Raypak MVB 504A, MVB 1504A, MVB 1104A, MVB 754A, MVB 2004A Installation & Operating Manual
INSTALLATION & OPERATING
INSTRUCTIONS
Models 504A–2004A
Types H, WH & P
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 other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3400.542A Effective: 10-04-13 Replaces: 05-21-13 P/N 241512 Rev. 2
Rev. 2 reflects the following:
Changes to: Table A on page 6, “Outdoor Installation” on page 9, “Applications and Modes” on page 16, Table J on
page 22, “Electrical Power Connections” on page 22, Table K on page 28, “High Limits” on pages 36-37, Wiring Diagram
on page 44, “Blower Check” on page 47, Table U on page 47, Filter Maintenance on page 55
Additions: “Motorized Combustion Air Dampers or Louvers” on page 11, “Flushing/Cleaning of System Piping” on
page 13, “Extractors, Draft Inducers, and Motorized Flue Dampers on page 28, Note on page 32, Fig. 47 on page 46.
Deletions: None
2
CONTENTS
WARNINGS 4
BEFORE INSTALLATION 5
Product Receipt 5
Model Identification 5
Ratings and Certifications 5
Installations at Elevation 5
Component Locations 6
General Information 6
GENERAL SAFETY 7
Time/Temperature Relationships in
Scalds 7
INSTALLATION 8
Installation Codes 8
Equipment Base 8
Clearances 8
Combustion and Ventilation Air 9
Conventional Combustion Air Supply 11
Water Piping 13
Hydronic Heating 15
Applications & Modes 16
Domestic Hot Water 17
Pool Heating 19
Gas Supply 21
Electrical Power Connections 22
Field Wiring Connection 24
Venting 27
Venting Installation Tips 30
Venting Configurations 30
Outdoor Installation 35
Controls 36
User Interface 38
WIRING DIAGRAM 44
START-UP 45
Pre Start-up 45
Start-Up 46
OPERATION 50
Lighting Instructions 50
To Turn Off Gas To Appliance 50
TROUBLESHOOTING 50
MAINTENANCE 53
Suggested Minimum
Maintenance Schedule 53
Preventative Maintenance Schedule 54
Filter Maintenance 55
Filter Replacement 55
APPENDIX 56
Inside Air Contamination 56
IMPORTANT INSTRUCTIONS FOR
THE COMMONWEALTH OF
MASSACHUSETTS 57
START-UP CHECKLIST 59
WARRANTY 60
3
WARNINGS
Pay Attention to These Terms
ndicates the presence of immediate hazards which will cause severe
DANGER:
I
personal injury, death or substantial property damage if ignored.
WARNING:
CAUTION:
NOTE:
DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
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.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
WARNING: Both natural gas and propane have an
odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.
WARNING: UL recognized fuel gas detectors are
recommended in all enclosed propane and natural
gas applications wherein there is a potential for an
explosive mixture of fuel gas to accumulate and their
installation should be in accordance with the
detector manufacturer's recommendations and/or
local laws, rules, regulations, or customs.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
CAUTION: This heater requires forced water
circulation when the burner is operating. See
minimum and maximum flow rates. Severe damage
will occur if the heater is operated without proper
water flow circulation.
CAUTION: Operation of this heater in low
temperature systems requires special piping.
Harmful internal condensation will occur if the inlet
water temperature does not exceed 120°F. Warranty
claims will be denied when condensation occurs.
CAUTION: If this heater is to be installed above
radiation level, it must be provided with a low water
cut-off device at the time of heater installation.
CAUTION: If this heater is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
4
BEFORE INSTALLATION
Raypak strongly recommends that this manual be reviewed thoroughly before installing your MVB heater.
Please review the General Safety information before
installing the heater. Factory warranty does not apply
to heaters that have been improperly installed or operated. (Refer to the warranty at the back of this
manual.) Installation and service must be performed
by a qualified installer, service agency or gas supplier.
If, after reviewing this manual, you still have questions
which this manual does not answer, please contact
your local Raypak representative or visit our website at
www.raypak.com.
Thank you for purchasing a Raypak product. We hope
you will be satisfied with the high quality and durability
of our equipment.
Product Receipt
On receipt of your heater it is suggested that you visually check for external damage to the shipping crate. If
the crate is damaged, make a note to that effect on the
Bill of Lading when signing for the shipment. Next,
remove the heater from the shipping packaging.
Report any damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that
you receive the correct number of packages as indicated on the Bill of Lading.
he upper rear jacket panel of the heater. The model
t
number will have the form H7-0504A or similar
depending on the heater size and configuration. The
letter(s) in the first group of characters identifies the
pplication (H = Hydronic Heating, WH = Domestic
a
Hot Water (DHW), and P = Pool heating). The number
hich follows identifies the firing mode (7 = electronic
w
modulation). The second group of characters identifies
the size of the heater (the four numbers representing
the approximate MBTUH input), and, where applicable, a letter, indicating the manufacturing series.
