INSTALLATION & OPERATING INSTRUCTIONS Models 504–2004 Types H, WH, P & WHP L 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.
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 2530, 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.
CONTENTS WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connection Venting Venting Installation Tips Venting Configurations Engineered V
WARNINGS Pay Attention to These Terms DANGER: WARNING: CAUTION: NOTE: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
BEFORE INSTALLATION the upper rear jacket panel of the heater. The model number will have the form H7-2004 or similar depending on the heater size and configuration. The letter(s) in the first group of characters identifies the application (H = Hydronic Heating, P = Pool Heating, WH = Domestic Hot Water (DHW), WHP = Water Heater for Pool Heating). The number which follows identifies the firing mode (7 = electronic modulation, 1 = On/Off).
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 Model No. 504 754 1104 1504 2004 Panels omitted for clarity Fig. 2: Component Locations – Front MBTUH Input* Max.* Min.* 750 525 500 1100 1500 1999 *H7 units only. 6 Water Conn. (NPT) Gas Conn.
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 recommended initial setting for the temperature control is 125°F. This section applies to Hot Water Supply Boilers and Hot Water Heaters ONLY.
Equipment Base The temperature of the water in the heater can be regulated by using the Raypak Modulating Temperature Control. To comply with safety regulations, the control is set at 120°F when shipped from the factory (Mode 3 default setting for Tank Target). 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.
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. Heater Side Min.
Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 1 2 t TT * 2 U.S. Installations Canadian Installations A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 ft (1.
Air Filter or sealed single-wall galvanized ducting. The duct will attach directly to the air collar located on the rear of the heater, using three or four sheet metal screws (not supplied) equally positioned around the circumference of the duct. The screen assembly should be removed before attaching any air duct to the heater. The screws and duct connection point must be sealed with RTV (not supplied). TruSeal is generally used when damaging contaminants are present in the mechanical room.
the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. 2. For heaters using a barometric damper in the vent system there shall be a permanent air supply opening(s) having a cross section area of not less than 1 in.2 per 7,000 BTUH (320 mm2 per kW) up to and including 1 million BTUH, plus 1 in.2 per 14,000 BTUH (160 mm2 per kW) in excess of 1 million BTUH.
feed valve. Test at standard operating pressure for at least 24 hours. CAUTION: This heater requires forced water circulation when the burner is operating. See Table F and Table G for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the heater to prevent heater operation without water circulation. 2. Make sure constant gauge pressure has been maintained throughout test. 3. Check for leaks. Repair if found. NOTE: Minimum pipe size for in/out connections is 2 in.
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. and manually adjusted to achieve an inlet temperature of 120°F (49°C) or higher as adjusted at the minimum temperature in this narrow temperature range (i.e.
Input Output Model No. MBTUH 504 500 420 1104 1100 924 754 750 1504 1500 2004 1999 630 1260 1679 20° ∆T gpm ∆P gpm 6.0 42 42 2.7 92 13.3 63 30° ∆T gpm ∆P gpm 2.9 32 1.7 32 13.3 63 8.0 1.4 62 6.7 112 26.9 46 Note: Basis for minimum flow is ∆T. Basis for maximum flow is gpm. Piping Min. Flow ∆P 28 84 40° ∆T 84 4.1 16.0 ∆P ∆T gpm 1.7 40 25 1.1 46 4.1 63 84 Max. Flow 8.0 16.0 34 40 40 40 ∆P ∆T 100 13.8 13 113 22.2 22 100 113 113 11.
Three-Way Valves NOTE: If local codes require a vacuum relief valve, acquire one locally and install per valve manufacturer’s instructions. Three-way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used. Raypak heaters are high-recovery, low-mass heaters which are not subject to thermal shock. See Fig. 16 and instructions on page 17 for adjusting the manual bypass.
The MVB must be equipped with a field-supplied external pump and bypass arrangement. This arrangement blends outlet water with the inlet water to 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 Water (WH1) versions, thereby reducing the likelihood of condensation forming on the heat exchanger. The pump also serves to circulate water through the heater from the main system piping. 1.
