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5.  COLD WATER RUN

NOTE:

 After testing at the factory it may be prudent to 

ship the piping assembly disassembled and attached to 

the heater pallet. This is done to avoid shipping damage 

and it must be reassembled on the jobsite. Use Figure 21 

to assist you in reassembling the piping.

Purpose

The  Cold  Water  Run  system  utilizes  a  variable-speed 

pump to inject the proper amount of water from the main 

system loop into the heater to maintain the optimum inlet 

temperature. This approach allows the full capacity of the 

heater to be utilized to meet the system load, while at the 

same  time  continuously  maintaining  the  optimum  inlet 

water temperature to prevent condensation.

Typical Cold Water Run Applications

•  Swimming pools.
•  Any system with steady-state (or “consistent”) return 

water temperature below 105°F (40.5ºC). 

CWR vs. CWS

•  Cold water start is for transient cold water operation.
•  Cold  water  run  is  for  continuous  operation  below 

105°F (40.5ºC) system return temperature.

•  Cold water start maintains design flow rate at system 

design  temperature  but  reduces  boiler  flow  rate 

during heavy bypass operation.

•  Cold water run maintains constant design flow rate 

in the boiler.

Installation

Before  beginning  the  installation,  it’s  important  to  first 

inspect the system and determine what materials you will 

need.  Some  parts  are  included  with  the  controller  while 

others you will need to provide. 

Installation Codes

Installations  must  be  in  accordance  with  local,  state, 

provincial,  and  national  codes,  laws,  regulations  and 

ordinances.  In  the  absence  of  local  codes,  installations 

must be in accordance with the latest editions of the:
•  National Fuel Gas Code, ANSI Z223.1/NFPA 54
•  National Electrical Code, ANSI/NFPA 70
•  For Canada only: CAN/CSA B149 Installation Code 

and CSA C22.1 C.E.C. Part 1 and Part 2

TO SYSTEM

FROM SYSTEM

HEATER

COLD WATER RUN 

INJECTOR PUMP

HEAT

CIRCULATING

PUMP

COLD WATER RUN ASSEMBLY 

INSTALLED CONFIGURATION

RAYTHERM MODELS

2100 TO 4001 ONLY

Figure 21.  Cold Water Run Assembly

Mounting the Control Box

NOTE:

  The  heater  should  not  be  located  in  an  area 

where  possible  water  leakage  will  result  in  damage  to 

the area adjacent to the heater or to the structure. When 

such  locations  cannot  be  avoided,  it  is  recommended 

that  a  suitable  drain  pan,  with  adequate  drainage,  be 

installed  under  the  heater.  The  pan  must  not  restrict 

combustion air flow.

The control box should be mounted on the side of the heater 

to which the system piping and pump assemblies are to 

be attached as shown in 

Figure 4

 through 

Figure 8

. The 

controller should be mounted so as to provide maximum 

support by using the mounting holes provided on the base 

of the controller to the side center brace on the heater. You 

will need to drill mounting holes for #10 hardware and 3/4" 

conduit access holes through the heater side panel for the 

routing of wiring and the sensor.

CAUTION:

  Remote-mounted  controller  must  be 

installed within 25 feet (7.6 m) of wire length to the heater.

Содержание Raypak Hi Delta 302C

Страница 1: ...dividuals specially trained and experienced in the installation and maintenance of this type of equipment and related system components Installation and service personnel are required by some states t...

Страница 2: ...Water Start on page 5 Caution revised on page 5 Revised first note on page 9 Figure 12 revised on page 9 Caution revised on page 9 Figure 21 revised on page 21 Obsolete text and figures relating to E...

Страница 3: ...oxes 16 Installing the Temperature Sensor 16 Installing the Three way Valve 16 Connecting Power to the Controller 16 Connecting the CWS Control to the Multi Boiler Interlock Box 16 Connecting the Boil...

Страница 4: ...zardous condition which could cause minor personal injury or product or property damage if ignored NOTE Indicates special instructions on installation operation or maintenance which are important but...

Страница 5: ...lves are available see manual Time Temperature Relationships in Scalds The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide...

Страница 6: ...ls locating dimples are provided for ease of drilling the mounting holes You will need to drill mounting holes through the heater side panel for the routing of wiring and the sensor Figure 3 Multi met...

Страница 7: ...mm 1 5 16 34 mm 6 5 8 168 mm LEFT SIDE CONTROL BOX MTG PANEL 11 16 17 mm 7 1 4 184 mm 11 1 8 283 mm Figure 5 Component Locations Raytherm Models 514 824 11 1 8 283 mm 10 5 16 262 mm CONTROL BOX MTG P...

Страница 8: ...the following upon a CALL FOR HEAT signal from the heater 1 CALL FOR HEAT LED on PCB illuminates GREEN 2 START UP MODE LED on PCB illuminates YELLOW It should go out in less than 7 minutes as the boil...

Страница 9: ...is energized and closes the contacts allowing 24VAC to energize the CFH terminal on the cold start circuit board a A two second delay occurs from the CFH signal to the output of power from terminal M...

Страница 10: ...unting the actuator to the valve ensure that the valve stem is oriented with the machined flat notch positioned parallel to the A and AB ports as shown in Figure 13 All actuators used by Raypak includ...

Страница 11: ...ow tab labeled High Pressure see Figure 17 This is for maintenance of the valve only If the valve stem begins leaking beneath the yellow tab the internal packing material must be replaced The High Pre...

Страница 12: ...cold start controller have 120 VAC Heater is in standby mode Correct wiring to match wiring diagram YES NO NO YES YES NO NO NO YES YES NO The unit is okay YES NO YES Correct wiring Is the actuator mo...

