Raypak 241275 User Manual
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place
for future reference.
Catalog No: 1000.57A Effective: 02-28-07 Replaces: 02-24-06 P/N 241275 Rev. 2
INSTALLATION AND OPERATING
INSTRUCTIONS
COLD WATER START & COLD WATER RUN
For Hi Delta & MVB
Heaters & Boilers
2
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. The most energy-efficient operation will
result when the temperature setting is the lowest that
satisfies the needs of the application.
Water temperature over 125°F can cause instant
severe burns or death from scalds. Children, disabled
and elderly are at highest risk of being scalded.
• Feel water before bathing or showering.
• Temperature limiting valves are available.
Maximum water temperatures occur just after the
heater’s burner has shut off. To determine the water
temperature being delivered, turn on a hot water
faucet and place a thermometer in the hot water
stream and read the thermometer.
3
NOTE: When this water heater is supplying general
purpose hot water for use by individuals, a thermostatically controlled mixing valve for reducing point of
use water temperature is recommended to reduce
the risk of scald injury. Contact a licensed plumber or
the local plumbing authority for further information.
Time/Temperature
Relationships in Scalds
The following chart details the relationship of water
temperature and time with regard to scald injury and
may be used as a guide in determining the safest
water temperature for your applications.
Table A: Time to Produce Serious Burn
Water temperature over 125°F can
cause instant severe burns or death
from scalds.
Children, disabled, and elderly are
at highest risk of being scalded.
See instruction manual before setting temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are
available, see manual.
Table courtesy of The Shriners Burn Institute
Water
Temp.
Time to Produce
Serious Burn
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About 1 second
4
COLD WATER START
Before arriving at the job site to begin 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.
1 Control Box
1 Temperature Sensor
1 Valve assembly with actuator (Shipped separately)
Wiring and mounting hardware (Provided by installer)
INSTALLATION
Check the Power Source
Check the power source:
AC = 108 VAC Minimum, 132 VAC MAX
AB = 108 VAC Minimum, 132 VAC MAX
BC = <1 VAC Maximum
Mounting the Control Box
The control box should be mounted on the side of the
heater to which the system piping and valve assembly
are to be attached. The controller should be mounted
so as to provide maximum support by using the
mounting holes provided on the base of the controller
to the side center brace on the heater. You will need to
drill mounting holes and holes through the heater side
panel for the routing of wiring and the sensor. A template is supplied for field-installed kits to locate the
control box properly.
Attaching the Temperature
Sensor
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. Ensure it
is installed using thermopaste (field supplied) and it is
held firmly at the bottom of the well.
Connecting the Valve
Assembly
Connect valve assembly “T CONNECTION “ into the
piping with the actuator input wiring facing the heater
side panel, as shown below. Route wiring to the control thru the bottom panel knockouts to TB2. Refer to
the wiring diagram provided on the inside of control
cover assembly.
NOTE: Four knockouts are located on the bottom
of the control for ease of installation.
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.
Fig. 1: Wiring Connections
Fig. 2: Multi-meter
CAUTION: Do not use for swimming pool applications
BLACK
CIRCUIT
BREAKER
WHITE
GREEN
GROUND
AB C
5
Connecting Power to the
Controller
Supply power from the 120 VAC power input from the
heater to the controller power inputs Terminal Block
(TB1). This is accomplished by connecting wiring from
the control box to the heater TB1 board 120 VAC
power input connections. Refer to wiring diagrams.
Fig. 3: Component Locations — Hi Delta
Fig. 4: Location of TB1 in Control Box
NOTE: If a “DIP” switch is provided on the control
PCB, verify that the switch settings are correct: 1 =
OFF, 2 = ON, 3 = OFF.
OPERATION
Verify the following upon a CALL FOR HEAT signal
from the heater:
1. CALL FOR HEAT LED on PCB illuminates GREEN.
2. START UP MODE LED on PCB illuminates YELLOW. Before 7 minutes it should go out if boiler
inlet temperature is approaching the set point temperature.
3. The “ACTUATOR” should be in the fully open position or move to the fully open position if not already
there. (Actuator at the fully CCW position)
4. Before 7 minutes time has elapsed if the control is
operating properly the “START UP MODE” LED
should go out. The inlet water temperature should
be stable at a temperature between 105° F and
120° F (Normally set to 110° F) cooresponding to
the Set Point Pot setting on the PCB. The actuator
should have stopped moving.
Fig. 5: Control PCB
Models X
302B-902B
7.0″
992B-2342B
13.20″
LEFT SIDE
Reset Switch
CALL FOR HEAT
START UP MODE
INLET TEMP ERROR
SENSOR OUT OF RANGE
Set
Point
Pot
6
Cold Start Sequence of
Operation
1) 120VAC to heater sends 120VAC to Cold Start
control on terminal block 1.
