilut- ed into the pool or spa water before being circulated through the heater .
20 The MVB 504-1504 heaters are wired for 120 V AC, 12 amps while the MVB 2004 heaters are wired for 120 V AC, 18 amps. Consult the wiring diagram shipped with the heater . Before starting the heater , check to ensure proper voltage to the heater and pump.
21 Field-Connected Controller s It is strongly recommended that all individually-pow- ered control modules and the heater should be supplied from the same power source. Check the P ower Source NO TE: Field-supplied isolation relays should be installed when field-connected controllers are mounted more than 50 equivalent feet (18 Ga) from heater .
22 Field W iring Connection V enting General Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent.
1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 2. Give special attention to the location of the vent termination to avoid possibility of property dam- age or personal injury . 3. Gases may form a white vapor plume in winter .
24 7. The vent terminal requires a 12 in. vent terminal clearance from the wall. 8. T erminate vent at least 1 ft above grade, including normal snow line. 9. Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane.
25 T able L: Category I V ertical V enting 1 V ent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. When vertical height exceeds 25 ft, consult factory prior to installation. * Subtract 10 ft per elbow .
26 Common V enting Manifolds that connect more than one heater to a com- mon chimney must be sized to handle the combined load. Consult available guides for proper sizing of the manifold and the chimney . At no time should the area of the common vent be less than the area of the largest heater exhaust outlet.
system. T urn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliances being inspected. Follow the manufacturer ’s instructions for lighting each appliance.
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.
29 * V ent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. ** Subtract 10 ft per elbow . Max. 4 elbows. T able N: Category III Horizontal V ent & Horizontal Direct V ent See T able L for Category I venting guidelines.
F r eeze Protection The Raypak electronic temperature control includes a freeze protection feature. In the event the temperature drops below 40° F at any of the boiler temperature sensors, the pump is turned on and will remain on until the temperature at all boiler sensors rises to 45° F .
31 Operating Modes Mode 1 – (H7 and WH1 models) Setpoint operation using primary piping. The heater outlet water temper- ature is controlled to the boiler target setpoint. See Fig. 27. Mode 2 – Setpoint operation using primary/secondary piping. The control operates the heater to satisfy a remote system sensor .
32 Mode 5 – Outdoor reset using primary/secondary pip- ing. The heater is operated as in Mode 2. However , the target temperature is based on outdoor reset. See Fig. 31. Mode 6 – Designed for an external input signal with primary piping. The external input signal can be pro- vided from a BMS, an EMS or a sequencing control.
33 T able O: T emperature Control Default Setpoints—Boiler Boiler (H7) Item Modes Default Setting Range Boil T arget 1, 2 140°F OFF , 70 to 220°F 3 160°F OFF , 70 to 190°F 4, 5, 6, 7 180°F OFF .
34 Definitions % OUT - Current percent modulation rate of heater . BOIL DSGN - Design boiler water temperature used in heat loss calculations. BOIL MASS - This setting allows adjustment in the field for high or low thermal masses; High thermal mass (setting=3) provides slower reaction, lower ther- mal mass (setting=1) provides faster reaction.
35 0-10VDC or 0-20 mA external input signal – When the 0-10VDC signal is selected, an input voltage of 1 VDC corresponds to a boiler target temperature of 50°F (10°C). An input voltage of 10 VDC corresponds to a boiler target temperature of 220°F (104°C).
36 Operation The Raypak electronic temperature control uses a Liquid Crystal Display (LCD) as a method of supply- ing information. The LCD is used to setup and monitor system operation by means of three push buttons ( Item , L and M ) shown at the bottom of Fig.
37 9. 24 V AC is sent from the NC contact of the High Gas Pressure Switch to the common terminal of the Low W ater Cut Off (if equipped). Upon loss of water in the heater , the Low Water Cut Of f (if equipped) will send a 24V AC signal to pin P3-4 of the UDB board to indicate a safety fault.
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Modulating T emper a tur e Control The heater is equipped with a Raypak modulating tem- perature control. Refer to information starting on page 31 for information on the setting and use of this con- trol.
