Raypak WH1-1003 Installation Manual

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: 1000.57I Effective: 02-27-13 Replaces: 07-22-10 P/N 241275 Rev. 10

Rev. 10 reflects the following:
Changes to:
Additions:

Deletions:

None

None

Illustrated Parts List (was on previous pages 34-39)

2

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 B
Actuator to Valve Orientation 12
Installing the Three-Way Valve 13
High Pressure Tab 13
Actuator 13
Cold Water Start Troubleshooting
Guide 14
Typical Cold Water Start Piping 15
Wiring Diagram 16
Heater Interface Wiring 17

CWS—MULTIPLE BOILER 18

Materials Included 18
Installation 18
Mounting the Control Boxes 18
Installing the Temperature Sensor 18
Installing the Three-Way Valve 18
Connecting Power to the Controller 18

all Position 12

Connecting Cold Water Start to Multi­Heater Interlock Box 18
Connecting Heater to Cold Water Start
Multi-Heater Interlock 18
Actuator to Valve Orientation 19
Three-Way Valve Ball Orientation 19
Valve Installation 19
4 Inch Valve Orientation 20
Connecting the Actuator 20
Typical Cold Water Start Multiple Boiler
Piping 21
Wiring Diagram 22

COLD WATER RUN 23

Purpose 23
Typical Cold Water Run Applications 23
CWR vs. CWS 23
Installation 23
Installation Codes 23
Mounting the
Injector & Heater Pump Comparison 24
Check the Power Source 25
Injector Pump Wiring 25
Injection Pump Cover Installation 27
Typical Cold Water Run Piping ­Heating Applications 29
Typical Cold Water Run Piping ­Pool Applications 29
Operation 30
Cold Run Sequence of Operation 30
Cold Water Run Troubleshooting
Guide 31
Wiring Diagrams 32

REPLACEMENT PARTS 34

Control B

ox 23

3

WARNINGS

Pay Attention to These Terms

DANGER:

WARNING:

CAUTION:

NOTE:

NOTE: Minimum 18 AWG, 105°C, stranded wire

must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause exces­sive tension on contact points. Install conduit as
appropriate. All high voltage wires must be the same
size (105°C, stranded wire) as the ones on the unit
or larger.

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.

Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.

NOTE: Piping diagrams in this manual are not
intended to replace an engineered piping system.

NOTE: Consult the factory for units with a 30 pound
pressure relief valve (PRV).

4

GENERAL SAFETY

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.

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 co urtesy of The Shriners Burn Institute

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

an cause instant severe burns or death from scalds.

c
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.

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(s) have 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.

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

5

COLD WATER START

CIRCUIT

B

REAKER

W

HITE

GROUND

B

LACK

GREEN

AB C

Before beginning the installation, it's important to first

nspect the system and determine what materials you

i
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)

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. 1 to assist in reassembling the pip­ing.

Fig. 2: Wiring Connections

Check the power source:

AC = 108 VAC Minimum, 132 VAC MAX
AB = 108 VAC Minimum, 132 VAC MAX

BC = <1 VAC Maximum

Fig. 1: Cold Water Start Assembly

Installation

Check the Power Source

CAUTION: Do not use for swimming pool applica-

tions

WARNING: Using a multi-meter, check the follow­ing voltages at the breaker panel prior to connecting
any equipment. Make sure proper polarity is followed
and house ground is proven.

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 as shown in Figs. 4–8. 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. On MVB and Hi Delta models, locating dimples
are provided for ease of drilling the mounting holes.
You will need to drill mounting holes through the heater
side panel for the routing of wiring and the sensor.

Fig. 3: Multi-meter

6

THREE-WAY VALVE

11-1/8”

1”

10-5/16”

11-1/8”

11/16”

7-1/4”

Installing the Temperature
Sensor

void routing wiring on or near other electrical wires,

A
conduit, motors, spark igniters or other sources of high

ntermittent voltage or current. The sensor should be

i
placed in the dry well on the inlet header, or as indicat­ed in the piping for multiple heaters, as shown on page

21. Ensure it is installed using thermal paste (field
supplied) and that it is held firmly at the bottom of the
well.

Connecting the Valve
Assembly

Connect the valve assembly into the bypass piping.
The branch (port B) is connected to the crossover pipe
(bypass between inlet and outlet). The actuator tail
stock should be oriented to point down. Refer to the
Actuator to Valve Orientation section.

Route wiring from the valve to the controller thru one
of the bottom panel conduit knockouts to TB2. Refer to
the wiring diagram provided on the inside of the con­troller cover assembly.

NOTE: Four knockouts are located on the bottom

f the control for ease of installation.

o

CAUTION: Miswiring the actuator may cause
unwarrantable damage. Verify the wire colors
against the actuator make and model.