2) 120/24VAC transformer and 120VAC-12VDC converter are powered.
3) 120/24VAC transformer outputs 24VAC to pin 2 of
terminal block 2
4) 24VAC leaves pin 2 of terminal block 2 and goes
to the modulating three way valve on the 2030VAC lead, and to the NO contacts of the SPST
relay located in the cold start control panel.
5) 120VAC-12VDC converter outputs 12VDC to pin 3
of terminal block 2.
6) The 12VDC signal leaves pin 2 of terminal block 2
and goes to the common terminal of the reset
switch, located on the bottom of the cold start control panel.
7) The 12VDC signal crosses over the reset switch
and goes to Pin FS on cold start circuit board.
8) Cold start control remains on standby until a Call
for heat occurs at heater.
9) TRIG terminal of Economaster connection on
heater CPW board outputs 24VAC to terminal 4 of
terminal block 3 located in Cold Start controller.
10) Terminal 4 of TB 3 sends 24VAC to the coil of the
SPST relay located in the cold start control panel.
11) The SPST relay coil is energized and closes the
contacts allowing 24VAC to energize the CFH pin
on the cold start circuit board.
a) A two second delay occurs from the CFH signal
waiting to send power from terminal MC of the cold
start circuit board.
12) J9 terminal on the heater CPW board (interlock
connection) outputs a 24 VAC signal to terminal 2
of terminal block 3 located in the cold start controller.
13) 24 VAC is sent from terminal 2 of terminal block 3
to the NO contacts of the DPST relay located in
the cold start control panel.
14) After the two second delay on the cold start circuit
board, pin MC outputs a 24 VAC signal to the coil
of the DPST relay located in the cold start control
panel.
15) The DPST relay coil energizes and closes the NO
contacts.
16) Once the NO contacts of the DPST close, the
heater 24 VAC is sent back to the heater to complete the Economaster circuit (pin 3 of terminal
block 3) and the interlock circuit (pin 1 of terminal
block 3) allowing the heater to fire.
17) Pin FR on the TVC board outputs 10VDC to the
modulating three way valve actuator to drive it fully
open for two-minutes waiting for the heater to
reach full fire.
18) After the two-minute delay the 10VDC output signal from pin FR reduces to approximately 8VDC at
the inverter thus slowing the pump to approximately 50 Hz.
19) The output signal continues to vary depending on
the heater inlet temperature.
The heater will lockout and shut down if the set point
on the inlet temperature is not achieved within sevenminutes from a call for heat.
The DIP switches on the 3-way valve actuator must be
set as indicated in the Fig. 6.
Fig. 6: Set Dip Switch Settings — Delta Actuator
NOTE: The minimum return water temperature to
the heater to prevent condensate is 105°F on standard heaters and 120°F on 87% Efficiency heaters.
Ensure that during operation the Set Point Pot is
adjusted properly.
Fig. 7: Delta Actuator — Actuator Shown in Full System
Flow Position
DIP SWITCH SETTINGS
FOR 3-WAY ACTUATOR
VDC
0-10
DA
FIXED
~
mA
2-10
RA
AUTO
6-9
MODE SELECTION SWITCH
DIRECT ACTING, ON INCREASING SIGNAL
SWITCH MUST BE IN THIS POSITION
TURN CLOCKWISE TO FURTHEST STOP
7
NOTE: Elodrive actuator is Nema 4 rated.
TROUBLESHOOTING
Check your power source using a Volt-Ohm meter;
check the following voltages at TB1 terminal block:
TB1-1 to TB1-2 = 108 VAC Minimum, 132 VAC
Maximum
TB1-1 to TB1-3 = 108 VAC Minimum, 132 VAC
Maximum
TB1-2 to TB1-3 = Must be less than .6 VAC
IF CALL FOR HEAT LED does not illuminate when the
heater has a CFH signal, check for 24VAC at the
heater CPW Board (J17-TRIG) output. If voltage is
present, check wiring using the wiring diagram. If voltage is not present, the problem exists in the heater.
IF VALVE DOES NOT MOVE: Check for voltage out at
TB2-1: Should be a 1VDC to 10VDC output to the
actuator valve. If no voltage is present, check for voltage at TB2-3, there should be a 12VDC signal. If the
12VDC signal is not present, verify that the converter
is wired correctly using the wiring diagram.
IF SENSOR OUT OF RANGE LED is illuminated: The
set point temperature has not been reached within the
7 minute time period.
• Push the Reset Switch (see Fig. 4) or remove
power and watch for proper operation.
• Check pump sizing and valve/piping sizing and correct as necessary.
• Replace sensor.
• Check wiring using wiring diagram.
Fig. 8: Elodrive Actuator — Rotation Knob Setting
Fig. 9: Elodrive Actuator — Actuator Shown in Full
System Flow Position
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