INSTALLATION & OPERATING INSTRUCTIONS Cold Water Start & Cold Water Run For Hi Delta, MVB & Raytherm Heaters & Boilers This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference. Catalog No: 1000.57H Effective: 07-22-10 Replaces: 09-01-09 P/N 241275 Rev.
Rev. 9 reflects the following: Changes to: “Connecting the Valve Assembly” on page 6, Fig. 10 on page 9, Figs 11-13 on page 10, Cold Water Start Troubleshooting Guide on page 14. Wiring Diagrams on pages 16 & 17, Cold Water Run piping on page 26, Piping Diagram for Heating Applications on page 29, CWR parts list on page 39 Additions: Note and Fig.
CONTENTS WARNINGS 4 GENERAL SAFETY 5 Time/Temperature Relationships in Scalds 5 COLD WATER START 6 Installation 6 Check Power Source 6 Mounting the Control Box 6 Installing the Temperature Sensor 7 Connecting the Valve Assembly 7 Connecting Power to the Controller 8 Connecting Boiler to Cold Water Start 8 Operation 8 Cold Start Sequence of Operation 9 Troubleshooting 10 Mounting the Actuator to the Valve 11 Mounting Brackets 11 Locating the Rotation Stop 11 Drive Linkage 12 Verifying Ball Position 12 Actuat
WARNINGS Pay Attention to These Terms DANGER: 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. CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
GENERAL SAFETY To 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 recommended initial setting for the temperature control is 125°F. Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat.
COLD WATER START BLACK Before beginning the installation, it's important to first inspect the system and determine what materials you will need. Some parts are included with the controller while others you will need to provide.
Installing the Temperature Sensor NOTE: Four knockouts are located on the bottom of the control for ease of installation. Avoid routing wiring on or near other electrical wires, conduit, motors, spark igniters or other sources of high intermittent voltage or current. The sensor should be placed in the dry well on the inlet header, or as indicated in the piping for multiple heaters, as shown on page 21.
22” 7-5/8” Reset Switch* *The reset switch may be located on the front control panel on some MVB models. 1-1/2” Fig. 9: Location of TB1 in Control Box Connecting Power to the Controller Fig. 7: Component Locations—Raytherm Models 2100–4001 Connect power from the 120 VAC power input of the heater to the controller power inputs Terminal Block (TB1). This is accomplished by connecting wiring from the control box to the heater 120 VAC power input connections. Refer to the heater wiring diagrams.
5. 120VAC-12VDC converter outputs 12VDC to the common terminal of the reset switch, located on the bottom of the cold start control panel. CALL FOR HEAT START UP MODE INLET TEMP ERROR SENSOR OUT OF RANGE 6. The 12VDC signal crosses over the reset switch and goes to Terminal FS on the cold start circuit board. 7. Cold start control is now in standby until a Call for Heat occurs at heater. 8.
The DIP switches on the three-way valve actuator must be set as indicated in the Fig. 11 below: MODE SELECTION SWITCH DIP SWITCH SETTINGS FOR 3-WAY ACTUATOR VDC mA 0-10 2-10 DA RA FIXED AUTO ~ 6-9 DIRECT ACTING, ON INCREASING SIGNAL NOTE: SIDE “B” MUST FACE AWAY FROM VALVE SWITCH MUST BE IN THIS POSITION TURN CLOCKWISE TO FURTHEST STOP SIDE “B” Fig. 11: Set Dip Switch Settings — Delta Actuator Fig.
• Mounting Brackets (Elodrive) Check pump sizing and valve/piping sizing and correct as necessary. There are different actuator mounting brackets on the three-way valves. When ordering a replacement bracket you will receive the newest design available from the manufacturer. If it appears to be different than the damaged bracket, the new and old are interchangeable and will fit all valve bodies. See Fig. 16. IF SENSOR OUT OF RANGE LED is illuminated: The sensor may have a short or open circuit.
• • If you do not see two openings at this point, continue rotating the stem and ball until you do. Once you can see two openings, STOP, as shown in Fig. 18. Then rotate the stem counterclockwise until only one opening remains e.g. you can see completely through the valve (through ports A and AB). Now the ball is correctly oriented inside of the valve body. Reassemble the valve, base and actuator, and then install the assembly into your piping system as indicated in this manual.
HIGH PRESSURE TAB Fig. 21: High Pressure Tab Actuator The ELODRIVE actuator has a manual override for the valve. The label located over the silver colored primary label states, “Please read manual before using manual override”. Using the Allen wrench supplied with the loose valve, place it in the hexagonal opening under the label. See Fig. 22. Fig.
Cold Water Start Troubleshooting Guide Step 1 Does TB1 of cold start controller have 120 VAC? Verify 120VAC at separate circuit breaker and correct. NO Is there a Call For Heat at the heater? YES YES Step 2 Heater is in standby mode NO Are the 120/24VAC transformer and 120VAC12VDC inverter in the cold start controller powered? Correct wiring to match wiring diagram NO YES Replace 120VAC-12VDC inverter or correct wiring.
