Raypak MVB 504A Installation & Operating Manual Download Page 16

Page: 16 / 64

For detailed information on the Versa IC™ control sys-

tem, see Catalog 5000.72. This manual can be found

in the document library at www.raypak.com.

Mode 1 (Type H Units Only)

This mode selection is for hydronic heating systems

with single or multiple boilers (Maximum 4 boilers) in

primary/secondary piping configuration with or without

Outdoor Air Reset (S4). The system temperature is

controlled by the System sensor (S3). The Boiler

Pump (P1) runs during any call for heat. The System

Pump (P2) runs whenever the system is enabled for

heating and the outdoor air temperature is lower than

the warm weather shut down (WWSD) temperature

setting (if utilized). The Boiler Pump and System Pump

are delayed “off” as user defined in the

ADJUST

menu.

Fig. 14: MODE 1 - Boiler Cascade with

Primary/Secondary Piping

Fig. 13: MODE 1 - Single Boiler with

Primary/Secondary Piping

Fig. 12: Air-Separation/Expansion Tank

Three-Way Valves

Three-way valves intended to regulate system water

temperatures by reducing flow in the boiler should not

be used. Raypak heaters are high-recovery, low-mass

heaters which are not subject to thermal shock.

Applications & Modes

The VERSA IC Control system is designed for a wide

range of applications. The installer/design engineer

should refer to the following Modes to determine which

best fits the intended application and functionality for

the unit being installed.

Type H models of MVB have three modes available to

them to address the various applications the units can

be applied to. Type WH units will only have the WH

configuration available to them for use with potable

water applications when directly connected to a hot

water storage tank.

piped in parallel with the heater with appropriate

valves to pre-vent the chilled medium from entering

the heater.

The piping system of a hot water heater connected to

heating coils located in air handling units where they

may be exposed to circulating refrigerated air, must be

equipped with flow control valves or other automatic

means to prevent gravity circulation of the heater

water during the cooling cycle. It is highly recommend-

ed that the piping be insulated.

Air-Separation/Expansion Tank

All heaters should be equipped with a properly sized

expansion tank and air separator fitting as shown in

Fig. 12 .

Summary of Contents for MVB 504A

Page 1: ...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 g...

Page 2: ... page 22 Table K on page 28 High Limits on pages 36 37 Wiring Diagram on page 44 Blower Check on page 47 Table U on page 47 Filter Maintenance on page 55 Additions Motorized Combustion Air Dampers or Louvers on page 11 Flushing Cleaning of System Piping on page 13 Extractors Draft Inducers and Motorized Flue Dampers on page 28 Note on page 32 Fig 47 on page 46 Deletions None ...

Page 3: ...er 17 Pool Heating 19 Gas Supply 21 Electrical Power Connections 22 Field Wiring Connection 24 Venting 27 Venting Installation Tips 30 Venting Configurations 30 Outdoor Installation 35 Controls 36 User Interface 38 WIRING DIAGRAM 44 START UP 45 Pre Start up 45 Start Up 46 OPERATION 50 Lighting Instructions 50 To Turn Off Gas To Appliance 50 TROUBLESHOOTING 50 MAINTENANCE 53 Suggested Minimum Maint...

Page 4: ... cause cancer birth defects or other reproductive harm WARNING Risk of electrical shock More than one disconnect switch may be required to de energize the equipment before servicing CAUTION This heater requires forced water circulation when the burner is operating See minimum and maximum flow rates Severe damage will occur if the heater is operated without proper water flow circulation CAUTION Ope...

Page 5: ...tandard war ranties Model Identification The model identification number and heater serial number are found on the heater rating plate located on the upper rear jacket panel of the heater The model number will have the form H7 0504A or similar depending on the heater size and configuration The letter s in the first group of characters identifies the application H Hydronic Heating WH Domestic Hot W...

