Raypak Boiler 5042004 User Guide

INSTALLATION & OPERATING  
INSTRUCTIONS  
Models 504–2004  
Types H, WH, P & WHP  
L
W
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. 3400.54E  
Effective: 03-25-10  
Replaces: 03-19-09  
P/N 241317 Rev. 6  
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WARNINGS  
Pay Attention to These Terms  
Indicates the presence of immediate hazards which will cause severe  
DANGER:  
WARNING:  
CAUTION:  
NOTE:  
personal injury, death or substantial property damage if ignored.  
Indicates the presence of hazards or unsafe practices which could cause  
severe personal injury, death or substantial property damage if ignored.  
Indicates the presence of hazards or unsafe practices which could cause  
minor personal injury or product or property damage if ignored.  
Indicates special instructions on installation, operation, or maintenance which  
are important but not related to personal injury hazards.  
DANGER: Make sure the gas on which the heater  
will operate is the same type as that specified on the  
heater rating plate.  
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.  
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.  
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.  
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.  
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.  
WARNING: To minimize the possibility of improper  
operation, serious personal injury, fire, or damage to  
the heater:  
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.  
Always keep the area around the heater free of  
combustible materials, gasoline, and other  
flammable liquids and vapors.  
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.  
Heater should never be covered or have any  
blockage to the flow of fresh air to the heater.  
WARNING: Risk of electrical shock. More than one  
disconnect switch may be required to de-energize  
the equipment before servicing.  
WARNING - CALIFORNIA PROPOSITION  
65: This product contains chemicals known to the  
State of California to cause cancer, birth defects or  
other reproductive harm.  
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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.  
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  
Ratings and Certifications  
Standards:  
Thank you for purchasing a Raypak product. We hope  
you will be satisfied with the high quality and durability  
of our equipment.  
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  
Product Receipt  
CAN 3.1  
-
latest edition, Industrial and  
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.  
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.  
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.  
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.  
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.  
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).  
Model Identification  
The model identification number and heater serial  
number are found on the heater rating plate located on  
5
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Component Locations  
HIGH VOLTAGE  
ELECTRICAL CONNECTIONS  
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  
Gas  
Vent  
Size  
(in.)  
MBTUH  
Input*  
Water  
Conn.  
(NPT)  
Conn.  
(NPT)  
Model  
No.  
Max.* Min.*  
N
1
1
P
1
1
1
1
1
Flue Intake  
504  
754  
500  
750  
350  
525  
770  
2
2
8
6
6
6
8
8
10  
10  
12  
14  
1104  
1504  
2004  
1100  
2-1/2 1-1/4  
2-1/2 1-1/4  
1500 1050  
1999 1400  
2-1/2  
2
Panels omitted for clarity  
Fig. 2: Component Locations – Front  
*H7 units only.  
Table A: Basic Data  
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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.  
Water temperature over 125°F can  
causeinstantsevereburnsordeath  
from scalds.  
Children, disabled, and elderly are  
at highest risk of being scalded.  
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.  
See instruction manual before set-  
ting temperature at water heater.  
Feel water before bathing or show-  
ering.  
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.  
Temperature limiting valves are  
available, see manual.  
Feel water before bathing or showering.  
Temperature limiting valves are available.  
Time/Temperature  
Relationships in Scalds  
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.  
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  
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.  
120°F  
125°F  
130°F  
135°F  
140°F  
145°F  
150°F  
155°F  
More than 5 minutes  
1-1/2 to 2 minutes  
About 30 seconds  
About 10 seconds  
Less than 5 seconds  
Less than 3 seconds  
About 1-1/2 seconds  
About 1 second  
Table courtesy of The Shriners Burn Institute  
Table B: Time to Produce Serious Burn  
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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).  
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.  
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: 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.  
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.  
Fig. 5: Modulating Temperature Control  
CAUTION: Hotter water increases the risk of  
scalding! There is a hot water scald potential if the  
thermostat is set too high.  
Clearances  
Indoor Installations  
Minimum Clearance  
from Combustible  
Surfaces  
Minimum  
Service  
Clearance  
INSTALLATION  
Heater  
Side  
Installation Codes  
Floor*  
Rear  
0”  
12”  
1”  
0”  
24”  
1”  
Installations must follow these codes:  
Right  
Side  
Left Side  
Top  
1”  
1”  
Local, state, provincial, and national codes, laws,  
regulations and ordinances  
0”  
10”  
24”  
1”  
National Fuel Gas Code, ANSI Z223.1/NFPA 54 –  
latest edition (NFGC)  
Front  
Vent  
Open  
1”  
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)  
*DO NOT install on carpeting.  
Table C: 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  
8
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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.  
Min. Clearance  
from Combustible  
Surfaces  
Minimum  
Service  
Clearance  
Heater  
Side  
Rear  
Front  
12”  
24”  
24”  
1”  
Open  
Right Side  
Left Side  
Top  
1”  
1”  
1”  
Unobstructed  
10”  
Vent  
Termination  
12”  
12”  
Table D: Clearances – Outdoor Installations  
Combustion and Ventilation Air  
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.  
Indoor Units  
Venting not shown for clarity. Heater must be vented per instruc-  
tions in this manual  
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.  
Fig. 6: Minimum Clearances from Combustible  
Surfaces – Indoor and 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.  
CAUTION: Combustion air must not be  
contaminated by corrosive chemical fumes which  
can damage the heater and void the warranty. (See  
the Appendix.)  
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  
NOTE: It is recommended that the intake vent be  
insulated to minimize sweating.  
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Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations  
U.S. Installations1  
Canadian Installations2  
Clearance above grade, veranda, porch,  
deck, or balcony  
A
1 ft (30 cm)  
1 ft (30 cm)  
4 ft (1.2m) below or to side  
of opening; 1 foot (30 cm)  
above opening  
Clearance to window or door that may be  
opened  
B
C
3 ft (91 cm)  
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  
D
5 ft (1.5m)  
*
E
F
Clearance to unventilated soffit  
Clearance to outside corner  
Clearance to inside corner  
*
*
*
*
*
G
6 ft (1.83m)  
3 ft (91 cm) within a height  
15 ft above the me-  
ter/regulator assembly  
Clearance to each side of center line ex-  
tended above meter/regulator assembly  
H
I
*
*
Clearance to service regulator vent outlet  
6 ft (1.83m)  
Clearance to non-mechanical air supply inlet 4 ft (1.2m) below or to side  
to building or the combustion air inlet to any  
of opening; 1 ft (30 cm)  
J
3 ft (91 cm)  
other appliance  
above opening  
3 ft (91 cm) above if within  
10 ft (3m) horizontally  
K
L
Clearance to mechanical air supply inlet  
6 ft (1.83m)  
7 ft (2.13m) t  
Clearance above paved sidewalk or paved  
driveway located on public property  
7 ft (2.13m)  
Clearance under veranda, porch, deck or  
balcony  
M
*
12 in. (30 cm) TT  
1
2
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code  
In accordance with the current CAN/CGA-B149 Installation Codes  
t
Vent 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 minimum of 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  
Table E: Vent/Air Inlet Termination Clearances  
10  
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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.  
