Raypak Mvb 5042004 Users Manual 6000.59 New RP2100

5042004 to the manual eee29350-205c-4070-96be-fadb19e65f8a

2015-02-02

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WARNINGS
BEFORE INSTALLATION

INSTALLATION & OPERATING

INSTRUCTIONS

CATALOG NO. 3400.54E Effective: 03-25-10 Replaces: 03-19-09 P/N 241317 Rev. 6

This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future

reference.

Models 504–2004

Types H, WH, P & WHP

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.

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.

Installation and service must be performed by a qualified installer, service agency or

the gas supplier.

Rev. 5 reflects the following:

Changes to: Air Filter instructions on page 11, minor text changes on pages 13 and 14, Figs. 10 and 11 on page 15,. Fig 12

and Table G on page 16, Fig 13 on page 17, minor text changes on page 20, Fig. 21 on page 22, Figs. 22-28 on pages 25-

30, Table N on page 29, Fig. 35 on page 32, Mode 8 description on page 33, minor text changes on pages 42, 43 and 46,

Troubleshooting chart on page 48.

Additions: Fig. 2 on page 6,Low-lead requirement on page 5, Fig. 8 on page 11, note on page 12, Caution on page 20, Fig.

22 on page 22, Fig. 36 on page 33, air filter instructions on pages 50 and 51.

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 12

Hydronic Heating 14

Gas Supply 19

Electrical Power Connections 20

Field Wiring Connection 22

Venting 22

Venting Installation Tips 24

Venting Configurations 24

Engineered Vent Systems 27

Outdoor Installation 29

Controls 30

Heater Sequence of Operation 37

WIRING DIAGRAMS 40

START-UP 42

Pre Start-up 42

Start-Up 43

OPERATION 46

Lighting Instructions 46

To Turn Off Gas To Appliance 47

UDB Fault History 47

TROUBLESHOOTING 48

MAINTENANCE 49

Suggested Minimum

Maintenance Schedule 49

Preventative Maintenance Schedule 49

Filter Maintenance 50

Filter Replacement 51

APPENDIX 51

Inside Air Contamination 51

IMPORTANT INSTRUCTIONS FOR

THE COMMONWEALTH OF

MASSACHUSETTS 52

WARRANTY 53

START-UP CHECKLIST 55

CONTENTS

DANGER: Indicates the presence of immediate hazards which will cause severe

personal injury, death or substantial property damage if ignored.

WARNING: Indicates the presence of hazards or unsafe practices which could cause

severe personal injury, death or substantial property damage if ignored.

CAUTION: Indicates the presence of hazards or unsafe practices which could cause

minor personal injury or product or property damage if ignored.

NOTE: Indicates special instructions on installation, operation, or maintenance which

are important but not related to personal injury hazards.

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.

• Heater should never be covered or have any

blockage to the flow of fresh air to the heater.

WARNING - CALIFORNIA PROPOSITION

65: This product contains chemicals known to the

State of California to cause cancer, birth defects or

other reproductive harm.

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.

WARNINGS

Pay Attention to These Terms

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.

BEFORE INSTALLATION

Raypak strongly recommends that this manual be re-

viewed 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 oper-

ated. (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 visu-

ally 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 indi-

cated on the Bill of Lading.

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 war-

ranty conditions, you must also specify the date of

installation.

Purchased parts are subject to replacement only

under the manufacturer’s warranty. Debits for defec-

tive replacement parts will not be accepted. Parts will

be replaced in kind only per Raypak’s standard war-

ranties.

Model Identification

The model identification number and heater serial

number are found on the heater rating plate located on

the upper rear jacket panel of the heater. The model

number will have the form H7-2004 or similar depend-

ing on the heater size and configuration. The letter(s)

in the first group of characters identifies the application

(H = Hydronic Heating, P = Pool Heating, WH =

Domestic Hot Water (DHW), WHP = Water Heater for

Pool Heating). The number which follows identifies the

firing mode (7 = electronic modulation, 1 = On/Off).

The second group of characters identifies the size of

the heater (three or four numbers representing the

approximate MBTUH input), and, where applicable, a

letter, indicating the manufacturing series.

Ratings and Certifications

Standards:

• ANSI Z21.56 · CSA 4.7 - latest edition, Gas-Fired

Pool Heaters

• 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 Wa-

ter Heaters

• SCAQMD Rule 1146.2

• Low-lead content (<.25%) CSA-verified

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

(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 4,500 ft elevation

without de-rating. Consult your local representative or

the factory for installations at altitudes over 4,500 ft

above sea level. No hardware changes are required to

the heaters for installations up to 10,000 ft (adjust-

ments may be required).

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 and any Raypak warranty on the vessel.

Altering the ASME or CSA ratings of the vessel also

violates national, state, and local approval codes.

General Information

Table A: Basic Data

HIGH VOLTAGE

ELECTRICAL CONNECTIONS

Component Locations

Panels omitted for clarity

Fig. 1: Component Locations – Side

Top panel, blower and gas train omitted for clarity

Fig. 4: Component Locations – Top

Fig. 3: Component Locations – Rear

Model

No.

MBTUH

Input* Water

Conn.

(NPT)

Gas

Conn.

(NPT)

Vent

Size

(in.)

Max.* Min.* N P Flue Intake

504 500 350 2 1 1 8 6

754 750 525 2 1 1 10 6

1104 1100 770 2-1/2 1-1/4 1 10 6

1504 1500 1050 2-1/2 1-1/4 1 12 8

2004 1999 1400 2-1/2 2 1 14 8

*H7 units only.

Panels omitted for clarity

Fig. 2: Component Locations – Front

GENERAL SAFETY

To meet commercial hot water use needs, the high

limit safety control on this water heater will shut off the

main gas valve before the outlet temperature reaches

210°F. However, water temperatures over 125°F can

cause instant severe burns or death from scalds.

When supplying general purpose hot water, the rec-

ommended 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 applica-

tions 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 con-

sidered when setting the water temperature on the

thermostat. The most energy-efficient operation will

result when the temperature setting is the lowest that

satisfies the needs of the application.

Water temperature over 125°F can cause instant

severe burns or death from scalds. Children, disabled

and elderly are at highest risk of being scalded.

• Feel water before bathing or showering.

• Temperature limiting valves are available.

Maximum water temperatures occur just after the

heater’s burner has shut off. To determine the water

temperature being delivered, turn on a hot water

faucet and place a thermometer in the hot water

stream and read the thermometer.

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.

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 set-

ting temperature at water heater.

Feel water before bathing or show-

ering.

Temperature limiting valves are

available, see manual.

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.

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

Table B: Time to Produce Serious Burn

Equipment Base

The heater should be mounted on a level, structurally

sound surface. The heater is approved for installation

on a combustible surface but must NEVER be

installed on carpeting. Gas-fueled equipment installed

in enclosed parking garages must be located at least

18 in. above the floor.

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.).

If the heater needs to be secured to the ground, use

the brackets that were used to bolt the heater to the

shipping pallet.

Clearances

Indoor Installations

When installed according to the listed minimum clear-

ances 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,

at least 24 in. on the rear and 10 in. above the top of

the heater is required. This will allow the heater to be

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”

Table C: Clearances – Indoor Installations

INSTALLATION

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)

The temperature of the water in the heater can be reg-

ulated by using the Raypak Modulating Temperature

Control. To comply with safety regulations, the control

is set at 120°F when shipped from the factory (Mode 3

default setting for Tank Target).

To adjust the water temperature, follow the instruction

for the operation of the control starting on page 30 of

this manual. The control is shown below for identifica-

tion purposes only. (See Fig. 5.)

CAUTION: Hotter water increases the risk of

scalding! There is a hot water scald potential if the

thermostat is set too high.

Fig. 5: Modulating Temperature Control

*DO NOT install on carpeting.

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.

Fig. 6: Minimum Clearances from Combustible

Surfaces – Indoor and Outdoor Installations

codes and the requirments of the gas supplier. Three

sides must be open in the area under the overhang.

Roof water drainage must be diverted away from

heaters installed under overhangs.

The combustion air intake terminal MUST be used for

outdoor installations. The elbow is shipped loose to be

installed on the rear of the heater at the job site.

Table D: Clearances – Outdoor Installations

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

These heaters are design-certified for outdoor installa-

tion. Heaters must not be installed under an overhang

unless they are in accordance with local installation

Combustion and Ventilation Air

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 sup-

plied 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 com-

ply with the requirements of the NFGC (U.S.) and

B149 (Canada), and all local codes.

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.

CAUTION: Combustion air must not be

contaminated by corrosive chemical fumes which

can damage the heater and void the warranty. (See

the Appendix.)

NOTE: It is recommended that the intake vent be

insulated to minimize sweating.

Venting not shown for clarity. Heater must be vented per instruc-

tions in this manual

Heater

Side

Min. Clearance

from Combustible

Surfaces

Minimum

Service

Clearance

Rear 12” 24”

Front Open 24”

Right Side 1” 1”

Left Side 1” 1”

Top Unobstructed 10”

Vent

Termination 12” 12”

U.S. Installations1Canadian Installations2

AClearance above grade, veranda, porch,

deck, or balcony 1ft (30 cm) 1 ft (30 cm)

BClearance to window or door that may be

opened

4ft (1.2m) below or to side

of opening; 1 foot (30 cm)

above opening

3ft (91 cm)

C Clearance to permanently closed window **

Vertical clearance to ventilated soffit located

above the terminal within a horizontal dis-

tance of 2 ft (61cm) from the centerline of the

terminal

5ft (1.5m) *

EClearance to unventilated soffit **

FClearance to outside corner **

GClearance to inside corner 6ft (1.83m) *

HClearance to each side of center line ex-

tended above meter/regulator assembly *

3ft (91 cm) within a height

15ft above the me-

ter/regulator assembly

IClearance to service regulator vent outlet *6ft (1.83m)

Clearance to non-mechanical air supply inlet

to building or the combustion air inlet to any

other appliance

4ft (1.2m) below or to side

of opening; 1 ft (30 cm)

above opening

3ft (91 cm)

KClearance to mechanical air supply inlet 3ft (91 cm) above if within

10 ft (3m) horizontally 6ft (1.83m)

LClearance above paved sidewalk or paved

driveway located on public property 7ft (2.13m) 7ft (2.13m) t

MClearance under veranda, porch, deck or

balcony *12 in. (30 cm) TT

1Inaccordance with the current ANSIZ223.1/NFPA54National Fuel Gas Code

2Inaccordance with the current CAN/CGA-B149 Installation Codes

tVent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves

both dwellings

TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimumof two sides beneath the floor and top of terminal 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

Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table E: Vent/Air Inlet Termination Clearances

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.

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. 27 (horizontal) or Fig. 28 (vertical) of this

manual (pages 28 and 29, respectively).

2. Provide adequate ventilation of the space occu-

pied by the heater(s) by an opening(s) for

ventilation air at the highest practical point com-

municating with the outdoors. The total

cross-sectional area shall be at least 1 in.2of free

area per 20,000 BTUH (111 mm2per kW) of total

input rating of all equipment in the room when the

opening is communicating directly with the out-

doors or through vertical duct(s). The total

cross-sectional area shall be at least 1 in.2of free

area per 10,000 BTUH (222 mm2per kW) of total

input rating of all equipment in the room when the

opening is communicating with the outdoors

through horizontal duct(s).

3. In cold climates, and to mitigate potential freeze-

up, Raypak highly recommends the installation of

a motorized sealed damper to prevent the circula-

tion of cold air through the heater during the

non-operating hours.

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 rear of the

heater, using three or four sheet metal screws (not

supplied) equally positioned around the circumference

of the duct. The screen assembly should be removed

before attaching any air duct to the heater. The screws

and duct connection point must be sealed with RTV

(not supplied). TruSeal is generally used when dam-

aging contaminants are present in the mechanical

room.

All ducting must be self-supported.

Conventional Combustion Air

Supply

U.S. Installations

All Air from Inside the Building

The confined space shall be provided with TWO per-

manent openings communicating directly with an

additional room(s) of sufficient volume so that the com-

bined 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 determina-

tion. Each opening shall have a minimum free area of

1 in.2per 1,000 BTUH (2,225 mm2per kW) of the total

input rating of all gas utilization equipment in the con-

fined 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 mini-

mum dimension of air openings shall be not less than

3 in. (76 mm) in any direction.

All Air from Outdoors

The confined space shall communicate with the out-

doors 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

are used, they shall be of the same cross-sectional

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 com-

mencing within 12 in. (305 mm) of the bottom of

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.

Fig. 8: Air Filter Box

the enclosure, shall be provided. The openings

shall communicate directly, or by ducts, with the

outdoors or spaces (crawl or attic) that freely com-

municate 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.2

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 rat-

ing 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 out-

doors 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:

a. 1 in.2per 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.

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.2

(65 cm2).

WARNING: Do not use the “one permanent

opening” method if the equipment room is under

negative pressure conditions.

CAUTION: All combustion air must be drawn from

outside of the building; the mechanical equipment

room must communicate directly with the outdoors.

Canadian Installations

2. For heaters using a barometric damper in the vent

system there shall be a permanent air supply

opening(s) having a cross section area of not less

than 1 in.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 require-

ment shall be in addition to the air opening for

ventilation air required in 1. (above).