Ratings and Certifications
Standards:
• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired
Hot Water Boilers
• CAN 3.1 - latest edition, Industrial and
Commercial Gas-Fired Package Boilers
• ANSI Z21.10.3 · CSA 4.3 - latest edition, Gas Water Heaters
• ANSI Z21.56 · CSA 4.7 - latest edition, Gas-Fired
Pool Heaters
• SCAQMD Rule 1146.2
• Low-lead content (<.25%) CSA-certified
All Raypak heaters are National Board Approved, and
design-certified and tested by the Canadian Standards
Association (CSA) for the U.S. and Canada. Each
heater is constructed in accordance with Section IV of
the American Society of Mechanical Engineers
Claims for shortages and damages must be filed with
the carrier by consignee. Permission to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.
When ordering parts, you must specify the model and
serial number of the heater. When ordering under warranty conditions, you must also specify the date of
installation.
Purchased parts are subject to replacement only
under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted. Parts will
be replaced in kind only per Raypak’s standard warranties.
Model Identification
The model identification number and heater serial
number are found on the heater rating plate located on
WARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube
bundle headers, or any ASME parts not
manufactured and/or approved by Raypak will
instantly void the ASME and CSA ratings of the
vessel. Altering the ASME or CSA ratings of the
vessel also violates national, state, and local
approval codes.
(ASME) Heater Pressure Vessel Code and bears the
ASME stamp. This heater also complies with the latest
edition of the ASHRAE 90.1 Standard.
Installations at Elevation
Rated inputs are suitable for up to 2,000 ft elevation
without de-rating. Consult your local representative or
the factory for installations at altitudes over 2,000 ft
above sea level. No hardware changes are required to
the heaters for installations up to 10,000 ft (adjustments may be required).
5
Component Locations
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.
504A 500 300 2 1 1 8 6
754A 750 450 2 1 1 10 6
1104A 1100 660 2-1/2 1-1/4 1 10 6
1504A 1500 900 2-1/2 1-1/4 1 12 8
MBTUH
Input*
Max.* Min.* N P Flue Intake
Water
Conn.
(NPT)
Gas
Conn.
(NPT)
Vent
Size
(in.)
Panels omitted for clarity
Fig. 2: Component Locations – Front
2004A 1999 1199 2-1/2 2 1 14 8
*H7 units only
Table A: Basic Data
6
GENERAL SAFETY
Water temperature over 125°F can
cau s e i nsta n t s e v er e b u r ns or d eath
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.
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
Table courtesy of The Shriners Burn Institute
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. For sanitary rinse applications where outlet temperatures of 180°F to 195°F are
required, a boiler is recommended since the 210°F
limit on water heaters will NOT allow the heater to
maintain these desired sanitary rinse temperatures.
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.
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.
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.
CAUTION: Hotter water increases the risk of
scalding! There is a hot water scald potential if the
thermostat is set too high.
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 B: Time to Produce Serious Burn
7
INSTALLATION
Heater
Side
Minimum Clearance
from Combustible
Surfaces
Minimum
Service
Clearance
Floor* 0” 0”
Rear 12” 24”
Right
Side
1” 1”
Left Side 1” 1”
Top 0” 10”
Front Open 24”
Vent 1” 1”
Installation Codes
Installations must follow these codes:
• Local, state, provincial, and national codes, laws,
regulations and ordinances
• National Fuel Gas Code, ANSI Z223.1/NFPA 54 –
latest edition (NFGC)
• National Electrical Code, ANSI/NFPA 70 - latest
edition (NEC)
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1,
(CSD-1) when required
• For Canada only: CAN/CSA B149 Natural Gas
and Propane Installation Code and CSA C22.1
C.E.C. Part 1 (C22.1)
Equipment Base
The heater should be mounted on a level, structurally
ound surface. The heater is approved for installation
s
on a combustible surface but must NEVER be
nstalled on carpeting. Gas-fueled equipment installed
i
in enclosed parking garages must be located at least
18 in. above the floor.
CAUTION: This heater should be located in an
area where water leakage will not result in damage
to the area adjacent to the appliances or to the
structure. When such locations cannot be avoided, it
is recommended that a suitable catch pan,
adequately drained, be installed under the
appliance. The pan must not restrict air flow.
In addition, the heater shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation or service (circulator replacement, control
replacement, etc.).
Fig. 5: Anchor Hole Locations
If the heater needs to be secured to the ground, use
the hole pattern shown in Fig. 5, following local codes.
Additional clearance may be required when using the
factory anchor bracket.
Clearances
Indoor Installations
*DO NOT install on carpeting.
Table C: Clearances – Indoor Installations
When installed according to the listed minimum clearances from combustible construction, these heaters
can still be serviced without removing permanent
structural construction around the heater. However, for
ease of servicing, a clearance of at least 24 in. in front,
1 in. on the side, at least 24 in. on the rear and 10 in.
above the top of the heater is required. This will allow
8
nstalled on the air filter intake at the rear of the unit
i
during installation. The intake elbow MUST be oriented with the open end facing downward.
eaters must not be installed under an overhang
H
unless clearances are in accordance with local instal-
ation codes and the requirements of the gas supplier.
l
Three sides must be open in the area under the overhang. Roof water drainage must be diverted away
from heaters installed under overhangs.