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.  
All ducting must be self-supported.  
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.  
Conventional Combustion Air  
Supply  
Fig. 8: Air Filter Box  
Direct Vent  
U.S. Installations  
If outside air is drawn through the intake pipe directly  
to the unit for combustion:  
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.2 per 1,000 BTUH (2,225 mm2 per 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.  
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.2 of free  
area per 20,000 BTUH (111 mm2 per 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.2 of free  
area per 10,000 BTUH (222 mm2 per kW) of total  
input rating of all equipment in the room when the  
opening is communicating with the outdoors  
through horizontal duct(s).  
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.  
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  
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  
In addition to the 3 previous steps, combustion air may  
be ducted directly to the heater by using PVC, CPVC  
11  
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the enclosure, shall be provided. The openings 2. For heaters using a barometric damper in the vent  
shall communicate directly, or by ducts, with the  
outdoors or spaces (crawl or attic) that freely com-  
municate with the outdoors.  
system there shall be a permanent air supply  
opening(s) having a cross section area of not less  
than 1 in.2 per 7,000 BTUH (320 mm2 per kW) up  
to and including 1 million BTUH, plus 1 in.2 per  
14,000 BTUH (160 mm2 per 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).  
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 mm2 per 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.2 per 2,000  
BTUH (1,100 mm2 per kW) of total input rat-  
ing of all equipment in the enclosure.  
WARNING: Care must be taken to ensure that the  
equipment room is not under negative pressure  
conditions.  
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 3. For heaters not using a barometric damper in the  
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:  
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.2 for each 30,000 BTUH (74  
mm2 per 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.  
a. 1 in.2 per 3,000 BTUH (740 mm2 per 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.  
WARNING: Do not use the “one permanent  
opening” method if the equipment room is under  
negative pressure conditions.  
4. Refer to the B149 Installation Code for additional  
information.  
Canadian Installations  
CAUTION: All combustion air must be drawn from  
outside of the building; the mechanical equipment  
room must communicate directly with the outdoors.  
Water Piping  
General  
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 The heater should be located so that any water leaks  
with the outdoors. The total cross-sectional area of will not cause damage to the adjacent area or struc-  
such an opening(s) shall be at least 10% of the tures.  
area required in 2. and 3. (below), but in no case  
shall the cross-sectional area be less than 10 in.2  
NOTE: In lieu of installing the System Temp Sensor  
(65 cm2).  
in the system return loop, an alternate system using  
a buffer tank (see Fig. 31) can be used for better sys-  
tem temperature control.  
12  
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feed valve. Test at standard operating pressure for  
at least 24 hours.  
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.  
2. Make sure constant gauge pressure has been  
maintained throughout test.  
3. Check for leaks. Repair if found.  
NOTE: Minimum pipe size for in/out connections is  
Cold Water Operation  
1
2 in. NPT for 504 and 754 models and 2- ⁄  
2
in NPT for  
1104–2004 models. Verify proper flow rates and ∆T  
as instructed in this manual.  
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.  
Relief Valve Piping  
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.  
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-  
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.  
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.  
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.  
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.  
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  
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  
13  
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longer than 7 minutes or where cold water operation is and manually adjusted to achieve an inlet temperature  
continuous, provisions must be made to mix higher of 120°F (49°C) or higher as adjusted at the minimum  
temperature outlet water with the colder inlet water temperature in this narrow temperature range (i.e.  
and thereby raise the inlet temperature to at least Range 75°F to 85°F – adjust bypass with temperature  
120°F (49°C) within the 7-minute time limit.  
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.  
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.  
*
*Maximum 4 times the pipe diameter or 12”, whichever is less.  
Fig. 10: Cold Water Run  
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).  
*
*Maximum 4 times the pipe diameter or 12”, whichever is less.  
Feedwater Regulator  
Fig. 9: Cold Water Start  
Cold Water Run  
Raypak recommends that a feedwater regulator be in-  
stalled and set at 12 psi minimum pressure at the  
Cold water run differs from cold water start in that the highest point of the system. Install a check valve or  
system water entering the heater remains below back flow device upstream of the regulator, with a  
120°F (49°C) continuously. Typically, this is the case in manual shut-off valve as required by local codes.  
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  
14  
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Input Output  
MBTUH  
20° ∆T  
30° ∆T  
40° ∆T  
Min. Flow  
Max. Flow  
∆P  
Model  
No.  
gpm ∆P gpm ∆P gpm ∆P gpm  
∆P  
1.1  
1.7  
4.1  
8.0  
16.0  
∆T gpm  
∆T  
8
504  
754  
500  
750  
420  
630  
42  
63  
92  
2.7  
6.0  
28  
42  
62  
84  
1.4  
2.9  
25  
32  
46  
63  
84  
34  
40  
40  
40  
40  
100 11.3  
100 13.8  
32  
46  
63  
84  
1.7  
4.1  
13  
16  
22  
30  
1104  
1100  
924  
13.3  
6.7  
113 18.6  
113 22.2  
113 27.2  
1504 1500  
2004 1999  
1260  
1679  
13.3  
8.0  
112 26.9  
16.0  
Note: Basis for minimum flow is ∆T. Basis for maximum flow is gpm.  
Table F: Heater Rates of Flow and Pressure Drops  
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.  
THERMOSTAT OR  
SYSTEM SENSOR  
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.  
*Maximum 4 times the pipe diameter or 12”, whichever is less.  
Air-Separation/Expansion Tank  
Fig. 12: Single Heater - Low-Temperature (Heat Pump)  
Application with Primary/Secondary Piping  
All heaters should be equipped with a properly sized  
expansion tank and air separator fitting as shown in  
Fig. 11.  
THERMOSTAT OR  
SYSTEM SENSOR  
*Maximum 4 times the pipe diameter or 12”, whichever is less.  
Fig. 11: Air-Separation/Expansion Tank  
Fig. 13: Dual Heaters (Reverse/Return)  
with Primary/Secondary Piping  
15  
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Three-Way Valves  
NOTE: If local codes require a vacuum relief valve,  
acquire one locally and install per valve  
manufacturer’s instructions.  
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.  
Potable Water and Space Heating  
CAUTION: When this heater is used for both  
potable water and space heating, observe the  
following to ensure proper operation.  
Domestic Hot Water  
1. All piping materials and components connected to  
the water heater for the space heating application  
shall be suitable for use with potable 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.  
2. Toxic chemicals, such as used for boiler treatment,  
shall not be introduced into the potable water used  
for space heating.  
