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58

START-UP CHECKLIST FOR FAN-ASSISTED 

RAYPAK PRODUCTS 

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

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

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

 

 

 

  

GAS SUPPLY DATA  

 

CLEARANCES 

Regulator Model & Size  

_________ / ______CFH  

Front Clearance 

_______________In.  

Gas Line Size (in room) 

________________In. NPT 

Right Side Clearance 

_______________In.   

Length of Gas Line 

________________Eq Ft 

Left Side Clearance 

_______________In.  

Low Gas Pressure Setting 

________________In. WC 

Rear Clearance 

_______________In.  

High Gas Pressure Setting 

________________In. WC 

Overhead Clearance 

_______________In.  

Gas Shut-Off Valve Type 

________________ 

 

  

( Ball, Lube cock) 

  

ELECTRICAL 

Sediment Trap 

________________Y/N 

Voltage Supply (VAC) 

No Load______ Load_____  

Port 

_______Std______Full 

Voltage -24 VAC 

_______________VAC   

 

 

Voltage Com to Ground  

_______________VAC  

VISUAL INSPECTION OF COMPONENTS 

Verify inspection was done and condition of components are in 

good working order with a “yes” 

Hot Surface Igniter                         

Auto High Limit Setting   

Manual Reset High Limit Setting  

_______________Ohms  

_______________deg F  

_______________deg F  

 Wiring Harness 

_________________ Y/N 

Operating Control Setting  

_______________deg F  

Burner/s (flame) 

_________________ Y/N  

 

  

Refractory (visual) 

_________________ Y/N 

Sketch plumbing on reverse side 

  

Remote flame sense 

_________________ Y/N  

WATER SUPPLY 

Covers in place for outdoor 

_________________ Y/N 

Flow Rate in GPM or Delta T 

_______________If Avail  

Measure flow rate at full fire  

VENTING 

 

Pump Economaster setting 

_______________Minutes  

Vent Size:  _____________ 

Stack Height:_______ 

Low Water Cutoff 

_______________Test  

Category:  _________ 

sketch vent on reverse side ***  Number of Tanks and Size 

Qty____  _______Gallons  

Vent Material: 

__________________ 

Plumbing Size 

_______________  

Vent Termination Type: 

__________________ 

Pump Size:   

_________ 

(boiler) 

 

Pump HP: ______  

Combustion Air Openings: 

Low __________  in2 

Impeller trim____________ 

Pump Model___________  

Ventilation air 

High __________ in2 

Louvers __________________ 

Screens________________  

EMISSIONS SETTINGS AND TEST INFORMATION 

(AT FULL FIRE) 

Nominal Factory Recommended Settings 

Blower Pressure Setting 

_________________In. WC 

See manual or card tag 

  

Supply Gas Pressure  

Verify stable pressure static & 

_________________In. WC  

dynamic condition  

See manual or card tag 

  

Pilot Gas Pressure 

_________________In. WC 

See manual or card tag 

  

Manifold Gas Pressure 

_________________In. WC 

See manual or card tag 

  

 

 

 

  

The following measurements must be obtained with a Combustion Analyzer. 

  

Free Oxygen 

_________________% 

See manual 

  

CO 

_________________PPM 

Less than 150 PPM 

  

CO2 

_________________% 

See manual 

  

 

 

 

  

Model Number:  ______________________________ 

Serial Number:  _______________________________  

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

barometric dampers, blast dampers or draft inducers   

Site Altitude Above Sea Level __________________Ft.  

Job Name  _______________________________________________________________________________________  

Address  _________________________________________________________________________________________  

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

Mechanical Contractor / Installer _______________________________________________________________________  

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

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

Содержание 2503

Страница 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 applian...

Страница 2: ...9 Warning on page 30 Note on page 30 Table M on page 32 High Limits on pages 34 35 Wiring Diagram on page 43 Blower Check on page 46 Additions Motorized Combustion Air Dampers or Louvers on page 11 Fl...

Страница 3: ...Hot Water 17 Gas Supply 19 Electrical Power Connections 20 Field Wiring Connection 21 Venting 26 Venting Installation Tips 28 Venting Configurations 28 Outdoor Installation 33 Controls 34 User Interfa...

Страница 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...

Страница 5: ...in kind only per Raypak s standard war ranties Model Identification The model identification number and heater serial number are found on the heater rating plate located on the upper rear jacket pane...

Страница 6: ...g 4 Component Locations Top Fig 3 Component Locations Rear HIGH VOLTAGE SWITCH LOW VOLTAGE SWITCH VERSA IC PIM Panels omitted for clarity Fig 2 Component Locations Front Max Min N P Flue Intake 2503 2...

Страница 7: ...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...

Страница 8: ...6 in on the rear and 10 in above the top of the heater is required This will allow 8 Heater Side Minimum Clearance from Combustible Surfaces Minimum Service Clearance Floor 0 0 Rear 12 36 One Side 1 1...

Страница 9: ...ater to be serviced without removing any structure around the heater Outdoor Installation These units may be installed outdoors when used with the outdoor air intake hood The outdoor hood must be orde...

Страница 10: ...t 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...

Страница 11: ...Motorized Combustion Air Dampers or Louvers When motorized dampers or louvers are communicat ing directly with outside combustion air they must be interlocked with each appliance in the equipment roo...