Heater
Side
Rear 12” 24”
Front Open 24”
Right Side 1” 1”
Left Side 1” 1”
Top Unobstructed 10”
Vent
Termination
Table D: Clearances – Outdoor Installations
Min. Clearance
from Combustible
Surfaces
12” 12”
Minimum
Service
Clearance
Combustion and Ventilation Air
NOTE: Use of this heater in construction areas
where fine particulate matter, such as concrete or
dry-wall dust, is present may result in damage to the
heater that is not covered by the warranty. If
operated in a construction environment, a clean
source of combustion air must be provided directly to
the heater.
Fig. 6: Minimum Clearances from Combustible
Surfaces – Indoor and Outdoor Installations
the heater to be serviced in its installed location without movement or removal of the heater.
Service clearances less than the minimum may
require removal of the heater to service either the heat
exchanger or the burner components. In either case,
the heater must be installed in a manner that will
enable the heater to be serviced without removing any
structure around the heater.
Outdoor Installations
Outdoor installation REQUIRES the use of the combustion air intake elbow. The intake elbow must be
ordered when ordering the unit and is shipped loose
for field installation. The intake air elbow MUST be
Indoor Units
This heater must be supplied with sufficient quantities
of non-contaminated air to support proper combustion
and equipment ventilation. Combustion air can be supplied via conventional means where combustion air is
drawn from the area immediately surrounding the
heater, or via direct vent, where combustion air is
drawn directly from outside. All installations must comply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can cause non-warrantied damage to the heater.
(See the Appendix.)
NOTE: It is recommended that the intake vent be
insulated to minimize sweating.
9
U.S. Installations
1
Canadian Installations
2
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 (1.2m) below or to side
of opening; 1 foot (30 cm)
above opening
3 ft (91 cm)
C Clearance to permanently closed window * *
D
Vertical clearance to ventilated soffit located
above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the
terminal
5 ft (1.5m) *
E Clearance to unventilated soffit * *
F Clearance to outside corner * *
G Clearance to inside corner 6 ft (1.83m) *
H
Clearance to each side of center line extended above meter/regulator assembly
*
I Clearance to service regulator vent outlet * 6 ft (1.83m)
J
Clearance to non-mechanical air supply inlet
to building or the combustion air inlet to any
other appliance
4 ft (1.2m) below or to side
of opening; 1 ft (30 cm)
above opening
3 ft (91 cm)
K Clearance to mechanical air supply inlet
3 ft (91 cm) above if within
10 ft (3m) horizontally
6 ft (1.83m)
L
Clearance above paved sidewalk or paved
driveway located on public property
7 ft (2.13m)
7 ft (2.13m) t
M
Clearance under veranda, porch, deck or
balcony
* 12 in. (30 cm) TT
1
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
2
In accordance with the current CAN/CSA-B149 Installation Codes
t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that se rves
both dwellings
TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of term inal and
underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)
* Clearances in accordance with local installation codes and the requirements of the gas supplier
3 ft (91 cm) within a
height 15 ft above the
meter/regulator assembly
Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table E: Vent/Air Inlet Termination Clearances
10
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. (see figure 37 for outdoor installation)
Fig. 8: Air Filter Box
Motorized Combustion Air Dampers or
Louvers:
When motorized dampers or louvers are communicat-
ng directly with outside combustion air, they must be
i
interlocked with each appliance in the equipment
oom, to ensure proper operation. See Field Wiring
r
Connection section of this manual for proper wiring
instructions, using Fan/Damper dry contacts and
external interlock
TruSeal™ Combustion Air
In addition to the 3 previous steps, combustion air may
be ducted directly to the heater by using PVC, CPVC
or sealed single-wall galvanized ducting. The duct will
attach directly to the air collar located on the inline Air
Filter Box (shipped loose), using 3-4 sheet metal
screws (not supplied) equally positioned around the
circumference of the duct. The screen assembly
should be removed before attaching any air duct. 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.
Direct Vent
If outside air is drawn through the intake pipe directly
to the unit for combustion:
1. Install combustion air direct vent in accordance
with Fig. 35 (horizontal) or Fig. 36 (vertical) of this
manual (pages 33 and 34, respectively).
2. Ventilation of the space occupied by the heater(s)
is recommended and can be provided by an opening(s) for ventilation air at the highest practical
point communicating with the outdoors. The total
cross-sectional areas should be at least 1 in.² of
free area per 20,000 BTUH (111 mm² per kW) of
total input rating of all equipment in the room,
when the opening is communicating directly with
the outdoors or through vertical duct(s). The total
cross-sectional area should be at least 1in.² of free
area per 10,000 BTUH (222 mm² per kW) of total
input rating of all equipment in the room, when the
opening is communicating with the outdoors
through horizontal duct(s). Damage to the equipment due to inadequate ventilation of the space is
not a warrantable failure.