SYSTEM  
SUPPLY  
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  
SYSTEM  
RETURN  
When a boiler or water heater is used in a pool heat-  
ing application, ensure that all the following installation  
requirements are met.  
Fig. 14: Single Domestic Hot Water Heater and Storage  
Tank  
MBTUH  
Soft (0-4 grains per gallon)  
Medium (5-15 grains per gallon) Hard* (16-25 grains per gallon)  
Model  
No.  
Input Output ∆T gpm ∆P MTS SHL ∆T gpm  
∆P  
MTS SHL ∆T gpm  
∆P  
MTS SHL  
504  
754  
500  
750  
420  
630  
17  
25  
30  
30  
50  
50  
60  
82  
3.6  
4.0  
2
2
5.9 13  
6.3 20  
65  
65  
5.5  
6.4  
2
2
9.3  
9
95  
10.4  
13.8  
2
2
18.1  
22.2  
10.2 13  
100  
113  
113  
113  
1104  
1504  
2004  
1045  
1425  
1900  
888  
6.4 2-1/2 7.6 20  
12.7 2-1/2 14.9 22  
92  
13.2 2-1/2 15.9 16  
22.3 2-1/2 26.3 22  
27.4 2-1/2 31.3 29  
18.7 2-1/2 22.6  
22.3 2-1/2 26.3  
27.4 2-1/2 31.3  
1211  
1615  
113  
113  
30 110 26.1 2-1/2 29.8 29  
∆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  
16  
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The MVB must be equipped with a field-supplied ex- 1. Turn on pump.  
ternal pump and bypass arrangement. This  
arrangement blends outlet water with the inlet water to 2. Turn on heater and wait until heater goes to full  
increase the inlet water temperature to a minimum of  
105°F (40°C) for Pool Heater (P and WHP) versions  
fire.  
and 120°F (49°C) for Hydronic Heating (H7) or 3. With the heater operating at 100% firing rate, set  
1
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.  
Valve A (the bypass) to ⁄  
B to fully open position. See Fig. 16.  
2
open position, and Valve  
4. Adjust Valve A until the inlet water temperature is  
105°F (40°C) or 120°F (49°C) depending upon  
heater type.  
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.  
NOTE: Opening the valve will increase the  
temperature and closing the valve will decrease the  
temperature.  
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.  
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.  
POOL  
THERMOSTAT  
FROM  
FILTER  
*
TO POOL  
CHEMICAL  
FEED  
*Maximum 4 times the pipe diameter or 12”, whichever is less.  
Fig. 15: Single Pool Heater Application  
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:  
Fig. 16: “H” Bypass Setting  
17  
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Pool/Spa Water Chemistry  
NOTE: For automatic temperature adjustment, a  
Cold Water Run (CWR) system can be used instead  
of a manual bypass. See Fig. 10.  
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: Chemical imbalance can cause severe  
damage to your heater and associated equipment.  
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.  
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.  
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.  
Other Pool and Spa  
Recommended Level(s)  
Water Temperature  
pH  
Fiberglass Pools  
68-88°F (20-31°C)  
7.3-7.4  
Fiberglass Spas  
Types  
89-104°F (31-40°C)  
7.3-7.4  
68-104°F (20-40°C)  
7.6-7.8  
Total Alkalinity (ppm)  
Calcium Hardness (ppm)  
Salt (ppm)  
120-150  
120-150  
80-120  
200-300  
150-200  
200-400  
6000 Maximum  
2-3  
6000 Maximum  
2-3  
6000 Maximum  
2-3  
Free Chlorine (ppm)*  
Total Dissolved Solids  
(ppm)  
3000 Maximum  
3000 Maximum  
3000 Maximum  
*Free Chlorine MUST NOT EXCEED 5 ppm!  
Table H: Water Chemistry  
18  
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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.  
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.  
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.  
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.  
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.  
Gas Supply  
Fig. 17: Gas Supply Connection  
DANGER: Make sure the gas on which the heater  
will operate is the same type as specified on the  
heater’s rating plate.  
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.  
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.  
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.  
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.  
Gas Supply Connection  
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).  
19  
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1 in. NPT  
1-1/4 in. NPT  
1-1/2 in. NPT  
2 in. NPT  
2-1/2 in. NPT  
Model  
No.  
N
P
N
P
150  
75  
N
150  
70  
P
N
P
N
P
504  
754  
15  
5
35  
15  
65  
35  
15  
10  
360  
175  
75  
250  
100  
60  
1104  
1504  
2004  
35  
35  
250  
150  
85  
225  
150  
85  
20  
20  
45  
275  
200  
35  
3
Natural Gas – 1,000 BTU/ft , 0.60 specific gravity at 0.5 in. WC pressure drop  
3
Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. WC pressure drop  
Table I: Maximum Equivalent Pipe Length  
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.  
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.  
The gas valve pressure regulator on the heater is  
nominally preset as noted in Table J.  
In Canada, CSA C22. 1 C.E.C. Part 1.  
During normal operation, carbon dioxide should be 8.5 The MVB 504-1504 heaters are wired for 120 VAC, 12  
to 9.0% at full fire for natural gas and between 9.5 and amps while the MVB 2004 heaters are wired for 120  
10.0% for propane gas. Carbon monoxide should be VAC, 18 amps. Consult the wiring diagram shipped  
‹100ppm.  
with the heater. Before starting the heater, check to  
ensure proper voltage to the heater and pump.  
Manifold Gas Pressure  
(High Fire Values)  
3
Model  
No.  
Boiler mounted pumps (up to ⁄  
4
hp) get their power  
supply directly from the boiler power supply (connec-  
tions in rear wiring box). Install a circuit breaker sized  
Natural Gas  
-0.1  
Propane Gas  
-0.1  
sufficiently for both the heater and the pump. Pumps  
504  
754  
3
larger than ⁄  
4
hp must use a separate power supply  
-0.4  
-1.0  
-2.4  
-1.0  
-0.1  
-0.2  
-0.6  
-0.5  
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.  
1104  
1504  
2004  
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.  
NOTE: Manifold pressures should be 0.2 in. WC.  
Table J: Manifold Gas Pressure Settings  
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.  
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  
3
(Com), 3 (GND) and 6 (Hot) – ⁄  
4
hp 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.  
Electrical Power Connections  
Installations must follow these codes:  
20  
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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  
FRONT WIRING PANEL LOW VOLTAGE ELECTRICAL CONNECTIONS  
Fig. 18: Wiring Electrical Connections  
Field-Connected Controllers  
Fig. 20: Multi-meter  
It is strongly recommended that all individually-pow-  
ered control modules and the heater should be  
supplied from the same power source.  
Making the Electrical Connections  
Refer to Fig. 18-21.  
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.  
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.  
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.  
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.  
Check the Power Source  
BLACK  
CIRCUIT  
5. Provide overload protection and a disconnect  
means for equipment serviceability as required by  
local and state code.  