LEFT SIDE

Fig. 5: Component Locations—Raytherm Models

514–824

Models X Y Z

302B-902B

992B-2342B

Fig. 4: Component Locations—Hi Delta

7″ 2″ 1-9/16″

13-1/4″ 1-5/16″ 6-5/8″

Fig. 6: Component Locations—Raytherm Models

926–1826

7

Reset Switch*

9-9/16”

5/16”

1-3/4”

22”

7

-5/8”

1-1/2”

*The reset switch may be located on the front control panel on some
MVB models.

Fig. 9: Location of TB1 in Control Box

Fig. 7: Component Locations—Raytherm Models

2100–4001

INSTALL
INSULATION ON
INSIDE OF REAR
PANEL

Fig. 8: Component Locations—MVB

Connecting Power to the
Controller

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.

Connecting Boiler to Cold Water
Start

The installer must provide five 18AWG stranded wires
between the heater and the controller terminal block.
Wiring is to be run in separate conduit from line volt­age to ensure proper operation. Refer to the diagrams
on page 17 for connection points depending on the
Raypak product being used.

Operation

Verify the following upon a CALL FOR HEAT signal
from the heater:

1. CALL FOR HEAT: LED on PCB illuminates
GREEN.

CAUTION: Install the foil-faced insulation on the
inside of the rear panel of MVB heaters as indicated
in Fig. 8. Use spray adhesive or high temp foil tape
to attach the insulation. Ensure that the foil faces the
heat exchanger assembly. Failure to install this insu­lation as directed can cause overheating of the com­ponents and may void the warranty on the control.

2. START UP MODE: LED on PCB illuminates YEL­LOW. It should go out in less than 7 minutes, as the
boiler inlet temperature approaches the setpoint
temperature.

3. The “ACTUATOR” should be in the fully open posi­tion or move to the fully open position if not already
there. (Actuator and ball rotated to the at-rest CCW
position).

8

Setpoint

Pot

CALL FOR HEAT
START UP MODE
I

NLET TEMP ERROR

SENSOR OUT OF RANGE

Fig. 10: Control PCB

4. If the control is operating properly, the “START UP
MODE” LED should go out in less than 7 minutes.
At this point, the inlet water temperature should be
stable at a temperature between 105°F and 120°F
corresponding to the Setpoint Pot setting on the
PCB. The actuator should have stopped moving.

NOTE: The minimum inlet water temperature to the
heater to prevent condensate is 105°F on heaters
with an efficiency of 85% or less, and 120°F on 87%
efficiency heaters. Ensure that during operation the
Setpoint Pot is adjusted properly.

NOTE: If a “DIP” switch is provided on the control
PCB, verify that the switch settings are: 1 = OFF, 2 =
ON, 3 = OFF.

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 con-

verter 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.

. 120VAC-12VDC converter outputs 12VDC to the

5

common terminal of the reset switch, located on
the bottom of the cold start control panel.

6. The 12VDC signal crosses over the reset switch
nd goes to Terminal FS on the cold start circuit

a
board.

7. Cold start control is now in standby until a Call for

Heat occurs at heater.

8. The heater outputs 24VAC to terminal 4 of termi-

nal block 3 located in Cold Start controller to
indicate a CFH from the heater.

9. Terminal 4 of TB 3 sends 24VAC to the coil of the

SPST relay located in the cold start control panel.

10. The SPST relay coil is energized and closes the

contacts allowing 24VAC to energize the CFH ter­minal on the cold start circuit board.
a) A two second delay occurs from the CFH sig-

nal to the output of power from terminal MC of
the cold start circuit board.

11. 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.

12. 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.

13. The DPST relay coil energizes and closes the NO

contacts.

14. Once the NO contacts of the DPST close, the

heater 24 VAC is sent back to the heater to com­plete the circuit (pin 3 of terminal block 3) and the
interlock circuit (pin 1 & 2 of terminal block 3)
allowing the heater to fire.

15. 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.

16. After the two-minute delay the 10VDC output sig-

nal from pin FR reduces to approximately 8VDC.

17. The output signal continues to vary depending on

the heater inlet temperature.

NOTE: The heater will lockout and shut down if the
setpoint on the inlet temperature is not achieved
within seven minutes from a call for heat.

9

D

IP SWITCH SETTINGS

F

OR 3-WAY ACTUATOR

VDC

0-10

DA

FIXED

~

mA

2-10

RA

AUTO

6-9

S

WITCH MUST BE IN THIS POSITION

TURN CLOCKWISE TO FURTHEST STOP

M

ODE SELECTION SWITCH

DIRECT ACTING, ON INCREASING SIGNAL

SIDE

“A”

NOTE:

SIDE “A” MUST
FACE AWAY
FROM VALV E

DETENT MUST BE

SET TO POSITION 4

S

IDE

“B”

NOTE:

SIDE “B” MUST
FACE AWAY
F

ROM VALV E

he DIP switches on the three-way valve actuator

T
must be set as indicated in the Fig. 11 below:

Fig. 11: Set Dip Switch Settings — Delta Actuator

Fig. 14: Elodrive Actuator — Actuator Shown in Full

System Flow Position

NOTE: The Elodrive actuator is NEMA 4 rated. No
outdoor cover is required.