Pool/Spa Water Chemistry NOTE: For automatic temperature adjustment, a Cold Water Run (CWR) system can be used instead of a manual bypass. See Fig. 10. CAUTION: Corrosive water voids all warranties. CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty. NOTE: Chemical imbalance can cause severe damage to your heater and associated equipment. Chemical imbalance can cause severe damage to the pool heater and associated equipment.
Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier for the correct levels for your water. The heater must be isolated from the gas supply piping system by closing the upstream manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa). Relieve test pressure in the gas supply line prior to reconnecting the heater and its manual shut-off valve to the gas supply line.
Model No. 504 1 in. NPT N 15 754 1104 5 P 35 15 1504 1-1/4 in. NPT 1-1/2 in. NPT 65 150 150 360 15 35 35 75 N P 35 75 10 2004 20 N 70 20 2 in. NPT P N 175 250 45 60 P 2-1/2 in. NPT N 100 250 225 35 85 85 150 150 P 275 200 Natural Gas – 1,000 BTU/ft3, 0.60 specific gravity at 0.5 in. WC pressure drop Propane Gas – 2,500 BTU/ft3, 1.53 specific gravity at 0.6 in.
WARNING: Using a multi-meter, check the following voltages at the circuit breaker panel prior to connecting any equipment. Make sure proper polarity is followed and house ground is proven. (See Fig. 19.) Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum FRONT WIRING PANEL LOW VOLTAGE ELECTRICAL CONNECTIONS Fig. 18: Wiring Electrical Connections Field-Connected Controllers Fig.
Venting NOTE: A grounding electrode conductor shall be used to connect the equipment grounding conductors, the equipment enclosures, and the grounded service conductor to the grounding electrode. CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the heater. General Field Wiring Connection Appliance Categories CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
Combustion Air Supply From Inside Building (Non-Direct Venting) From Outside Building (Direct Venting) Exhaust Configuration Heater Venting Category Horizontal Throughthe-Wall Venting III Vertical Venting I Vertical Venting I Horizontal Throughthe-Wall Venting III Certified Materials B-Vent Equivalent Combustion Air Inlet Material Stainless Steel AL29-4C B-Vent Equivalent Stainless Steel AL29-4C Galvanized Steel PVC ABS CPVC Table K: Venting Category Requirements 6.
1. Vent must terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, window or gravity air inlet to the building. 5. Within 6 ft (1.8 m) of any gas service regulator vent outlet. 6. Less than 1 ft (305 mm) above grade level. 2. The vent must not be less than 7 ft above grade when located adjacent to public walkways. 7.
Model No. Certified Vent Material 504 754 1104 1504 2004 Vent Size (in.) 8 Category I (Type B Equivalent) 10 10 12 Vertical Vent Height1 (ft) Min. Max. 5 25 Combustion Air Intake Pipe Material Galvanized Steel, PVC, ABS, CPVC Air Inlet Max. Length* (ft) 6” Ø 8” Ø 45 100** 14 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.
common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. Common Venting Manifolds that connect more than one heater to a common 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. 1. Seal any unused opening in the common venting system. 2.
4. Place in operation the appliances being inspected. Follow the manufacturer’s instructions for lighting each appliance. Adjust thermostat so appliance will operate continuously. Model No. Vent Size (in.) Volume of Flue Products (CFM) 754 10 260 1504 12 504 5. Check the pressure at a pressure tap located 12 in. above the bottom joint of the first vertical vent pipe. Pressure should be anywhere between -0.01 and -0.08 in. WC. 1104 6.
• • • • NOTE: While a drain connection is required in the vent of all Cat. III horizontal MVB installations, the drain can be accomplished in several different ways. The figures in this manual show the drain in a vent tee, however, this can also be accomplished using an inline collector for condensing stacks or an inline vertical or horizontal collector available from several of the listed vent manufacturers.
Certified Vent Material Model No. 504 Vent Size (in.) Maximum Horizontal Vent Length (ft)** 8 754 Category III 1104 1504 10 10 12 2004 ** Subtract 10 ft per elbow. Max. 4 elbows. t Adapters supplied by others. Combustion Air Intake Pipe Material Air Inlet Max.
vent cap can condense as they leave the cap. Improper location can result in damage to adjacent structures or building finish. For maximum efficiency and safety, the following precautions must be observed: 1. 2. 3. 4. 5. 6. NOTE: The vent cap and air intake hood must be furnished by the heater manufacturer in accordance with its listing (sales order option D-11). NOTE: Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.