BREAKER  
WHITE  
GREEN  
6. Install heater controls, thermostats, or building  
management systems in accordance with the  
applicable manufacturers’ instructions.  
GROUND  
A
B
C
7. Conduit should not be used as the earth ground.  
Fig. 19: Wiring Connections  
21  
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Venting  
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.  
CAUTION: Proper installation of flue venting is  
critical for the safe and efficient operation of the  
heater.  
General  
Field Wiring Connection  
Appliance Categories  
CAUTION: Label all wires prior to disconnection  
when servicing controls. Wiring errors can cause im-  
proper and dangerous operation. Verify proper  
operation after servicing.  
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.  
DANGER: SHOCK HAZARD  
Make sure electrical power to the heater is discon-  
nected to avoid potential serious injury or damage to  
components.  
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.  
HIGH VOLTAGE  
WIRING  
See Table K for appliance category requirements.  
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.  
Fig. 21: High Voltage Wiring Location  
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.  
LOCATOR DIMPLES  
FOR OPTIONAL  
COMPONENTS  
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.  
Fig. 22: Locator Dimples for Optional Components  
22  
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Combustion  
Air Supply  
Exhaust  
Configuration  
Heater Venting  
Category  
Certified  
Materials  
Combustion Air  
Inlet Material  
Vertical  
Venting  
B-Vent  
I
Equivalent  
From Inside Building  
(Non-Direct Venting)  
Horizontal Through-  
the-Wall Venting  
Stainless Steel  
AL29-4C  
III  
I
Vertical  
Venting  
B-Vent  
Equivalent  
Galvanized Steel  
PVC  
From Outside Building  
(Direct Venting)  
ABS  
CPVC  
Horizontal Through-  
the-Wall Venting  
Stainless Steel  
AL29-4C  
III  
Table K: Venting Category Requirements  
6. Un-insulated single-wall metal vent pipe shall not  
be used outdoors in cold climates for venting gas-  
fired equipment.  
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.  
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.  
Vent Terminal Location  
NOTE: During winter months check the vent cap  
and make sure no blockage occurs from build-up of  
snow or ice.  
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.  
1. Condensate can freeze on the vent cap. Frozen  
condensate on the vent cap can result in a blocked  
flue condition.  
10. DO NOT terminate above any door, window, or  
gravity air intake. Condensate can freeze, causing  
ice formations.  
2. Give special attention to the location of the vent  
termination to avoid possibility of property dam-  
age or personal injury.  
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.  
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.  
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.  
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.  
U.S. Installations  
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.  
Refer to the latest edition of the National Fuel Gas  
Code.  
Vent termination requirements are as follows:  
23  
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1. Vent must terminate at least 4 ft below, 4 ft hori- 5. Within 6 ft (1.8 m) of any gas service regulator  
zontally from or 1 ft above any door, window or  
gravity air inlet to the building.  
vent outlet.  
6. Less than 1 ft (305 mm) above grade level.  
2. The vent must not be less than 7 ft above grade  
when located adjacent to public walkways.  
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.  
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 8. Underneath a verandah, porch or deck, unless the  
in no case above or below unless 4 ft horizontal  
distance is maintained, from electric meters, gas  
meters, regulators, and relief equipment.  
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).  
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.  
Venting Installation Tips  
Support piping:  
horizontal runs—at least every 5 ft  
vertical runs—use braces  
under or near elbows  
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.  
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.  
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.  
Canadian Installations  
Natural Draft Vertical Venting  
(Category I)  
Refer to latest edition of the B149 Installation code.  
A vent shall not terminate:  
Installation  
1. Directly above a paved sidewalk or driveway  
which is located between two single-family dwell-  
ings and serves both dwellings.  
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.  
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.  
The maximum and minimum venting length for Cate-  
gory I appliances shall be determined per the NFGC  
(U.S.) or B149 (Canada).  
4. Above a meter/regulator assembly within 3 ft (915  
mm) horizontally of the vertical centre-line of the  
regulator.  
24  
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Vertical Vent  
Height1 (ft)  
Air Inlet  
Certified  
Vent  
Material  
Combustion Air  
Intake Pipe  
Material  
Model  
No.  
Vent Size  
(in.)  
Max. Length* (ft)  
Min.  
Max.  
6” Ø  
8” Ø 10” Ø  
504  
754  
8
Galvanized  
Steel,  
10  
10  
12  
14  
45  
100**  
Category I  
(Type B  
Equivalent)  
PVC,  
1104  
1504  
2004  
5
25  
ABS,  
CPVC  
45  
85**  
1
Vent 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.  
Table L: Category I Vertical Venting  
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.  
Fig. 23: Vertical Venting  
25  
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Common Venting  
common venting system placed in operation, while the  
other appliances remaining connected to the common  
Manifolds that connect more than one heater to a com- venting system are not in operation.  
mon chimney must be sized to handle the combined  
load. Consult available guides for proper sizing of the 1. Seal any unused opening in the common venting  
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.  
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.  
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.  
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.  
CAUTION: Vent connectors for natural draft  
venting systems must be Type B or better.  
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  
Fig. 24: Typical Common Venting  
26  
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Volume of  
Flue Products  
(CFM)  
Model  
No.  
Vent Size  
(in.)  
4. Place in operation the appliances being inspected.  
Follow the manufacturer’s instructions for lighting  
each appliance. Adjust thermostat so appliance  
will operate continuously.  
504  
754  
8
170  
260  
380  
510  
680  
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.  
10  
10  
12  
14  
1104  
1504  
2004  
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.  
NOTE: Data for 100% firing rate.  
Table M: Typical Volume of Flue Products  
Horizontal Through-the-Wall Direct  
Venting (Category III)  
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.  
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.  
Fig. 25: Horizontal Through-the-Wall Venting  
NOTE: For extractor sizing, typical CO2 levels are  
8.5% for natural gas and 9.5% for LP gas and flue  
temperature of 350° F.  
OPTIONAL HORIZONTAL THROUGH-THE-WALL VENTING  
(CATEGORY IV)  
Fig. 26: Alt. Horizontal Through-the-Wall Venting  
27  
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75’ of straight flue pipe  
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.  
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.  
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.  
WARNING: No substitutions of flue pipe or vent  
cap material are allowed. Such substitutions would  
jeopardize the safety and health of inhabitants.  
Installation  
Direct Vent—Vertical  
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).  
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 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:  
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.  
28  
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Air Inlet  
Maximum  
Horizontal  
Vent Length  
(ft)**  
Certified  
Vent  
Material  
Vent  
Size  
(in.)  
Combustion Air  
Intake Pipe  
Material  
Max. Length** (ft)  
Model  
No.  