3. In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of
a motorized sealed damper to prevent the circulation of cold air through the heater during the
non-operating hours.
All ducting MUST be self-supported.
Conventional Combustion Air
Supply
CAUTION: Use TruSeal combustion air if
damaging airborne contaminants are or may be
present in the heater area. See the Appendix of this
manual regarding air contamination.
U.S. Installations
All Air from Inside the Building
The confined space shall be provided with TWO permanent openings communicating directly with an
additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for a
room large in comparison (NFGC). The total input of all
gas utilization equipment installed in the combined
space shall be considered in making this determination. Each opening shall have a minimum free area of
1 in.2 per 1,000 BTUH (2,225 mm2per kW) of the total
input rating of all gas utilization equipment in the confined space, but not less than 100 in.2(645 cm2). One
opening shall commence within 12 in. (305 mm) of the
top, and one opening shall commence within 12 in.
(305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than
3 in. (76 mm) in any direction.
11
All Air from Outdoors
Canadian Installations
The confined space shall communicate with the outdoors in accordance with one of the methods below.
The minimum dimension of air openings shall not be
less than 3 in. (76 mm) in any direction. Where ducts
re used, they shall be of the same cross-sectional
a
area as the net free area of the openings to which they
connect.
1. Two permanent openings, one commencing
within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of
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.
a. Where directly communicating with the out-
doors or where communicating to the
outdoors through vertical ducts, each open-
ing shall have a minimum free area of 1 in.
per 4,000 BTUH (550 mm2per kW) of total
input rating of all equipment in the enclosure.
b. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in.2per 2,000
BTUH (1,100 mm2per kW) of total input rating of all equipment in the enclosure.
2. One permanent opening, commencing within 12
in. (305 mm) of the top of the enclosure, shall be
permitted where the equipment has clearances of
at least 1 in. (25 mm) from the sides and back and
6 in. (152 mm) from the front of the appliance. The
opening shall directly communicate with the outdoors or shall communicate through a vertical or
horizontal duct to the outdoors or spaces that
freely communicate with the outdoors, and shall
have a minimum free area of:
2
a. 1 in.
per 3,000 BTUH (740 mm2per kW) of
the total input rating of all equipment located in
the enclosure, and
b. Not less than the sum of the areas of all vent
connectors in the confined space.
WARNING: Do not use the “one permanent
opening” method if the equipment room is under
negative pressure conditions.
AUTION: All combustion air must be drawn from
C
the air outside of the building; the mechanical equipment room must communicate directly with the
outdoors.
1. Ventilation of the space occupied by the heater
shall be provided by an opening(s) for ventilation
air at the highest practical point communicating
with the outdoors. The total cross-sectional area of
such an opening(s) shall be at least 10% of the
area required in 2. and 3. (below), but in no case
shall the cross-sectional area be less than 10 in.
(65 cm2).
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
2
than 1 in.2per 7,000 BTUH (320 mm2per kW) up
to and including 1 million BTUH, plus 1 in.2per
14,000 BTUH (160 mm2per kW) in excess of 1
million BTUH. This opening(s) shall be either
located at or ducted to a point not more than 18 in.
(450 mm) nor less than 6 in. (152 mm) above the
floor level. The duct can also “goose neck” through
the roof. The duct is preferred to be straight down
and terminated 18 in. (450 mm) from the floor, but
not near piping. This air supply opening requirement shall be in addition to the air opening for
ventilation air required in 1. (above).
WARNING: Care must be taken to ensure that the
equipment room is not under negative pressure
conditions.
3. For heaters not using a barometric damper in the
vent system, and when air supply is provided by
natural air flow from outdoors for a power burner
and there is no draft regulator, drafthood or similar
flue gas dilution device installed in the same
space, in addition to the opening for ventilation air
required in 1., there shall be a permanent air supply opening(s) having a total cross-sectional area
of not less than 1 in.2for each 30,000 BTUH (74
mm2per kW) of total rated input of the burner(s),
and the location of the opening(s) shall not interfere with the intended purpose of the opening(s)
for ventilation air referred to in 1. This opening(s)
can be ducted to a point not more than 18 in. (450
mm) nor less than 6 in. (152 mm) above the floor
level. The duct can also “goose neck” through the
roof. The duct is preferred to be straight down 18
in. (450 mm) from the floor, but not near piping.
2
12
4. Refer to the B149 Installation Code for additional
information
Water Piping
Leaks must be repaired at once to prevent damage to
the heater. NEVER use petroleum-based stop-leak
compounds.
To perform hydrostatic test:
General
The heater should be located so that any water leaks
will not cause damage to the adjacent area or struc-
tures.
CAUTION: This heater requires forced water
circulation when the burner is operating. See Table F
and Table G for minimum and maximum flow rates.
The pump must be interlocked with the heater to
prevent heater operation without water circulation.
