Raypak MVB 504A Installation & Operating Manual
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Raypak MVB 504A Installation & Operating Manual

Modulating vertical boiler types h, wh & p
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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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  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 504A–2004A Types H, WH & P WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, exposure to hazardous materials* or loss of life. Review the information in this manual carefully. *This unit contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans.
  • Page 2 Rev. 2 reflects the following: Changes to: Table A on page 6, “Outdoor Installation” on page 9, “Applications and Modes” on page 16, Table J on page 22, “Electrical Power Connections” on page 22, Table K on page 28, “High Limits” on pages 36-37, Wiring Diagram on page 44, “Blower Check”...

  • Page 3: Table Of Contents

    CONTENTS Venting Installation Tips WARNINGS Venting Configurations BEFORE INSTALLATION Product Receipt Outdoor Installation Model Identification Controls Ratings and Certifications User Interface Installations at Elevation WIRING DIAGRAM Component Locations START-UP General Information Pre Start-up Start-Up GENERAL SAFETY Time/Temperature Relationships in OPERATION Scalds Lighting Instructions To Turn Off Gas To Appliance...

  • Page 4: Warnings

    WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored.

  • Page 5: Before Installation

    If, after reviewing this manual, you still have questions Ratings and Certifications which this manual does not answer, please contact your local Raypak representative or visit our website at www.raypak.com. Standards: Thank you for purchasing a Raypak product. We hope •...

  • Page 6: Component Locations

    Component Locations Fig. 3: Component Locations – Rear Panels omitted for clarity Fig. 1: Component Locations – Side Top panel, blower and gas train omitted for clarity Fig. 4: Component Locations – Top General Information Vent MBTUH Water Conn. Size Model Input* Conn.

  • Page 7: General Safety

    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.

  • Page 8: Installation

    INSTALLATION Equipment Base The heater should be mounted on a level, structurally Installation Codes sound surface. The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed Installations must follow these codes: in enclosed parking garages must be located at least 18 in.

  • Page 9: Combustion And Ventilation Air

    installed on the air filter intake at the rear of the unit during installation. The intake elbow MUST be orient- ed with the open end facing downward. Heaters must not be installed under an overhang unless clearances are in accordance with local instal- lation codes and the requirements of the gas supplier.
  • Page 10 Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening;...

  • Page 11: Conventional Combustion Air Supply

    3. In cold climates, and to mitigate potential freeze- opening shall commence within 12 in. (305 mm) of the up, Raypak highly recommends the installation of top, and one opening shall commence within 12 in. a motorized sealed damper to prevent the circula- (305 mm) of the bottom of the enclosure.
  • Page 12 Canadian Installations All Air from Outdoors The confined space shall communicate with the out- CAUTION: All combustion air must be drawn from doors in accordance with one of the methods below. the air outside of the building; the mechanical equip- The minimum dimension of air openings shall not be ment room must communicate directly with the less than 3 in.

  • Page 13: Water Piping

    1104A–2004A models. Verify proper flow rates and seals within the unit, causing a non-warrantable and ∆T as instructed in this manual. failure. When required, Raypak recommends the boil- Relief Valve Piping er be isolated from the system piping prior to flushing or cleaning with any cleaning agent.
  • Page 14 inlet to increase the heater inlet temperature above water is kept in a narrow temperature range of no 120°F (49°C). This precautionary measure should pre- more than 10°F (5°C), a permanent manual bypass vent the products of combustion from condensing can be employed and manually adjusted to achieve an beyond the ability of the condensate management sys- inlet temperature of 120°F (49°C) or higher as adjust-...

  • Page 15: Hydronic Heating

    5. If this process does not raise the inlet water tem- perature to 105°F (40°C) for Pool Heater (P) Raypak recommends that a feedwater regulator be in- versions and 120°F (49°C) for Hydronic Heating stalled and set at 12 psi minimum pressure at the (H7) or Domestic Hot Water (WH7) versions and highest point of the system.