Page 6: ...ty Fig 4 Component Locations Top Fig 3 Component Locations Rear Panels omitted for clarity Fig 2 Component Locations Front Model No MBTUH Input Water Conn NPT Gas Conn NPT Vent Size in Max Min N P Flue Intake 504A 500 300 2 1 1 8 6 754A 750 450 2 1 1 10 6 1104A 1100 660 2 1 2 1 1 4 1 10 6 1504A 1500 900 2 1 2 1 1 4 1 12 8 2004A 1999 1199 2 1 2 2 1 14 8 H7 units only ...

Page 7: ...f To determine the water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer NOTE When this water heater is supplying general purpose hot water for use by individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed p...

Page 8: ...in in front 1 in on the side at least 24 in on the rear and 10 in above the top of the heater is required This will allow 8 Table C Clearances Indoor Installations INSTALLATION Installation Codes Installations must follow these codes Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition NFGC National Electrical Code ANSI...

Page 9: ...ordering the unit and is shipped loose for field installation The intake air elbow MUST be Combustion and Ventilation Air Indoor Units This heater must be supplied with sufficient quantities of non contaminated air to support proper combustion and equipment ventilation Combustion air can be sup plied via conventional means where combustion air is drawn from the area immediately surrounding the hea...

Page 10: ...ft 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t M Clearance under veranda porch deck or balcony 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code 2 In accordance with the current CAN CSA B149 I...

Page 11: ... operation See Field Wiring Connection section of this manual for proper wiring instructions using Fan Damper dry contacts and external interlock TruSeal Combustion Air In addition to the 3 previous steps combustion air may be ducted directly to the heater by using PVC CPVC or sealed single wall galvanized ducting The duct will attach directly to the air collar located on the inline Air Filter Box...

Page 12: ...ll be provided by an opening s for ventilation air at the highest practical point communicating with the outdoors The total cross sectional area of such an opening s shall be at least 10 of the area required in 2 and 3 below but in no case shall the cross sectional area be less than 10 in 2 65 cm2 2 For heaters using a barometric damper in the vent system there shall be a permanent air supply open...

Page 13: ...rantable failure When required Raypak recommends the boil er be isolated from the system piping prior to flushing or cleaning with any cleaning agent Cold Water Operation This heater is equipped with a proprietary condensate evaporation system which will evaporate any conden sate that may begin to accumulate inside the primary heat exchanger with water temperatures as low as 120 F 49 C Heaters ope...

Page 14: ...m Fig 9 Cold Water Start Maximum 4 times the pipe diameter or 12 whichever is less water is kept in a narrow temperature range of no more than 10 F 5 C a permanent manual bypass can be employed and manually adjusted to achieve an inlet temperature of 120 F 49 C or higher as adjust ed at the minimum temperature in this narrow temperature range i e Range 75 F to 85 F adjust bypass with temperature a...

Page 15: ...cal codes 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 NOTE Hot water heating systems all have unique levels of operating diversity that must be accounted for in the system desig...

Page 16: ... are high recovery low mass heaters which are not subject to thermal shock Applications Modes The VERSA IC Control system is designed for a wide range of applications The installer design engineer should refer to the following Modes to determine which best fits the intended application and functionality for the unit being installed Type H models of MVB have three modes available to them to address...

Page 17: ...olled by the Supply sensor S3 whenever the indirect call for heat is not active The DHW Supply sensor S5 determines the indirect call tank setpoint During an indirect call for heat the boiler firing rate is determined by the water temperature at the Indirect Supply sensor S6 and the Target Max setting when using the Indirect DHW sensor S5 The Boiler Pump P1 runs during all heat calls regardless of...

Page 18: ...kel tubes are recommended for water softened below 5 grains per gallon Table G Domestic Water Heater Flow Rate Requirements 3 4 Grains Per Gallon 5 15 Grains Per Gallon 16 25 Grains Per Gallon T F GPM P ft wc MTS in SHL ft wc T F GPM P ft wc MTS in SHL ft wc T F GPM P ft wc MTS in SHL ft wc 504A 17 50 3 6 2 8 3 17 50 3 6 2 8 3 9 95 10 4 2 25 7 754A 26 50 4 0 2 8 7 17 73 7 8 2 17 3 14 90 11 4 2 25 ...

