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INSTALLATION & OPERATING
INSTRUCTIONS
Models 504–2004
L
Types H, WH, P & WHP
W
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 ot
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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 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
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CONTENTS WARNINGS 4 Outdoor Installation 29 BEFORE INSTALLATION 5 Controls 30 Product Receipt 5 Heater Sequence of Operation 37 Model Identification 5 WIRING DIAGRAMS 40 Ratings and Certifications 5 START-UP 42 Installations at Elevation 5 Pre Start-up 42 Component Locations 6 Start-Up 43 General Information 6 OPERATION 46 GENERAL SAFETY 7 Lighting Instructions 46 Time/Temperature Relationships in To Turn Off Gas To Appliance 47 Scalds 7 UDB Fault History 47 INSTALLATION 8 TROUBLESHOOTING 48 Ins
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WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. Indicates special ins
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the upper rear jacket panel of the heater. The model BEFORE INSTALLATION number will have the form H7-2004 or similar depend- ing on the heater size and configuration. The letter(s) Raypak strongly recommends that this manual be re- in the first group of characters identifies the application viewed thoroughly before installing your MVB heater. (H = Hydronic Heating, P = Pool Heating, WH = Please review the General Safety information before Domestic Hot Water (DHW), WHP = Water Heater for install
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Component Locations HIGH VOLTAGE ELECTRICAL CONNECTIONS Fig. 3: Component Locations – Rear Panels omitted for clarity Fig. 1: Component Locations – Side Top panel, blower and gas train omitted for clarity Fig. 4: Component Locations – Top General Information Gas Vent MBTUH Water Conn. Size Model Input* Conn. (NPT) (in.) No. (NPT) Max.* Min.* N P Flue Intake 504 500 350 2 1 1 8 6 754 750 525 2 1 1 10 6 1104 1100 770 2-1/2 1-1/4 1 10 6 1504 1500 1050 2-1/2 1-1/4 1 12 8 2004 1999 1400 2-1/2 2 1 14
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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
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The temperature of the water in the heater can be reg- Equipment Base ulated by using the Raypak Modulating Temperature Control. To comply with safety regulations, the control The heater should be mounted on a level, structurally is set at 120°F when shipped from the factory (Mode 3 sound surface. The heater is approved for installation default setting for Tank Target). on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed To adjust the water temperatu
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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 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. Min. Clearance Minimum Heater from Combustible Service Side Surfaces Clearance Rear 12” 24” Front Open 24” Right Side 1” 1” Left Side 1” 1” Top Unobstruc
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Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 2 U.S. Installations Canadian Installations Clearance above grade, veranda, porch, A 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening; 1 foot (30 cm) B 3 ft (91 cm) opened above opening C Clearance to permanently closed window ** Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- D 5
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or sealed single-wall galvanized ducting. The duct will Air Filter attach directly to the air collar located on the rear of the heater, using three or four sheet metal screws (not An air filter is supplied standard with the heater. This supplied) equally positioned around the circumference filter is shipped loose for field installation. Refer to the of the duct. The screen assembly should be removed Air Filter Kit Installation Instructions (Part No. 241338) before attaching any air duct to the h
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the enclosure, shall be provided. The openings 2. For heaters using a barometric damper in the vent shall communicate directly, or by ducts, with the system there shall be a permanent air supply outdoors or spaces (crawl or attic) that freely com- opening(s) having a cross section area of not less 2 2 municate with the outdoors. than 1 in. per 7,000 BTUH (320 mm per kW) up 2 to and including 1 million BTUH, plus 1 in. per 2 a. Where directly communicating with the out- 14,000 BTUH (160 mm per kW
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feed valve. Test at standard operating pressure for CAUTION: This heater requires forced water at least 24 hours. circulation when the burner is operating. See Table F and Table G for minimum and maximum flow rates 2. Make sure constant gauge pressure has been and water pump selection. The pump must be maintained throughout test. interlocked with the heater to prevent heater operation without water circulation. 3. Check for leaks. Repair if found. NOTE: Minimum pipe size for in/out connections i
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longer than 7 minutes or where cold water operation is and manually adjusted to achieve an inlet temperature continuous, provisions must be made to mix higher of 120°F (49°C) or higher as adjusted at the minimum temperature outlet water with the colder inlet water temperature in this narrow temperature range (i.e. and thereby raise the inlet temperature to at least Range 75°F to 85°F – adjust bypass with temperature 120°F (49°C) within the 7-minute time limit. at 75°F (24°C)) so that when temper
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Input Output 20° ∆T 30° ∆T 40° ∆T Min. Flow Max. Flow Model No. MBTUH gpm ∆P gpm ∆P gpm ∆P gpm ∆P ∆T gpm P ∆ T ∆ 504 500 420 42 2.7 28 1.4 25 1.1 34 100 11.3 8 754 750 630 63 6.0 42 2.9 32 1.7 32 1.7 40 100 13.8 13 1104 1100 924 92 13.3 62 6.7 46 4.1 46 4.1 40 113 18.6 16 1504 1500 1260 84 13.3 63 8.0 63 8.0 40 113 22.2 22 2004 1999 1679 112 26.9 84 16.0 84 16.0 40 113 27.2 30 Note: Basis for minimum flow is T ∆ . Basis for maximum flow is gpm. Table F: Heater Rates of Flow and Pressure Drops Pi
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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 Potable Water and Space Heating heaters which are not subject to thermal shock. See Fig. 16 and instructions on page 17 for adjusting the CAUTION: When this heater is used for both manual bypass. potabl
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The MVB must be equipped with a field-supplied ex- 1. Turn on pump. ternal pump and bypass arrangement. This arrangement blends outlet water with the inlet water to 2. Turn on heater and wait until heater goes to full increase the inlet water temperature to a minimum of fire. 105°F (40°C) for Pool Heater (P and WHP) versions and 120°F (49°C) for Hydronic Heating (H7) or 3. With the heater operating at 100% firing rate, set 1 Domestic Hot Water (WH1) versions, thereby reducing Valve A (the bypass
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Pool/Spa Water Chemistry NOTE: For automatic temperature adjustment, a Cold Water Run (CWR) system can be used instead CAUTION: Corrosive water voids all warranties. of a manual bypass. See Fig. 10. CAUTION: Combustion air must not be contami- NOTE: Chemical imbalance can cause severe nated by corrosive chemical fumes which can damage to your heater and associated equipment. damage the heater and void the warranty. Chemical imbalance can cause severe damage to the Winterizing Your Heater pool he
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Further advice should be obtained from your pool or The heater must be isolated from the gas supply pip- spa builder, accredited pool shop, or chemical suppli- ing system by closing the upstream manual shut-off er for the correct levels for your water. valve during any pressure testing of the gas supply piping system at test pressures equal to or less than Automatic Chlorinators and 1/2 psi (3.45 kPa). Relieve test pressure in the gas Chemical Feeders supply line prior to reconnecting the heater
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1 in. NPT 1-1/4 in. NPT 1-1/2 in. NPT 2 in. NPT 2-1/2 in. NPT Model No. N P N P N P N P N P 504 15 35 65 150 150 360 754 5 15 35 75 70 175 250 1104 15 35 35 75 100 250 225 1504 10 20 20 45 60 150 150 275 2004 35 85 85 200 3 Natural Gas – 1,000 BTU/ft , 0.60 specific gravity at 0.5 in. WC pressure drop 3 Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. WC pressure drop Table I: Maximum Equivalent Pipe Length When connecting additional gas utilization equipment • National Electrical C