  • Page 16: Applications & Modes

    (if utilized). The Boiler Pump and System Pump temperatures by reducing flow in the boiler should not are delayed “off” as user defined in the ADJUST be used. Raypak heaters are high-recovery, low-mass menu. heaters which are not subject to thermal shock.

  • Page 17: Domestic Hot Water

    NOTE: MODE 1 can also be used for process heat- ing applications in conjunction with a buffer/storage tank when operating temperatures above 160°F are required. Care must be given to ensure water hard- ness is no more than 15 grains per gallon for scale free operation.
  • Page 18 WATER HARDNESS SOFT* MEDIUM HARD* 3-4 Grains Per Gallon 5-15 Grains Per Gallon 16-25** Grains Per Gallon Model (°F) (ft wc) (in) (ft wc) (°F) (ft wc) (in) (ft wc) (°F) (ft wc) (in) (ft wc) 504A 10.4 25.7 754A 17.3 11.4 25.3...

  • Page 19: Pool Heating

    Automatic Chemical Feeders All chemicals must be introduced and completely dilut- ed into the water before being circulated through the heater. High chemical concentrations will result when the pump is not running (e.g. overnight). POOL THERMOSTAT FROM FILTER NOTE: High chemical concentrates from feeders TO POOL AUTO LIMIT SET TO 110°F...
  • Page 20 Other Pool and Spa Recommended Level(s) Fiberglass Pools Fiberglass Spas Types Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C) 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)* Total Dissolved Solids...

  • Page 21: Gas Supply

    Gas Supply CAUTION: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with natural DANGER: Make sure the gas on which the heater and propane gases is recommended. Apply will operate is the same type as specified on the sparingly only on male pipe ends, leaving the two heater’s rating plate.

  • Page 22: Electrical Power Connections

    Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. WC pressure drop Table I: Maximum Equivalent Pipe Length The MVB 504A-1504A heaters are wired for 120 VAC, Manifold Gas Pressure Setting 12 amps while the MVB 2004A heaters are wired for High Fire Values (in.

  • Page 23: Making The Electrical Connections

    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.) Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum Fig.

  • Page 24: Field Wiring Connection

    Fig. 23: Wiring Location Fig. 24: Locator Dimples for Optional Components NOTE: A grounding electrode conductor shall be closure (including a remote thermostat) across these used connect equipment grounding terminals will enable the MVB unit to run. Caution conductors, the equipment enclosures, and the should be used to ensure neither of the terminals grounded service conductor to the grounding becomes connected to ground.
  • Page 25 Caution should be used to ensure nei- than 4 connected boilers, an external sequencer ther of these terminals becomes connected to such as the Raypak Temp Tracker Mod+ Hybrid ground. can be used. NOTE: Alternately, a thermostat contact closure can 2.
  • Page 26 MASTER FOLLOWERS VERSA MASTER Fig. 27: MVB Cascade System Wiring Cascade System Pump and Sensor Wiring 1. On the boiler designated as the Master, connect the system pump enable wiring to the terminal block at the rear of the unit. The connections are dry contacts rated for pilot duty only (5A maxi- mum).

  • Page 27: Venting

    Alarm Connection 5. Connect the Enable/Disable wiring to terminals 11 and 12 on the field wiring strip located on the Master boiler (See Fig. 25). This connection must An alarm annunciator or light may be connected to the be provided through dry contacts closure. alarm contacts on the field wiring terminals.
  • Page 28 CAUTION: Vent piping is hot. Raypak recom- 2. Give special attention to the location of the vent mends the use of double wall or insulated wall pipe termination to avoid possibility of property dam- to prevent personal injury.
  • Page 29 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.