NOTE: Minimum pipe size for in/out connections is
2 in. NPT for 504A and 754A models and 2-1⁄2 in NPT
for 1104A–2004A models. Verify proper flow rates
and ∆T as instructed in this manual.
Relief Valve Piping
WARNING: Pressure relief valve discharge piping
must be piped near the floor and close to a drain to
eliminate the potential of severe burns. Do not pipe
to any area where freezing could occur. Refer to
local codes.
Temperature & Pressure Gauge
. Connect fill water supply. Fill heater with water.
1
Carefully fill the rest of the system, making sure to
eliminate any entrapped air by using high-point
vents. Close feed valve. Test at standard operating
pressure for at least 24 hours.
2. Make sure constant gauge pressure has been
maintained throughout test.
3. Check for leaks. Repair any that are found.
Flushing/Cleaning of System Piping
Many of the chemicals used to perform this function
will harm the heat exchanger as well as some gaskets
and seals within the unit, causing a non-warrantable
failure. When required, Raypak recommends the boiler be isolated from the system piping prior to flushing
or cleaning with any cleaning agent.
Cold Water Operation
CAUTION: Damage due to internal condensation
may occur if the heater inlet water temperature does
not exceed 120°F (49°C) within 7 minutes of startup.
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 applicable national, state and
local codes.
Hydrostatic Test
Unlike many types of heaters, this heater does not require hydrostatic testing prior to being placed in
operation. The heat exchanger has already been factory-tested and is rated for 160 psi operating pressure.
However, Raypak does recommend hydrostatic testing of the piping connections to the heater and the rest
of the system prior to operation. This is particularly
true for hydronic systems using expensive glycolbased anti-freeze. Raypak recommends conducting
the hydrostatic test before connecting gas piping or
electrical supply.
This heater is equipped with a proprietary condensate
evaporation system which will evaporate any condensate that may begin to accumulate inside the primary
heat exchanger with water temperatures as low as
120°F (49°C).
Heaters operated with an inlet temperature of less
than 120°F (49°C) MUST have a low-temperature
operation system (Figs. 9, 10 and 11) to prevent problems with condensation. Inlet water temperatures
below 120°F (49°C) can excessively cool the products
of combustion, resulting in collection of condensate in
the heat exchanger area beyond the capacity of the
condensate evaporation system.
Failure to reach or exceed 120°F (49°C) may damage
or cause failure of the heat exchanger, combustion
chamber, or other parts within the combustion chamber. It can cause operational problems, bad
combustion, sooting, flue gas leakage and reduced
service life of the appliance and the vent system. A
bypass allows part of the heater discharge water to be
mixed with the cooler water returning to the heater
13
inlet to increase the heater inlet temperature above
*
*
120°F (49°C). This precautionary measure should pre-
ent the products of combustion from condensing
v
beyond the ability of the condensate management system employed in this heater in most installations.
Warranty claims will be denied for damage or fail-
res caused by condensation.
u
Cold Water Starts
Cold water starts, where the inlet water temperature
remains below 120°F (49°C) must
have cold water
start protection. Known protection methods consist
of mixing heated outlet water with the inlet water using
a bypass to raise the inlet to 120°F (49°C) or higher.
Once the system is heated up and has return water
temperatures of 120°F (49°C) or higher, the mixing of
outlet water with inlet water is no longer needed and
the bypass can be shut off. If the bypass is not shut off
as the system heats up, the outlet temperature may
continue to climb and trip the high limit, thereby shutting down the heater. Thus an automatic valve system,
such as a three-way proportional valve to control the
bypass, should be used.
water is kept in a narrow temperature range of no
more than 10°F (5°C), a permanent manual bypass
an be employed and manually adjusted to achieve an
c
inlet temperature of 120°F (49°C) or higher as adjusted at the minimum temperature in this narrow
temperature range (i.e. Range 75°F to 85°F – adjust
ypass with temperature at 75°F (24°C)) so that when
b
temperature is 85°F (29°C), minimum inlet temperature would be 130°F (54°C). An injector pump
arrangement may also be utilized to keep the heater
loop at or above 120°F (49°C). An injector pump
arrangement may be used to keep the heater loop at
or above 120°F (49°C). An injector pump approach
has the added value of being able to adjust automatically to changes in the system water coming back to
the heater.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 9: Cold Water Start
Cold Water Run
Cold water run differs from cold water start in that the
system water entering the heater remains below
120°F (49°C) continuously. Typically, this is the case in
swimming pool heating and water source heat pump
applications, as well as some others. If the system
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 10: Cold Water Run
“H” Bypass
Adjustment of the manual bypass valve is critical to
proper operation of the heater. The manual bypass
valve should be adjusted to achieve a minimum inlet
water temperature of 105°F (40°C) for Pool Heater (P)
versions and 120°F (49°C) for Hydronic Heating (H7)
or Domestic Hot Water (WH7) versions and a system
supply water temperature below 140°F (60°C). When
starting with a cold pool, make initial adjustments.
Make final adjustments when pool water approaches
desired temperature.
