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INSTALLATION & OPERATING
Models 504A–2004A
Types H, WH & P
WARNING: Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury, exposure to hazardous materials* or loss of
life. Review the information in this manual carefully. *This unit contains materials that
have been identified as carcinogenic, or possibly carcinogenic, to humans.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3400.542A
INSTRUCTIONS
Effective: 10-04-13
Replaces: 05-21-13
P/N 241512 Rev. 2
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Table of Contents
Related Manuals for Raypak MVB 2004A
Summarization of Contents
Installation and Operating Warnings
Safety Terms and Warnings
Defines DANGER, WARNING, CAUTION, NOTE and lists critical safety warnings for operation.
Before Installation Procedures
Product Receipt and Model Identification
Procedures for receiving the heater, checking for damage, and identifying the model number and serial number.
Ratings and Certifications
Lists applicable standards and certifications for the heater, including ASME and CSA compliance.
Component Locations and Data
Component Location Diagrams
Illustrates component locations from side, front, rear, and top views of the heater unit.
General Information and Basic Data
Provides basic data for heater models including MBTUH, water and gas connections, and vent size.
General Safety Information
Scald Hazard and Prevention
Details scald risks from hot water temperatures over 125°F and provides safety recommendations.
Installation Requirements
Installation Codes and Equipment Base
Outlines required installation codes and specifies base mounting criteria, including on combustible surfaces.
Clearances for Indoor Installations
Specifies minimum clearances from combustible surfaces and for service access for indoor installations.
Combustion and Ventilation Air Supply
Discusses requirements for providing adequate combustion and ventilation air for proper heater operation.
Vent/Air Inlet Termination Clearances
Provides clearance requirements for vent and air inlet terminations per US and Canadian codes.
Air Filter and Combustion Air Options
Details air filter installation and options for direct/conventional combustion air supply.
Outdoor Air Supply Requirements
Specifies requirements for drawing combustion air from outdoors for US and Canadian installations.
Water Piping and Cold Water Operation
Covers water piping, relief valve piping, hydrostatic tests, and cold water operation considerations.
Cold Water Starts and Bypass Systems
Explains handling cold water starts and the use of bypass systems for temperature control.
Hydronic Heating System Design
Provides guidance on pump selection, feedwater regulators, and piping for hydronic systems.
Applications and Operating Modes
Describes different application modes (1, 2, 3) for Type H units and related components.
DHW and Indirect Heating Modes
Details Mode 2 and Mode 3 for indirect DHW and system loop configurations.
Potable Water and Space Heating Considerations
Addresses requirements when using the heater for both potable water and space heating.
Pool Heating and Winterization Procedures
Covers specific installation requirements for pool heating and how to winterize the heater.
Pool Water Chemistry and Feeders
Outlines recommended pool water chemistry and guidelines for chemical feeders.
Gas Supply Requirements and Connections
Details gas supply pressure, connections, and safety precautions for gas lines.
Electrical Power Connections
Specifies codes and guidelines for making electrical power connections to the heater.
Electrical Wiring Procedures and Checks
Explains how to make electrical connections and perform checks using a multi-meter.
Field Wiring and Sensor Connections
Guides on field wiring, connecting enable/disable signals, and outdoor sensors.
Indirect Sensor and Control Signal Wiring
Details wiring for indirect DHW sensors and optional building control signals.
Cascade System Pump and Sensor Wiring
Instructions for wiring pumps and sensors in a cascade system configuration.
Appliance Venting Categories
Defines heater categories based on venting pressure and condensate production.
Vent Stack Support and Terminal Location
Provides guidelines on supporting vent stacks and locating vent terminals.
U.S. Vent Termination Requirements
Specifies vent termination requirements according to US National Fuel Gas Code.
Canadian Vent Terminations and Vertical Venting
Covers Canadian venting termination rules and details on Category I vertical venting.
Common Venting Procedures
Explains how to properly set up and inspect common venting systems.
Engineered Vent Systems
Discusses considerations for engineered vent systems and provides typical common venting diagrams.
Horizontal Through-the-Wall Venting
Details installation requirements for Category III horizontal through-the-wall venting.
Direct Vent - Vertical Installation
Covers installation guidelines for vertical direct vent systems, including termination.
Outdoor Installation and Freeze Protection
Provides instructions for outdoor installation and methods for freeze protection.
Heater Controls
Ignition and High Limit Controls
Explains ignition control functions, manual reset high limit, and optional adjustable high limit.
Flow, Water Level, and Gas Pressure Switches
Describes the function of flow switches, low water cut-off, and optional high/low gas pressure switches.
User Interface and Setpoint Adjustment
Details the user interface, menus, and how to adjust setpoints for optimal operation.
Setup and Adjustment Menu Options
Lists and describes various adjustable parameters available in the setup/adjust menu.
Boiler Menu Parameters
Presents items related to boiler operation, ignition, temperature, and blower speed.
Monitor Menu Parameters
Details parameters available in the monitor menu for tracking boiler performance and history.
Toolbox Menu and Outdoor Reset Concept
Explains the toolbox menu for error codes and the concept of outdoor reset for temperature control.
Reset Ratio Calculation
Describes the settings used to determine the reset ratio for temperature control.
Start-Up Procedures
Pre Start-up Procedures and Checks
Covers filling the system, purging air, inspecting the vent, and performing pre-start-up checks.
Preparation and Gas Pressure Checks
Details preparation steps, power supply checks, manometer connections, and gas supply pressure verification.
Blower, Manifold, and User Tests
Guides on performing blower checks, manifold pressure checks, and the user test function.
Safety Inspection and Leak Testing
Leak Test Procedure: Gas Valve
Provides a detailed procedure for leak testing the dual-seat gas valve.
Post Start-Up Checks
Lists final checks to be performed after initial start-up and burner ignition.
Operation and Troubleshooting
Lighting Instructions and Shutdown Procedures
Explains how to light the appliance and procedures for turning off the gas supply.
MVB Error Codes and Heater Faults
Introduces error codes and general fault conditions displayed by the controller.
MVB Fault Text Descriptions
Provides a table detailing error items, their descriptions, and troubleshooting steps.
PIM™ LED Error Code Listing
Lists error codes indicated by PIM™ LED lights and recommended troubleshooting actions.
Maintenance Schedule
Suggested Minimum Maintenance Schedule Overview
Outlines recommended daily, monthly, and yearly maintenance tasks for optimal operation.
Weekly, Monthly, and Annual Tasks
Details specific maintenance tasks to be performed on a weekly, monthly, semi-annual, and annual basis.
Filter Replacement and Maintenance
Provides instructions on how to replace the air filter and guidelines for filter maintenance.
Appendix and Special Instructions
Inside Air Contamination Effects
Explains how indoor air contaminants can affect condensate acidity and heater materials.
Massachusetts Installation Requirements
Details specific requirements for installing gas appliances in the Commonwealth of Massachusetts.
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