  • Page 30: Venting Installation Tips

    Vertical Venting (Category I) Canadian Installations Refer to latest edition of the B149 Installation Code. Installation A vent shall not terminate: Natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head 1. Directly above a paved sidewalk or driveway that expels the exhaust gases from the flue.
  • Page 31 Vertical Vent Air Inlet Certified Combustion Air Model Vent Size Height (ft) Max. Length* (ft) Vent Intake Pipe (in.) Material Material Min. Max. 6” Ø 8” Ø 10” Ø 504A Galvanized 754A 100** Steel, Category I PVC, 1104A (Type B ABS, Equivalent) CPVC...
  • Page 32 3. Insofar as is practical, close all building doors and 7. Any improper operation of the common venting windows and all doors between the space in which system should be corrected so that the installation the appliances remaining connected to the com- conforms with the NFGC (U.S.) or B149 (Canada).
  • Page 33 Volume of Model Vent Size Flue Products (in.) (CFM) 504A 754A 1104A 1504A 2004A NOTE: Data for 100% firing rate. Table M: Typical Volume of Flue Products Horizontal Through-the-Wall Direct Venting (Category III) Fig. 35: Horizontal Through-the-Wall Direct Venting Installation These installations utilize the heater-mounted blower to vent the combustion products to the outdoors.
  • Page 34 The direct vent cap Fig. 36: Direct Vent - Vertical must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved Installation stainless steel flue direct vent cap must be used (sales order option D-15).

  • Page 35: Outdoor Installation

    Outdoor Installation The vent cap is not considered in the overall length of the venting system. Units installed outdoors must be vented with listed Care must be taken during assembly that all joints are Category I (Type B double-wall or equivalent) vent sealed properly.

  • Page 36: Controls

    Ignition Control Functions When there is a call for heat, and all safeties are closed, then the combustion air blower starts to purge air from the combustion chamber. After the pre-purge, the igniter is energized. The standard ignition module will lock-out after failing to light 3 times during a call for heat.

  • Page 37: Flow Switch

    Standard The fixed setting manual reset high limit is built into the PIM™, it utilizes a dual element sensor located on the outlet (see Fig. 38). To reset a high limit lock-out, press and release the RESET button located on the user interface.

  • Page 38: User Interface

    Blocked Vent Switch For detailed descriptions of the various screens, con- sult the VERSA IC Control I&O Manual (Catalog #5000.72). This heater is equipped with a blocked vent pressure switch to prevent the operation of the heater when too Adjusting the MVB Setpoint much of the vent is blocked.
  • Page 39 Item Application Range Description Default Enable or Disable the operation of boilers. 4 boiler range, 1 is BOILER 1 ON <> OFF enabled by default H MODE 1,2,3 TARGET RSET <> SETP SETP RSET = Outdoor Reset, SETP =Setpoint TANK SETP OFF, 50°F to 150°F 125°F Tank set point temperature...
  • Page 40 Boiler Menu The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information Item Application Description IGNITION Current State of Ignition LIMIT TEMP Current Limit Temperature AUX TEMP H MODE 3 Current Auxiliary Temperature EMS Vdc Current EMS signal in Volts DC...
  • Page 41 Monitor Menu The Monitor Menu records and displays critical Boiler information, such as, Cycle times, Run times, and Maximum/Minimum temperature readings depending on the setup. Item Application Description RUN TIME Burner 1 Burner run time (hours). Press UP/DOWN for 1 sec to clear. Cycles Burner Number of burner cycles.
  • Page 42 MAX HEAT be set to OFF again by the user. (See VERSA IC Manual for details.) P/N 104901 Software number of the Raypak VERSA Resets to factory settings. Press UP and DOWN for 1 second to show CLR and load DEFAULTS factory defaults to all settings.

  • Page 43: Reset Ratio

    RESET RATIO The control uses the four following settings to determine the reset ratio: Boiler Start (Boil START) The Boil START temperature is the theoretical boiler supply water temperature that the heating system requires when the outdoor air temperature equals the OUT START temperature setting. The Boil START is typically set to the desired building temperature. Outdoor Start (OUT START) The OUT START temperature is the outdoor air temperature at which the control provides the Boil START water temperature to the system.