For the H-bypass, use the following instructions to set
the manual bypass:
1. Turn on pump.
2. Turn on heater and wait until heater goes to full
fire.
14
Notes: Basis for minimum flow is ∆T . Basis for maximum flow is gpm.
GPM
P
(ft WC)
GPM
P
(ft WC)
GPM
P
(ft WC)
GPM
P
(ft WC)
T
(°F)
GPM
P
(ft WC)
T
(°F)
504A 42 2.7 28 1.4 N/A N/A 25 1.1 34 100 11.3 8
754A 63 6.0 42 2.9 32 1.8 32 1.8 39 100 13.8 13
1104A 92 13.3 62 6.7 47 4.3 47 4.3 39 113 18.6 16
1504A N/A N/A 84 13.3 65 8.4 65 8.4 39 113 22.2 22
2004A N/A N/A 112 26.9 86 16.7 86 16.7 39 113 27.2 30
M
ax Flow
M
VB
Model
2
0°
T
3
0°
T
3
9°
T
M
in Flow
Table F: Heater Rates of Flow and Pressure Drops
NOTE: Opening the valve will increase the
temperature and closing the valve will decrease the
temperature.
3. With the heater operating at 100% firing rate, set
Valve A (the bypass) to 1⁄2 open position, and Valve
B to fully open position. See Fig. 16.
4. Adjust Valve A until the inlet water temperature is
105°F (40°C) or 120°F (49°C) depending upon
heater type.
5. If this process does not raise the inlet water temperature to 105°F (40°C) for Pool Heater (P)
versions and 120°F (49°C) for Hydronic Heating
(H7) or Domestic Hot Water (WH7) versions and
Valve A is fully open, then slowly throttle Valve B
closed to increase the inlet water temperature to
the required temperature.
NOTE: For automatic temperature adjustment, a
Cold Water Run (CWR) system can be used instead
of a manual bypass. See Fig. 10.
Hydronic Heating
Pump Selection
In order to ensure proper performance of your heater
system, you must install a correctly-sized pump. Raypak requires designing for a ∆T within the range of
16°F to 39°F (9°C to 22°C). See Table F for acceptable flow rates for each model (∆T is the temperature
difference between the inlet and outlet water when the
heater is firing at full rate).
Feedwater Regulator
Raypak recommends that a feedwater regulator be installed and set at 12 psi minimum pressure at the
highest point of the system. Install a check valve or
back flow device upstream of the regulator, with a
manual shut-off valve as required by local codes.
Piping
All high points should be vented. A heater installed
above radiation level must be provided with a low water cut-off device (sales order option F-10). This
heater, when used in connection with a refrigeration
system, must be installed so that the chilled medium is
NOTE: Hot water heating systems all have unique
levels of operating diversity that must be accounted
for in the system design. The system should always
include adequate system flow in excess of the
connected boiler flow for proper operation. Where
the system flow may drop below the connected
boiler flow a buffer/decoupler may be needed.
Failure to design for adequate flow (i.e. bypasses, 3
way control valves, flow limiting balance devices,
buffer tanks, etc.) will result in boiler short cycling
and may reduce boiler life. Always contact your local
Fig. 11: “H” Bypass Setting
Raypak representative for system design assistance
to avoid these issues.
15
piped in parallel with the heater with appropriate
valves to pre-vent the chilled medium from entering
the heater.
The piping system of a hot water heater connected to
eating coils located in air handling units where they
h
may be exposed to circulating refrigerated air, must be
equipped with flow control valves or other automatic
means to prevent gravity circulation of the heater
water during the cooling cycle. It is highly recommended that the piping be insulated.
Air-Separation/Expansion Tank
All heaters should be equipped with a properly sized
expansion tank and air separator fitting as shown in
Fig. 12 .
or detailed information on the Versa IC™ control sys-
F
tem, see Catalog 5000.72. This manual can be found
in the document library at www.raypak.com
Fig. 13: MODE 1 - Single Boiler with
Primary/Secondary Piping
.
Mode 1 (Type H Units Only)
Fig. 12: Air-Separation/Expansion Tank
Three-Way Valves
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.
Applications & Modes
The VERSA IC Control system is designed for a wide
range of applications. The installer/design engineer
should refer to the following Modes to determine which
best fits the intended application and functionality for
the unit being installed.
Type H models of MVB have three modes available to
them to address the various applications the units can
be applied to. Type WH units will only have the WH
configuration available to them for use with potable
water applications when directly connected to a hot
water storage tank.
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4). The system temperature is
controlled by the System sensor (S3). The Boiler
Pump (P1) runs during any call for heat. The System
Pump (P2) runs whenever the system is enabled for
heating and the outdoor air temperature is lower than
the warm weather shut down (WWSD) temperature
setting (if utilized). The Boiler Pump and System Pump
are delayed “off” as user defined in the ADJUST
menu.