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 sup-

ply 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 inter-

fere 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.

4. Refer to the B149 Installation Code for additional

information.

Water Piping

General

The heater should be located so that any water leaks

will not cause damage to the adjacent area or struc-

tures.

WARNING: Care must be taken to ensure that the

equipment room is not under negative pressure

conditions.

NOTE: In lieu of installing the System Temp Sensor

in the system return loop, an alternate system using

a buffer tank (see Fig. 31) can be used for better sys-

tem temperature control.

Relief Valve Piping

Temperature & Pressure Gauge

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 re-

quire hydrostatic testing prior to being placed in

operation. The heat exchanger has already been fac-

tory-tested and is rated for 160 psi operating pressure.

However, Raypak does recommend hydrostatic test-

ing 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 glycol-

based anti-freeze. Raypak recommends conducting

the hydrostatic test before connecting gas piping or

electrical supply.

Leaks must be repaired at once to prevent damage to

the heater. NEVER use petroleum-based stop-leak

compounds.

To perform hydrostatic test:

1. Connect fill water supply. With bleed valve open,

fill heater with water. When water flows from bleed

valve, shut off water. Close bleed valve. 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 if found.

Cold Water Operation

This heater is equipped with a proprietary condensate

evaporation system which will evaporate any conden-

sate 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 manual bypass (see

Fig. 16) or an approved low-temperature operation

system (Figs. 9 and 10) to prevent problems with con-

densation. This piping is similar to a

primary/secondary boiler installation, with a bypass

acting as the secondary boiler piping. Raypak strong-

ly recommends that thermometer(s) be placed into the

heater piping next to the in/out header to facilitate tem-

perature adjustment. 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 con-

densate evaporation system.

Failure to reach or exceed 120°F (49°C) within 7 min-

utes 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 inlet to increase the heater inlet temperature

above 120°F (49°C). This precautionary measure

should prevent the products of combustion from con-

densing beyond the ability of the condensate

management system employed in this heater in most

installations. Warranty claims will be denied for

damage or failures caused by condensation.

Cold water operation issues are applicable to both

cold water start and cold water run applications. Cold

water operation for 7 minutes or less on initial daily

start-up is acceptable. Where cold water starts will last

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.

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 start-

up.

CAUTION: This heater requires forced water

circulation when the burner is operating. See Table F

and Table G for minimum and maximum flow rates

and water pump selection. The pump must be

interlocked with the heater to prevent heater

operation without water circulation.

NOTE: Minimum pipe size for in/out connections is

2 in. NPT for 504 and 754 models and 2-1⁄2in NPT for

1104–2004 models. Verify proper flow rates and ∆T

as instructed in this manual.

longer than 7 minutes or where cold water operation is

continuous, provisions must be made to mix higher

temperature outlet water with the colder inlet water

and thereby raise the inlet temperature to at least

120°F (49°C) within the 7-minute time limit.

Cold Water Starts

Cold water starts, where the inlet water temperature

remains below 120°F (49°C) for more than 7 minutes,

must have cold water start protection. Known pro-

tection 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 out-

let temperature may continue to climb and trip the high

limit, thereby shutting down the heater. Thus an auto-

matic valve system, such as a three-way proportional

valve or a modulating two-way valve to control the

bypass, should be utilized.

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. If the system water is kept in

a narrow temperature range of no more than 10°F

(5°C), a permanent manual bypass can be employed

and manually adjusted to achieve an inlet temperature

of 120°F (49°C) or higher as adjusted at the minimum

temperature in this narrow temperature range (i.e.

Range 75°F to 85°F – adjust bypass with temperature

at 75°F (24°C)) so that when temperature is 85°F

(29°C), minimum inlet temperature would be 130°F

(54°C). An injector pump arrangement may also be uti-

lized 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 to changes in the system water

coming back to the heater take-off.

Hydronic Heating

Pump Selection

In order to ensure proper performance of your heater

system, you must install a correctly-sized pump. Ray-

pak requires designing for a ∆T within the range of

10°F to 40°F (5°C to 20°C). See Table F for accept-

able 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 in-

stalled 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.

Fig. 9: Cold Water Start

Fig. 10: Cold Water Run

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Table F: Heater Rates of Flow and Pressure Drops

Note: Basis for minimum flow is ∆T. Basis for maximum flow is gpm.

Piping

All high points should be vented. A heater installed

above radiation level must be provided with a low wa-

ter 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

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

heating coils located in air handling units where they

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 recommend-

ed 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. 11.

Fig. 11: Air-Separation/Expansion Tank

THERMOSTATOR

SYSTEM SENSOR

Fig. 12: Single Heater - Low-Temperature (Heat Pump)

Application with Primary/Secondary Piping

THERMOSTATOR

SYSTEM SENSOR

Fig. 13: Dual Heaters (Reverse/Return)

with Primary/Secondary Piping

Model

No.

Input Output 20° ∆T 30° ∆T 40° ∆T Min. Flow Max. Flow

MBTUH gpm ∆P gpm ∆P gpm ∆P gpm ∆P ∆T gpm ∆P ∆T

504 500 420 42 2.7 28 1.4 25 1.1 34 100 11.3 8

754 750 630 63 6.0 42 2.9 32 1.7 32 1.7 40 100 13.8 13

1104 1100 924 92 13.3 62 6.7 46 4.1 46 4.1 40 113 18.6 16

1504 1500 1260 84 13.3 63 8.0 63 8.0 40 113 22.2 22

2004 1999 1679 112 26.9 84 16.0 84 16.0 40 113 27.2 30

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Potable Water and Space Heating

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.

Pool Heating

When a boiler or water heater is used in a pool heat-

ing application, ensure that all the following installation

requirements are met.

SYSTEM

SUPPLY

SYSTEM

RETURN

Fig. 14: Single Domestic Hot Water Heater and Storage

Tank

CAUTION: When this heater is used for both

potable water and space heating, observe the

following to ensure proper operation.

∆T = Temperature rise, °F

∆P = Pressure drop through heat exchanger, ft

SHL = System head loss, ft (based on heater and tank placed no more than 5 ft apart and equivalent length of 50 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.

Table G: Domestic Water Heater Flow Rate Requirements

NOTE: If local codes require a vacuum relief valve,

acquire one locally and install per valve

manufacturer’s instructions.

Model

No.

MBTUH Soft (0-4 grains per gallon) Medium (5-15 grains per gallon) Hard* (16-25 grains per gallon)

Input Output ∆T gpm ∆P MTS SHL ∆T gpm ∆P MTS SHL ∆T gpm ∆P MTS SHL

504 500 420 17 50 3.6 2 5.9 13 65 5.5 2 9.3 9 95 10.4 2 18.1

754 750 630 25 50 4.0 2 6.3 20 65 6.4 2 10.2 13 100 13.8 2 22.2

1104 1045 888 30 60 6.4 2-1/2 7.6 20 92 13.2 2-1/2 15.9 16 113 18.7 2-1/2 22.6

1504 1425 1211 30 82 12.7 2-1/2 14.9 22 113 22.3 2-1/2 26.3 22 113 22.3 2-1/2 26.3

2004 1900 1615 30 110 26.1 2-1/2 29.8 29 113 27.4 2-1/2 31.3 29 113 27.4 2-1/2 31.3

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. See

Fig. 16 and instructions on page 17 for adjusting the

manual bypass.

Domestic Hot Water

When designing the water piping system for domestic

hot water applications, water hardness should be con-

sidered. Table G indicates the suggested flow rates for

soft, medium and hard water. Water hardness is ex-

pressed in grains per gallon.

The MVB must be equipped with a field-supplied ex-

ternal pump and bypass arrangement. This

arrangement blends outlet water with the inlet water to

increase the inlet water temperature to a minimum of

105°F (40°C) for Pool Heater (P and WHP) versions

and 120°F (49°C) for Hydronic Heating (H7) or

Domestic Hot Water (WH1) versions, thereby reducing

the likelihood of condensation forming on the heat

exchanger. The pump also serves to circulate water

through the heater from the main system piping.

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.

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

and WHP) versions and 120°F (49°C) for Hydronic

Heating (H7) or Domestic Hot Water (WH1) 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.

The use of a bypass is required for proper operation in

a pool heating application. Use the following instruc-

tions to set the manual bypass:

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.

1. Turn on pump.

2. Turn on heater and wait until heater goes to full

fire.

3. With the heater operating at 100% firing rate, set

Valve A (the bypass) to 1⁄2open 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 tem-

perature to 105°F (40°C) for Pool Heater (P and

WHP) versions and 120°F (49°C) for Hydronic

Heating (H7) or Domestic Hot Water (WH1) ver-

sions and Valve A is fully open, then slowly throttle

Valve B closed to increase the inlet water temper-

ature to the required temperature.

POOL

THERMOSTAT

FROM

FILTER

TO POOL

CHEMICAL

FEED

Fig. 15: Single Pool Heater Application

NOTE: Opening the valve will increase the

temperature and closing the valve will decrease the

temperature.

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Fig. 16: “H” Bypass Setting

Pool/Spa Water Chemistry

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 exchang-

er tubes, reducing heater efficiency and damaging the

heater. If the pH drops below 7.2, this will cause cor-

rosion of the heat exchanger and severely damage the

heater. Heat exchanger damage resulting from chem-

ical imbalance is not covered by the warranty.

For your health and the protection of your pool equip-

ment, it is essential that your water be chemically

balanced. The following levels must be used as a

guide for balanced water.

Occasional chemical shock dosing of the pool or spa

should not damage the heater providing the water is

balanced.

Automatic chemical dosing devices and salt chlorina-

tors are usually more efficient in heater water, unless

controlled, they can lead to excessive chlorine level

which can damage your heater.

NOTE: Chemical imbalance can cause severe

damage to your heater and associated equipment.

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 below-

freezing temperatures.

Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool and Spa

Types

Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)

pH 7.3-7.4 7.3-7.4 7.6-7.8

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: Water Chemistry

CAUTION: Corrosive water voids all warranties.

CAUTION: Combustion air must not be contami-

nated by corrosive chemical fumes which can

damage the heater and void the warranty.

NOTE: For automatic temperature adjustment, a

Cold Water Run (CWR) system can be used instead

of a manual bypass. See Fig. 10.

Further advice should be obtained from your pool or

spa builder, accredited pool shop, or chemical suppli-

er for the correct levels for your water.

Automatic Chlorinators and

Chemical Feeders

All chemicals must be introduced and completely dilut-

ed 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.

Gas Supply

Gas piping must have a sediment trap ahead of the

heater gas controls, and a manual shut-off valve lo-

cated outside the heater jacket. It is recommended

that a union be installed in the gas supply piping adja-

cent to the heater for servicing. The gas supply

pressure to the heater must not exceed 10.5 in. WC for

natural gas or 13.0 in. WC for propane gas. A pounds-

to-inches regulator must be installed to reduce the gas

supply pressure if it is higher than noted above. This

regulator should be placed a minimum distance of 10

times the pipe diameter upstream of the heater gas

controls. Refer to Table I for maximum equivalent pipe

lengths.

Gas Supply Connection

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.

DANGER: Make sure the gas on which the heater

will operate is the same type as specified on the

heater’s rating plate.

CAUTION: The heater must be disconnected from

the gas supply during any pressure testing of the gas

supply system at test pressures in excess of 1/2 psi

(3.45 kPa).

The heater must be isolated from the gas supply pip-

ing system by closing the upstream manual shut-off

valve during any pressure testing of the gas supply

piping system at test pressures equal to or less than

1/2 psi (3.45 kPa). Relieve test pressure in the gas

supply line prior to reconnecting the heater and its

manual shut-off valve to the gas supply line. FAILURE

TO FOLLOW THIS PROCEDURE MAY DAMAGE

THE GAS VALVE. Over-pressurized gas valves are

not covered by warranty. The heater and its gas con-

nections shall be leak-tested before placing the

appliance in operation. Use soapy water for leak test.

DO NOT use an open flame.

Gas Supply Pressure

A minimum of 4.0 in. WC and a maximum of 10.5 in.

WC upstream gas pressure is required under load and

no-load conditions for natural gas. A minimum of 4.0

in. WC and a maximum of 13.0 in. WC is required for

propane gas. The gas pressure regulator(s) supplied

on the heater is for low-pressure service. If upstream

pressure exceeds these values, an intermediate gas

pressure regulator, of the lockup type, must be

installed.

Fig. 17: Gas Supply Connection

CAUTION: Do not use Teflon tape on gas line pipe

thread. A pipe compound rated for use with natural

and propane gases is recommended. Apply

sparingly only on male pipe ends, leaving the two

end threads bare.

CAUTION: Support gas supply piping with

hangers, not by the heater or its accessories. Make

sure the gas piping is protected from physical

damage and freezing, where required.

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.

• National Electrical Code and any other national,

state, provincial or local codes or regulations hav-

ing jurisdiction.

• Safety wiring must be NEC Class 1.

• Heater must be electrically grounded as required

by the NEC.

• In Canada, CSA C22. 1 C.E.C. Part 1.

The MVB 504-1504 heaters are wired for 120 VAC, 12

amps while the MVB 2004 heaters are wired for 120

VAC, 18 amps. Consult the wiring diagram shipped

with the heater. Before starting the heater, check to

ensure proper voltage to the heater and pump.