  • Page 44: Wiring Diagram

    WIRING DIAGRAM - Models 504A–2004A...

  • Page 45: Start-Up

    START-UP 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. NOTE: The following steps must be performed by a factory-trained technician.

  • Page 46: Start-Up

    Preparation 3. If the gas pressure is greater than 14.0 in. WC, turn off the main gas shut-off valve, upstream of the heater. WARNING: Do not turn on gas at this time. Start-Up Check Power Supply NOTE: The values in Tables T and V represent the With multi-meter at incoming power, check voltage conditions when the heater is at full firing rate at sea between:...
  • Page 47 Blower Check Manifold Gas Pressure Setting High Fire Values (in. WC) Model 1. Check blower suction using the manometer Natural Gas Propane Gas attached to the air pressure tee, with the heater fir- ing at 100% input. The reading should be as noted 504A -4.1 -4.4...
  • Page 48 Leak Test Procedure: Dual-Seat Gas Safety Inspection Valve 1. Check all thermostats and high limit settings. Proper leak testing requires three pressure test points 2. During the following safety checks leave manome- in the gas train. Remove the upper front panel and ters hooked up, check and record.
  • Page 49 8. To test the fixed manual reset high limit built into the PIM™, first set dip switch #8 on the PIM™ to the ON position. This will activate a Commission Test Mode which will turn on the amber Alarm/Test LED on the PIM™. The fixed high limit setting is temporarily overridden to match the setpoint potentiometer position on the PIM™.

  • Page 50: Operation

    OPERATION 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 Lighting Instructions gas or propane gas. 1. Before operation, make sure you have read all of To Turn Off Gas To Appliance the safety information in this manual.
  • Page 51 2. Note the error code, either through the flash code WARNING: When servicing or replacing any on the PIM™ and/or from the Toolbox menu on the components of this unit be certain that: user interface, and reference the explanation of •...
  • Page 52 LED Error Code Listing Active errors detected are indicated by LED lights on the PIM™. LED Code Error Mode Recommended Troubleshooting Normal Operation Red LED steady ON, Check that the proper ID card is securely connected. Perform a ID Card Fault Green Power power and system restart.

  • Page 53: Maintenance

    MAINTENANCE Sensor Resistance Values Suggested Minimum Water Sensor / Outdoor Sensor Maintenance Schedule Water Temperature (°F) Resistance (ohms) 32550 Regular service by a qualified service agency and 25340 maintenance must be performed to ensure maximum operating efficiency. 19870 15700 Daily and monthly maintenance as outlined below may be performed by onsite maintenance staff.

  • Page 54: Preventive Maintenance Schedule

    3. Check that area is free from combustible materi- Weekly als, gasoline, and other flammable vapors and liquids. For low-pressure heaters, test low-water cut-off device. (With heater in pre-purge, depress the low 4. Check air filter and replace as necessary. water cut-off test button.

  • Page 55: Filter Maintenance

    7. Test safety/safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV. Filter Maintenance NOTE: Use Raypak replacement filters, kit number 012553F (12”X12”) for models 504A-1104A and kit number 012552F (16”X16”) for models 1504A- 2004A. •...

  • Page 56: Appendix

    APPENDIX • metal fabrication plants • beauty shops • refrigeration repair shops Inside Air Contamination • photo processing plants • auto body shops • plastic manufacturing plants All heaters experience some condensation during • furniture refinishing areas and establishments start-up. The condensate from flue gas is acidic. •...

  • Page 57: Important Instructions For The Commonwealth Of

    Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance (b) EXEMPTIONS: The following equipment is exempt from with regulation 248 CMR 4.00 and 5.00 for installation of 248 CMR 5.08(2)(a)1 through 4: through – the – wall vented gas appliances as follows: 1.

  • Page 59: Start-Up Checklist

    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.

  • Page 60: Warranty

    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.
  • Page 61 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.
  • Page 64 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

This manual is also suitable for:

Mvb 1504aMvb 1104aMvb 754aMvb 2004a

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