6” Ø  
8” Ø  
10” Ø  
504  
754  
8
t
10  
10  
12  
14  
45  
Galvanized Steel,  
PVC,  
100  
Category III  
1104  
1504  
2004  
75  
ABS,  
CPVC  
t
45  
85  
** Subtract 10 ft per elbow. Max. 4 elbows.  
t
Adapters supplied by others.  
Table N: Category III Horizontal Vent & Horizontal Direct Vent  
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.  
Fig. 28: Direct Vent - Vertical  
WARNING: No substitutions of flue pipe or vent  
cap material are allowed. Such substitutions would  
jeopardize the safety and health of inhabitants.  
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.  
Outdoor Installation  
See Table L for Category I venting guidelines.  
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.  
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  
Care must be taken when locating the heater out-  
doors, because the flue gases discharged from the  
29  
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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:  
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).  
NOTE: Condensate can freeze on the vent cap.  
Frozen condensate on the vent cap can result in a  
blocked flue condition.  
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).  
Freeze Protection  
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.  
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  
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.  
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.  
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.  
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.  
6. Adjacent brick or masonry surfaces must be pro-  
tected with a rust-resistant sheet metal plate.  
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.  
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.  
Fig. 29: Outdoor Venting  
30  
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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.  
Fig. 31: Buffer Tank Piping  
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.  
Fig. 30: Differential Graph  
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.  
*
*Maximum 4 times the pipe diameter or 12”, whichever is less.  
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.  
Fig. 32: Mode 2 Primary/Secondary Piping  
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.  
Operating Modes  
Mode 1 (Not supported) – Setpoint operation using  
primary piping. The heater outlet water temperature is  
controlled to the boiler target setpoint.  
31  
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trol operates the boiler burner to maintain the boiler  
target at the boiler outlet sensor.  
ELECTRONIC  
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.  
Fig. 33: Mode 3 Dedicated DHW  
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.  
*
*Maximum 4 times the pipe diameter or 12”, whichever is less.  
Fig. 35: Mode 7 Primary/Secondary Piping with  
External Target Temp  
0-10 VDC  
0-20 mA*  
Boiler Target  
--- (OFF)  
50°F  
0
0
2
1
2
4
68.9°F  
3
6
87.8°F  
4
8
106.7°F  
125.6°F  
144.1°F  
163.3°F  
182.2°F  
201.1°F  
220°F  
5
10  
12  
14  
16  
18  
20  
*
6
*Maximum 4 times the pipe diameter or 12”, whichever is less.  
7
Fig. 34: Mode 5 Primary/Secondary Piping with  
Outdoor Reset  
8
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-  
9
10  
*Requires a 500Ω resistor.  
Table O: 0-10 VDC or 0-20 mA External Input Signal  
32  
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2-10 VDC  
4-20 mA*  
Boiler Target  
--- (OFF)  
--- (OFF)  
50°F  
RAYPAK  
MODULATING  
TEMP CONTROL  
0
1
2
3
4
5
6
7
8
9
0
2
4
6
71.3°F  
8
92.5°F  
OUTDOOR AIR  
SENSOR  
10  
12  
14  
16  
18  
20  
113.8°F  
135°F  
156.3°F  
177.5°F  
198.8°F  
220°F  
10  
*Requires a 500Ω resistor.  
Table P: 2-10 VDC or 4-20 mA External Input Signal  
*
*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.  
Fig. 36: Mode 8 Primary/Secondary Piping with  
External Direct Drive  
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.  
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.  
BOIL TARGET - Target temperature that the heater is  
trying to maintain.  
Definitions  
‘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.).  
NOTE: The defined terms are not active in all  
modes of control operation.  
DEM 1 - Indicates 24 VDC signal has been supplied to  
the H+D terminal.  
% OUT - Current percent modulation rate of heater.  
BOIL DSGN - Design boiler water temperature used in  
heat loss calculations.  
DEM 2 - Indicates 24 VDC Flame Proof signal is pres-  
ent.  
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.  
DIFF - The operating differential of the heater; The  
heater outlet water temperature is allowed to rise  
1
above the BOIL TARGET temperature by ⁄  
2
of 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).  
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.  
33  
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Boiler (H7)  
Default Setting  
Item  
Modes  
Range  
OFF, 70 to 220°F  
OFF, 70 to 190°F  
OFF, 70 to 220°F  
OFF, 120 to 225°F  
OFF, 120 to 190°F  
OFF, 80 to 180°F  
0:00 to 3:00 min  
1 (Low), 2 (Med), 3 (High)  
Auto, 2 to 42°F  
OFF, 70 to 190°F  
2 to 10°F  
2
140°F  
160°F  
180°F  
200°F  
180°F  
135°F  
0:00 min  
1 (Low)  
Auto  
Boil Target  
3
5, 7  
2, 5, 7, 8  
Boil Max  
3
Boil Min  
‘Burner’ Delay  
Boil Mass  
Diff  
2, 3, 5, 7  
All  
All  
2, 3, 5, 7  
DHW Target  
DHW Diff  
‘Pump’ Dly  
Outdr Start  
Outdr Design  
Boil Start  
3
3
120°F  
5°F  
All  
5
3:00 min  
70°F  
OFF, 0:20 to 9:55 min, ON  
35 to 85°F  
5
-10°F  
135°F  
180°F  
70°F  
-60 to 32°F  
5
35 to 150°F  
Boil Dsgn  
WWSD  
5
120 to 220°F  
5
35 to 100°F  
Units  
All  
N/A  
7
°F  
°F or °C  
Mode  
2
2, 3, 5, 7, 8  
External Input Signal  
Offset  
2 to 10 VDC  
0°F  
2 to 10 VDC or 0 to 10 VDC  
-10°F to 10°F  
7
Table Q: Temperature Control Default Setpoints—Boiler  
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  
‘Burner’ Delay  
Boil Mass  
Diff  
2
All  
All  
2
70°F  
0:00 min  
1 (Low)  
1°F  
OFF, 45 to 106°F  
0:00 to 3:00 min  
1 (Low), 2 (Med), 3 (High)  
1 to 3°F  
‘Pump’ Dly  
Units  
All  
All  
N/A  
3:00 min  
°F  
OFF, 0:20 to 9:55 min, ON  
°F or °C  
Mode  
2
2
Table R: Temperature Control Default Setpoints—Pool Heater  
34  
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Water Heater (WH1)  
Modes Default Setting  
Item  
Range  
OFF, 70 to 190°F  
OFF, 70 to 190°F  
OFF, 120 to 190°F  
OFF, 80 to 180°F  
0:00 to 3:00 min  
1 (Low), 2 (Med), 3 (High)  
Auto, 2 to 42°F  
2
3, 7  
2, 3, 6, 7  
2, 3, 7  
All  
140°F  
160°F  
180°F  
135°F  
0:00 min  
1 (Low)  
Auto  
Boil Target  
Boil Max  
Boil Min  
‘Burner’ Delay  
Boil Mass  
Diff  
All  
2, 3, 7  
3
DHW Target  
DHW Diff  
‘Pump’ Dly  
Units  
120°F  
5°F  
OFF, 70 to 190°F  
2 to 10°F  
3
All  
3:00 min  
°F  
OFF, 0:20 to 9:55 min, ON  
°F or °C  
All  
Mode  
N/A  
7
3
2, 3, 7  
External Input Signal  
Offset  
2 to 10 VDC  
0°F  
2 to 10 VDC or 0 to 10 VDC  
-10°F to 10°F  
7
Table S: Modulating Temperature Control Default Setpoints—Water Heater  
installing a 500 Ω resistor on the external input signal  
device’s terminals.  