Page 19: ...stalled 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...

Page 20: ... 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 chlori...

Page 21: ...t pressures in excess of 1 2 psi 3 45 kPa Gas Supply Pressure A minimum of 4 0 in WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 10 5 in WC under load and no load condi tions for natural gas A minimum of 4 0 in WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 13 0 in WC is required for propane gas The gas pressure regula...

Page 22: ...wer for pumps larger than 3 4 HP must be a sepa rate circuit wired through the pump contactor Power to the MVB heater should be connected to terminals 1 2 and 3 as noted in Fig 20 All low voltage wiring including sensors interlocks enable disable and var ious options are wired into terminals 1 24 on the front wiring panel as noted in Fig 25 Electrical Power Connections Installations must follow th...

Page 23: ... Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source NOTE Field supplied isolation relays should be installed when field connected controllers are mounted more than 50 equivalent feet 18 AWG from heater See wiring diagrams WARNING Using a multi meter check the following voltages at the circuit ...

Page 24: ...feet 4 Mount the outdoor sensor on an exterior surface of the building preferably on the north side in an area that will not be affected by direct sunlight and that will be exposed to varying weather conditions 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 Field...

Page 25: ...e installation 2 When the Indirect DHW call for heat is active the PIM communicates this to the VERSA The VERSA calculates the optimal operation and sends the firing rate and pump output requests to the PIM so it can activate the Indirect DHW pump and Boiler pump as needed If an optional Indirect DHW sensor is connected the PIM will pass this signal to the VERSA This allows the VERSA to optimize t...

Page 26: ...onnections are dry contacts rated for pilot duty only 5A maxi mum 2 Connect the boiler pump enable wires to the termi nal block at the rear of their unit The connections are dry contacts rated for pilot duty only 5A maxi mum 3 Connect the system supply sensor to terminals 6 and 7 on the field wiring strip located on the Master PIM See Fig 25 4 Connect the Outdoor sensor if used to terminals 8 and ...

Page 27: ...close during fault or lockout conditions and the maximum voltage across the contacts is 30 VAC or 30 VDC See the Field Wiring as shown in Fig 25 In a cascade system the alarm output of the master boiler will be active if either the master boiler or follow er s have a lockout condition The alarm output of the follower boilers will only energize if a lockout condition occurs on that specific boiler ...

Page 28: ...is any question about the appliance categorization and suitability of a vent material for application on a Category I or III vent system Using improper venting materials can result in personal injury death or property damage CAUTION Condensate drains for the vent piping are required for installations of the MVB Follow vent manufacturer instructions for installation and location of condensate drain...

Page 29: ...bove any door window or gravity air inlet to the building 2 The vent must not be less than 7 ft above grade when located adjacent to public walkways 3 Terminate vent at least 3 ft above any forced air inlet located within 10 ft 4 Vent must terminate at least 4 ft horizontally and in no case above or below unless 4 ft horizontal distance is maintained from electric meters gas meters regulators and ...

Page 30: ...ate a thermal driving head that expels the exhaust gases from the flue The nega tive draft must be within the range of 01 to 08 in WC as measured 12 in above the appliance flue out let to ensure proper operation Vent material must be listed by a nationally recognized test agency The venting for Category I appliances shall be deter mined per the NFGC U S or B149 Canada The connection from the appli...

Page 31: ...for proper sizing of the manifold and the chimney At no time should the area of the common vent be less than the area of the largest heater exhaust outlet Common venting systems may be too large once an existing unit is removed At the time of removal of an existing appliance the following steps must be fol lowed with each appliance remaining connected to the common venting system placed in operati...

Page 32: ...lined above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use 7 Any improper operation of the common venting system should be corrected so that the installation conforms with the NFGC U S or B149 Canada When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum s...

Page 33: ...5 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 75 of straight flue pipe 65 of straight flue pipe and one elbow 55 of straight flue pipe and two elbows 45 of straight pipe and three elbows The ve...