Boiler mounted pumps (up to 3⁄4hp) get their power

supply directly from the boiler power supply (connec-

tions in rear wiring box). Install a circuit breaker sized

sufficiently for both the heater and the pump. Pumps

larger than 3⁄4hp must use a separate power supply

and run the power through the optional pump contac-

tor which is located in the rear wiring box. Use

appropriately-sized wire as defined by NEC, CSA

and/or local codes. All primary wiring should be 125%

of minimum rating.

If any of the original wire as supplied with the heater

must be replaced, it must be replaced with 105°C wire

or its equivalent.

All high voltage wiring connections to the MVB heater

are made inside the rear wiring box as shown in Fig.

18. Pump power should be taken from terminals 2

(Com), 3 (GND) and 6 (Hot) – 3⁄4hp and smaller ONLY.

Power to the MVB heater should be connected to ter-

minals 1, 2, and 3 as noted in Fig. 18. All low voltage

wiring, including sensors, interlocks, enable/disable,

and various options are wired into terminals 1–20 on

the front wiring panel as noted in Fig. 18.

When connecting additional gas utilization equipment

to the gas piping system, the existing piping must be

checked to determine if it has adequate capacity for

the combined load.

The gas valve pressure regulator on the heater is

nominally preset as noted in Table J.

During normal operation, carbon dioxide should be 8.5

to 9.0% at full fire for natural gas and between 9.5 and

10.0% for propane gas. Carbon monoxide should be

‹100ppm.

Electrical Power Connections

Installations must follow these codes:

Natural Gas – 1,000 BTU/ft3, 0.60 specific gravity at 0.5 in. WC pressure drop

Propane Gas – 2,500 BTU/ft3, 1.53 specific gravity at 0.6 in. WC pressure drop

Table I: Maximum Equivalent Pipe Length

NOTE: Manifold pressures should be ±0.2 in. WC.

Table J: Manifold Gas Pressure Settings

Model

No.

1 in. NPT 1-1/4 in. NPT 1-1/2 in. NPT 2 in. NPT 2-1/2 in. NPT

N P N P N P N P N P

504 153565150 150 360

754 5 15 35 75 70 175 250

1104 15 35 35 75 100 250 225

1504 10 20 20 45 60 150 150 275

2004 35 85 85 200

Model

No.

Manifold Gas Pressure

(High Fire Values)

Natural Gas Propane Gas

504 -0.1 -0.1

754 -0.4 -0.1

1104 -1.0 -0.2

1504 -2.4 -0.6

2004 -1.0 -0.5

CAUTION: For proper operation, no more than a

30% drop in gas supply pressure from no-load to full-

load conditions is acceptable. Under no

circumstances should the pressure be outside the

listed operational range.

Check the power source:

AC = 108 VAC Minimum, 132 VAC MAX

AB = 108 VAC Minimum, 132 VAC MAX

BC = <1 VAC Maximum

Making the Electrical Connections

Refer to Fig. 18-21.

1. Verify that circuit breaker is properly sized by

referring to heater rating plate. A dedicated circuit

breaker should be provided.

2. NOTE: Current draw noted on rating plate does

not include pump current.

3. Turn off all power to the heater. Verify that power

has been turned off by testing with a multi-meter

prior to working with any electrical connections or

components.

4. Observe proper wire colors while making electri-

cal connections. Many electronic controls are

polarity sensitive. Components damaged by im-

proper electrical installation are not covered by

warranty.

5. Provide overload protection and a disconnect

means for equipment serviceability as required by

local and state code.

6. Install heater controls, thermostats, or building

management systems in accordance with the

applicable manufacturers’ instructions.

7. Conduit should not be used as the earth ground.

Field-Connected Controllers

It is strongly recommended that all individually-pow-

ered control modules and the heater should be

supplied from the same power source.

Check the Power Source

NOTE: Field-supplied isolation relays should be

installed when field-connected controllers are

mounted more than 50 equivalent feet (18 AWG)

from heater. See wiring diagrams.

FRONT WIRING PANEL LOW VOLTAGE ELECTRICAL CONNECTIONS

Fig. 18: Wiring Electrical Connections

CIRCUIT

BREAKER

WHITE

GROUND

BLACK

GREEN

AB C

Fig. 19: Wiring Connections

Fig. 20: Multi-meter

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.

WARNING: Using a multi-meter, check the

following voltages at the circuit breaker panel prior to

connecting any equipment. Make sure proper

polarity is followed and house ground is proven.

(See Fig. 19.)

Field Wiring Connection

Venting

General

Appliance Categories

Heaters are divided into four categories based on the

pressure produced in the exhaust and the likelihood of

condensate production in the vent.

Category I – A heater which operates with a non-pos-

itive vent static pressure and with a vent gas

temperature that avoids excessive condensate pro-

duction in the vent.

Category II – A heater which operates with a non-pos-

itive vent static pressure and with a vent gas

temperature that may cause excessive condensate

production in the vent.

Category III – A heater which operates with a positive

vent pressure and with a vent gas temperature that

avoids excessive condensate production in the vent.

Category IV – A heater which operates with a positive

vent pressure and with a vent gas temperature that

may cause excessive condensate production in the

vent.

See Table K for appliance category requirements.

HIGH VOLTAGE

WIRING

CAUTION: Label all wires prior to disconnection

when servicing controls. Wiring errors can cause im-

proper and dangerous operation. Verify proper

operation after servicing.

Fig. 21: High Voltage Wiring Location

DANGER: SHOCK HAZARD

CAUTION: Proper installation of flue venting is

critical for the safe and efficient operation of the

heater.

NOTE: For additional information on appliance

categorization, see appropriate ANSI Z21 Standard

and the NFGC (U.S.), or B149 (Canada), or

applicable provisions of local building codes.

WARNING: Contact the manufacturer of the vent

material if there is any question about the appliance

categorization and suitability of a vent material for

application on a Category III or IV vent system.

Using improper venting materials can result in

personal injury, death or property damage.

NOTE: A grounding electrode conductor shall be

used to connect the equipment grounding

conductors, the equipment enclosures, and the

grounded service conductor to the grounding

electrode.

Make sure electrical power to the heater is discon-

nected to avoid potential serious injury or damage to

components.

LOCATOR DIMPLES

FOR OPTIONAL

COMPONENTS

Fig. 22: Locator Dimples for Optional Components

CAUTION: Condensate drains for the vent piping

are required for installations of the MVB. Follow vent

manufacturer instructions for installation and location

of condensate drains in the vent. Condensate drain

must be primed with water to prevent gas flue leak

and must be routed to an appropriate container for

neutralization before disposal, as required by local

codes.

Support of Vent Stack

The weight of the vent stack or chimney must not rest

on the heater vent connection. Support must be pro-

vided in compliance with applicable codes. The vent

should also be installed to maintain proper clearances

from combustible materials. Use insulated vent pipe

spacers where the vent passes through combustible

roofs and walls.

Vent Terminal Location

1. Condensate can freeze on the vent cap. Frozen

condensate on the vent cap can result in a blocked

flue condition.

2. Give special attention to the location of the vent

termination to avoid possibility of property dam-

age or personal injury.

3. Gases may form a white vapor plume in winter.

The plume could obstruct a window view if the ter-

mination is installed near windows.

4. Prevailing winds, in combination with below-freez-

ing temperatures, can cause freezing of

condensate and water/ice build-up on buildings,

plants or roofs.

5. The bottom of the vent terminal and the air intake

shall be located at least 12 in. above grade, includ-

ing normal snow line.

Table K: Venting Category Requirements

NOTE: During winter months check the vent cap

and make sure no blockage occurs from build-up of

snow or ice.

6. Un-insulated single-wall metal vent pipe shall not

be used outdoors in cold climates for venting gas-

fired equipment.

7. Through-the-wall vents for Category II and IV

appliances and non-categorized condensing appli-

ances shall not terminate over public walkways or

over an area where condensate or vapor could

create a nuisance or hazard or could be detrimen-

tal to the operation of regulators, relief valves, or

other equipment. Where local experience indi-

cates that condensate is a problem with Category

I and III appliances, this provision shall also apply.

8. Locate and guard vent termination to prevent acci-

dental contact by people or pets.

9. DO NOT terminate vent in window well, stairwell,

alcove, courtyard or other recessed area.

10. DO NOT terminate above any door, window, or

gravity air intake. Condensate can freeze, causing

ice formations.

11. Locate or guard vent to prevent condensate from

damaging exterior finishes. Use a rust-resistant

sheet metal backing plate against brick or mason-

ry surfaces.

12. DO NOT extend exposed vent pipe outside of

building beyond the minimum distance required

for the vent termination. Condensate could freeze

and block the vent pipe.

U.S. Installations

Refer to the latest edition of the National Fuel Gas

Code.

Vent termination requirements are as follows:

Combustion

Air Supply

Exhaust

Configuration

Heater Venting

Category

Certified

Materials

Combustion Air

Inlet Material

From Inside Building

(Non-Direct Venting)

Vertical

Venting IB-Vent

Equivalent

Horizontal Through-

the-Wall Venting III Stainless Steel

AL29-4C

From Outside Building

(Direct Venting)

Vertical

Venting IB-Vent

Equivalent Galvanized Steel

PVC

ABS

CPVC

Horizontal Through-

the-Wall Venting III Stainless Steel

AL29-4C

Venting Installation Tips

Support piping:

• horizontal runs—at least every 5 ft

• vertical runs—use braces

• under or near elbows

Venting Configurations

For heaters connected to gas vents or chimneys, vent

installations shall be in accordance with the NFGC

(U.S.), or B149 (Canada), or applicable provisions of

local building codes.

Natural Draft Vertical Venting

(Category I)

Installation

Natural draft venting uses the natural buoyancy of the

heated flue products to create a thermal driving head

that expels the exhaust gases from the flue. The nega-

tive draft must be within the range of -.01 to -.08 in.

WC as measured 12 in. above the appliance flue out-

let to ensure proper operation. Vent material must be

listed by a nationally recognized test agency.

The maximum and minimum venting length for Cate-

gory I appliances shall be determined per the NFGC

(U.S.) or B149 (Canada).

1. Vent must terminate at least 4 ft below, 4 ft hori-

zontally from or 1 ft above any door, window or

gravity air inlet to the building.

2. The vent must not be less than 7 ft above grade

when located adjacent to public walkways.

3. Terminate vent at least 3 ft above any forced air

inlet located within 10 ft.

4. Vent must terminate at least 4 ft horizontally, and

in no case above or below unless 4 ft horizontal

distance is maintained, from electric meters, gas

meters, regulators, and relief equipment.

5. Terminate vent at least 6 ft away from adjacent

walls.

6. DO NOT terminate vent closer than 5 ft below roof

overhang.

7. The vent terminal requires a 12 in. vent terminal

clearance from the wall.

8. Terminate vent at least 1 ft above grade, including

normal snow line.

9. Multiple direct vent installations require a 4 ft

clearance between the ends of vent caps located

on the same horizontal plane.

Canadian Installations

Refer to latest edition of the B149 Installation code.

A vent shall not terminate:

1. Directly above a paved sidewalk or driveway

which is located between two single-family dwell-

ings and serves both dwellings.

2. Less than 7 ft (2.13 m) above a paved sidewalk or

paved driveway located on public property.

3. Within 6 ft (1.8 m) of a mechanical air supply inlet

to any building.

4. Above a meter/regulator assembly within 3 ft (915

mm) horizontally of the vertical centre-line of the

regulator.

5. Within 6 ft (1.8 m) of any gas service regulator

vent outlet.

6. Less than 1 ft (305 mm) above grade level.

7. Within the 3 ft (915 mm) of a window or door which

can be opened in any building, any non-mechani-

cal air supply inlet to any building or the

combustion air inlet of any other appliance.

8. Underneath a verandah, porch or deck, unless the

verandah, porch or deck is fully open on a mini-

mum of two sides beneath the floor, and the

distance between the top of the vent termination

and the underside of the verandah, porch or deck

is greater than 1 ft (305 mm).

WARNING: Examine the venting system at least

once a year. Check all joints and vent pipe

connections for tightness, corrosion or deterioration.

WARNING: The Commonwealth of Massachusetts

requires that sidewall vented heaters, installed in

every dwelling, building or structure used in whole or

in part for residential purposes, be installed using

special provisions as outlined on page 53 of this

manual.

Table L: Category I Vertical Venting

1Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further

details. When vertical height exceeds 25 ft, consult factory prior to installation.

* Subtract 10 ft per elbow. Max. 4 elbows.

** Adapters supplied by others.

Fig. 23: Vertical Venting

Model

No.

Certified

Vent

Material

Vent Size

(in.)

Vertical Vent

Height1(ft) Combustion Air

Intake Pipe

Material

Air Inlet

Max. Length* (ft)

Min. Max. 6” Ø 8” Ø 10” Ø

504

Category I

(Type B

Equivalent)

5 25

Galvanized

Steel,

PVC,

ABS,

CPVC

45 100**754 10

1104 10

1504 12

45 85**

2004 14

The diameter of vent flue pipe should be sized accord-

ing to the NFGC (U.S.) and B149 (Canada).