Страница 13: ...CLOSED POSITION 3 PIPE ALL RELIEF VALVES TO DRAIN OR AS LOCAL CODES REQUIRE 4 BUFFER TANK REQUIRED WHEN WATER VOLUME IN BOILER LOOP IS NOT ADEQUATE TO PROVIDE STABLE TEMPERATURE CONTROL CONSULT FACTO...

Страница 14: ...14 Wiring Diagrams Cold Water Start...

Страница 15: ...15 HEATER INTERFACE WIRING FOR CWS OR CWR CWS CWR CONTROL OR MULTIPLE BOILER INTERFACE CWS CWR CONTROL OR MULTIPLE BOILER INTERFACE CWS CWR CONTROL OR MULTIPLE BOILER INTERFACE Heater Interface Wiring...

Страница 16: ...ure 9 for detailed instruction Connecting the CWS Control to the Multi Boiler Interlock Box Installer to provide four 18AWG stranded wires between pins 7 10 on the Cold Start Control and 7 10 on the M...

Страница 17: ...into your piping system in accordance with this manual Valve Installation To properly install this valve port AB must be connected to the combined outlet of the heater s and port B must be attached to...

Страница 18: ...S LOCAL CODES REQUIRE 3 LOCATE UNIONS TO FACILITATE SERVICING OF PLUMBING SIDE 4 BUFFER TANKS MAY BE REQUIRED TO PROVIDE STABLE TEMPERATURE CONTROL ON SYSTEMS WITH VARIABLE FLOW OR LOW WATER VOLUME CO...

Страница 19: ...19 CWS CONTROL BOX ASSY SEE PAGE 16 FOR HEATER INTERFACE WIRING SEE PAGE 17 Wiring Diagram Multiple Boiler...

Страница 20: ...d to provide Installation Codes Installations must be in accordance with local state provincial and national codes laws regulations and ordinances In the absence of local codes installations must be i...

Страница 21: ...120 454 3 25 13 9 13 38 8 1632 5 6 68 257 4 45 25 0 1911 1 3 2002C 132 499 7 26 14 4 19 56 8 1634 6 1 74 280 1 46 25 6 1935 3 4 2072C 132 499 7 27 15 0 19 56 8 1634 6 1 75 283 9 47 26 1 1935 3 4 2342...

Страница 22: ...90 340 7 25 13 9 13 2 39 4 1630 4 7 60 227 1 37 20 6 1911 1 3 1414 1468 90 340 7 27 15 0 14 0 41 8 1632 5 65 60 227 1 40 22 2 1911 1 3 1571 1631 90 340 7 30 16 7 14 5 43 3 1632 5 65 60 227 1 45 77 0 1...

Страница 23: ...shown in Figure 24 5 Remove the pump junction box cover shown in Figure 24 and locate the 9 wires inside DECAL COVER Figure 24 Pump Wiring Decal and Junction Box 6 Wire in accordance with the low volt...

Страница 24: ...n before proceeding 14 Secure from installation Injection Pump Cover Installation Required for Outdoor Installation Only Before Starting 1 Turn off power to the unit at the circuit breaker 2 Turn off...

Страница 25: ...e 30 Reposition the pump body so that the electrical box points downward 3 Insert and tighten all eight 8 bolts securing the pump body in place 4 You will now be able to install the pump cover See Fig...

Страница 26: ...ALL RELIEF VALVES TO DRAIN OR AS LOCAL CODES REQUIRE 4 SYSTEM FLOW MUST EXCEED HEATER FLOW AT ALL TIMES Typical Cold Water Run Piping Pool Apps SEE NOTE 4 NOTES 1 LOCATE UNIONS TO FACILITATE SERVICING...

Страница 27: ...old run circuit board pin MC outputs a 24VAC signal to terminal AL0 of the Hitachi inverter 8 The AL0 relay closes and outputs a 24VAC signal to the coil of the DPST relay located in the cold run cont...

Страница 28: ...e 120VAC or 230VAC Heater is in standby mode Correct Wiring YES NO NO YES YES NO NO NO YES YES NO The unit is okay YES NO YES Correct wiring Is the injector pump modulating after 2 1 2 minutes NO Corr...

Страница 29: ...29 Wiring Diagrams Cold Water Run SEE PAGE 17...

Страница 30: ...part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag completely filled in with the heater serial number model number etc and shipped to...

Страница 31: ...31 7 ILLUSTRATED PARTS LISTS Cold Water Start Manufactured from 2006 through current...

Страница 32: ...32 1 M 8 M Cold Water Start...

Страница 33: ...33 Cold Water Start Multiple Boiler Interlock...

Страница 34: ...34 NOTE Sizing is specific to the application...

Страница 35: ...35 4 C 1 S 1 S 1 S 1 S 1 C 5 C 2 C 3 C 7 C 9 C 10 C 10 C 4 S 8 C 3 S MVB MODELS ONLY 2 S 7 C Cold Water Run Manufactured 2006 thru current except 302B and 402B thru 5 31 2015...

Страница 36: ...36 9 M 4 M RAYTHERM MODELS 2100 4001 ONLY 1 H 5 M 6 M 7 M 8 M 10 M 12 M 11 M 4 M 2 M 1 M Cold Water Run...

Страница 37: ...37 NOTE Sizing is specific to the application...

Страница 38: ...38 NOTES...

Страница 39: ...39 NOTES...

Страница 40: ...Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 ISO 9001 REGISTERED QUALITY MANAGEMENT SYSTEM www raypak com...

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