Wells 2072 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: 1000.57H Effective: 07-22-10 Replaces: 09-01-09 P/N 241275 Rev. 9

Rev. 9 reflects the following: Changes to: “Connecting the Valve Assembly” on page 6, Fig. 10 on page 9, Figs 11-13 on page 10, Cold Water Start

Troubleshooting Guide on page 14. Wiring Diagrams on pages 16 & 17, Cold Water Run piping on page 26, Piping Diagram for Heating Applications on page 29, CWR parts list on page 39 Additions: Note and Fig. 1 on page 6, Caution on page 7, “Mounting Brackets” on page 11 through “Actuator” on page 13, “Actuator to Valve Orientation” on page 19 through “Connecting the Actuator” on page 20, Piping Diagram for Pool Applications on page 29, Wiring Diagram on page 33 Deletions: None

CONTENTS

WARNINGS 4 GENERAL SAFETY 5

Time/Temperature Relationships in Scalds 5

COLD WATER START 6

Installation 6 Check Power Source 6 Mounting the Control Box 6 Installing the Temperature Sensor 7 Connecting the Valve Assembly 7 Connecting Power to the Controller 8 Connecting Boiler to Cold Water Start 8 Operation 8 Cold Start Sequence of Operation 9 Troubleshooting 10 Mounting the Actuator to the Valve 11 Mounting Brackets 11 Locating the Rotation Stop 11 Drive Linkage 12 Verifying Ball Position 12 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

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 Control Box 23 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

ILLUSTRATED PARTS LISTS 34

Cold Water Start/Multiple Boiler 34 Cold Water Run 38

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).

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

COLD WATER START

CIRCUIT

REAKER

HITE

GROUND

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

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.

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

Reset Switch*

9-9/16”

5/16”

1-3/4”

22”

-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).

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

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.

IP SWITCH SETTINGS

OR 3-WAY ACTUATOR

VDC

0-10

FIXED

2-10

AUTO

6-9

WITCH MUST BE IN THIS POSITION

TURN CLOCKWISE TO FURTHEST STOP

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

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.

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.

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.

• 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

+ 28 hidden pages