Fig. 14: MODE 1 - Boiler Cascade with
Primary/Secondary Piping
16
NOTE: MODE 1 can also be used for process heating applications in conjunction with a buffer/storage
tank when operating temperatures above 160°F are
required. Care must be given to ensure water hardness is no more than 15 grains per gallon for scale
free operation.
Fig. 15: MODE 2 - Single Boiler with Indirect
on System Loop
Mode 2 (Type H Units Only)
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4) with indirect DHW on the system loop (with or without priority). The system
temperature is controlled by the System sensor (S3).
The Indirect DHW sensor (S5) determines the indirect
call/tank setpoint. The system temperature is boosted
to Target Max when using the Indirect DHW sensor
(S5) during an indirect call for heat. Priority mode toggles off the System Pump (P2) when an indirect call for
heat is present. The Boiler Pump (P1) runs during any
call for heat. The Indirect DHW Pump (P3) runs during
an indirect call for heat with no “off” delay. The Boiler
Pump (P1) and System Pump (P2) delay “off” as user
defined in the ADJUST menu. The System Pump (P2)
runs whenever the system is enabled for heating and
the outdoor air temperature is lower than the WWSD
temperature setting (if utilized) unless an indirect call
for heat is present with priority.
Fig. 16: MODE 3 - Single Boiler with Indirect
on Boiler Loop
Mode 3 (Type H Units Only)
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4) with indirect DHW on the boiler loop (with priority). The system temperature is
controlled by the Supply sensor (S3) whenever the
indirect call for heat is not active. The DHW Supply
sensor (S5) determines the indirect call/tank setpoint.
During an indirect call for heat the boiler firing rate is
determined by the water temperature at the Indirect
Supply sensor (S6) and the Target Max setting when
using the Indirect DHW sensor (S5). The Boiler Pump
(P1) runs during all heat calls regardless of priority.
The Indirect DHW Pump (P3) runs during an indirect
call for heat with no “off” delay. The Boiler Pump (P1)
and System Pump (P2) delay “off” as user defined in
the ADJUST menu. The system pump (P2) runs
whenever the system is enabled for heating and the
outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect call for
heat is present.
NOTE: A Tank Aquastat can be used in lieu of the
Indirect DHW Sensor (S5). See the Versa IC manual for additional details.
Domestic Hot Water
When designing the water piping system for domestic
hot water applications, water hardness should be considered. Table G indicates the suggested flow rates for
soft, medium and hard water. Water hardness is expressed in grains per gallon.
17
∆T = Temperature rise, °F
3-4 Grains Per Gallon 5-15 Grains Per Gallon 16-25** Grains Per Gallon
T
(°F)
GPM
P
(ft wc)
MTS
(in)
SHL
(ft wc)
T
(°F)
GPM
P
(ft wc)
MTS
(in)
SHL
(ft wc)
T
(°F)
GPM
P
(ft wc)
MTS
(in)
SHL
(ft wc)
504A 17 50 3.6 2 8.3 17 50 3.6 2 8.3 9 95 10.4 2 25.7
7
54A 26 50 4.0 2 8.7 17 73 7.8 2 17.3 14 90 11.4 2 25.3
1104A 21 85 11.5 2 1/2 16.2 21 85 11.5 2 1/2 16.2 15 116 19.6 2 1/2 27.8
1
504A 27 94 18.4 2 1/2 24.0 24 105 22.5 2 1/2 29.3 22 115 26.5 2 1/2 34.6
2004A 29 117 32.6 2 1/2 40.9 29 117.2 32.6 2 1/2 40.9 29 117 32.6 2 1/2 40.9
SOFT*
MEDIUM
HARD*
MVB
M
odel
WATER HARDNESS
∆P = Pressure drop through heat exchanger, ft
SHL = System head loss, ft (based on heater and tank connections of no more than 100 eq. ft. of tubing)
gpm = Gallons per minute, flow rate
MTS = Minimum tubing size
*Must utilize optional cupro-nickel tubes. If over 25 grains per gallon, a water softener/treatment system must be utilized.
**Caution: For scale free operation with "Hard Water" (16-25 grains per gallon of total hardness), the operating control must NOT be set
higher than 130 F. For higher than 130 F operation, a water softener/treatment system must be utilized.
***Care should be given to prevent over-softening of the water as over-softened water can become aggressive. Cupro-nickel tubes are
recommended for water softened below 5 grains per gallon.
Table G: Domestic Water Heater Flow Rate Requirements
NOTE: WH units will operate to a maximum tank
temperature of 160°F. For temperatures required
above 160°F an “H” model boiler must be used and
great care must be given to ensure water hardness
is no more than 15 grains per gallon for scale free
operation. MODE 1 should be used and configured
for setpoint operation for process heating applications.
Potable Water and Space Heating
CAUTION: When this heater is used for both
potable water and space heating, observe the
following to ensure proper operation.
Fig. 17: WH Units - Single Water Heater with Tank
H Units - Single Boiler with Process Tank
WH – Direct DHW Configuration
When the unit is ordered as a “WH” configuration the
only application available to it is direct DHW with single or multiple heaters (Maximum 4 heaters). The tank
temperature is controlled by the System sensor (S3).