The connection from the appliance vent to the stack

must be as direct as possible. The horizontal breach-

ing of a vent must have an upward slope of not less

than 1/4 inch per linear foot from the heater to the vent

terminal. The horizontal portions of the vent shall also

be supported for the design and weight of the material

employed to maintain clearances and to prevent phys-

ical damage or separation of joints.

Termination

The vent terminal should be vertical and should termi-

nate outside the building at least 2 ft above the highest

point of the roof that is within 10 ft. The vent cap

should have a minimum clearance of 4 ft horizontally

from and in no case above or below (unless a 4 ft hori-

zontal distance is maintained) electric meters, gas

meters, regulators and relief equipment. The distance

of the vent terminal from adjacent public walkways,

adjacent buildings, open windows and building open-

ings must be consistent with the NFGC (U.S.) or B149

(Canada). Gas vents supported only by flashing and

extended above the roof more than 5 ft should be se-

curely guyed or braced to withstand snow and wind

loads.

CAUTION: A listed vent cap terminal adequately

sized, must be used to evacuate the flue products

from the building.

Common Venting

Manifolds that connect more than one heater to a com-

mon chimney must be sized to handle the combined

load. Consult available guides for proper sizing of the

manifold and the chimney. At no time should the area

of the common vent be less than the area of the

largest heater exhaust outlet.

Common venting systems may be too large once an

existing unit is removed. At the time of removal of an

existing appliance, the following steps must be fol-

lowed with each appliance remaining connected to the

common venting system placed in operation, while the

other appliances remaining connected to the common

venting system are not in operation.

1. Seal any unused opening in the common venting

system.

2. Visually inspect the venting system for proper size

and horizontal pitch and verify there is no block-

age, restriction, leakage, corrosion or other unsafe

condition.

3. Insofar as is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the com-

mon venting system are located and other spaces

of the building. Turn on clothes dryers and any ap-

pliance not connected to the common vent

system. Turn on any exhaust fans, such as range

hoods and bathroom exhausts, at maximum

speed. Do not operate summer exhaust fan. Close

fireplace dampers.

Fig. 24: Typical Common Venting

WARNING: Vent connectors serving appliances

vented by natural draft shall not be connected into

any portion of mechanical draft systems operating

under a positive pressure.

CAUTION: Vent connectors for natural draft

venting systems must be Type B or better.

4. Place in operation the appliances being inspected.

Follow the manufacturer’s instructions for lighting

each appliance. Adjust thermostat so appliance

will operate continuously.

5. Check the pressure at a pressure tap located 12

in. above the bottom joint of the first vertical vent

pipe. Pressure should be anywhere between -0.01

and -0.08 in. WC.

6. After it has been determined that each appliance

remaining connected to the common venting sys-

tem properly vents when tested as outlined above,

return doors, windows, exhaust fans, fireplace

dampers and other gas burning appliances to their

previous conditions of use.

7. Any improper operation of the common venting

system should be corrected so that the installation

conforms with the NFGC (U.S.) or B149 (Canada).

When re-sizing any portion of the common venting

system, the common venting system should be re-

sized to approach the minimum size as

determined using the appropriate tables in Ap-

pendix G in the NFGC (U.S.) or B149 (Canada).

Engineered Vent Systems

Table M provides boiler discharge vent volumes of flue

products at full fire for the calculation of appropriate

vent sizing for common venting.

NOTE: Data for 100% firing rate.

Table M: Typical Volume of Flue Products

WARNING: Vent connectors serving any other

appliances shall not be connected into any portion of

mechanical draft systems operating under a positive

pressure. If an MVB heater is installed to replace an

existing heater, the vent system MUST be verified to

be of the correct size and Category. If it is NOT, it

MUST be replaced.

NOTE: For extractor sizing, typical CO2levels are

8.5% for natural gas and 9.5% for LP gas and flue

temperature of 350° F.

Model

No.

Vent Size

(in.)

Volume of

Flue Products

(CFM)

504 8 170

754 10 260

1104 10 380

1504 12 510

2004 14 680

Horizontal Through-the-Wall Direct

Venting (Category III)

Fig. 25: Horizontal Through-the-Wall Venting

OPTIONAL HORIZONTAL THROUGH-THE-WALL VENTING

(CATEGORY IV)

Fig. 26: Alt. Horizontal Through-the-Wall Venting

• 75’ of straight flue pipe

• 65’ of straight flue pipe and one elbow

•55’ of straight flue pipe and two elbows

• 45’ of straight pipe and three elbows

The vent cap is not considered in the overall length of

the venting system.

The vent must be installed to prevent flue gas leakage.

Care must be taken during assembly to ensure that all

joints are sealed properly and are airtight. The vent

must be installed to prevent the potential accumulation

of condensate in the vent pipes. It is required that:

1. The vent must be installed with a condensate

drain located in proximity to the heater as directed

by the vent manufacturer.

2. The vent must be installed with a slight upward

slope of not less than 1/4 inch per foot of horizon-

tal run to the vent terminal.

3. The vent must be insulated through the length of

the horizontal run.

Termination

The flue direct vent cap MUST be mounted on the ex-

terior of the building. The direct vent cap cannot be

installed in a well or below grade. The direct vent cap

must be installed at least 1 ft above ground level and

above normal snow levels. The Raypak-approved

stainless steel flue direct vent cap must be used (sales

order option D-15). The vent terminal must be located

NO CLOSER than 12” off the wall.

Direct Vent—Vertical

Installation

These installations utilize the heater-mounted blower

to draw combustion air from outdoors and force the

heated flue products through the vent pipe under posi-

tive pressure. The vent material must be in

accordance with the above instructions for vent mate-

rials. Vent material must be listed by a nationally

recognized test agency.

The connection from the appliance flue to the stack

must be as direct as possible and should be the same

size or larger than the vent outlet.

WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

NOTE: While a drain connection is required in the

vent of all Cat. III horizontal MVB installations, the

drain can be accomplished in several different ways.

The figures in this manual show the drain in a vent

tee, however, this can also be accomplished using

an inline collector for condensing stacks or an inline

vertical or horizontal collector available from several

of the listed vent manufacturers.

Fig. 27: Horizontal Through-the-Wall Direct Venting

CAUTION: This venting system requires the

installation of a condensate drain in the vent piping

per the vent manufacturer’s instructions. Failure to

install a condensate drain in the venting system will

void all warranties on this heater.

Installation

These installations utilize the heater-mounted blower

to vent the combustion products to the outdoors.

Combustion air is taken from inside the room and the

vent is installed horizontally through the wall to the out-

doors. Adequate combustion and ventilation air must

be supplied to the equipment room in accordance with

the NFGC (U.S.) or B149 (Canada).

The total length of the horizontal through-the-wall flue

system should not exceed 75 equivalent ft in length. If

horizontal run exceeds 75 equivalent ft, an appropri-

ately sized variable-speed extractor must be used.

Each elbow used is equal to 10 ft of straight pipe. This

will allow installation in one of the four following

arrangements:

** Subtract 10 ft per elbow. Max. 4 elbows.

tAdapters supplied by others.

Table N: Category III Horizontal Vent & Horizontal Direct Vent

See Table L for Category I venting guidelines.

It is recommended that the intake vent be insulated in

colder climates.

Termination

The flue terminal should be vertical and should termi-

nate outside the building at least 2 ft above the highest

point of the roof within 10 ft. The vent cap should have

Fig. 28: Direct Vent - Vertical

a minimum clearance of 4 ft horizontally from and in no

case above or below (unless a 4 ft horizontal distance

is maintained) electric meters, gas meters, regulators

and relief equipment. The distance of the vent terminal

from adjacent public walkways, adjacent buildings,

open windows and building openings must be consis-

tent with the NFGC (U.S.) or B149 (Canada).

Flues supported only by flashing and extended above

the roof more than 5 ft should be securely guyed or

braced to withstand snow and wind loads.

The air inlet opening MUST be installed 1 ft above the

roof line or above normal snow levels that might ob-

struct combustion air flow. This dimension is critical to

the correct operation of the heater and venting system

and reduces the chance of blockage from snow. The

vent cap must have a minimum 3 ft vertical clearance

from the air inlet opening.

Outdoor Installation

Outdoor models must be vented with listed vent mate-

rial per the following instructions and installed with the

optional factory-supplied outdoor vent kit. A special

vent cap and air intake hood are provided in accor-

dance with CSA requirements. These must be

installed as illustrated in Fig. 29.

Care must be taken when locating the heater out-

doors, because the flue gases discharged from the

Model

No.

Certified

Vent

Material

Vent

Size

(in.)

Maximum

Horizontal

Vent Length

(ft)**

Combustion Air

Intake Pipe

Material

Air Inlet

Max. Length** (ft)

6” Ø 8” Ø 10” Ø

504

Category III

Galvanized Steel,

PVC,

ABS,

CPVC

45 100t

754 10

1104 10

1504 12

45 85t

2004 14

CAUTION: This venting system requires the

installation of a condensate drain in the vent piping

per the vent manufacturer’s instructions. Failure to

install a condensate drain in the venting system will

void all warranties on this heater.

WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

Freeze Protection

The Raypak electronic temperature control includes a

freeze protection feature. In the event the temperature

drops below 40°F at any of the boiler temperature sen-

sors, the pump is turned on and will remain on until the

temperature at all boiler sensors rises to 45°F.

Controls

The Raypak electronic temperature control is pro-

vided to maintain the desired system water

temperature. The control has various modes of opera-

tion which are described on the following pages.

To minimize short cycling, locate the system (target)

sensor as follows:

Setpoint: The intended system supply temperature.

vent cap can condense as they leave the cap.

Improper location can result in damage to adjacent

structures or building finish. For maximum efficiency

and safety, the following precautions must be

observed:

1. Outdoor models must be installed outdoors and

must use the outdoor vent cap and air intake hood

available from the manufacturer (sales order

option D-11).

2. Periodically check venting system. The heater’s

venting areas must never be obstructed in any

way and minimum clearances must be observed

to prevent restriction of combustion and ventilation

air. Keep area clear and free of combustible and

flammable materials.

3. Do not locate adjacent to any window, door, walk-

way, or gravity air intake. The vent must be

located a minimum of 4 ft horizontally from such

areas.

4. Install above grade level and above normal snow

levels.

5. Vent terminal must be at least 3 ft above any

forced air inlet located within 10 ft.

6. Adjacent brick or masonry surfaces must be pro-

tected with a rust-resistant sheet metal plate.

Fig. 29: Outdoor Venting

WARNING: Installation, adjustment and service of

heater controls, including timing of various operating

functions, must be performed by a qualified installer,

service agency or the gas supplier. Failure to do so

may result in control damage, heater malfunction,

property damage, personal injury, or death.

WARNING: Turn off the power to the heater before

installation, adjustment or service of any heater

controls. Failure to do so may result in board

damage, heater malfunction, property damage,

personal injury, or death.

CAUTION: This appliance has provisions to be

connected to more than one supply source. To

reduce the risk of electric shock, disconnect all such

connections before servicing.

CAUTION: Risk of electric shock: More than one

disconnect switch may be required to de-energize

the equipment before servicing.

NOTE: Condensate can freeze on the vent cap.

Frozen condensate on the vent cap can result in a

blocked flue condition.

NOTE: The vent cap and air intake hood must be

furnished by the heater manufacturer in accordance

with its listing (sales order option D-11).

Deadband: Deadband is a band of temperature sens-

ing where no action occurs. All temperature controllers

have a deadband and the purpose is to prevent short-

cycling of the heater. The on-board temperature

controller has a deadband of 2ºF around the differen-

tial.

Differential: A heat source must be operated with a

temperature differential in order to prevent short-

cycling. The temperature differential is divided around

the “target” temperature or set-point. The Call For Heat

(CFH) contact will close in the controller when the

water temperature is below the target temperature by

1/2 of the differential setting, and will open when the

water temperature is above the target temperature by

1/2 of the differential setting. See Fig. 30.

For systems with less than 4:1 turndown, the control

should be placed in the system return, upstream of the

inlet piping to the heater, as shown in Figs. 32, 34 and

35. This placement will avoid short cycling the heat

source. Raypak recommends using a smaller differen-

tial setting when controlling the water temperature on

the return side. As a starting point, set the return differ-

ential to 10ºF and this will allow the system return

temperature to vary 5ºF above and 5ºF below the set-

point.

For systems with more than 4:1 turndown, the recom-

mended location of the system (target) sensor is in the

system supply loop, downstream of the outlet piping

from the heater. When controlling systems with more

than 4:1 turndown; set the supply side differential to

20ºF and the temperature will vary ±10ºF around the

setpoint.

In lieu of installing the target sensor in the system

return, a properly-sized buffer tank can be installed as

shown in Fig. 31. Consult factory for buffer tank sizing.

Operating Modes

Mode 1 (Not supported) – Setpoint operation using

primary piping. The heater outlet water temperature is

controlled to the boiler target setpoint.

Mode 2 – Setpoint operation using primary/secondary

piping. The control operates the heater to satisfy a

remote system sensor. The heater is turned off based

on boiler target and boiler differential (factory default

H7, P and WHP boilers). See Fig. 32.

Mode 3 – Dedicated DHW operation using UniTemp

80 piping. A call for heat is determined by the DHW

sensor and the DHW boiler target. The heater outlet

water is also controlled to the boiler target temperature

(factory default WH1 water heaters). See Fig. 33.