Page 34: ...eel flue direct vent cap must be used sales order option D 15 The vent terminal must be located NO CLOSER than 12 off the wall Direct Vent Vertical Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent com bustion products to the outdoors The total length of air supply pipe cannot exceed the distances listed in Tables L and N Each elbow us...

Page 35: ...e elbow are provided in accor dance with CSA requirements These must be installed directly on the vent pipe as illustrated in Fig 36 Care must be taken when locating the heater out doors because the flue gases discharged from the 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 followi...

Page 36: ...there is a call for heat and all safeties are closed then the combustion air blower starts to purge air from the combustion chamber After the pre purge the igniter is energized The standard ignition module will lock out after failing to light 3 times during a call for heat To reset the lock out press and release the RESET button located on the user interface The con trol will automatically reset a...

Page 37: ... or air pockets Fig 41 Low Water Cut Off High Low Gas Pressure Switches Optional The optional low gas pressure switch mounts upstream of the gas valve on the inlet flange to the gas valve and is accessible through the removable access panels on the side or front of the heater to reset the gas pressure switch as necessary It is used to ensure that sufficient gas pressure is present for proper valve...

Page 38: ...A IC Control I O Manual Catalog 5000 72 Adjusting the MVB Setpoint To adjust the setpoint on the MVB Use the MENU key to scroll to the SETUP ADJUST menu then use the ITEM key to scroll to the SET POINT item Adjust the Setpoint using the UP and DOWN arrow keys Minimum is 50 F Maximum is the PIM value and the default is 180 F for H models and 125 F for WH models View Menu The VIEW menu is the defaul...

Page 39: ...erature 220 F TARGET MIN H MODE 1 2 3 OFF 50 F to 190 F Minimum target system temperature 50 F TARGET DIFF H MODE 1 2 3 2 F to 42 F Differential for target system temperature 10 F DHW SENSOR H MODE 1 2 3 OFF ON Selects whether a DHW sensor is used for indirect DHW tank OFF DHW DIFF H MODE 2 3 2 F to 10 F Differential for the target indirect DHW tank temperature 6 F IND SUPPLY H MODE 2 3 OFF 50 F t...

Page 40: ...ffset OPERATOR All Operator Limit Potentiometer PIM setting AUTO DIFF H MODE 1 2 3 Current auto differential PUMP PREPt All Duration of pump prepurge BLOW PREPt All Duration of blower prepurge BLOW PREPr All Blower during prepurge BLOW POSTt All Duration of blower postpurge BLOW POSTr All Blower during postpurge MIN RATE All Minimum modulation rate during operation START RATE All Start modulation ...

Page 41: ...boiler outlet temperature Press UP DOWN for 1 sec to clear INLET HI All Records the highest boiler inlet temperature Press UP DOWN for 1 sec to clear INLET LO All Records the lowest boiler outlet temperature Press UP DOWN for 1 sec to clear OUTDOOR HI H MODE 1 2 3 Records the highest outdoor temperature Press UP DOWN for 1 sec to clear OUTDOOR LO H MODE 1 2 3 Records the lowest outdoor temperature...

Page 42: ...y degree the outdoor temperature drops the tempera ture of the heating water will increase one degree With the VERSA both ends of the slope are adjustable It is factory set at 70 F water temperature Boil START at 70 F outdoor air OUT START and 180 F water temperature Boil DESIGN at 10 F out door air OUT DESIGN Each building has different heat loss characteristics A very well insulated building wil...

Page 43: ...nnual temperature where the building is located This temperature is used when completing heat loss calculations for the building Boiler Design Boil DESIGN The Boil DESIGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the OUT DESIGN temperature Warm Weather Shut Down WWSD When the outdoor air temperature rises above the WWSD setting the co...

Page 44: ...44 WIRING DIAGRAM Models 504A 2004A ...

Page 45: ...one Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to turn the gas control valve handle Never use tools If the handle 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 immed...

Page 46: ...approximately 15 seconds after the blower starts the igniter should start to glow observable through the observation port located at the front below the gas valve Look into the sight glass located just below the gas valve near the front of the unit to check igniter operation Gas valve should open in 45 60 sec onds 3 The heater ignites at 30 to 50 of full rate as indicated on the LCD display of the...