Troubleshooting

Fig. 12: Delta Actuator — Actuator Shown in Full

System Flow Position

CAUTION: Delta actuator requires the use of the
factory-supplied weatherproof cover for outdoor
installations.

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 between
pins 4 and 5 of TB3 on the cold start control. 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 pin FS on the control board, there should be a
12VDC signal. If the 12VDC signal is not present, ver­ify that the converter is wired correctly using the wiring
diagram.

Fig. 13: Elodrive Actuator — Rotation Knob Setting

Set adjustment knob to Position 4

IF INLET TEMP ERROR is illuminated: The setpoint
temperature has not been reached within the 7 minute
time period.

• Push the Reset Switch (see Fig. 9) or remove
power and watch for proper operation.

10

Check pump sizing and valve/piping sizing and cor-

•
rect as necessary.

IF SENSOR OUT OF RANGE LED is illuminated: The
sensor may have a short or open circuit.

• Press and release the Reset Switch (see Fig. 9)
and watch for proper operation.

• Replace sensor.

• Check wiring using wiring diagram.

Mounting the Actuator to the
Valve

When mounting the actuator to the valve, ensure that
the valve stem is oriented with the machined flat notch
positioned parallel to the “A” and “AB” ports as shown
in Fig. 15.

All actuators used by Raypak include the “spring
return” safety feature. This means that upon loss of
power during operation the valve automatically rotates
back to the full system flow position avoiding high limit
lockouts or other issues.

Mounting Brackets (Elodrive)

There are different actuator mounting brackets on the
three-way valves. When ordering a replacement
bracket you will receive the newest design available

rom the manufacturer. If it appears to be different than

f
the damaged bracket, the new and old are inter­changeable and will fit all valve bodies. See Fig. 16.

A

B

AB

Flat Notch

Fig. 15: Orient Notch Parallel with “A” and “AB” Ports

Flow

Fig. 16: Elodrive Mounting Bracket

Locating the Rotation Stop
(Elodrive)

An internal rotation stop device is built into the actua­tor mounting bracket and this can be installed only two
ways for proper operation of the valve. The stop is
labeled on each side with either “D” or “P”. This indi­cates that the valve is set up for either a diverting
application or proportional (mixing) application.
Raypak uses the three-way valve in a mixing applica­tion therefore the “P” designator must be facing away
from the bracket.

The valve rotates in a clockwise direction when it is
operating. The rotational stop must be positioned so
that the drive linkage can rotate. The drive linkage is
keyed to allow only 90 degrees of rotation. Ensure that
the key is positioned so the linkage may rotate clock­wise as shown in Fig. 17.

11

• If you do not see two openings at this point, con-

PORT A B

POSITION ROTATIONAL
STOP SO THAT DRIVE
LINKAGE CAN ROTATE

tinue rotating the stem and ball until you do.

• Once you can see two openings, STOP, as shown
n Fig. 18. Then rotate the stem counterclockwise

i
until only one opening remains e.g. you can see

ompletely through the valve (through ports A and

c
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.

Fig. 17: Elodrive Rotational Stop Positioning

Drive Linkage (Elodrive)

The drive linkage for the 2” NPT and 2-1/2” NPT three­way valves originally were supplied with an orientation
groove in the end of the stem. This groove has now
been removed by the vendor. All new linkage stems
will have a smooth end. Using the groove to determine
ball position inside of the valve is not reliable and
should be avoided.

Verifying Ball Position

All field-installed valves must have the ball properly
positioned. Occasionally differences occur from the
manufacturer of the valve body. The square stem that
the drive linkage attaches to should have a machined
notch to verify ball position, however on occasion it is
not there. To properly orient the ball follow these
instructions PRIOR to installation into your plumbing
system.

• Remove the actuator and base from the valve
body.

• With port “AB” facing you, rotate the valve stem
approximately 45 degrees clockwise. You must
see two port openings if the ball is correctly orient­ed.

Fig. 18: Verifying Ball Position

Actuator to Valve Orientation

Install the actuator so that the tail is pointing downward
as shown in Fig. 19. You may also install it horizontal­ly, however, DO NOT mount it so that the tail is
pointing up as shown in Fig. 20. Doing so will allow
water and debris to collect in the cup where the wiring
exits the actuator, potentially causing damage.

Fig. 19: Recommended Orientation of Actuator

12

Fig. 20: Incorrect Orientation of Actuator

HIGH
PRESSURE
TAB

INSERT ALLEN
WRENCH UNDER
THIS LABEL

Installing the Three-Way Valve

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.