Deadband: Deadband is a band of temperature sensing where no action occurs. All temperature controllers have a deadband and the purpose is to prevent shortcycling of the heater. The on-board temperature controller has a deadband of 2ºF around the differential. Differential: A heat source must be operated with a temperature differential in order to prevent shortcycling. The temperature differential is divided around the “target” temperature or set-point.
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 target according to a linear scale (see Tables O & P). The control operates the boiler burner to maintain the boiler target at the system sensor. See Fig. 35. ELECTRONIC Fig.
2-10 VDC 4-20 mA* Boiler Target 1 2 --- (OFF) 0 2 3 4 0 4 6 8 --- (OFF) 50°F 71.3°F 92.5°F 5 10 113.8°F 7 14 156.3°F 18 198.8°F 6 8 9 10 *Requires a 500Ω resistor. 12 16 20 RAYPAK MODULATING TEMP CONTROL OUTDOOR AIR SENSOR 135°F 177.5°F 220°F Table P: 2-10 VDC or 4-20 mA External Input Signal * *Maximum 4 times the pipe diameter or 12”, whichever is less. Mode 8 – This mode is for remote firing control of the heater via an external sequencer such as the Raypak TempTracker MOD+.
Item Modes Boil Target 3 2 Boiler (H7) Default Setting 2, 5, 7, 8 Boil Max 3 Boil Min 2, 3, 5, 7 Boil Mass All ‘Burner’ Delay 140°F OFF, 70 to 220°F 180°F OFF, 70 to 220°F 160°F 5, 7 Range OFF, 70 to 190°F 200°F OFF, 120 to 225°F 135°F OFF, 80 to 180°F 180°F All 0:00 min Diff 2, 3, 5, 7 Auto DHW Diff 3 OFF, 120 to 190°F 0:00 to 3:00 min 1 (Low) 1 (Low), 2 (Med), 3 (High) 3 120°F OFF, 70 to 190°F ‘Pump’ Dly All 3:00 min OFF, 0:20 to 9:55 min, ON Outdr Design 5 -
Item Boil Target Water Heater (WH1) Modes Default Setting 3, 7 160°F 2 140°F OFF, 70 to 190°F 180°F OFF, 120 to 190°F 0:00 to 3:00 min Boil Max 2, 3, 6, 7 ‘Burner’ Delay All 0:00 min Diff 2, 3, 7 Auto DHW Diff 3 Boil Min Boil Mass 2, 3, 7 135°F OFF, 70 to 190°F OFF, 80 to 180°F 1 (Low) 1 (Low), 2 (Med), 3 (High) 3 120°F OFF, 70 to 190°F ‘Pump’ Dly All 3:00 min OFF, 0:20 to 9:55 min, ON Mode N/A 3 2, 3, 7 Offset 7 DHW Target Units External Input Signal All Range
Rank Item Field Number Field Type Fault Description 1 FP Err Warning Flame proof warning BOIL OUT OPn Error Boiler outlet sensor open BOIL IN OPn Error Boiler inlet sensor open SUP OPn Error System sensor open OUTDR OPn DHW OPn 0 E01 2 BOIL OUT 4 BOIL IN 3 5 6 7 SUP 8 OUTDR 10 DHW 9 11 Err Error SHr Error SHr Error SHr Error SHr Error SHr UNITS - Selects the temperature units to be displayed (°F or °C).
Heater Sequence of Operation 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 ignition module. If all limits are satisfied and there is a call for heat: 1. The heater pump is powered and begins circulating water through the heat exchanger. 2.
High Limit—Auto Reset (Optional) Modulating Temperature Control This heater may be equipped with an optional adjustable auto reset high limit temperature device. This heater is equipped with a Raypak modulating temperature control. Refer to information starting on page 30 for information on the setting and use of this control. The optional adjustable auto reset high limit is located inside the heater junction box. Adjust the setting to approx. 20°F (10°C) above desired outlet temperature. Fig.