The Boiler Pump (P1) runs during any call for heat.
The System Pump (P2) output is active whenever the
system is enabled. The Boiler Pump is delayed “off”
after the Tank Target temperature is achieved and as
user defined in the ADJUST menu.
NOTE: If local codes require a vacuum relief valve,
acquire one locally and install per valve
manufacturer’s instructions.
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 heating.
3. If the heater will be used to supply potable water,
it shall not be connected to any heating system or
components previously used with a non-potable
water heating appliance.
4. When the system requires water for space heating
at temperatures higher than 140°F (60°C), a
means such as a mixing valve shall be installed to
temper the water in order to reduce scald hazard
potential.
18
*
P
OOL
THERMOSTAT
FROM
F
ILTER
T
O POOL
C
HEMICAL
FEED
A
UTO LIMIT
S
ET TO 110°F
Automatic Chemical Feeders
All chemicals must be introduced and completely diluted into the water before being circulated through the
eater. High chemical concentrations will result when
h
the pump is not running (e.g. overnight).
NOTE: High chemical concentrates from feeders
that are out of adjustment will cause rapid corrosion
to the heat exchanger. Such damage is not covered
under the warranty.
NOTE: Failure of a heat exchanger due to lime
scale build-up on the heating surface, low pH or
other chemical imbalance is non-warrantable.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can cause unwarrantable damage to the heater.
Pool Heating
When a boiler or water heater is used in a pool heating application, ensure that all the following installation
requirements are met.
The MVB must be equipped with an 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) versions and 120°F (49°C) for
Hydronic Heating (H7) or Domestic Hot Water (WH7)
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.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 18: Single Pool Heater Application
CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can
damage the heater and can cause unwarrantable
damage to the heater.
Winterizing Your Heater
Heaters installed outdoors as pool heaters in freezing
climate areas should be shut down for the winter. To
shut down the heater, turn off manual main gas valve
and main gas shut-off. Close isolation valves. Drain
the heater using the hose bibs located on the bottom
of the heat exchanger.
NOTE: There are 2 separate drains on the MVB
that must BOTH be drained to protect the heat
exchanger. These are both accessible by removing
the lower front door from the heater. Drain any
piping of all water that may experience belowfreezing temperatures.
Pool/Spa Water Chemistry
CAUTION: Corrosive water can cause unwar-
rantable damage to the heater.
CAUTION: Power to the heater should be
interlocked with the main system pump to make sure
the heater does not fire without the main system
pump in operation. Improper flow control can
damage the heater. Uncontrolled flow (too high) or
restricted flow (too low) can seriously damage the
heater. Follow these instructions to make sure your
heater is properly installed.
To complete the installation of the pool heater, the pool
thermostat must be installed in the main return water
line, upstream of the heater. This will ensure that the
heater will be energized at the right time.
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. 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 exchanger tubes, reducing heater efficiency and damaging the
heater. If the pH drops below 7.2, this will cause corrosion of the heat exchanger and severely damage the
heater. Heat exchanger damage resulting from chemical imbalance is not covered by the warranty.
19
Recommended Level(s) Fiberglass Pools Fiberglass Spas
Other Pool and Spa
ypes
T
ater Temperature
W
H
p
8-88°F (20-31°C)
6
.3-7.4
7
9-104°F (31-40°C)
8
.3-7.4
7
8-104°F (20-40°C)
6
.6-7.8
7
Total Alkalinity (ppm) 120-150 120-150 80-120
Calcium Hardness (ppm) 200-300 150-200 200-400
Salt (ppm) 6000 Maximum 6000 Maximum 6000 Maximum
Free Chlorine (ppm)* 2-3 2-3 2-3
Total Dissolved Solids
(ppm)
3000 Maximum 3000 Maximum 3000 Maximum
*Free Chlorine MUST NOT EXCEED 5 ppm!
Table H: Pool Water Chemistry
For your health and the protection of your pool equipment, it is essential that your water be chemically
balanced. The following levels must be used as a
guide for balanced water.
NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will cause
rapid corrosion to the heat exchanger. Such damage
is not covered under the warranty.
Occasional chemical shock dosing of the pool or spa
should not damage the heater providing the water is
balanced.
NOTE: Failure of a heat exchanger due to lime
scale build-up on the heating surface, low pH or
Automatic chemical dosing devices and salt chlorina-
other chemical imbalance is non-warrantable.
tors are usually more efficient in heater water, unless
controlled, they can lead to excessive chlorine level
which can damage your heater.
Further advice should be obtained from your pool or
spa builder, accredited pool shop, or chemical supplier for the correct levels for your water.
Automatic Chlorinators and
Chemical Feeders
All chemicals must be introduced and completely diluted into the pool or spa water before being circulated
through the heater. Do not place sanitizing chemicals
in the skimmer. High chemical concentrations will
result when the pump is not running (e.g. overnight).
Chlorinators must feed downstream of the heater and
have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off.
20
Loading...