When threading any pipe into the ports of the three­way valve, a backing wrench MUST be employed. You
must capture the valve body with a secondary wrench
to avoid damaging the internal seals. Valve bodies
leaking from improper installation are non-war­rantable.

High Pressure Tab

Located between the valve body and the actuator
mounting bracket, is a yellow tab labeled “High
Pressure” see Fig. 21. This is for maintenance of the
valve only.

If the valve stem begins leaking beneath the yellow tab
the internal packing material must be replaced. The
“High Pressure” tab is held on with two screws located
under the mounting bracket.

To replace the packing material, all water pressure
must be removed from the valve assembly and the
assembly must be isolated from the system water.
Then remove the actuator and bracket, then remove
the two screws holding the “High Pressure” tab in
place.

At this point the packing material can be removed and
replaced just like any other valve assembly. The pack­ing material is not available from Raypak.

By pressing the red release button on the tail of the
actuator and simultaneously rotating the Allen wrench
you can rotate the ball clockwise. Once you release or
remove the Allen wrench the ball will return to its orig­inal position by way of the “spring return”. This is an
easy way to determine if the ball is oriented properly
inside of the valve.

Fig. 22: Actuator

13

Step9

Step8

Step10

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Is there a Call For

H

eat at the heate

r

?

Are the 120/24VAC

transformer and 120VAC-

12VDC inverter in the cold

start controller powered?

Replace 120VAC-12VDC

inverter or correct wiring.

D

oes the cold start 12VDC inverter

output 12VDC to the reset switch

and to common pin FS of the cold

start circuit board?

Does the cold start 120/24VAC
transformer output 24VAC to pin
2

of TB2 and the valve actuator?

Replace transformer or

correct the wiring

Replace circuit board

Are the terminals 1-4 of TB3

connected to N.O. contacts of

DPDT relay?

Does cold start DPDT

relay coil receive 24VAC

from MC on circuit board?

Are terminals 1-4 of TB3

correctly connected back

to the heater?

Call our Technical Service Department

1-805-278-5300

NO

Verify 120VAC at separate
c

ircuit breaker and correct.

YES

D

oes TB1 of cold start

controller have 120

V

AC?

Heater is in standby mode

Correct wiring to

match wiring diagram

YES

N

O

N

O

YES

Y

ES

N

O

N

O

NO

YES

YES

NO

The unit is okay

YES

NO

YES

Correct wiring

Is the actuator modulating after

2-1/2 minutes?

NO

Correct wiring

YES

Is the heater tripping the high

limit?

YES

NO

Verify actuator is set to reverse acting

and three-way valve is not installed

backwards.

2” & 2-1/2” valve must

rotate CW on decreasing 0-

10VDC signal. 4” valve will

rotate CCW.

YES

Correct settings or valve

orientation

NO

Is 24VAC present at CFH

terminal on cold start circuit

board?

Check and verify 24VAC between pin 4 and 5

of TB3 in cold start controller and correct.

Is 0-10VDC present at

connection FR of cold start

circuit board?

NO

Replace cold start circuit board

YES

NO

YES

Does cold start circuit board lock-out on

“Sensor out of Range”?

NO

YES

Is sensor resistance correct?

YES

NO

Replace sensor

Is system water

temperature
below 32ºF?

NO

YES

Does the reset switch send

12VDC to terminal FS on the

cold start circuit board?

NO

YES

Cold Water Start Troubleshooting Guide

14

NOTES:

1.LOCATE UNIONS TO FA CILITATE 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

ISNOT ADEQUAT E TO PROVIDE STA BLE TEMPERATU RE CONTROL.

CONSULT FA CTORY FOR TA NK SIZING.

5.SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES.

Typical Cold Water Start Piping

15

BRACKET RESTS AGAINST
VALVE MOUNTING CHASIS

* VALVE NOT DEPICTED

Panel Control and Wrapper Control Cover Assembly

with Support Valve Cover; Full Assembly

Wiring Diagrams—Cold Water Start

16

HEATER INTERFACE WIRING FOR CWS OR CWR

CWS/CWR
C

ONTROL OR
MULTIPLE BOILER
INTERFACE

C

WS/CWR

C

ONTROL OR

M

ULTIPLE BOILER

INTERFACE

CWS/CWR
CONTROL OR
MULTIPLE BOILER
INTERFACE

17

COLD WATER START—

Installing the Three-way Valve

MULTIPLE HEATER

(Maximum 4 heaters)

Materials Included

1 Cold Start Control Box
1 Multi-Boiler Interlock Box
1 Water Sensor & Well
1 Three-way Diverting Valve assembly with Actuator

NOTE: Flanges, bolts and gaskets for flanged
valves supplied by others.

Installation

Mounting the Control Boxes

Cold Start Control and Multi-Boiler Interlock should be
mounted in such a manner as to allow for easy access
for wiring of the boiler interlock connections.