Fig. 32: Mode 2 Primary/Secondary Piping

Fig. 30: Differential Graph

Fig. 31: Buffer Tank Piping

*Maximum 4 times the pipe diameter or 12”, whichever is less.

trol operates the boiler burner to maintain the boiler

target at the boiler outlet sensor.

Mode 7 – Designed for an external input signal with

primary/secondary piping. The external input signal

can be provided from a BMS, an EMS or an external

control. The external input signal changes the boiler

target according to a linear scale (see Tables O & P).

The control operates the boiler burner to maintain the

boiler target at the system sensor. See Fig. 35.

Mode 4 (Not supported) – Outdoor reset using pri-

mary piping. The heater is operated as in Mode 1.

However, the target temperature is based on outdoor

reset.

Mode 5 – Outdoor reset using primary/secondary pip-

ing. The heater is operated as in Mode 2. However, the

target temperature is based on outdoor reset. See Fig.

34.

Mode 6 (Not supported) – Designed for an external

input signal with primary piping. The external input sig-

nal can be provided from a BMS, an EMS or a

sequencing control. The external input signal changes

the boiler target according to a linear scale. The con-

Fig. 35: Mode 7 Primary/Secondary Piping with

External Target Temp

Fig. 34: Mode 5 Primary/Secondary Piping with

Outdoor Reset

0-10 VDC 0-20 mA* Boiler Target

0 0 --- (OFF)

1 2 50°F

2 4 68.9°F

3 6 87.8°F

4 8 106.7°F

5 10 125.6°F

6 12 144.1°F

7 14 163.3°F

8 16 182.2°F

9 18 201.1°F

10 20 220°F

Table O: 0-10 VDC or 0-20 mA External Input Signal

*Requires a 500Ω resistor.

ELECTRONIC

Fig. 33: Mode 3 Dedicated DHW

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Mode 8 – This mode is for remote firing control of the

heater via an external sequencer such as the Raypak

TempTracker MOD+. The Boil Max setting is the

heater shutdown temperature (max temperature). The

heater is enabled via dry contact at the Enable/Disable

connection at the low voltage terminal strip, and the fir-

ing rate is controlled by a 0-10 VDC signal from the

external sequencer. A control signal of ≥0.5 VDC

equates to minimum fire, and a signal of 10 VDC

equates to 100% firing rate.

Definitions

% OUT - Current percent modulation rate of heater.

BOIL DSGN - Design boiler water temperature used in

heat loss calculations.

BOIL MASS - This setting allows adjustment in the

field for high or low thermal masses; High thermal

mass (setting=3) provides slower reaction, lower ther-

mal mass (setting=1) provides faster reaction.

BOIL MAX - Highest outlet water temperature that the

control is allowed to use as a target temperature.

BOIL MIN - Lowest outlet water temperature that the

control is allowed to use as a target temperature.

2-10 VDC 4-20 mA* Boiler Target

0 0 --- (OFF)

1 2 --- (OFF)

2 4 50°F

3 6 71.3°F

4 8 92.5°F

5 10 113.8°F

6 12 135°F

7 14 156.3°F

8 16 177.5°F

9 18 198.8°F

10 20 220°F

Table P: 2-10 VDC or 4-20 mA External Input Signal

*Requires a 500Ω resistor.

NOTE: The defined terms are not active in all

modes of control operation.

BOIL ON - Accumulated runtime of heater (up to 999

hours, then resets to 0).

BOIL OUT - Actual heater outlet water temperature.

BOIL START - Starting boiler water temperature.

BOIL SUP - Actual system supply water temperature.

BOIL TARGET - Target temperature that the heater is

trying to maintain.

‘BURNER’ DELAY - Holds control output at ignition

setting from the start of the ignition sequence to the

specified burner delay time (0 to 3:00 min.).

DEM 1 - Indicates 24 VDC signal has been supplied to

the H+D terminal.

DEM 2 - Indicates 24 VDC Flame Proof signal is pres-

ent.

DIFF - The operating differential of the heater; The

heater outlet water temperature is allowed to rise

above the BOIL TARGET temperature by 1⁄2of this dif-

ferential before the heater shuts off. For example, if

the heater target temperature is set to 160°F (71°C)

and the differential is set to 10°F (5°C), on temperature

rise, the heater will shut off at 165°F (74°C). Once the

heater shuts off, it will not come on again until the tem-

perature falls to 155°F (68°C).

RAYPA K

MODULATING

TEMP CONTROL

OUTDOOR AIR

SENSOR

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Fig. 36: Mode 8 Primary/Secondary Piping with

External Direct Drive

NOTE: For Modes 7 and 8, connect to pins 13 and

14 on the low-voltage panel. See page 21. Use

these modes for systems using an external signal.

Table Q: Temperature Control Default Setpoints—Boiler

Boiler (H7)

Item Modes Default Setting Range

Boil Target

2 140°F OFF, 70 to 220°F

3 160°F OFF, 70 to 190°F

5, 7 180°F OFF, 70 to 220°F

Boil Max 2, 5, 7, 8 200°F OFF, 120 to 225°F

3 180°F OFF, 120 to 190°F

Boil Min 2, 3, 5, 7 135°F OFF, 80 to 180°F

‘Burner’ Delay All 0:00 min 0:00 to 3:00 min

Boil Mass All 1 (Low) 1 (Low), 2 (Med), 3 (High)

Diff 2, 3, 5, 7 Auto Auto, 2 to 42°F

DHW Target 3 120°F OFF, 70 to 190°F

DHW Diff 3 5°F 2 to 10°F

‘Pump’ Dly All 3:00 min OFF, 0:20 to 9:55 min, ON

Outdr Start 5 70°F 35 to 85°F

Outdr Design 5 -10°F -60 to 32°F

Boil Start 5 135°F 35 to 150°F

Boil Dsgn 5 180°F 120 to 220°F

WWSD 5 70°F 35 to 100°F

Units All °F °F or °C

Mode N/A 2 2, 3, 5, 7, 8

External Input Signal 7 2 to 10 VDC 2 to 10 VDC or 0 to 10 VDC

Offset 7 0°F -10°F to 10°F

Pool Heater (P, WHP)

Item Modes Default Setting Range

Boil Target 2 78°F OFF, 45 to 106°F

Boil Max 2 86°F OFF, 70 to 106°F

Boil Min 2 70°F OFF, 45 to 106°F

‘Burner’ Delay All 0:00 min 0:00 to 3:00 min

Boil Mass All 1 (Low) 1 (Low), 2 (Med), 3 (High)

Diff 2 1°F 1 to 3°F

‘Pump’ Dly All 3:00 min OFF, 0:20 to 9:55 min, ON

Units All °F °F or °C

Mode N/A 2 2

Table R: Temperature Control Default Setpoints—Pool Heater

EXTERNAL INPUT SIGNAL – Selects external input

signal range (0-10VDC or 2-10VDC):

0-10VDC or 0-20 mA external input signal – When

the 0-10VDC signal is selected, an input voltage of 1

VDC corresponds to a boiler target temperature of

50°F (10°C). An input voltage of 10 VDC corresponds

to a boiler target temperature of 220°F (104°C). As the

voltage varies between 1 VDC and 10 VDC, the boiler

target temperature varies linearly between 50°F

(10°C) and 220°F (104°C) (refer to Table O). If a volt-

age below 0.5 VDC is received, the boiler target

temperature is displayed as “– – –” indicating that

there is no longer an internal call for heat. A 0-20 mA

signal can be converted to a 0-10 VDC signal by

installing a 500 Ω resistor on the external input signal

device’s terminals.

2-10VDC or 4-20 mA external input signal – When

the 2-10VDC signal is selected, an input voltage of 2

VDC corresponds to a boiler target temperature of

50°F (10°C). An input voltage of 10 VDC corresponds

to a boiler target temperature of 220°F (104°C). As the

voltage varies between 2 VDC and 10 VDC, the boiler

target temperature varies linearly between 50°F

(10°C) and 220°F (104°C) (refer to Table P). If a volt-

age below 1.5 VDC is received, the boiler target

temperature is displayed as “– – –” indicating that

there is no longer an internal call for heat. A 4-20 mA

signal can be converted to a 2-10 VDC signal by

Water Heater (WH1)

Item Modes Default Setting Range

Boil Target 2 140°F OFF, 70 to 190°F

3, 7 160°F OFF, 70 to 190°F

Boil Max 2, 3, 6, 7 180°F OFF, 120 to 190°F

Boil Min 2, 3, 7 135°F OFF, 80 to 180°F

‘Burner’ Delay All 0:00 min 0:00 to 3:00 min

Boil Mass All 1 (Low) 1 (Low), 2 (Med), 3 (High)

Diff 2, 3, 7 Auto Auto, 2 to 42°F

DHW Target 3 120°F OFF, 70 to 190°F

DHW Diff 3 5°F 2 to 10°F

‘Pump’ Dly All 3:00 min OFF, 0:20 to 9:55 min, ON

Units All °F °F or °C

Mode N/A 3 2, 3, 7

External Input Signal 7 2 to 10 VDC 2 to 10 VDC or 0 to 10 VDC

Offset 7 0°F -10°F to 10°F

Table S: Modulating Temperature Control Default Setpoints—Water Heater

installing a 500 Ω resistor on the external input signal

device’s terminals.

FP - Flame proof warning.

MODE - Operating mode of the heater.

OFFSET - The Offset setting allows the boiler target

temperature to be fine tuned to the external input sig-

nal. The control reads the external input signal and

converts this to a boiler target temperature. The Offset

setting is then added to the boiler target temperature.

OUTDR - Outdoor air temperature.

OUTDR DESIGN - Design outdoor air temperature

used in the heat loss calculation.

OUTDR START - Starting outdoor air temperature.

PUMP DLY - Sets the operating time of the pump once

the CFH is satisfied.

TANK - Current DHW tank temperature (Mode 3).

TANK DIFF - Storage tank differential (Mode 3).

TANK TARGET - Target temperature in the DHW

storage tank (Mode 3).

UNITS - Selects the temperature units to be displayed

(°F or °C).

WWSD - Selects the outdoor temperature that shuts

the heater off, no matter what the demand. NOTE: The

WWSD segment will be displayed on the LCD.

Operation

The Raypak electronic temperature control uses a

Liquid Crystal Display (LCD) as a method of supply-

ing information. The LCD is used to setup and monitor

system operation by means of three push buttons

(Item,Land M) shown at the bottom of Fig. 37.

All items displayed by the control are organized into

two menus, the view menu and the adjust menu. The

active menu is displayed in the upper right hand side

of the display in the menu field. The default menu is

the view menu.

When the temperature control is powered up, the con-

trol turns on all segments in the display for 2 seconds,

then the software version is displayed for 2 seconds.

At the end of that 4 second period, the control enters

the normal operating mode and “VIEW” is displayed.

Pressing the scroll button “scrolls” through the dis-

played values in the “VIEW” menu.

To make an adjustment to a setting in the control,

begin by selecting the “ADJUST” menu. To change

from the view menu to the adjust menu, simultaneous-

ly press and hold all three buttons for 1 second. The

menu name, “ADJUST” will be displayed in the menu

field.

The menu will automatically revert back to the view

menu after 20 seconds of keyboard inactivity. Then

scroll to the desired item using the scroll button. Fi-

nally, use the Lor Mbutton to make the adjustment.

In the absence of other information, the values pro-

vided in Tables Q, R and S should be used as default

settings.

Modulating

Control

Item

DHW

Modulation

External Input

Signal

Offset

Fig. 37: Modulating Temperature Control Display

Item Field

Displays an

abbreviated

name of the

selected item

Buttons

Selects

Menus,

Items and

adjusts

settings

{

Menu Field

Displays the current menu

Number Field

Displays the

current value of

the selected

item

Status Field

Displays the

current status

of the control’s

inputs, outputs

and operation

Rank Item Field Number Field Type Fault Description

0 E01 Err Error EEPROM error

1 FPErr Warning Flame proof warning

2 BOIL OUT SHr Error Boiler outlet sensor short

3 BOIL OUT OPn Error Boiler outlet sensor open

4 BOIL IN SHr Error Boiler inlet sensor short

5 BOIL IN OPn Error Boiler inlet sensor open

6 SUP SHr Error System sensor short

7 SUP OPn Error System sensor open

8 OUTDR SHr Error Outdoor sensor short

9 OUTDR OPn Error Outdoor sensor open

10 DHW SHr Error DHW sensor short

11 DHW OPn Error DHW sensor open

Table T: Error Codes

The optional single-try ignition module will lock out

after failing to light one time. To reset it, press and

release the small, recessed black push button located

inside of the cut-out on the lower right-hand corner of

the ignition module case. Turning off the power to

the heater WILL NOT reset the ignition module.

High Limit—Manual Reset

This heater is equipped with a fixed setting manual re-

set high limit temperature device as standard or it may

have an optional adjustable setting manual reset high

temperature device.

The fixed setting manual reset high limit is located on

the In/Out header of the heat exchanger on the right

side of the heater (accessible through the front door

for reset as necessary).

The optional adjustable manual reset high limit is lo-

cated inside the heater junction box. Push the reset

button and adjust the setting to approx. 40°F (20°C)

above desired outlet temperature.