EXTERNAL INPUT SIGNAL – Selects external input  
signal range (0-10VDC or 2-10VDC):  
FP - Flame proof warning.  
MODE - Operating mode of the heater.  
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.  
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.  
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  
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).  
35  
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Rank  
Item Field  
Number Field  
Type  
Fault Description  
0
1
E01  
FP  
Err  
Error  
Warning  
Error  
Error  
Error  
Error  
Error  
Error  
Error  
Error  
Error  
Error  
EEPROM error  
Flame proof warning  
Boiler outlet sensor short  
Boiler outlet sensor open  
Boiler inlet sensor short  
Boiler inlet sensor open  
System sensor short  
System sensor open  
Outdoor sensor short  
Outdoor sensor open  
DHW sensor short  
Err  
2
BOIL OUT  
BOIL OUT  
BOIL IN  
BOIL IN  
SUP  
SHr  
3
OPn  
4
SHr  
5
OPn  
6
SHr  
7
SUP  
OPn  
8
OUTDR  
OUTDR  
DHW  
SHr  
9
OPn  
10  
11  
SHr  
OPn  
DHW  
DHW sensor open  
Table T: Error Codes  
UNITS - Selects the temperature units to be displayed  
Menu Field  
Item Field  
(°F or °C).  
Displays the current menu  
Displays an  
abbreviated  
name of the  
selected item  
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.  
Number Field  
Displays the  
current value of  
the selected  
item  
Operation  
Status Field  
Displays the  
DHW  
External Input  
Modulation Offset Signal  
current status  
of the control’s  
inputs, outputs  
and 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, L and M) shown at the bottom of Fig. 37.  
Modulating  
Control  
Buttons  
Selects  
Item  
Menus,  
Items and  
adjusts  
settings  
{
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.  
Fig. 37: Modulating Temperature Control Display  
menu name, “ADJUST” will be displayed in the menu  
field.  
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.  
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 L or M button 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.  
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  
36  
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Heater Sequence of Operation  
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.  
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.  
Code  
On  
Condition  
System OK; No faults present  
Possible control fault; Check power  
Low air  
3. The igniter is powered, and once proven, heats up  
for 20 seconds.  
Off  
1 Flash  
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.  
Flame in combustion chamber;  
No call for heat  
2 Flashes  
3 Flashes  
4 Flashes  
5 Flashes  
6 Flashes  
Ignition lockout  
Low HSI current  
Low 24 VAC  
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.  
Internal fault; Replace control  
Table U: Ignition Module  
Diagnostic LED Flash Codes  
High Limit—Manual Reset  
Ignition Module  
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.  
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.  
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.  
Fig. 38: Ignition Module  
Fig. 39: High Limit (Manual Reset)  
37  
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High Limit—Auto Reset (Optional)  
Modulating Temperature Control  
This heater may be equipped with an optional adjust- This heater is equipped with a Raypak modulating  
able auto reset high limit temperature device.  
temperature control. Refer to information starting on  
page 30 for information on the setting and use of this  
The optional adjustable auto reset high limit is located control.  
inside the heater junction box. Adjust the setting to  
approx. 20°F (10°C) above desired outlet temperature.  
Fig. 42: Modulating Temperature 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.  
Fig. 40: Adjustable High Limit (Auto Reset)  
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. 43: Low Water Cut-Off  
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-  
Fig. 41: Flow Switch  
38  
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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.  
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.  
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. 46: Blocked Vent Switch  
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.  
Fig. 44: High/Low Gas Pressure Switch  
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. 47: UDB Diagnostic Board  
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).  
Fig. 45: Air Pressure Switch  
39  
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WIRING DIAGRAM - Models H & WH  
40  
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WIRING DIAGRAM - Models P & WHP  
41  
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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.  
START-UP  
NOTE: The following steps must be performed by a  
factory-trained technician.  
WHAT TO DO IF YOU SMELL GAS:  
Do not try to light any appliance.  
Pre Start-up  
Do not touch any electrical switch; do not use any  
telephone in your building.  
Filling System (Heating Boilers)  
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.  
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.  
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.  
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.  
Initial Start-up  
Venting System Inspection  
Required tools  
1. Check all vent pipe connections and flue pipe ma-  
terial.  
(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  
2. Make sure vent terminations are installed per code  
and are clear of all debris or blockage.  
For Your Safety  
(1) Amp probe  
WARNING: If you do not follow these instructions  
exactly, a fire or explosion may result causing  
property damage, personal injury or loss of life.  
(Metric Allen wrenches will be required for servicing  
the gas valve, but not during start-up)  
NOTE: Digital manometers are not recommended.  
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.  
Preparation  
WARNING: Do not turn on gas at this time.  
42  
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Check Power Supply  
3. If the gas pressure is greater than 14.0 in. WC,  
turn off the main gas shut-off valve, upstream of  
the heater.  
With multi-meter at incoming power, check voltage  
between:  
Start-Up  
Hot - Common (≈120 VAC)  
Hot - Ground (≈120 VAC)  
Common - Ground (< 1 VAC)  
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.  
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.  
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.  
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. 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).  
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. 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.  
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.  
5. Wait until the controller indicates 100% on the fir-  
ing rate display screen (approximately 30  
seconds).  
Blower Check  
TO BURNER  
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.  
GAS  
B
A
C
D
Fig. 48: Gas Pressure Measurement Locations  
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.  
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).  
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  
43  
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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.  
CAUTION: Special manifold and air settings may  
be required.  
Finishing  
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.  
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.  
Manifold Check  
3. Start-up is complete and the heater should be  
operating properly.  
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.  
Safety Inspection  
1. Check all thermostats and high limit settings.  
2. During the following safety checks leave manome-  
ters hooked up, check and record.  
2. If the pressure reading differs by more than 0.2  
in. WC, STOP – Call the factory for directions  
on what to do next!  
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.  
Air Pressure  
Setting  
Tolerance  
Model No.  