Installing the Temperature Sensor

Temperature sensor to be installed in a drywell with
thermal paste at the location indicated in the diagram
on page 21 to ensure proper operation of the control
system. Installer must ensure the drywell extends at
least 2 inches into the water flow path. Sensor wiring
must be run in separate conduit from line voltage and
should be a minimum of 18 AWG shielded cable. Refer
to diagram on page 22 for wiring information.

Install three-way diverting valve into common boiler
piping manifold as shown in the diagram on page 18.

oiler common outlets to be connected at port AB.

B
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). It is recommended that three-way valve be
installed as near the main system piping as is feasible.
Route control wiring in separate conduit to the Cold
Water Start control box and wire as shown in the dia­gram on page 19.

Connecting Power to the Controller

Installer to provide a dedicated 120V circuit with local
disconnect to the Cold Water Start Control. Refer to
wiring Fig. 9 on page 8 for detailed instruction.

Connecting Cold Water Start to
Multi-Heater Interlock Box

Installer to provide four 18AWG stranded wires
between pins 7-10 on the Cold Start Control and 7-10
on the Multi-Boiler Interlock as shown in the diagram
on page 22. Do not use solid core wire when wiring
any portion of the Cold Start Multi-Boiler system.

Connecting Heater to Cold Water
Start Multi-Heater Interlock

Installer to provide five 18AWG stranded wires
between each boiler and Multi-Boiler Interlock box.
Wiring to be run in separate conduit from line voltage
to ensure proper operation. Refer to the diagram on
page 22 for connection points depending on Raypak
product being used.

Total Load

(MBTU)

600-1000 2” NPT 2 57 70 3.5 ft 22 14.4 012228

1001-1800 2.5” NPT 2.5 74 100 4.2 ft 30.2 16.8 012229

1801-2600 2.5” NPT 3 100 150 5.2 ft 29.1 20.1 012230

2601-4000 4” FLG* 4 152 220 4.8 ft 30.5 22.9 012231

4001-6000 4” FLG* 4 254 330 3.9 ft 30.5 20.3 012232

6001-8000 4” FLG* 6 327 440 4.2 ft 30.5 22.5 012233

Standard boiler pump options offered by Raypak may NOT be appropriate for these applications.

*CAUTION: Approved for closed loop systems only.

Valve

Size

Minimum
Pipe Size

Cv

Table B: Valve Sizing Chart

Flow
Rate

(gpm)

18

Valve

Pressure

Drop

∆T @

Max Size

∆T @

Min. Size

Order

No.

Actuator to Valve Orientation

LOCKING BOLT

WING NUT

PORT A B

Install the actuator so that the tail is pointing horizon­tally as shown in Fig. 26 or is pointing down. DO NOT

ount it so that the tail is pointing up as shown in Fig.

m

20. Doing so will allow water and debris to collect in
the cup where the wiring exits the actuator, potentially

causing damage.

Three-Way Valve Ball Orientation

The ball orientation must be verified prior to mounting
the flanged valve into the piping system. With the
flanged four-inch valve it is a fairly simple procedure.
Do not use the groove on the end of the drive linkage
to verify.

First, remove the actuator by removing the wing-nut
underneath the mount bracket near the tail. Second,
loosen the locking bolt on top of the actuator that
clamps to the drive linkage. See Fig. 23.

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 sys-

em in accordance with this manual.

t

Valve Installation

To properly install this valve port “AB” must be con­nected to the combined outlet of the heater(s); and
port “B” must be attached to the bypass between the
combined inlet and the combined outlet, as shown on
page 21. The valve body has the port designators cast
into the drive linkage housing. See Fig. 25.

Fig. 23: Removing the Actuator (Elodrive)

Once this has been done, remove the actuator by lift­ing straight off the drive linkage shaft.

Now the ball position must be verified. Using pliers,
grasp the base of the drive linkage. While looking into
port AB, rotate the drive linkage counterclockwise
about 45 degrees. See Fig. 24. You should see two
partial openings similar to Fig. 18.

If you do not see the two partial openings after 45
degrees of rotation, continue rotating until you do.
Once you see the two partial openings, STOP. Now
rotate the shaft in the reverse direction (clockwise)
until you can see straight through to valve from port AB
to port A.

Fig. 24: Rotating the Drive Linkage

Fig. 25: Valve Orientation

19

NOTE: SIDE A MUST
FACE AWAY FROM
VALVE BODY

DETENT MUST BE
SET TO POSITION 2

NOTE: SIDE A
MUST FACE AWAY
FROM 4” VALVE BODY

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

alve body). The valve body should be installed so that

v
the actuator input shaft is in the vertical or horizontal
position. The Actuator stem should never be hanging
downward.

The actuator, as shipped from the factory, is in the hor­izontal position when the valve is installed as shown in
Fig. 26. The actuator position can be changed to suit
job site conditions.