NOTES: 1. LOCATE UNIONS TO FACILITATE SERVICING OF PLUMBING SIDE. 2. PLUMB SWING CHECK VALVE IN GRAVITY-CLOSED POSITION. 3. PIPE ALL RELIEF VALVES TO DRAIN, OR AS LOCAL CODES REQUIRE. 4. BUFFER TANK REQUIRED WHEN WATER VOLUME IN BOILER LOOP IS NOT ADEQUATE TO PROVIDE STABLE TEMPERATURE CONTROL. CONSULT FACTORY FOR TANK SIZING. 5. SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES.
Wiring Diagrams—Cold Water Start BRACKET RESTS AGAINST VALVE MOUNTING CHASIS * VALVE NOT DEPICTED Panel Control and Wrapper Control Cover Assembly with Support Valve Cover; Full Assembly 16
HEATER INTERFACE WIRING FOR CWS OR CWR CWS/CWR CONTROL OR MULTIPLE BOILER INTERFACE CWS/CWR CONTROL OR MULTIPLE BOILER INTERFACE CWS/CWR CONTROL OR MULTIPLE BOILER INTERFACE 17
COLD WATER START— MULTIPLE HEATER Installing the Three-way Valve Install three-way diverting valve into common boiler piping manifold as shown in the diagram on page 18. Boiler common outlets to be connected at port AB. Discharge to system from port A with bypass port being port B. Common pipe sizing may be larger than three-way valve port connections requiring the use of increasers for installation (see Table B for valve sizing).
Actuator to Valve Orientation Reinstall the actuator and bracket assembly in reverse order, and ensure that the ball assembly is properly oriented. Mount the flanged valve into your piping system in accordance with this manual. Install the actuator so that the tail is pointing horizontally as shown in Fig. 26 or is pointing down. DO NOT mount it so that the tail is pointing up as shown in Fig. 20.
4-Inch Valve Orientation The valve must be installed so that the combined boiler outlets enter through Port "AB" (See Fig. 26). Port "B" is the bypass port and port "A" is the return to the system (port designations are cast into the stem of the valve body). The valve body should be installed so that the actuator input shaft is in the vertical or horizontal position. The Actuator stem should never be hanging downward.
5. 6. NOTES: 1. 2. 3. 4. PLUMB SWING CHECK VALVE IN GRAVITY-CLOSED POSITION. PIPE ALL RELIEF VALVES TO DRAIN, OR AS LOCAL CODES REQUIRE. LOCATE UNIONS TO FACILITATE SERVICING OF PLUMBING SIDE. BUFFER TANKS MAY BE REQUIRED TO PROVIDE STABLE TEMPERATURE CONTROL ON SYSTEMS WITH VARIABLE FLOW OR LOW WATER VOLUME. CONSULT FACTORY FOR SELECTION CRITERIA. MAXIMUM 4 TIMES THE PIPE DIAMETER OR 12”, WHICHEVER IS LESS. SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES.
FOR HEATER INTERFACE WIRING (SEE PAGE 17) CWS CONTROL BOX ASSY (SEE PAGE 16) Wiring Diagram Multiple Heater 22
COLD WATER RUN CWR vs. CWS • NOTE: After testing at the factory it may be prudent to ship the piping assembly disassembled and attached to the heater pallet. This is done to avoid shipping damage and it must be reassembled on the jobsite. Use Fig. 29 to assist you in reassembling the piping. • • • Cold water start is for transient cold water operation. Cold water run is for continuous operation below 105°F system return temperature.
Injector & Heater Pump Comparison Heater Pump Injector Pump Heater Model Flow Temp. Rise Press. Drop Pump Model/Imp. Flow Temp. Rise Pump Model-hp 302 32 16 2 112 13 40 1911-1⁄4 hp 402 34 20 2 112 17 40 1911-1⁄4 hp 502 42 20 2.3 1630/4.0 22 40 1911-1⁄4 hp 652 55 20 4.1 1630/4.0 28 40 1911-1⁄4 hp 752 63 20 5.7 1630/4.2 32 40 1911-1⁄4 hp 902 76 20 8.4 1630/4.2 38 40 1911-1⁄4 hp 992 83 20 5.2 1630/4.7 42 40 1911-1⁄4 hp 1262 107 20 9.
Heater Pump Injector Pump Heater Model Flow Temp. Rise Press. Drop Pump Model/Imp. Flow Temp. Rise Pump Model-hp 926/962 79 20 8.5 1630/4.7 50 32 1911-1⁄4 hp 1083/1125 90 21 12.0 1630/4.7 50 37 1911-1⁄4 hp 1178/1223 90 22 12.5 1630/4.7 60 33 1911-1⁄3 hp 1287/1336 90 25 13.2 1630/4.7 60 37 1911-1⁄3 hp 1414/1468 90 27 14.0 1632/5.65 60 40 1911-1⁄3 hp 1571/1631 90 30 14.5 1632/5.65 60 45 1911-1⁄3 hp 1758/1826 90 34 15.4 1632/5.