Страница 12: ...UH 740 mm2 per kW of the total input rating of all equipment located in 12 the enclosure and b Not less than the sum of the areas of all vent connectors in the confined space Canadian Installations 1...

Страница 13: ...ny that are found Flushing Cleaning of System Piping Many of the chemicals used to perform this function will harm the heat exhcanger as well as some ogas kets and seals within the unit casing a non w...

Страница 14: ...d Water Run Cold water run differs from cold water start in that the system water entering the heater remains below 120 F 49 C continuously Typically this is the case in water source heat pump applica...

Страница 15: ...g 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 a...

Страница 16: ...lower than the WWSD temperature setting if utilized unless an indirect call for heat is present with priority Fig 13 MODE 1 Single Boiler with Primary Secondary Piping Fig 15 MODE 2 Single Boiler with...

Страница 17: ...lieu of the Indirect DHW Sensor S5 See the Versa IC manu al for additional details Domestic Hot Water When designing the water piping system for domestic hot water applications water hardness should...

Страница 18: ...264 15 7 4 20 0 3003 29 176 11 0 4 12 8 20 255 21 7 4 25 6 19 264 23 1 4 27 3 3503 29 205 16 3 4 18 8 23 264 26 8 4 31 0 23 264 26 8 4 31 0 4003 29 234 25 6 4 28 9 26 264 33 5 4 37 7 26 264 33 5 4 37...

Страница 19: ...rate is the same type as specified on the heater s rating plate CAUTION The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in ex...

Страница 20: ...EC Class 1 Heater must be electrically grounded as required by the NEC In Canada CSA C22 1 C E C Part 1 The MVB heaters are wired for a 240 VAC single phase power supply Consult the wiring diagram shi...

Страница 21: ...ents 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 warran...

Страница 22: ...connected to ground Wiring the Outdoor Sensor 1 There is no connection required if an outdoor sen sor is not used in this installation 2 If using an Outdoor Sensor option B 32 connect the sensor wires...

Страница 23: ...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 th...

Страница 24: ...nnections 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 pilo...

Страница 25: ...maximum 3 The System and DHW pump outputs are not used in the Cascade Follower configuration Fig 28 VERSA Follower Modbus BMS Communication The VERSA IC control is equipped as standard with a communi...

Страница 26: ...r which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent See Table J for appliance category requirements CAUTION Proper...

Страница 27: ...lock vent pipe U S Installations Refer to the latest edition of the National Fuel Gas Code Vent termination requirements are as follows 1 Vent must terminate at least 4 ft below 4 ft hori zontally fro...

Страница 28: ...er or near elbows Venting Configurations For heaters connected to gas vents or chimneys vent installations shall be in accordance with the NFGC U S or B149 Canada or applicable provisions of local bui...

Страница 29: ...than 5 ft should be securely guyed or braced to withstand snow and wind loads Common Venting The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters This is...

Страница 30: ...pane gas and flue temperature of 350 F at 100 firing rate meas ured at a test port 12 above the flue collar NOTE Data for 100 firing rate Table L Typical Vent Pressure and Volume of Flue Products Fig...

Страница 31: ...allation 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 throu...

Страница 32: ...pproved 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 Subtract 10 ft per elbow Max 4 elbows Table M Categor...

Страница 33: ...debris etc The stainless steel flue direct vent cap must be fur nished by the heater manufacturer in accordance with its listing sales order option D 15 Outdoor Installation Units installed outdoors...

Страница 34: ...tch may be required to de energize the equipment before servicing NOTE Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Ignition Control F...

Страница 35: ...er 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 Low Water Cut Off Hig...

Страница 36: ...C 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 i...

Страница 37: ...3 Current system supply temperature Boil OUTLET All Current boiler outlet temperature Boil INLET All Current boiler inlet temperature Boil T All Current temperature difference between boiler outlet an...

Страница 38: ...rature 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...

Страница 39: ...fset 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 PRE...

Страница 40: ...oiler 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 tempe...

Страница 41: ...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 Bo...

Страница 42: ...ual 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 temper...

Страница 43: ...43 WIRING DIAGRAM Models 2503 4003...

Страница 44: ...your building Immediately call your gas supplier from a neigh bor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand...

Страница 45: ...er wait 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 loc...

Страница 46: ...1 4 3 2 in WC Table S MVB Air Pressure Settings Table T MVB Manifold Pressure Settings User Test Set DIP switch 1 on the VERSA IC control to ON Set USER TEST ON in the ToolBox Menu to start the user...

Страница 47: ...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 s...

Страница 48: ...RSA IC will 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 re...

Страница 49: ...ater 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...

Страница 50: ...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 Blow...

Страница 51: ...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...

Страница 52: ...c 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 E...

Страница 53: ...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 i...

Страница 54: ...ing should be 40 75 ohms at 77 F 5 Check flame signal strength Flame signal should be greater than 1 microampere as measured at the 2 pins on the bottom of the PIM 6 Check firing rate control by check...

Страница 55: ...ontaminated ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners ch...

Страница 56: ...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...

Страница 57: ...MENT 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 warr...

Страница 58: ...utes Vent Size _____________ Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material ____...

Страница 59: ...59...

Страница 60: ...60 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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