Under no circumstances should the actuator be posi­tioned such that the electrical connection is pointing
upwards (see Fig. 20) as this can allow for moisture or
debris to enter the actuator assembly and potentially
damage the actuator.

Before installing into the piping system, verify the
valve is positioned properly by referring to Fig. 26 and
the diagram on page 21.

Fig. 27: Elodrive actuator used on 4” valves

(Actuator shown in full system flow position.)

Connecting the Actuator

The 4-inch valve is shipped loose, and must be field
wired. Connect the actuator leads to the Cold Water
Start control panel, as indicated in the wiring diagram
on Page 16.

The actuator for the 4” valves rotates opposite to the
direction of the smaller actuators. On an Elodrive
actuator, Side A must be facing away from the valve.

Fig. 26: Valve Orientation (Elodrive Actuator)

Fig. 28: Rotational Setting for Elodrive Actuator

Used on 4” Valves

20

1.PLUMB SWING CHECK VALVE IN GRAVI TY-CLOSED POSITION.

2.PIPE ALL RELIEF VALVES TO DRAIN, OR AS LOCAL CODES REQUIRE.

3.LOCATE UNIONS TO FACILITATE SERVICING OF PLUMBING SIDE.

4.BUFFER TANKS MAY BE REQUIRED TO PROVIDE STABLE TEMPERAT URE

CONTROL ON SYSTEMS WITH VARIABLE FLOW OR LOW WATE R VOLUME.

CONSULT FACTORY FOR SELECTION CRITERIA.

5.MAXIMUM 4 TIMES THE PIPE DIAMETER OR 12”, WHICHEVER IS LESS.

6.SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES.

Typical Cold Water Start Multiple Heater Piping

21

CWS CONTROL

BOX ASSY

(SEE PAGE 16)

FOR HEATER INTERFACE WIRING

(SEE PAGE 17)

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

hipping damage and it must be reassembled on the

s
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.

• Cold water start maintains design flow rate at sys­tem design temperature but reduces boiler flow
rate during heavy bypass operation.

• Cold water run maintains constant design flow rate
in the boiler.

Installation

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.

Installation Codes

Installations must be in accordance with local, state,
provincial, and national codes, laws, regulations and
ordinances. In the absence of local codes, installa­tions must be in accordance with the latest editions of
the:

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, ANSI/NFPA 70

• For Canada only: CAN/CSA B149 Installation Code
and CSA C22.1 C.E.C. Part 1 and Part 2

Fig. 29: Cold Water Run Assembly

Purpose

The Cold Water Run system utilizes a variable-speed
pump to inject the proper amount of water from the
main system loop into the heater to maintain the opti­mum inlet temperature. This approach allows the full
capacity of the heater to be utilized to meet the system
load, while at the same time continuously maintaining
the optimum inlet water temperature to prevent con­densation.

Typical Cold Water Run
Applications

• Swimming pools.

• Any system with steady-state (or “consistent”)
return water temperature below 105°F.

Mounting the Control Box

NOTE: The heater should not be located in an area

where possible water leakage will result in damage
to the area adjacent to the heater or to the structure.
When such locations cannot be avoided, it is rec­ommended that a suitable drain pan, with adequate
drainage, be installed under the heater. The pan
must not restrict combustion air flow.

The control box should be mounted on the side of the
heater to which the system piping and pump assem­blies are to be attached as shown in Figs. 4–8 on
pages 7 & 8. 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 for #10 hardware and 3/4” conduit
access holes through the heater side panel for the
routing of wiring and the sensor.

CAUTION: Remote mounted controller must be
installed within 25 feet of wire length to the heater.

23

Injector & Heater Pump Comparison

Heater

Model

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 9.6 1630/4.7 54 40 1911-1⁄3hp

1532 120 22 12.4 1632/5.6 62 42 1911-1⁄3hp

1802 120 25 13 1632/5.6 68 45 1911-1⁄3hp

2002 132 26 19 1634/6.1 74 46 1935-3⁄4hp

Flow

Heater Pump Injector Pump

Temp.

Rise

Press.

Drop

Pump

Model/Imp.

Flow

Temp.

Rise

Pump

Model-hp

2072 132 27 19 1634/6.1 75 47 1935-3⁄4hp

2342 132 30 21.4 1634/6.1 80 50 1935-3⁄4hp

Table C: Injector and Heater Pump Specifications—Hi Delta

Heater

Model

503 58 15 2.4 1611 29 30 1911-1⁄4 hp

753 63 21 5.6 1611 44 30 1911-1⁄4 hp

1003 87 20 8.2 1630 58 30 1911-1⁄3 hp

1253 86 25 12.2 1630 73 30 1911-1⁄3 hp

1503 100 26 18.5 1632 87 30 1911-1⁄3 hp

1753 109 28 26 1634 102 30 1911-1⁄3 hp

2003 116 30 36.2 1636 116 30 1935-3⁄4 hp

Flow

Heater Pump Injector Pump

Temp.