Blocked Vent Switch er valve/regulator performance. The low gas pressure switch automatically shuts down the heater if gas supply drops below the factory setting of 3.0 in. WC for natural gas or propane gas. 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. This switch is located on the right side of the heater near the right rear corner.
WIRING DIAGRAM - Models H & WH 40
WIRING DIAGRAM - Models P & WHP 41
START-UP BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell near the floor because some gas is heavier than air and will settle on the floor. NOTE: The following steps must be performed by a factory-trained technician. WHAT TO DO IF YOU SMELL GAS: Pre Start-up • • Filling System (Heating Boilers) • Fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal system operation, and fill system through feed pressure.
Check Power Supply 3. If the gas pressure is greater than 14.0 in. WC, turn off the main gas shut-off valve, upstream of the heater. With multi-meter at incoming power, check voltage between: Start-Up Hot - Common (≈120 VAC) NOTE: The values in Tables V, W and X represent the conditions when the heater is at full firing rate at sea level. Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) NOTE: Pressure and combustion data are provided with the heater.
with the blower suction within the tolerances specified in Table T, contact the factory. The reference amp draw reading may help to indicate if there is a problem with the system or if blower adjustment is required. CAUTION: Special manifold and air settings may be required. Finishing NOTE: Most commercially available amp probes are not accurate enough and/or are not shielded well enough to read accurately in the heater environment. Blower amp draw readings are for reference only. 1.
Leak Test Procedure: Dual-Seat Gas Valve 7. After no leakage has been verified at all valve seats and test valves, open downstream leak test valve and restore electrical power to the heater. 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 bleedle valve located upstream of the combination gas valve on the supply manifold.
8. 9. OPERATION for operation as outlined by manufacturer. Burner should be operating and should go off when controls are tested. When safety devices are restored, burners should re-ignite after pre-purge time delay. Lighting Instructions 1. Before operation, make sure you have read all of the safety information in this manual. Test limit control: While burner is operating, move indicator on high limit control below actual water temperature.
UDB Fault History 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. To view the fault codes in the UDB history file: 1. Press the UP or DOWN buttons on the membrane switch for 2 seconds to access the fault history. To Turn Off Gas To Appliance 2. Press either button to scroll through the recorded faults in history. 1.
TROUBLESHOOTING Step 1 Does the power switch provide power to the control panel? Check the switch and/or line voltage NO Is there a Call For Heat? YES NO Unit is in standby mode. YES Step 2 NO Is Disable connection intact? Reattach. YES Step 3 Does the combustion air blower come on? Is there 120VAC at the blower or blower relay? NO Check and correct power connections at main terminal block, circuit breaker panel or blower relay.
MAINTENANCE by local codes. 3. Check that area is free from combustible materials, gasoline, and other flammable vapors and liquids. Suggested Minimum Maintenance Schedule 4. Check air filter and replace as necessary. Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. 5. Follow pre-start-up check in the Start-up section. 6. Visually inspect burner flame. It should be light blue at full input.
Weekly 6. Perform leakage test on gas valves (See Fig. 49.) and procedure on page 45. For low-pressure heaters, test low-water cut-off device. (With heater in pre-purge, depress the low water cut-off test button. Appliance should shut-off and ignition fault light should come on. Depress reset button on front of heater control panel to reset). 7. Test air switch in accordance with manufacturer’s instructions. (Turn panel switch to the “On” position until blower is proven, then turn the switch to “Off.” 8.
Filter Replacement stainless steel, which is commonly used in high efficiency systems. The heater can be supplied with corrosion-resistant, non-metallic intake air vent material. You may, however, choose to use outside combustion air for one or more of these reasons: 1. Remove the filter box cover by loosening and removing the two wing nuts holding it in place. 1. Installation is in an area containing contaminants listed below which will induce acidic condensation. 2.
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows: (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1.
LIMITED PARTS WARRANTY MVB – TYPES H AND WH MODELS 504-2004 SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
LIMITED PARTS WARRANTY MVB – TYPES P & WHP MODELS 504–2004 SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
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. Additionally this form will be used to record all equipment operation functions and required settings.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