Block ed V ent Switch This heater is equipped with a blocked vent pressure switch to prevent the operation of the heater when too much of the vent is blocked.
41 WIRING DIA GRAM - Models H & WH.
WIRING DIA GRAM - Models P & WHP 42.
43 ST ART -UP Pre Star t-up Filling System (Heating Boilers) Fill system with water . Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent.
44 Check P ower Supply With multi-meter at incoming power , check voltage between: Hot - Common (≈120 V AC) Hot - Ground (≈120 V AC) Common - Ground (< 1 V AC) Attach Manometers to Measure Pr essures 1.
45 2. If the pressure reading differs by more than ± 0.2 in. WC, STOP – Call the factory for directions on what to do next! Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record.
46 Leak T est Procedur e: Dual-Seat Gas V alve Proper leak testing requires three pressure test points in the gas train. Remove the access panel on the rear of the heater to access the gas valve for this test. T est point A is a blee- dle valve located upstream of the combination gas valve on the supply manifold.
47 for operation as outlined by manufacturer . Burner should be operating and should go off when con- trols are tested. When safety devices are restored, burners should re-ignite after pre-purge time delay . 8. T est limit control: While burner is operating, move indicator on high limit control below actual water temperature.
48 d. Gas is on at the meter and the heater . e. Incoming dynamic gas pressure to the gas valve is NOT less than 4.0 in. WC for natural gas or propane gas. T o T ur n Of f Gas T o A ppliance 1. Shut off manual gas valve field installed near gas inlet connection on back of heater .
49 TR OUBLESHOO TING Ste p 8 Ste p 7 Ste p 6 Ste p 9 Step 1 Step 2 Step 3 Step 4 Step 5 Is there a Call For Heat? Is Disable connection intact? Does the combustion air blower come on? Is 4-20mA presen.
50 UDB F ault Histor y T o view the fault codes in the UDB history file: 1. Press and hold the switch labeled “SW1” for 5 sec- onds to access the fault history . LED 17 will begin to flash when the history has been accessed. See Fig. 44 on page 40.
51 by local codes. 3. Check that area is free from combustible materi- als, gasoline, and other flammable vapors and liquids. 4. Check for and remove any obstruction to the flow of combustion or ventilation air to heater . 5. Follow pre-start-up check in the Start-up section.
52 6. Perform leakage test on gas valves (See Fig. 46.) and procedure on page 46. 7. T est air switch in accordance with manufacturer ’s instructions. (T urn panel switch to the “On” posi- tion until blower is proven, then turn the switch to “Off.
53 (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required T o Be V ented" in the most current edition of NFP A 54 as adopted by the Board; and 2.
54 LIMITED PARTS WARRANTY MVB – TYPES H AND WH MODELS 504-2004 SCOP E Ray pak, Inc. (“ Ray pak ”) w arr ants to the o rig inal ow ner th at al l par ts of this hea ter w hic h a re actu al ly m .
55 LIMI TED P ARTS WARRANTY MVB – TYPE P & WHP MODELS 504–2004 SCOP E Ray pak, Inc. (“ Ray pak ”) w arr ants to th e orig in al ow ner th at al l parts o f this h eater w hic h a re actu a.
56 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS - M V B Thi s s ta rt-u p ch ec klis t is to b e c o mpl ete ly fill ed o u t b y t he s erv ic e tec hn ic ian s tar tin g up th e R ayp a k Boi le r or He ater for the first time. All information may be used for warra nty purposes an d to ensure that the ins tallation is corre ct.
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ww w .raypak.c om Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.
An important point after buying a device Raypak 504-2004 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Raypak 504-2004 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Raypak 504-2004 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Raypak 504-2004 you will learn all the available features of the product, as well as information on its operation. The information that you get Raypak 504-2004 will certainly help you make a decision on the purchase.
If you already are a holder of Raypak 504-2004, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Raypak 504-2004.
However, one of the most important roles played by the user manual is to help in solving problems with Raypak 504-2004. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Raypak 504-2004 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