Rise

Table D: Injector and Heater Pump Specifications—MVB

Press.

Drop

Pump

Model

Flow

Temp.

Rise

Pump

Model-hp

24

CIRCUIT

BREAKER

WHITE

GROUND

BLACK

GREEN

AB C

Heater

Heater Pump Injector Pump

Model

Flow

Temp.

ise

R

Press.

rop

D

Pump

odel/Imp.

M

Flow

Temp.

ise

R

Pump
odel-hp

M

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 1632/5.65 60 50 1911-1⁄3 hp

2100 172 20 11.0 1641/6.9 130 26 1935-3⁄4hp

2500 200 21 15.8 1641/6.9 130 32 1935-3⁄4hp

3001 200 25 16.7 1641/6.9 130 38 1935-3⁄4hp

3500 200 29 17.5 1641/6.9 130 44 1935-3⁄4hp

4001 200 33 18.7 1641/6.9 130 50 1935-3⁄4hp

Table E: Injector and Heater Pump Specifications—Raytherm

Check the Power Source

WARNING: Using a multi-meter, check the follow-

ing voltages at the circuit breaker panel prior to con­necting any equipment. Make sure proper polarity is
followed and house ground is proven.

HOT (L1)

HOT (L2)

Fig. 31: Multi-meter

Injector Pump Wiring

The 3-phase cold water run pump is shipped loose
and must be field wired.

Fig. 30: Wiring Connections

Check the power source:

AC = 104 VAC Minimum, 126 VAC MAX
AB = 208 VAC Minimum, 252 VAC MAX
BC = 104 VAC Minimum, 126 VAC MAX

Before Starting

1. Turn off power to the unit at the circuit breaker.

2. Turn off gas supply.

3. Shut off the water supply to the heater and, if nec­essary, drain water from the system.

25

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)

Red Red (8) and White (2)

White Pink (7) and Blue (1)

ellow (4) and Black (5) and

———————

Y
Violet (6)

Green Ground Lug

Table F: Cold Water Run Control Panel and Injector

Pump Wiring

Cover

Fig. 32: Pump Wiring Decal and Junction Box

5. Remove the pump junction box cover shown in
Fig. 32 and locate the 9 wires inside.

6. Wire in accordance with the low voltage (230 VAC)
decal located next to the pump junction box (do
not connect high voltage 460 volt power to the
control box).

7. In the absence of the pump mounted decal, use
Table F to complete the wiring between the cold
water run control box and the 3-phase injector
pump. Use wire nuts (field supplied) to complete
these connections and ensure that all connections
are tight.

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. Turn the electrical supply on to the heater and to
the cold water run system.

11. Turn heater on to receive a “call-for-heat” and ver­ify the injector pump is rotating in the proper
direction (clockwise). The pump volute has an
arrow cast into the housing indicating the proper
rotational direction. See Fig. 34.

Directional Arrow

26

Fig. 34: Directional Arrow

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

roper direction before proceeding.

p

14. Secure from installation.

Injection Pump Cover
Installation (Required for
Outdoor Installation Only)

Before Starting

1. Turn off power to the unit at the circuit breaker.

2. Turn off gas supply.

3. Shut off the water supply to the heater and, if nec-

essary, drain water from the system.

4. Allow heater to cool down before attempting work.

In order to install the pump cover, you will need to
rotate the pump body so that the electrical box is point­ing downward, as outlined in the following steps:

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.

1. Loosen and remove the eight (8) 9/16” bolts hold­ing the pump body in place. See Fig. 35.

Fig. 36: Remove the pump body

Fig. 35: Remove the eight bolts holding the pump body

in place

Fig. 37: Be sure not to damage the seal when removing

or replacing the pump body

27

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. 40: Pump cover - angle view

Fig. 39: Place the cover on the pump

28

Typical Cold Water Run Piping - Heating Applications

ALTE RNATE SENSOR POSITION

12” MAX, OR MIN FEASIBLE

NOTES:

1.LOCATE UNIONS TO FACILITATE SERVICING OF PLUMBING SIDE.

2.PLUMB SWING CHECK VA LVE IN GRAVITY-CLOSED POSITION.

3.PIPE ALL RELIEF VALVES TO DRAIN, OR AS LOCAL CODES REQUIRE.

4.SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES.

SEE NOTE 4

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.USE REDUCING TEES WHERE INDICATED.

5.SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES.

Typical Cold Water Run Piping - Pool Applications

29

Operation

Run full system flow for two minutes.

•

• Initiate PID pump control to achieve target inlet
emperature by slowing injector pump.

t

• Boiler ∆T will not increase during bypass operation.

• If target temperature is not achieved after 7 min-

utes from “call for heat”, the system will shut down.