Setting (in. WC)  
504  
754  
1104  
1504  
2004  
-2.3  
-2.9  
-4.0  
-4.0  
-4.1  
0.2 in. WC  
0.2 in. WC  
0.2 in. WC  
0.2 in. WC  
0.2 in. WC  
4. Check thermostats for ON-OFF operation.  
5. Check high limits for ON-OFF operation.  
6. While in operation, check flow switch operation.  
Table V: MVB Air Pressure Settings  
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.  
Setting  
Model No.  
Amp Draw  
Tolerance  
+0.0/-0.2  
+0.0/-0.2  
+0.0/-0.2  
+0.0/-0.2  
+0.0/-0.5  
504  
754  
1104  
1504  
2004  
1.9  
2.9  
5.5  
8.1  
13.0  
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.  
Table W: MVB Amp Draw (Reference Only)  
Follow-Up  
Manifold Gas Pressure Setting  
High Fire Values (in. WC)  
Model No.  
Safety checks must be recorded as performed.  
Turn heater on. After main burner ignition:  
Natural Gas  
Propane Gas  
504  
754  
-0.1  
-0.1  
-0.1  
-0.2  
-0.6  
-0.5  
1. Check manometer for proper readings.  
-0.4  
2. Cycle heater several times and re-check readings.  
1104  
1504  
2004  
-1.0  
-2.4  
3. Remove all manometers and replace caps and  
screws.  
-1.0  
Table X: MVB Manifold Pressure Settings  
4. Check for gas leaks one more time.  
44  
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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.  
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).  
TO BURNER  
GAS  
B
A
C
D
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.  
Fig. 49: Leak Test Procedure  
Post Start-Up Check  
Check off steps as completed:  
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.  
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.  
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.  
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. Remove rubber tube and manometers. Close  
each test point bleedle valve as the tubes are  
removed.  
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  
45  
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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.  
OPERATION  
Lighting Instructions  
8. Test limit control: While burner is operating, move 1. Before operation, make sure you have read all of  
indicator on high limit control below actual water  
temperature. Burner should go off while blower  
the safety information in this manual.  
and circulator continue to operate. Raise setting 2. Remove upper front panel.  
on limit control above water temperature and  
burner should re-ignite after pre-purge time delay. 3. Set the thermostat to the lowest setting.  
NOTE: Ignition control may have to be reset  
after this portion of the test.  
4. Turn off all electrical power to the appliance.  
9. Test ignition system safety device:  
a. Open manual gas valve. Turn power on.  
b. Set thermostat to call for heat.  
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.  
c. When the heater is in operation, pull hose off  
the air switch. The burner should go off almost 7. Wait 5 minutes to clear out any gas. Then smell for  
immediately.  
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.  
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.  
8. Turn on all electrical power to the appliance.  
10. To restart system, follow lighting instructions in the 9. Set thermostat to desired setting. The appliance  
Operation section.  
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.  
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 10. If the appliance will not operate, follow the instruc-  
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.  
tions “To Turn Off Gas To Appliance,” and call your  
service technician or gas supplier.  
11. Replace upper front panel.  
13. Observe several operating cycles for proper oper-  
ation.  
12. If heater fails to start, verify the following:  
14. Set the heater thermostat to desired temperature.  
a. There are no loose connections or that the  
service switch is off.  
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.  
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.  
46  
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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.  
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.  
To Turn Off Gas To Appliance  
2. Press either button to scroll through the recorded  
faults in history.  
1. Shut off manual gas valve field installed near gas  
inlet connection on back of heater.  
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.  
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.  
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. Replace access panel.  
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.  
NOTE: Once the history has been cleared, it cannot  
be recovered.  
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.  
47  
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TROUBLESHOOTING  
Does the power switch provide  
NO  
Check the switch and/or  
line voltage  
power to the control panel?  
Step 1  
Is there a Call For  
YES  
NO  
Unit is in standby mode.  
Heat?  
YES  
NO  
Is Disable connection intact?  
Step 2  
Reattach.  
YES  
Check and correct power  
connections at main terminal  
block, circuit breaker panel or  
blower relay.  
Is there 120VAC at the blower or  
blower relay?  
Does the combustion air  
blower come on?  
NO  
NO  
Step 3  
YES  
Is 4-20mA present at the quick  
disconnects on the black and blue  
wires of the temperature controller?  
Is diagnostic board  
indicating open  
safeties?  
Replace temperature  
NO  
NO  
NO  
controller.  
YES  
YES  
Correct Safety  
YES  
Does F2 on ignition module  
have AC power?  
Is there continuity in the wire  
between F2 and Pin J5-6?  
Repair or  
Replace wire.  
NO  
Correct the shutter  
setting or blower  
amp draw.  
Is blower pressure setting  
(vacuum) correct?  
Is 24VAC at the NC side of  
the air pressure switch?  
NO  
NO  
Step 4  
YES  
YES  
Replace air pressure switch.  
Is 24VAC at PS on ignition module?  
Is connecting plug secure?  
Step 5  
Step 6  
Correct wiring.  
NO  
YES  
Is Amp draw during heat-  
up for HSI greater than  
3.1 Amps?  
Does igniter prove?  
YES  
NO  
NO  
Replace HSI  
YES  
NO  
Is air switch bouncing?  
NO  
YES  
Step 7  
Is the flame sensor signal to the  
ignition module greater than 1 uA DC?  
Is gas pressure correct?  
YES  
NO  
YES  
Is static and dynamic inlet gas  
pressure correct?  
Correct the gas pressure.  
NO  
Is the unit running?  
Step 8  
Step 9  
YES  
YES  
NO  
The unit is okay  
Call our Technical Service Department  
1-805-278-5300  
48  
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by local codes.  
MAINTENANCE  
3. Check that area is free from combustible materi-  
als, gasoline, and other flammable vapors and  
liquids.  
Suggested Minimum  
Maintenance Schedule  
4. Check air filter and replace as necessary.  
Regular service by a qualified service agency and  
maintenance must be performed to ensure maximum  
operating efficiency.  
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.  
Maintenance as outlined below may be performed by  
the owner.  
Daily  
7. Check operation of safety devices. Refer to manu-  
facturers’ instructions.  
1. Check that the area where the heater is installed  
is free from combustible materials, gasoline, and  
other flammable vapors and liquids.  
8. Follow oil-lubricating instructions on pump (if re-  
quired). Over-oiling will damage pump.  
Water-lubricated circulators do not need oiling.  
2. Check for and remove any obstruction to the flow  
of combustion or ventilation air to heater.  
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.  
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.  
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.  
2. Visually inspect burner flame.  
3. Visually inspect venting system for proper func-  
tion, deterioration or leakage.  
Periodically  
1. Check relief valve. Refer to manufacturer’s  
instructions on valve.  
4. Visually inspect for proper operation of the con-  
densate drain in the venting. If leaks are observed  
repair at once.  
2. Test low water cut-off (if equipped). Refer to manu-  
facturer’s instructions.  