Page 47: ... the user test function USER TEST is displayed in the Title Field UP keystrokes are used to advance through the user test The Boil MIN MAX steps for burner operation are only run for enabled boilers Local Heat DHW EMS demands must be present for burner operation On the first press of the Up button the test step is held and HOLD is flashed at 1Hz On the second press of the Up button the test step i...

Page 48: ... point B bleedle valve and open the upstream manual gas valve Make sure that test point A B bleedle valves have been opened so as to allow gas to flow This will bring gas pressure to the second valve seat 5 Open the bleedle valve at test point C and connect a second rubber tube to it Connect the other end of the tube to a manometer and look for a build up of pressure Increasing pressure indicates ...

Page 49: ...l allow one time operation of the limit and then must be returned to normal operation by turning dip switch 8 back to the OFF position Power to the unit must then be cycled off then on to return to nor mal operation 9 Test ignition system safety device a Close manual gas valve Turn power on b Close Enable Disable circuit to call for heat c The burner should attempt three trials for igni tion for t...

Page 50: ...water temperature or manual reset high limit is not tripped c Enable Disable circuit is closed d Gas is on at the meter and the heater e Incoming dynamic gas pressure to the gas valve is NOT less than 4 0 in WC for natural gas or propane gas To Turn Off Gas To Appliance 1 Shut off manual gas valve field installed near gas inlet connection on back of heater 2 Remove upper front panel 3 Adjust setpo...

Page 51: ... replace control DELTA T Temperature difference between the inlet and outlet exceeded the set point Check water flow LOW 24VAC Low 24 VAC power Check power supply wiring and transformer BLOW SPEED Blower speed out of range Check blower wiring and blower WARNING Do not use this appliance if any part has been under water Improper or dangerous operation may result Contact a qualified service technici...

Page 52: ... the gas supply See table for more information 4 flashes N A N A 5 flashes Low Voltage Fault Check the 24 VAC input voltage The voltage must be above 18 0 VAC 6 flashes N A N A 7 flashes Hi Limit Fault Check for proper water flow Check hi limit and outlet sensor 8 flashes Sensor Fault See VERSA for fault identification Check sensor wiring 9 flashes N A N A 10 flashes N A N A 11 flashes N A N A 12 ...

Page 53: ...nc tion deterioration or leakage 4 Visually inspect for proper operation of the con densate drain in the venting If leaks are observed repair at once 5 Check air vents for leakage Yearly Beginning Of Each Heating Season Schedule annual service by qualified service agency 1 Visually check top of vent for soot Call service person to clean Some sediment at bottom of vent is normal 2 Visually inspect ...

Page 54: ... see light blue flame at full input rate Weekly For low pressure heaters test low water cut off device With heater in pre purge depress the low water cut off test button Appliance should shut off and ignition fault light should come on Depress reset button on front of heater control panel to reset Monthly 1 Check flue vent stack or outlet dampers 2 Test blower air pressure See Blower Check on page...

Page 55: ...ty safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV Filter Maintenance Inspect quarterly Replace when tracking pressure exceeds 0 5 in WC at 100 fan speed Filter Replacement 1 Remove the filter box cover by loosening and removing the two wing nuts holding it in place 2 Remove the filter by lifting it straight up and out of the slot in the filter box 3 Reverse...

Page 56: ...stion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners chlorine based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varnish removers hydrochloric acid muriatic acid cements and glues antistatic fabric softeners used in clothes dryers chloride type bleaches detergents an...

Page 57: ... 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 sh...

Page 58: ...58 ...

Page 59: ...nutes Vent Size _____________ Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size _______________ Vent Termination Type __________________ Pump Size _________ boiler Pump HP ______ Combustion Air Openings Low __________ in2 Impeller trim____________ Pu...

Page 60: ...vel 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 pa...

Page 61: ...CEMENT 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...

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Page 64: ...64 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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