Fig. 41: Control Board

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. Once the NO contacts of the DPST close, the
heater 24 VAC is sent back to the heater to com­plete the circuit (pin 3 of terminal block 3) and the
interlock circuit (pin 1 & 2 of terminal block 3)
allowing the heater to fire.

11. Pin SC of the cold run circuit board sends 10VDC
to Pin 1 (Forward) on Hitachi Inverter.

12. PCS terminal on Inverter outputs 12VDC signal to
the common terminal of the reset switch located
on the bottom of the cold run control panel.

13. The 12VDC signal crosses over the reset switch
and goes to Pin FS and to pin S1 on cold run cir­cuit board.

14. Pin FR on the TVC board outputs 10VDC to pin O
of the Inverter to drive injector pump at full speed
for two-minutes waiting for the heater to reach full
fire.

15. 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.

16. The output signal continues to vary depending on
the heater inlet temperature.

Cold Run Sequence of
Operation

1. Supply separate 220VAC, 1 phase, 60 Hz power
for the Hitachi Inverter (blue-colored inverter), or
120VAC or 220VAC, 1 phase, 60 Hz power for the
AC Tech Inverter (white-colored inverter).

2. Call for heat occurs at heater.

3. The heater outputs 24VAC to terminal 4 of termi­nal block 3 located in Cold Run controller.

4. Terminal 4 of TB 3 sends 24VAC to the coil of the
SPST relay located in the cold run control panel.

5. The SPST relay coil is energized and closes the
contacts allowing 24VAC from the Cold Run con­trol transformer to be sent to the CFH terminal of
the Cold Run circuit board.
a) A two second delay occurs from the CFH sig-

nal waiting to send power from terminal MC of
the cold run circuit board.

6. 24 VAC is sent from terminal 2 of terminal block 3
to the NO contacts of the DPST relay located in
the cold run control panel.

The heater will lockout and shut down if the set point
on the inlet temperature is not achieved within 7 min­utes from a call for heat.

The DIP switches on the Hitachi Inverter must be set
as indicated on Fig. 42 below.

Fig. 42: DIP Switch Settings (Hitachi)

30

Step9

Step8

Step10

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Is there a Call For

Heat at the heate

r

?

Is the inverter in the

cold run controller powered?

Replace inverter or

correct wiring

Does the cold run inverter output 12VDC from PCS to the

reset switch

,

Pin S1 andpin FS of the cold run circuit board?

Replace circuit board

Are the terminals 1-2 of TB3

connected to N.O. contacts of

DPDT relay?

Does cold run terminal AL0

relay coil receive 24VAC

from MC on circuit board?

Are terminals 1-4 of TB3 correctly

connected back to the heater?

Call our Technical Service Department

1-805-278-5300

NO

Verify 120VAC* or 230VAC*
from separate circuit breaker

YES

Does TB1 of cold run

controller have 120VAC*

or 230VAC*?

Heater is in standby mode

C

orrect Wiring

Y

ES

NO

NO

YES

Y

ES

N

O

NO

NO

YES

YES

NO

The unit is okay

YES

NO

YES

Correct wiring

Is the injector pump

modulating after 2-1/2

minutes?

NO

Correct wiring

YES

Is the heater tripping the high

limit?

YES

NO

Verify pump is rotating in proper

direction

Pump must decrease

RPM’s on decreasing 0-

10VDC signal

YES

Correct 3 phase pump wiring

NO

Is 24VAC present at CFH

connection on cold run circuit

board?

Check and verify 24VAC between pin 4 and 5

of TB3 in cold run controller and correct.

Is 0-10VDC present at

connection FR of cold run circuit

board and pin 0 of the inverter?

NO

Replace cold run circuit board

or correct wiring.

YES

Does cold run circuit board lock-out on

“Sensor out of Range”?

NO

YES

Is sensor resistance correct?

YES

NO

Replace sensor

Is the system

water temperature

º

NO

YES

*NOTE: See wiring diagrams

f

or proper supply voltage based

o

n inverter used on heater.

Cold Water Run Troubleshooting Guide

31

Wiring Diagram—Cold Water Run (Hitachi Inverter)

17

32

Wiring Diagram—Cold Water Run (AC Tech Inverter)

(SEE PAGE 17)

33

REPLACEMENT PARTS

To order replacement parts, consult the Raypak Illustrated
Parts Lists 9300.82 for Cold Water Start and 9300.83 for
Cold Water Run.

NOTE: To receive the correct part, it is important that
you state the model number and serial number when
ordering.

Any part returned for replacement under standard
company warranties must be properly tagged with
RAYPAK return parts tag, completely filled in with the
heater serial number, model number, etc., and shipped
to the Company freight prepaid. If determined defective
by the Company and within warranty, the part will
be returned in kind or equal substitution, freight collect.
Credit will not be issued.

RAYPAK, INC.

2151 Eastman Avenue

Oxnard, CA 93030

34

35

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] Fax [phone]

Litho in U.S.A.

36