5. Check air vents for leakage.  
Preventive Maintenance  
Schedule  
Yearly (Beginning Of Each Heating  
Season)  
The following procedures are recommended and are  
good practice for all MVB installations.  
Schedule annual service call by qualified service  
agency.  
Daily  
1. Visually check top of vent for soot. Call service  
person to clean. Some sediment at bottom of vent  
is normal.  
1. Check gauges, monitors and indicators.  
2. Check instrument and equipment settings. (See  
“Post Start-Up Check” on page 45.)  
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  
3. Check burner flame. (Should see light blue flame  
at full input rate).  
49  
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Weekly  
6. Perform leakage test on gas valves (See Fig. 49.)  
and procedure on page 45.  
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).  
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.  
Monthly  
As Required  
1. Check flue, vent, stack, or outlet dampers.  
1. Recondition or replace low water cut-off device (if  
equipped).  
2. Test blower air pressure. (See “Blower Check” on  
page 43.)  
2. Check drip leg and gas strainers.  
3. Test high and low gas pressure interlocks (if  
equipped). (See “Safety Inspection” on page 44.)  
3. Check flame failure detection system. (See “Post  
Start-Up Check,” page 45.)  
Semi-Annually  
4. Check igniter. (Resistance reading should be 42-  
70 ohms at ambient temperature).  
1. Recalibrate all indicating and recording gauges.  
2. Check flame failure detection system components.  
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).  
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.  
6. Check firing rate control by checking the manifold  
pressure. (See “Manifold Check” on page 44).  
5. Check air filter and replace as necessary.  
7. Test safety/safety relief valves in accordance with  
ASME Heater and Pressure Vessel Code Section  
IV.  
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.)  
Filter Maintenance  
NOTE: Use Raypak replacement filters, kit number  
012552F (12”X12”) for models 504-1104 and kit  
number 012553F (16”X16”) for models 1504-2004.  
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.  
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.  
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.  
50  
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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:  
Filter Replacement  
1. Remove the filter box cover by loosening and  
removing the two wing nuts holding it in place.  
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  
Fig. 50: Remove the Air Filter Box Cover  
chlorinated waxes/cleaners  
2. Remove the filter by lifting it straight up and out of  
the slot in the filter box.  
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:  
Fig. 51: Remove the Air Filter  
dry cleaning/laundry areas  
metal fabrication plants  
beauty shops  
refrigeration repair shops  
photo processing plants  
auto body shops  
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.  
plastic manufacturing plants  
furniture refinishing areas and establishments  
new building construction  
remodeling areas  
APPENDIX  
open pit skimmers  
Inside Air Contamination  
Check for areas and products listed above before in-  
stalling heater. If found:  
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  
remove products permanently, OR  
install TruSeal direct vent.  
51  
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Important Instructions for the Commonwealth of Massachusetts  
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:  
(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  
(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:  
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.  
(c) MANUFACTURER REQUIREMENTS - GAS EQUIP-  
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. 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  
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:  
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.  
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.  
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.  
(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.  
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".  
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).  
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.  
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.  
52  
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LIMITED PARTS WARRANTY  
MVB – TYPES H AND 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 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  
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 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. 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 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  
Mailing Address  
Model Number  
Serial Number  
Date of Installation  
Installation Site  
Contractor/Installer  
City  
State  
Zip Code  
Daytime Telephone Number  
RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com  
53  
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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  
Mailing Address  
Model Number  
Serial Number  
Date of Installation  
Installation Site  
Contractor/Installer  
City  
State  
Zip Code  
Daytime Telephone Number  
RAYPAK, INC 2151 Eastman Avenue Oxnard, CA 93030-9786 (805) 278-5300 Fax (800) 872-9725 www.raypak.com  
54  
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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  
Regulator Model & Size  
Gas Line Size (in room)  
Length of Gas Line  
Low Gas Pressure Setting  
High Gas Pressure Setting  
Gas Shut-Off Valve Type  
( Ball, Lube cock)  
CLEARANCES  
Front Clearance  
Right Side Clearance  
Left Side Clearance  
Rear Clearance  
_________ / ______CFH  
________________In. NPT  
________________Eq Ft  
________________In. WC  
________________In. WC  
________________  
_______________In.  
_______________In.  
_______________In.  
_______________In.  
_______________In.  
Overhead Clearance  
ELECTRICAL  
Sediment Trap  
Port  
________________Y/N  
_______Std______Full  
Voltage Supply (VAC)  
Voltage -24 VAC  
Voltage Com to Ground  
Hot Surface Igniter  
Auto High Limit Setting  
Manual Reset High Limit Setting  
Operating Control Setting  
No Load______ Load_____  
_______________VAC  
_______________VAC  
_______________Ohms  
_______________deg F  
_______________deg F  
_______________deg F  
VISUAL INSPECTION OF COMPONENTS  
Verify inspection was done and condition of components are in  
good working order with a “yes”  
Wiring Harness  
Burner/s (flame)  
Refractory (visual)  
Remote flame sense  
Covers in place for outdoor  
_________________ Y/N  
_________________ Y/N  
_________________ Y/N  
_________________ Y/N  
_________________ Y/N  
Sketch plumbing on reverse side  
WATER SUPPLY  
Flow Rate in GPM or Delta T  
Measure flow rate at full fire  
Pump Economaster setting  
Low Water Cutoff  
_______________If Avail  
_______________Minutes  
_______________Test  
Qty____ _______Gallons  
_______________  
Pump HP: ______  
Pump Model___________  
Screens________________  
VENTING  
Vent Size: _____________  
Category: _________  
Vent Material:  
Vent Termination Type:  
Combustion Air Openings:  
Ventilation air  
Stack Height:_______  
sketch vent on reverse side *** Number of Tanks and Size  
__________________  
__________________  
Low __________ in2  
High __________ in2  
Plumbing Size  
Pump Size: _________(boiler)  
Impeller trim____________  
Louvers __________________  
EMISSIONS SETTINGS AND TEST INFORMATION  
(AT FULL FIRE)  
Nominal Factory Recommended Settings  
Blower Pressure Setting  
Supply Gas Pressure  
_________________In. WC  
_________________In. WC  
See manual or card tag  
See manual or card tag  
Verify stable pressure static & dynamic condition  
Pilot Gas Pressure  
Manifold Gas Pressure  
_________________In. WC  
_________________In. WC  
See manual or card tag  
See manual or card tag  
The following measurements must be obtained with a Combustion Analyzer.  
NOX  
Free Oxygen  
CO  
_________________PPM  
_________________%  
_________________PPM  
_________________%  
Less than 20 PPM (If required by Certifying Agency)  
See manual  
Less than 150 PPM  
See manual  
CO2  
Model Number: ______________________________  
*** Note: draw venting with details, such as extractors,  
barometric dampers, blast dampers or draft inducers  
Serial Number: _______________________________  
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  
55  
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Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468  
Litho in U.S.A.  
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