Heater Sequence of Operation

If all limits are satisfied and there is a call for heat:

1. The heater pump is powered and begins circulat-

ing water through the heat exchanger.

2. The blower is powered and goes through a 15 sec-

ond prepurge beginning when air flow is proven by

closure of the blower suction air pressure switch.

3. The igniter is powered, and once proven, heats up

for 20 seconds.

4. The gas valve is then energized for a 4 second

trial for ignition period. Trial for ignition is fixed at

50% input. The heater is allowed to modulate once

flame is proven and the firing rate will adjust to

match the load based on the configuration and set-

tings of the temperature control or external input.

5. Once the heat demand is satisfied the gas valve

will close and the blower will run a 30 second post

purge. The heater pump will continue to circulate

water for 0 to 10 minutes depending on the pump

delay setting on the Raypak modulating tempera-

ture control.

Ignition Module

When additional heat is needed, the combustion air

blower starts to purge air from the combustion cham-

ber for 15 seconds. On proof-of-air flow, the

air-proving switch closes and the igniter is energized.

To ensure safe operation, the gas valve cannot open

until the igniter is verified. The main burner is automat-

ically lit when the device is powered and pre-purged.

The heater performs its own safety check and opens

the main valve only after the igniter is proven to be

capable of ignition. The standard ignition module will

attempt to light three times before locking out. To reset

it, turn off power to the heater, wait 30 seconds and re-

apply power.

Fig. 38: Ignition Module

Table U: Ignition Module

Diagnostic LED Flash Codes

Code Condition

On System OK; No faults present

Off Possible control fault; Check power

1Flash Low air

2Flashes Flame in combustion chamber;

No call for heat

3Flashes Ignition lockout

4Flashes Low HSI current

5Flashes Low 24 VAC

6Flashes Internal fault; Replace control

Fig. 39: High Limit (Manual Reset)

Modulating Temperature Control

This heater is equipped with a Raypak modulating

temperature control. Refer to information starting on

page 30 for information on the setting and use of this

control.

Low Water Cut-Off (Optional)

The optional low water cut-off automatically shuts

down the burner whenever water level drops below the

level of the sensing probe. A 5-second time delay pre-

vents premature lockout due to temporary conditions

such as power fluctuations or air pockets.

High & Low Gas Pressure Switches

(Optional)

The optional low gas pressure switch connection

mounts upstream of the gas valve (on the inlet flange

to the gas valve) and is accessible through the remov-

able access panels on the rear of the heater to reset

the gas pressure switch, as necessary. It is used to

ensure that sufficient gas pressure is present for prop-

High Limit—Auto Reset (Optional)

This heater may be equipped with an optional adjust-

able auto reset high limit temperature device.

The optional adjustable auto reset high limit is located

inside the heater junction box. Adjust the setting to

approx. 20°F (10°C) above desired outlet temperature.

Flow Switch

This standard, dual-purpose control, mounted and

wired in series with the main gas valve, shuts off

heater in case of pump failure or low water flow.

Fig. 40: Adjustable High Limit (Auto Reset)

Fig. 41: Flow Switch

Fig. 42: Modulating Temperature Control

Fig. 43: Low Water Cut-Off

Blocked Vent Switch

This heater is equipped with a blocked vent pressure

switch to prevent the operation of the heater when too

much of the vent is blocked. This switch is located on

the right side of the heater near the right rear corner.

UDB Diagnostic Board

This heater is equipped with a diagnostic board which

will indicate faults as they occur. Refer to the Trouble-

shooting section for instructions on accessing,

reviewing and clearing these faults.

Air Pressure Switch

This heater is equipped with an air pressure switch to

prove the operation of the blower before allowing the

ignition control to begin a Call for Heat. It is located on

the right side of the lower flange of the blower mount-

ing assembly, directly behind the junction box.

Fig. 45: Air Pressure Switch

Fig. 46: Blocked Vent Switch

Fig. 47: UDB Diagnostic Board

er valve/regulator performance. The low gas pressure

switch automatically shuts down the heater if gas sup-

ply drops below the factory setting of 3.0 in. WC for

natural gas or propane gas.

The optional high gas pressure switch connection

mounts down-stream of the gas valve. Special ports

are located on the backside of the gas valve and

accessible from the front of the heater (to reset the gas

pressure switch) or through the removable access

panels on the rear of the heater (to reset the gas pres-

sure switch), as necessary. If the gas pressure

regulator in the valve fails, the high gas pressure

switch automatically shuts down the burner.

Operation of either the High or Low Gas Pressure

Switch will turn on an LED inside the switch housing.

Push the top of the plastic switch housing as shown in

Fig. 44 to reset a tripped pressure switch. The white

LED will go out when the switch is reset.

Fig. 44: High/Low Gas Pressure Switch

NOTE: The wiring diagrams in this manual show all

standard options. Refer to the large wiring diagram

provided with your heater for options installed on

your specific unit(s).

WIRING DIAGRAM - Models H & WH

WIRING DIAGRAM - Models P & WHP

START-UP

Pre Start-up

Filling System (Heating Boilers)

Fill system with water. Purge all air from the system.

Lower system pressure. Open valves for normal sys-

tem operation, and fill system through feed pressure.

Manually open air vent on the compression tank until

water appears, then close vent.

Air Purge (Domestic Hot Water

Heaters)

Purge all air from system before heater operation. This

can be normally accomplished by opening a down-

stream valve.

Raypak offers an optional air vent valve for the MVB

heaters which can be installed directly into the inlet

side of the header to ensure that air is purged from the

system. This option also includes an adapter to allow

the air vent to be piped (in the field) to a suitable drain

as re-quired by the jurisdiction having authority.

Venting System Inspection

1. Check all vent pipe connections and flue pipe ma-

terial.

2. Make sure vent terminations are installed per code

and are clear of all debris or blockage.

For Your Safety

This appliance has a hot surface igniter. It is equipped

with an ignition device which automatically lights the

burners. Do not try to light the burners by hand.

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

BEFORE OPERATING, smell all around the appliance

area for gas. Be sure to smell near the floor because

some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

•Do not try to light any appliance.

• Do not touch any electrical switch; do not use any

telephone in your building.

• Immediately call your gas supplier from a neigh-

bor’s telephone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the fire

department.

• Use only your hand to push in or turn the gas con-

trol knob. Never use tools. If the knob will not turn

by hand, do not try to repair it, call a qualified serv-

ice technician. Forced or attempted repair may

result in a fire or explosion.

• Do not use this appliance if any part has been

under water, immediately call a qualified service

technician to inspect the appliance and to replace

any part of the control system and any gas control

which has been under water.

• Check around unit for debris and remove com-

bustible products, i.e. gasoline, etc.

Pre Start-up Check

1. Verify the heater is filled with water.

2. Check system piping for leaks. If found, repair

immediately.

3. Vent air from system. Air in system can interfere

with water circulation.

4. Purge air from gas line to heater.

Initial Start-up

Required tools

• (1) 12-0-12 (24” scale) U-tube manometer

• (2) 6-0-6 (12” scale) U-tube manometer

• Screwdrivers (assorted sizes and shapes)

• (1) Crescent wrench (8” or 10”)

• (1) Multi-meter

• (1) Amp probe

(Metric Allen wrenches will be required for servicing

the gas valve, but not during start-up)

Preparation

NOTE: Digital manometers are not recommended.

WARNING: Do not turn on gas at this time.

CAUTION: An air vent valve should be installed at

the highest point in the system for proper operation.

If water piping is located higher than the header, the

air vent valve should be relocated to the highest

point in the installed system.

NOTE: The following steps must be performed by a

factory-trained technician.

Check Power Supply

With multi-meter at incoming power, check voltage

between:

Hot - Common (≈120 VAC)

Hot - Ground (≈120 VAC)

Common - Ground (< 1 VAC)

Attach Manometers to Measure Pressures

1. Turn off main gas valve.

2. Attach (1) 12” scale manometer to an upstream

bleedle valve on the gas supply pipe to the heater

(Measure point “A” in Fig. 48).

3. Attach (1) 24” scale manometer to the manifold

pressure tap located on the elbow downstream of

the valve (Measure point “D” in Fig. 48).

4. Attach (1) 12” scale manometer near the fan-prov-

ing switch. Pull black cap from air pressure switch

tee and connect the manometer. NOTE: Retain

caps for reinstallation later.

Check Gas Supply Pressure

1. Slowly turn on main gas shut-off valve.

2. Read the gas supply pressure from the manome-

ter; minimum supply pressure for natural gas is 4.0

in. WC, recommended supply is 7.0 in. WC, mini-

mum supply pressure for propane gas is 4.0 in.

WC, recommended supply is 11.0 in. WC (dynam-

ic readings, full fire input).

WARNING: If Common - Ground is > 1 VAC,

STOP: Contact electrician to correct ground failure.

Failure to do this may burn out 120V-24V

transformer, or may cause other safety control

damage or failure.

Start-Up

1. Turn power on.

2. Turn on the heater, wait approximately 15 seconds

after the blower starts, and the igniter should start

to glow (observable through the observation port

located at the front, bottom of the heater). Look

into the sight glass located at the bottom of the

front panel to check igniter operation. Gas valve

should open in 45-60 seconds.

3. The heater ignites at 50% of full rate (as indicated

on the LCD display of the temperature control

located in the upper right of the front panel).

4. If the burner fails to light on the first trial, it will try

for ignition up to three times before going into lock-

out with the standard ignition module. If the heater

is equipped with the optional single-try ignition

module, it will go into lockout.

5. Wait until the controller indicates 100% on the fir-

ing rate display screen (approximately 30

seconds).

Blower Check

1. Check blower suction using the manometer

attached to the fan pressure switch tee, with the

heater firing at 100% input. The reading should be

as noted in Table V for both natural and propane

gas.

2. FOR REFERENCE ONLY: Measure the blower

amp draw with the heater firing at 100% input and

compare the measured value to the values in

Table U. The amp draw is measured with a clamp-

on type amp probe clamped to the 14 AWG black

power wire going into the blower.

3. When firing at 100%, the desired heater combus-

tion CO2 is between 8.5 and 9.0% for natural gas

and 9.5 and 10.0% for propane with CO less than

100 ppm. If this combustion cannot be achieved

GAS

TO BURNER

Fig. 48: Gas Pressure Measurement Locations

3. If the gas pressure is greater than 14.0 in. WC,

turn off the main gas shut-off valve, upstream of

the heater.

NOTE: The values in Tables V, W and X represent

the conditions when the heater is at full firing rate at

sea level.

NOTE: Pressure and combustion data are provided

with the heater.

with the blower suction within the tolerances spec-

ified in Table T, contact the factory. The reference

amp draw reading may help to indicate if there is

a problem with the system or if blower adjustment

is required.

Manifold Check

1. Check manifold gas pressure at the gas valve out-

let pressure tap (connection “D” in Fig. 48). This

pressure should read per the values in Table X for

natural and propane gas.

2. If the pressure reading differs by more than ± 0.2

in. WC, STOP – Call the factory for directions

on what to do next!

Safety Inspection

1. Check all thermostats and high limit settings.

2. During the following safety checks leave manome-

ters hooked up, check and record.

3. If other gas-fired appliances in the room are on the

same gas main, check all pressures on the MVB

with all other equipment running.

4. Check thermostats for ON-OFF operation.

5. Check high limits for ON-OFF operation.

6. While in operation, check flow switch operation.

7. Check the low gas pressure switch (if provided).

(For proper adjustment, use the attached

manometers, if available, to set pressure. The

scales on the switch are approximate only.) Low

gas pressure switch (if provided) must be set at

3.0 in. WC for natural gas and propane gas.

8. Make sure that the high gas pressure switch (op-

tional) is set to 3.0 in. WC for both natural gas and

propane gas.

Follow-Up

Safety checks must be recorded as performed.

Turn heater on. After main burner ignition:

1. Check manometer for proper readings.

2. Cycle heater several times and re-check readings.

3. Remove all manometers and replace caps and

screws.

4. Check for gas leaks one more time.

Finishing

1. Record all data on the “Start-up Checklist” located

at the back of this manual.

2. Disconnect the manometers and reconnect the

cap on the fan pressure switch tee and reinsert the

sealing screws into the bleedle valves.

3. Start-up is complete and the heater should be

operating properly.

Model No. Air Pressure

Setting (in. WC)

Setting

Tolerance

504 -2.3 ± 0.2 in. WC

754 -2.9 ± 0.2 in. WC

1104 -4.0 ± 0.2 in. WC

1504 -4.0 ± 0.2 in. WC

2004 -4.1 ± 0.2 in. WC

Table V: MVB Air Pressure Settings

Model No. Amp Draw Setting

Tolerance

504 1.9 +0.0/-0.2

754 2.9 +0.0/-0.2

1104 5.5 +0.0/-0.2

1504 8.1 +0.0/-0.2

2004 13.0 +0.0/-0.5

Table W: MVB Amp Draw (Reference Only)

Model No.

Manifold Gas Pressure Setting

High Fire Values (in. WC)

Natural Gas Propane Gas

504 -0.1 -0.1

754 -0.4 -0.1

1104 -1.0 -0.2

1504 -2.4 -0.6

2004 -1.0 -0.5

Table X: MVB Manifold Pressure Settings

NOTE: Most commercially available amp probes

are not accurate enough and/or are not shielded well

enough to read accurately in the heater

environment. Blower amp draw readings are for

reference only.

