Raypak 504-2004 - Manual

7 GENERAL SAFETY To meet commercial hot water use needs, the highlimit safety control on this water heater is adjustable upto 210°F. However, water temperatures over 125°Fcan cause instant severe burns or death from scalds.When supplying general purpose hot water, the rec-ommended initial setting fo...

Equipment Base The heater should be mounted on a level, structurallysound surface. The heater is approved for installationon a combustible surface but must NEVER beinstalled on carpeting. Gas-fueled equipment installedin enclosed parking garages must be located at least18 in. above the floor. In add...

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 awayfrom heaters installed under overhangs. The combustion air intake terminal MUST be used for outdoor installatio...

11 Optional Construction 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 Vent If outside air is drawn through the intake pipe directlyto the unit for combustion: ...

b. Where communicating with the outdoorsthrough horizontal ducts, each opening shallhave a minimum free area of 1 in. 2 per 2,000 BTUH (1,100 mm 2 per kW) of total input rat- ing of all equipment in the enclosure. 2. One permanent opening , commencing within 12 in. (305 mm) of the top of the enclosu...

Relief Valve Piping Hydrostatic Test Unlike many types of heaters, this heater does not re-quire hydrostatic testing prior to being placed inoperation. The heat exchanger has already been fac-tory-tested and is rated for 160 psi operating pressure.However, Raypak does recommend hydrostatic test-ing ...

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

16 Domestic Hot Water When designing the water piping system for domestichot water applications, water hardness should be con-sidered. Table G indicates the suggested flow rates forsoft, medium and hard water. Water hardness is ex-pressed in grains per gallon. Potable Water and Space Heating 1. All ...

18 Pool/Spa Water Chemistr y Chemical imbalance can cause severe damage toyour heater and associated equipment. Maintain yourwater chemistry according to the chart below. If themineral content and dissolved solids in the waterbecome too high, scale forms inside the heat exchang-er tubes, reducing he...

19 Further advice should be obtained from your pool orspa 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 circulate...

20 The MVB 504-1504 heaters are wired for 120 VAC, 12amps while the MVB 2004 heaters are wired for 120VAC, 18 amps. Consult the wiring diagram shippedwith the heater. Before starting the heater, check toensure proper voltage to the heater and pump. Boiler mounted pumps (up to 3 ⁄ 4 hp) get their pow...

21 Field-Connected Controllers It is strongly recommended that all individually-pow-ered control modules and the heater should besupplied from the same power source. Check the Power Source NOTE: Field-supplied isolation relays should be installed when field-connected controllers aremounted more than...

22 Field Wiring Connection Venting General Appliance Categories Heaters are divided into four categories based on thepressure produced in the exhaust and the likelihood ofcondensate production in the vent. Category I – A heater which operates with a non-pos- itive vent static pressure and with a ven...

24 7. The vent terminal requires a 12 in. vent terminalclearance from the wall. 8. Terminate vent at least 1 ft above grade, includingnormal snow line. 9. Multiple direct vent installations require a 4 ftclearance between the ends of vent caps locatedon the same horizontal plane. Canadian Installati...

25 Table L: Category I Vertical Venting 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. Ter mination The vent termi...

26 Common Venting Manifolds that connect more than one heater to a com-mon chimney must be sized to handle the combinedload. Consult available guides for proper sizing of themanifold and the chimney. At no time should the areaof the common vent be less than the area of thelargest heater exhaust outl...

system. Turn on any exhaust fans, such as rangehoods and bathroom exhausts, at maximumspeed. Do not operate summer exhaust fan. Closefireplace dampers. 4. Place in operation the appliances being inspected.Follow the manufacturer’s instructions for lightingeach appliance. Adjust thermostat so applian...

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 ofthe venting system. The vent must be installed to prevent flue gas leakage.Care must be t...

29 * Vent 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. Table N: Category III Horizontal Vent & Horizontal Direct Vent See Table L for Category I venting guidelines. It is recommended that t...

Freeze Protection The Raypak electronic temperature control includes afreeze protection feature. In the event the temperaturedrops below 40° F at any of the boiler temperaturesensors, the pump is turned on and will remain on untilthe temperature at all boiler sensors rises to 45° F. Controls The Ray...

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 aremote system...

32 Mode 5 – Outdoor reset using primary/secondary pip- ing. The heater is operated as in Mode 2. However, thetarget 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 ...

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 thermalmass (setting=3) provides slower reaction, lower ther-mal ...

36 Operation The Raypak electronic temperature control uses aLiquid Crystal Display (LCD) as a method of supply-ing information. The LCD is used to setup and monitorsystem operation by means of three push buttons( Item , L and M ) shown at the bottom of Fig. 34. All items displayed by the control ar...

43 START-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 untilwater appears, then close vent. ...

44 Check Power Supply With multi-meter at incoming power, check voltagebetween: Hot - Common (≈120 VAC) Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) Attach Manometers to Measure Pressures 1. Turn off main gas valve. 2. Attach (1) 12” scale manometer to an upstreambleedle valve on the gas sup...

47 for operation as outlined by manufacturer. Burnershould be operating and should go off when con-trols are tested. When safety devices are restored,burners should re-ignite after pre-purge timedelay. 8. Test limit control: While burner is operating, moveindicator on high limit control below actual...

48 d. Gas is on at the meter and the heater. e. Incoming dynamic gas pressure to the gasvalve is NOT less than 4.0 in. WC for naturalgas or propane gas. To Tur n Off Gas To Appliance 1. Shut off manual gas valve field installed near gasinlet connection on back of heater. 2. Remove upper front panel....

49 TROUBLESHOOTING Step 8 Step 7 Step 6 Step 9 Step 1 Step 2 Step 3 Step 4 Step 5 Is there a Call For Heat? Is Disable connection intact? Does the combustion air blower come on? Is 4-20mA present at the quick disconnects on the black and blue wires of the temperature controller? Is 24VAC at the NC s...

50 UDB Fault Histor y To 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 beginto flash when the history has been accessed. SeeFig. 44 on page 40. 2. Press the switch labeled “SW2” to scroll throughthe re...

51 by local codes. 3. Check that area is free from combustible materi-als, gasoline, and other flammable vapors andliquids. 4. Check for and remove any obstruction to the flowof combustion or ventilation air to heater. 5. Follow pre-start-up check in the Start-up section. 6. Visually inspect burner ...

52 6. Perform leakage test on gas valves (See Fig. 46.)and procedure on page 46. 7. Test air switch in accordance with manufacturer’sinstructions. (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....

53 (b) EXEMPTIONS: The following equipment is exempt from248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "EquipmentNot Required To Be Vented" in the most current edition ofNFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas...

56 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS - M V B 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...