Raypak 5042004 - Manual

7 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...

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. I...

9 Fig. 6: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations codes and the requirments of the gas supplier. Three sides must be open in the area under the overhang. Roof water drainage must be diverted away from heaters installed under overhangs. The combustion air intak...

11 Air Filter An air filter is supplied standard with the heater. This filter is shipped loose for field installation. Refer to the Air Filter Kit Installation Instructions (Part No. 241338) for details. Direct Vent If outside air is drawn through the intake pipe directly to the unit for combustion:...

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 outdoors. a. Where directly communicating with the out- doors or where communicating to the outdoors through vertical ducts, each op...

Relief Valve Piping Temperature & 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 appli...

14 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...

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

16 Potable Water and Space Heating 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water. 2. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space...

18 Pool/Spa Water Chemistry 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, redu...

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. Automatic Chlorinators and Chemical Feeders All chemicals must be introduced and completely dilut- ed into the pool or spa water before being circul...

20 • National Electrical Code and any other national, state, provincial or local codes or regulations hav- ing jurisdiction. • Safety wiring must be NEC Class 1. • Heater must be electrically grounded as required by the NEC. • In Canada, CSA C22. 1 C.E.C. Part 1. The MVB 504-1504 heaters are wired f...

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

Venting Installation Tips Support piping: • horizontal runs—at least every 5 ft • vertical runs—use braces • under or near elbows 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 pro...

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. ** Adapters supplied by oth...

26 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...

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 pressure at a pressure tap located 12 in. above the bottom joint of the first vertical vent pipe. Pressure ...

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...

29 ** Subtract 10 ft per elbow. Max. 4 elbows. t Adapters supplied by others. Table N: Category III Horizontal Vent & Horizontal Direct Vent See Table L for Category I venting guidelines. It is recommended that the intake vent be insulated in colder climates. Termination The flue terminal should...

Freeze Protection The Raypak electronic temperature control includes a freeze protection feature. In the event the temperature drops below 40°F at any of the boiler temperature sen- sors, the pump is turned on and will remain on until the temperature at all boiler sensors rises to 45°F. Controls The...

31 Deadband: Deadband is a band 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 2ºF around the differen- tial. Differential: A heat source mu...

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 t...

Mode 8 – This mode is for remote firing control of the heater 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 s...

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

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...

42 START-UP 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 ven...

43 Check Power Supply With multi-meter at incoming power, check voltage between: 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 upstream bleedle valve on the gas s...

45 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 A is a blee- dle valve located upstream of the combination gas valve on the supply...

46 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. Test limit control: While burner is operating, move indicator on high limit control below a...

48 TROUBLESHOOTING 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 present at the quick disconnects on the black and blue wires of the tem perature controlle r? Is 24VAC at th...

49 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. Maintenance as outlined below may be performed by the owner. Daily 1. Check that the area where the heater is installed is fre...

50 6. Perform leakage test on gas valves (See Fig. 49.) and procedure on page 45. 7. Test air switch in 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 Require...

51 Filter Replacement 1. Remove the filter box cover by loosening and removing the two wing nuts holding it in place. 2. Remove the filter by lifting it straight up and out of the slot in the filter box. 3. Reverse steps 1 and 2 to install the new filter. Use Raypak replacement filters, kit number 0...

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 ...

55 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. Additi...