CAUTION: Special manifold and air settings may

be required.

Leak Test Procedure: Dual-Seat Gas

Valve

Proper leak testing requires three pressure test points

in the gas train.

Remove the access panel on the rear of the heater to

access the gas valve for this test. Test point A is a blee-

dle valve located upstream of the combination gas

valve on the supply manifold.

Test point B is a bleedle valve located between the two

automatic gas valve seats.

Test point C is a bleedle valve located downstream of

both automatic gas valve seats and upstream of the

manual valve. Refer to Fig. 49.

These tests are to be conducted with the electrical

power to the heater turned OFF.

1. Manually close the downstream leak test valve.

2. Open the bleedle valve at test point A and connect

a manometer to it. Verify that there is gas pressure

and that it is within the proper range (NOTE: must

not exceed 14.0 in. WC).

3. Open test point B and connect a rubber tube to it.

Connect the other end of the tube to a manometer

and look for a build-up of pressure. Increasing

pressure indicates a leaking gas valve which must

be replaced.

4. Next, close the upstream manual gas valve (field

supplied) and remove the manometers from the

bleedle valves in test point A and test point B.

Connect a rubber tube from the test point A blee-

dle valve to the test point B bleedle valve and

open the upstream manual gas valve. Make sure

that test point A & B bleedle valves have been

opened so as to allow gas to flow. This will bring

gas pressure to the second valve seat.

5. Open the bleedle valve at test point C and connect

a second rubber tube to it. Connect the other end

of the tube to a manometer and look for a build-up

of pressure. Increasing pressure indicates a leak-

ing gas valve which must be replaced.

6. Remove rubber tube and manometers. Close

each test point bleedle valve as the tubes are

removed.

7. After no leakage has been verified at all valve

seats and test valves, open downstream leak test

valve and restore electrical power to the heater.

Post Start-Up Check

Check off steps as completed:

1. Verify that the heater and heat distribution units or

storage tank are filled with water.

2. Confirm that the automatic air vent (if used) was

opened two full turns during the venting proce-

dure.

3. Verify that air has been purged from the system.

4. Verify that air has been purged from the gas pip-

ing, and that the piping has been checked for

leaks.

5. Confirm that the proper start-up procedures were

followed.

6. Inspect burner to verify flame.

7. Test safety controls: If heater is equipped with a

low water cut-off or additional safety controls, test

Fig. 49: Leak Test Procedure

GAS

TO BURNER

for operation as outlined by manufacturer. Burner

should be operating and should go off when con-

trols are tested. When safety devices are restored,

burners should re-ignite after pre-purge time

delay.

8. Test limit control: While burner is operating, move

indicator on high limit control below actual water

temperature. Burner should go off while blower

and circulator continue to operate. Raise setting

on limit control above water temperature and

burner should re-ignite after pre-purge time delay.

NOTE: Ignition control may have to be reset

after this portion of the test.

9. Test ignition system safety device:

a. Open manual gas valve. Turn power on.

b. Set thermostat to call for heat.

c. When the heater is in operation, pull hose off

the air switch. The burner should go off almost

immediately.

d. Reattach hoses. Burner should re-ignite after

pre-purge time delay. NOTE: Ignition control

may have to be reset after this portion of

the test.

10. To restart system, follow lighting instructions in the

Operation section.

11. Check to see that the high limit control is set

above the design temperature requirements of the

system. For multiple zones: Check to make sure

the flow is adjusted as required in each zone.

12. Check that the heater is cycled with the thermo-

stat. Raise the setting on the thermostat to the

highest setting and verify that the heater goes

through the normal start-up cycle. Reduce to the

lowest setting and verify that the heater goes off.

13. Observe several operating cycles for proper oper-

ation.

14. Set the heater thermostat to desired temperature.

15. Review all instructions shipped with this heater

with owner or maintenance person, return to enve-

lope and give to owner or place the instructions

inside front panel on heater.

OPERATION

Lighting Instructions

1. Before operation, make sure you have read all of

the safety information in this manual.

2. Remove upper front panel.

3. Set the thermostat to the lowest setting.

4. Turn off all electrical power to the appliance.

5. This appliance is equipped with an ignition device

which automatically lights the burner. Do not try to

light the burner by hand.

6. Turn on main manual gas valve field installed near

gas inlet connection on back of heater.

7. Wait 5 minutes to clear out any gas. Then smell for

gas, especially near the floor. If you then smell

gas, STOP! Follow the steps in the safety informa-

tion on the front cover of this manual. If you do not

smell gas, go to next step.

8. Turn on all electrical power to the appliance.

9. Set thermostat to desired setting. The appliance

will operate. The igniter will glow after the pre-

purge time delay (15 seconds). After igniter

reaches temperature (30 seconds) the main valve

should open. System will try for ignition up to three

times (one time on optional single-try ignition mod-

ule). If flame is not sensed, lockout will

commence.

10. If the appliance will not operate, follow the instruc-

tions “To Turn Off Gas To Appliance,” and call your

service technician or gas supplier.

11. Replace upper front panel.

12. If heater fails to start, verify the following:

a. There are no loose connections or that the

service switch is off.

b. High temperature limit switch is set above wa-

ter temperature or manual reset high limit is

not tripped.

c. Thermostat is set above water temperature.

d. Gas is on at the meter and the heater.

e. Incoming dynamic gas pressure to the gas

valve is NOT less than 4.0 in. WC for natural

gas or propane gas.

To Turn Off Gas To Appliance

1. Shut off manual gas valve field installed near gas

inlet connection on back of heater.

2. Remove upper front panel.

3. Set the thermostat to lowest setting.

4. Turn off all electrical power to the appliance if serv-

ice is to be performed.

5. Replace access panel.

UDB Fault History

To view the fault codes in the UDB history file:

1. Press the UP or DOWN buttons on the membrane

switch for 2 seconds to access the fault history.

2. Press either button to scroll through the recorded

faults in history.

3. The most recent fault recorded will be the first fault

displayed (the last 16 faults are stored in the his-

tory, on a rolling basis). There is no time or date

stamp associated with these faults.

4. When the history of faults has been exhausted,

pushing the UP or DOWN buttons again will roll

the fault history over and it will start again.

5. To exit the fault history, wait for 10 seconds and

the board will automatically exit the history mode.

To clear the fault history, press and hold both the UP

and DOWN buttons for 5 seconds while the power is

on.

Diagnostic information is provided any time a fault is

recorded. This information is intended to assist in

locating the problem with the heater, but is not exhaus-

tive.

If multiple fault conditions occur at the same time, only

the fault that caused the heater to shut down will be

recorded in the history.

NOTE: Once the history has been cleared, it cannot

be recovered.

TROUBLESHOOTING

Ste

Step 1

Step 2

Step 3

Step 4

Step 5

Is there a Call For

Heat?

Is Disable connection intact?

Does the combustion air

blower come on?

Is 4-20mA present at the quick

disconnects on the black and blue

wires of the tem

erature controlle

Is 24VAC at the NC side of

the air pressure switch?

Does F2 on ignition module

have AC

owe

Is blower pressure setting

(vacuum) correct?

Does i

niter

rove?

Is airswitch bouncing?

Call our Technical Service Department

Is gas pressure correct?

Is there continuity in the wire

between F2 and Pin J5-6?

Replace airpressure switch.

Correct the shutter

setting or blower

amp draw.

NO Check the switch and/or

line voltage

YES

Does the power switch provide

power to the control panel?

Unit is in standby mode.

Reattach.

YES

Is diagnostic board

indicating open

safeties?

Check and correct power

connections at main terminal

block, circuitbreaker panel or

blower relay.

YES

Is 24VAC at PS on ignition module?

Is connecting plug secure?

YES

Is the flame sensor signal to the

nition module

reater than 1 uA DC?

YES

The unit is oka

YES

Replace HSI

NO Correct the gas pressure.

Repairor

lace wire.

Correct wiring.

YES

Is Amp draw during heat-

up for HSI greater than

3.1 Amps?

YES

Is there 120VAC at the blower or

blower relay?

Is the unit runnin

Is static and dynamic inlet gas

pressure correct?

YES

Replace temperature

controller.

Correct Safet

YES

1-805-278-5300

MAINTENANCE

Suggested Minimum

Maintenance Schedule

Regular service by a qualified service agency and

maintenance must be performed to ensure maximum

operating efficiency.

Maintenance as outlined below may be performed by

the owner.

Daily

1. Check that the area where the heater is installed

is free from combustible materials, gasoline, and

other flammable vapors and liquids.

2. Check for and remove any obstruction to the flow

of combustion or ventilation air to heater.

Monthly

1. Check for piping leaks around pumps, mixing

valves, relief valves, and other fittings. If found,

repair at once. DO NOT use petroleum-based

stop-leak compounds.

2. Visually inspect burner flame.

3. Visually inspect venting system for proper func-

tion, deterioration or leakage.

4. Visually inspect for proper operation of the con-

densate drain in the venting. If leaks are observed

repair at once.

5. Check air vents for leakage.

Yearly (Beginning Of Each Heating

Season)

Schedule annual service call by qualified service

agency.

1. Visually check top of vent for soot. Call service

person to clean. Some sediment at bottom of vent

is normal.

2. Visually inspect venting system for proper func-

tion, deterioration or leakage. Ensure that

condensate drain is inspected and ensure that

condensate is being directed to appropriate con-

densate management system or drain, as required

by local codes.

3. Check that area is free from combustible materi-

als, gasoline, and other flammable vapors and

liquids.

4. Check air filter and replace as necessary.

5. Follow pre-start-up check in the Start-up section.

6. Visually inspect burner flame. It should be light

blue at full input. Remove and visually inspect hot

surface igniter and sensor for damage, cracking or

debris build-up.

7. Check operation of safety devices. Refer to manu-

facturers’ instructions.

8. Follow oil-lubricating instructions on pump (if re-

quired). Over-oiling will damage pump.

Water-lubricated circulators do not need oiling.

9. To avoid potential of severe burn, DO NOT REST

HANDS ON OR GRASP PIPES. Use a light touch;

return piping will heat up quickly.

10. Check blower and blower motor.

11. Check for piping leaks around pumps, relief valves

and other fittings. Repair, if found. DO NOT use

petroleum-based stop-leak.

Periodically

1. Check relief valve. Refer to manufacturer’s

instructions on valve.

2. Test low water cut-off (if equipped). Refer to manu-

facturer’s instructions.

Preventive Maintenance

Schedule

The following procedures are recommended and are

good practice for all MVB installations.

Daily

1. Check gauges, monitors and indicators.

2. Check instrument and equipment settings. (See

“Post Start-Up Check” on page 45.)

3. Check burner flame. (Should see light blue flame

at full input rate).

6. Perform leakage test on gas valves (See Fig. 49.)

and procedure on page 45.

7. Test air switch in accordance with manufacturer’s

instructions. (Turn panel switch to the “On” posi-

tion until blower is proven, then turn the switch to

“Off.”

8. Inspect and clean burner using shop air.

As Required

1. Recondition or replace low water cut-off device (if

equipped).

2. Check drip leg and gas strainers.

3. Check flame failure detection system. (See “Post

Start-Up Check,” page 45.)

4. Check igniter. (Resistance reading should be 42-

70 ohms at ambient temperature).

5. Check flame signal strength. (Flame signal should

be greater than 1 microampere as measured at

the 2 pins on the upper left corner of the ignition

control).

6. Check firing rate control by checking the manifold

pressure. (See “Manifold Check” on page 44).

7. Test safety/safety relief valves in accordance with

ASME Heater and Pressure Vessel Code Section

IV.

Weekly

For low-pressure heaters, test low-water cut-off

device. (With heater in pre-purge, depress the low

water cut-off test button. Appliance should shut-off

and ignition fault light should come on. Depress reset

button on front of heater control panel to reset).

Monthly

1. Check flue, vent, stack, or outlet dampers.

2. Test blower air pressure. (See “Blower Check” on

page 43.)

3. Test high and low gas pressure interlocks (if

equipped). (See “Safety Inspection” on page 44.)

Semi-Annually

1. Recalibrate all indicating and recording gauges.

2. Check flame failure detection system components.

3. Check firing rate control by checking the manifold

pressure. (See “Manifold Check” on page 44.)

4. Check piping and wiring of all interlocks and shut-

off valves.

5. Check air filter and replace as necessary.

Annually

1. Test flame failure detection system and pilot turn-

down.

2. Test high limit and operating temperature. (See

“Post Start-Up Check,” page 45.)

3. Check flame sensor.

4. Conduct a combustion test at full fire. Carbon diox-

ide should be 8.5 to 9.0% at full fire for natural gas,

and between 9.5 to 10.0% for propane gas.

Carbon monoxide should be < 100 ppm.

5. Check valve coil for 60 cycle hum or buzz. Check

for leaks at all valve fittings using a soapy water

solution (while heater is operating). Test other

operating parts of all safety shut-off and control

valves and increase or decrease settings

(depending on the type of control) until the safety

circuit opens. Reset to original setting after each

device is tested.

Filter Maintenance

• Inspect quarterly

• Replace when tracking pressure exceeds -0.5 in.