4. Locate the pump junction box and wiring decal shown in Fig. 32. 230 VAC 3 ø Line Low Voltage Pump Wiring Black Orange (3) and Gray (9) White Pink (7) and Blue (1) Red Red (8) and White (2) ——————— Green Yellow (4) and Black (5) and Violet (6) Ground Lug Table F: Cold Water Run Control Panel and Injector Pump Wiring Fig. 33: Cold Water Run Control Panel and Injector Pump Wiring 8. Re-install the injector pump junction box cover. 9. Turn on the water and gas supply. 10.
12. If the pump is rotating in the proper direction, secure the heater from installation. 13. If the pump is rotating incorrectly, turn off power and swap ONLY two of the line voltage leads into the pump (for example, swap the red and black leads). Confirm that the pump now rotates in the proper direction before proceeding. 14. Secure from installation. 2. Remove the pump body then rotate it so that the electrical box is pointing downward, ensuring not to damage the seal. See Figs. 36, 37 and 38.
Fig. 40: Pump cover - angle view Fig. 38: Reposition the pump body so that the electrical box points downward 3. Insert and tighten all eight (8) bolts, securing the pump body in place. 4. You will now be able to install the pump cover. See Figs. 39 and 40. Fig.
Typical Cold Water Run Piping - Heating Applications ALTERNATE SENSOR POSITION NOTES: 1. 2. 3. 4. LOCATE UNIONS TO FACILITATE SERVICING OF PLUMBING SIDE. PLUMB SWING CHECK VALVE IN GRAVITY-CLOSED POSITION. PIPE ALL RELIEF VALVES TO DRAIN, OR AS LOCAL CODES REQUIRE. SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES. 12” MAX, OR MIN FEASIBLE Typical Cold Water Run Piping - Pool Applications NOTES: 1. 2. 3. 4. 5. SEE NOTE 4 29 LOCATE UNIONS TO FACILITATE SERVICING OF PLUMBING SIDE.
Operation • • • • 7. After the two second delay on the cold run circuit board, pin MC outputs a 24 VAC signal to terminal AL0 of the Hitachi inverter. 8. The AL0 relay closes and outputs a 24 VAC signal to the coil of the DPST relay located in the cold run control panel. 9. The DPST relay coil energizes and closes the NO contacts. 10.
Cold Water Run Troubleshooting Guide *NOTE: Step 1 See wiring diagrams for proper supply voltage based on inverter used on heater.
17 Wiring Diagram—Cold Water Run (Hitachi Inverter) 32
(SEE PAGE 17) Wiring Diagram—Cold Water Run (AC Tech Inverter) 33
ILLUSTRATED PARTS LISTS 34 Cold Water Start
Cold Water Start 35
Cold Water Start Multiple Boiler Interlock 36
CALL OUT 1-C 9-C 2-C 3-C 4-C 5-C 6-C 7-C 8-C 1-H 1-M 7-M 2-M 3-M 4-M 5-M 6-M 1-S 2-S 3-S 4-S DESCRIPTION PC BOARD ASSY-CONTROL RELAY - DPDT 24VDC COIL TRANSFORMER POWER SUPPLY 120VAC/12VDC RELAY - DPDT 24V RELAY - SPDT 24V GROUND LUG TEMP SENSOR 10K (NOT SHOWN) ALARM RESET SWITCH INLET ADAPTER 2-1/2 NPT PUMP-WATER BR 2" FLANGE, 1/4 HP PUMP-WATER CI 2" FLANGE, 1/4 HP PUMP-WATER BR 2" FLANGE, 1/2 HP PUMP-WATER CI 2" FLANGE, 1/2 HP PUMP-WATER BR 2-1/2" FLANGE, 3/4 HP PUMP-WATER CI 2-1/2" FLANGE, 3/4 HP PU
Cold Water Run 38
CALL OUT 1-C 11-C HI DELTA HI DELTA SS MVB PC BOARD ASSY-CONTROL DESCRIPTION 011717F N/A 011717F RAYTHERM 011717F RELAY - DPDT 24VDC 005962F N/A 005962F 005962F 2-C RELAY - DPDT 24VAC 011720F N/A 011720F 011720F 3-C RELAY - SPDT 24VAC 009039F N/A 009039F 009039F 4-C INVERTER 011835F N/A 011835F 011835F INVERTER - DUAL VOLTAGE 012984F N/A 012984F 012984F 013070F 9-C CHIP - PROGRAMMED 013070F N/A 013070F 5-C 10-C TRANSFORMER 011718F N/A 011718F 011718F 6-C TE
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