WC at 100% fan speed, except for models 1104

and 2004, which need to be replaced when track-

ing pressure exceeds -0.7 in. WC at 100% fan

speed.

NOTE: Use Raypak replacement filters, kit number

012552F (12”X12”) for models 504-1104 and kit

number 012553F (16”X16”) for models 1504-2004.

Filter Replacement

1. Remove the filter box cover by loosening and

removing the two wing nuts holding it in place.

2. Remove the filter by lifting it straight up and out of

the slot in the filter box.

3. Reverse steps 1 and 2 to install the new filter. Use

Raypak replacement filters, kit number 012552F

(12”X12”) for models 504-1104 and kit number

012553F (16”X16”) for models 1504-2004.

APPENDIX

Inside Air Contamination

All heaters experience some condensation during

start-up. The condensate from flue gas is acidic.

Combustion air can be contaminated by certain vapors

in the air which raise the acidity of the condensate.

Higher acidity levels attack many materials including

stainless steel, which is commonly used in high effi-

ciency systems. The heater can be supplied with

corrosion-resistant, non-metallic intake air vent materi-

al. You may, however, choose to use outside

combustion air for one or more of these reasons:

1. Installation is in an area containing contaminants

listed below which will induce acidic condensation.

2. You want to reduce infiltration into your building

through openings around windows and doors.

3. You are using AL29-4C stainless steel vent pipe,

which is more corrosion-resistant than standard

metallic vent pipe. In extremely contaminated ar-

eas, this may also experience deterioration.

Products causing contaminated combustion air:

• spray cans containing chloro/fluorocarbons

• permanent wave solutions

• chlorinated waxes/cleaners

• chlorine-based swimming pool chemicals

• calcium chloride used for thawing

• sodium chloride used for water softening

• refrigerant leaks

• paint or varnish removers

• hydrochloric acid/muriatic acid

• cements and glues

• antistatic fabric softeners used in clothes dryers

• chloride-type bleaches, detergents, and cleaning

solvents found in household laundry rooms

• adhesives used to fasten building products

• similar products

Areas where contaminated combustion air commonly

exists:

• dry cleaning/laundry areas

• metal fabrication plants

• beauty shops

• refrigeration repair shops

• photo processing plants

• auto body shops

• plastic manufacturing plants

• furniture refinishing areas and establishments

• new building construction

• remodeling areas

• open pit skimmers

Check for areas and products listed above before in-

stalling heater. If found:

• remove products permanently, OR

• install TruSeal direct vent.

Fig. 50: Remove the Air Filter Box Cover

Fig. 51: Remove the Air Filter

(b) EXEMPTIONS: The following equipment is exempt from

248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled "Equipment

Not Required To Be Vented" in the most current edition of

NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled

equipment installed in a room or structure separate from the

dwelling, building or structure used in whole or in part for res-

idential purposes.

MENT VENTING SYSTEM PROVIDED. When the

manufacturer of Product Approved side wall horizontally

vented gas equipment provides a venting system design or

venting system components with the equipment, the instruc-

tions provided by the manufacturer for installation of the

equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting sys-

tem design or the venting system components; and

2. A complete parts list for the venting system design or vent-

ing system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIP-

MENT VENTING SYSTEM NOT PROVIDED. When the

manufacturer of a Product Approved side wall horizontally

vented gas fueled equipment does not provide the parts for

venting the flue gases, but identifies "special venting sys-

tems", the following requirements shall be satisfied by the

manufacturer:

1. The referenced "special venting system" instructions shall

be included with the appliance or equipment installation

instructions; and

2. The "special venting systems" shall be Product Approved

by the Board, and the instructions for that system shall

include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product

Approved side wall horizontally vented gas fueled equip-

ment, all venting instructions, all parts lists for venting

instructions, and/or all venting design instructions shall

remain with the appliance or equipment at the completion of

the installation.

GAS PRESSURE SUPERVISION

The Commonwealth of Massachusetts requires listed high

and low gas pressure switches (manual reset) for any model

with a maximum firing input greater than 1,000,000 Btu/Hr in

accordance with 248 CMR 7.04(11)(d).

A gas pressure regulator (field supplied) is required in the

gas train ahead of the heater, for heaters having input rates

greater than 1,000,000 Btu/Hr, in accordance with 248 CMR

7.04 Figure 3B requirements.

The Commonwealth of Massachusetts requires compliance

with regulation 248 CMR 4.00 and 5.00 for installation of

through – the – wall vented gas appliances as follows:

(a) For all side wall horizontally vented gas fueled equipment

installed in every dwelling, building or structure used in

whole or in part for residential purposes, including those

owned or operated by the Commonwealth and where the

side wall exhaust vent termination is less than seven (7) feet

above finished grade in the area of the venting, including but

not limited to decks and porches, the following requirements

shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS.

At the time of installation of the side wall horizontal vented

gas fueled equipment, the installing plumber or gasfitter shall

observe that a hard wired carbon monoxide detector with an

alarm and battery back-up is installed on the floor level

where the gas equipment is to be installed. In addition, the

installing plumber or gasfitter shall observe that a battery

operated or hard wired carbon monoxide detector with an

alarm is installed on each additional level of the dwelling,

building or structure served by the side wall horizontal vent-

ed gas fueled equipment. It shall be the responsibility of the

property owner to secure the services of qualified licensed

professionals for the installation of hard wired carbon

monoxide detectors

a. In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an attic, the

hard wired carbon monoxide detector with alarm and battery

back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can

not be met at the time of completion of installation, the owner

shall have a period of thirty (30) days to comply with the

above requirements; provided, however, that during said

thirty (30) day period, a battery operated carbon monoxide

detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each

carbon monoxide detector as required in accordance with

the above provisions shall comply with NFPA 720 and be

ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be

permanently mounted to the exterior of the building at a min-

imum height of eight (8) feet above grade directly in line with

the exhaust vent terminal for the horizontally vented gas

fueled heating appliance or equipment. The sign shall read,

in print size no less than one-half (1/2) inch in size, "GAS

VENT DIRECTLY BELOW. KEEP CLEAR OF ALL

OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side

wall horizontally vented gas fueled equipment shall not

approve the installation unless, upon inspection, the inspec-

tor observes carbon monoxide detectors and signage

installed in accordance with the provisions of 248 CMR

5.08(2)(a)1 through 4.

Important Instructions for the Commonwealth of Massachusetts

LIMITED PARTS WARRANTY

MVB – TYPES HAND WH

MODELS 504-2004

SCOPE

Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free

from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Wa rranty. Labor

charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but a re the

owner’s responsibility.

HEAT EXCHANGER WARRANTY

Domestic Hot Water

Five (5) years from date of heater installation. Includes copper heat exchanger with bronze waterways.

Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze waterways.

Space Heating (Closed Loop System)

Ten (10) years from date of heater installation. Includes both cupro-nickel and copper heat exchanger with bronze water-ways.

Thermal Shock Warranty

Twenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large

changes exceeding 150°F between the water temperature at intake and heater temperature, or operating at heater temperatures exc eed-

ing 230°F).

ANY OTHER PART MANUFACTURED BY RAYPAK

One (1) year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records,

whichever comes first.

SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE

VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.

ADDITIONAL WARRANTY EXCLUSIONS

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;

2. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding heater design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the heater system;

7. Failing to eliminate air from, or replenish water in, the connected water system;

8. Chemical contamination of combustion air or use of chemical additives to water.

PARTS REPLACEMENT

Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested,

with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for

only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but R aypak

will apply any such warranty as may be provided to it by the parts manufacturer.

TO MAKE WARRANTY CLAIM

Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and descriptio nof the prob-

lem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, co ntact Service

Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must fir st be

received from Raypak before replacement of any part.

EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY

This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN

LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER-

CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST

RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROV IDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK

SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE,

FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states

do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above

limitation or exclusion may not apply to you.

This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We su ggest that

you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective

date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manuf acture plus

thirty (30) days.

Original Owner Model Number

Mailing Address Serial Number

Date of Installation

City State Zip Code Installation Site

Daytime Telephone Number Contractor/Installer

RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com

LIMITED PARTS WARRANTY

MVB – TYPES P & WHP

MODELS 504–2004

SCOPE

Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free

from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor

charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the

owner’s responsibility.

HEAT EXCHANGER WARRANTY

Five (5) years from date of heater installation. Includes cupo-nickel heat exchanger with bronze and cast iron waterways.

Thermal Shock Warranty

Twenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large

changes exceeding 150°F between the water temperature at intake and heater temperature, or operating at heater temperatures exceed-

ing 230°F).

ANY OTHER PART MANUFACTURED BY RAYPAK

One (1) Year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records,

whichever comes first.

SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE

VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.

ADDITIONAL WARRANTY EXCLUSIONS

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;

2. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding heater design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the heater system;

7. Chemical contamination of combustion air or use of chemical additives to water.

8. Misuse or neglect, including but not limited to freeze-ups, operating the heater with cabinet door off, having flow restrictions or obstruc-

tions between the heater outlet and pool/spa or not maintaining proper chemical balance (pH level must be between 7.2 and 7.8 and

total alkalinity between 100 and 150 PPM. Total Dissolved Solids (TDS) must be no greater than 2500 PPM).

PARTS REPLACEMENT

Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested,

with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for

only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak

will apply any such warranty as may be provided to it by the parts manufacturer.

TO MAKE WARRANTY CLAIM

Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the prob-

lem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service

Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be

received from Raypak before replacement of any part.

EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY

This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN

LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER-

CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST

RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK

SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE,

FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states

do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above

limitation or exclusion may not apply to you.

This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that

you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective

date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manufacture plus

thirty (30) days.

Original Owner Model Number

Mailing Address Serial Number

Date of Installation

City State Zip Code Installation Site

Daytime Telephone Number Contractor/Installer

RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com

START-UP CHECKLIST FOR FAN-ASSISTED

RAYPAK PRODUCTS

This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater

for the first time. All information may be used for warranty purposes and to ensure that the installation is correct.

Additionally this form will be used to record all equipment operation functions and required settings.

GAS SUPPLY DATA CLEARANCES

Regulator Model & Size _________ /______CFH Front Clearance _______________In.

Gas Line Size (in room) ________________In. NPT Right Side Clearance _______________In.

Length of Gas Line ________________Eq Ft Left Side Clearance _______________In.

Low Gas Pressure Setting ________________In. WC Rear Clearance _______________In.

High Gas Pressure Setting ________________In. WC Overhead Clearance _______________In.

Gas Shut-Off Valve Type ________________

(Ball, Lube cock) ELECTRICAL

Sediment Trap ________________Y/N Voltage Supply (VAC) No Load______ Load_____

Port _______Std______Full Voltage -24 VAC _______________VAC

Voltage Com to Ground _______________VAC

VISUAL INSPECTION OF COMPONENTS

Verify inspection was done and condition of components are in

good working order with a “yes”

Hot Surface Igniter

Auto High Limit Setting

Manual Reset High Limit Setting

_______________Ohms

_______________deg F

Wiring Harness _________________ Y/N Operating Control Setting _______________deg F

Burner/s (flame) _________________ Y/N

Refractory (visual) _________________ Y/N Sketch plumbing on reverse side

Remote flame sense _________________ Y/N WATER SUPPLY

Covers in place for outdoor _________________ Y/N Flow Rate in GPM or Delta T _______________IfAvail

Measure flow rate at full fire

VENTING Pump Economaster setting _______________Minutes

Vent Size: _____________ Stack Height:_______ Low Water Cutoff _______________Test

Category: _________ sketch vent on reverse side *** Number of Tanks and Size Qty____ _______Gallons

Vent Material: __________________ Plumbing Size _______________

Vent Termination Type: __________________ Pump Size: _________

(boiler) Pump HP: ______

Combustion Air Openings: Low __________ in2 Impeller trim____________ Pump Model___________

Ventilation air High __________ in2 Louvers __________________ Screens________________

EMISSIONS SETTINGS AND TEST INFORMATION

(AT FULL FIRE)

Nominal Factory Recommended Settings

Blower Pressure Setting _________________In. WC See manual or card tag

Supply Gas Pressure

Verify stable pressure static &

_________________In. WC

dynamic condition

See manual or card tag

Pilot Gas Pressure _________________In. WC See manual or card tag

Manifold Gas Pressure _________________In. WC See manual or card tag

The following measurements must be obtained with a Combustion Analyzer.

NOX _________________PPM Less than 20 PPM (If required by Certifying Agency)

Free Oxygen _________________% See manual

CO _________________PPM Less than 150 PPM

CO2 _________________% See manual

Model Number: ______________________________ Serial Number: _______________________________

*** Note: draw venting with details, such as extractors,

barometric dampers, blast dampers or draft inducers

Site Altitude Above Sea Level __________________Ft.

Job Name _______________________________________________________________________________________

Address _________________________________________________________________________________________

Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; Roof______; Below Grade______

Mechanical Contractor / Installer _______________________________________________________________________

Date and Time of Start-up _____________Print Name and Signature of Start-up Technician_________________________

Information must be faxed to: (805) 278-5471 in order to ensure warranty consideration Attn: Service Manager

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468

Litho in U.S.A.

Raypak Mvb 5042004 Users Manual 6000.59 New RP2100

5042004 to the manual eee29350-205c-4070-96be-fadb19e65f8a

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