CLIN 0007 Bldg 280 Boiler Information.pdf

Qty Description & Tag

Tag: Building 1 and 280

2 Raypak Model H7-754A MVB Non-condensing, Hot Water Boiler to include:

Cast Iron Headers 84% Thermal Efficiency Copper finned tubing ASME Stamped 60 PSIG ASME Relief Valve Automatic Air Vent T&P Gauge – shipped loose 4-Pass Heat Exchanger Natural Gas fired Versa IC Modulating Controller with Display Connections – Rear Water, Gas, Flue & Electrical.

60# PRV

Limit Control – Fixed Manual – 240F Air Filter – shipped loose Boiler Pump Relay 120VAC 1-Phas 60Hx Power Water Temperature Sensor – 2 mounted / 3 loose

ANSI Z21.13

Diagnostics with Fault Memory Drain Valves (2) Alarm Dry Contact Enable/Disable Connections Flow Switch Freeze Protection Full Electronic Modulation Hot Srface Ignition (HIS) 3-Try Manual Gas Shut Off Valve Modbus RTU BMS Port – 3 Wire RS485 T&P Gauge – Shipped Loose for field installation

- SUBMITTAL –

12 Kimler Drive Maryland Heights, MO 63043 314-878-4313 fax 314-878-6029

Job: Missouri Air National Guard Building 1, 28, and 280

Engineer:

Contractor: Integrated Facility Services Order No.: 20-10738

Prepared By: Ed Masterson Date: , 2020

Shipping Weight: 670 lbs.

Capacity: 750 MBH Input / 630 MBH Output

Optional features include are:

CSD-1/GE Gap Well for sensor Vent Termination (Specify side wall or vertical termination)

Tag: Building 28

Raypak Model H7-150 A MVB ondensing, Hot Water

Cast Iron Headers 8 % Thermal Efficiency Copper finned tubing ASME Stamped 60 PSIG ASME Relief Valve Automatic Air Vent T&P Gauge – shipped loose 4-Pass Heat Exchanger Natural Gas fired Versa IC Modulating Controller with Display Connections – Rear Water, Gas, Flue & Electrical.

60# PRV

Limit Control – Fixed Manual – 240F Air Filter – shipped loose Boiler Pump Relay 120VAC 1-Phas 60Hx Power Water Temperature Sensor – 2 mounted / 3 loose

ANSI Z21.13

Diagnostics with Fault Memory Drain Valves (2) Alarm Dry Contact Enable/Disable Connections Flow Switch Freeze Protection Full Electronic Modulation Hot Srface Ignition (HIS) 3-Try Manual Gas Shut Off Valve Modbus RTU BMS Port – 3 Wire RS485 T&P Gauge – Shipped Loose for field installation

Shipping Weight: 780 lbs.

Capacity: 1,500 MBH Input / 1, MBH Output

Optional features include are:

CSD-1/GE Gap Well for sensor Vent Termination (Specify side wall or vertical termination)

Raypak Model H7-150 A MVB

Missouri Air National Guard Building 1, 28, and 280

Integrated Facility Services

1503A

INSTALLATION & OPERATING

INSTRUCTIONS

CATALOG NO. 3400.542C

Effective: 06-01-19 Replaces: 05-28-18 P/N 241512 Rev. 4

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.

Models 504A–2004A Types H, WH & P

Revision 4 reflects the following changes:

Replaced Raypak logo on the front cover page. Updated the elevation rating on page 5. Update the “User Interface” sec-tion on page 38. Updated the Wiring Diagram on page 44. Updated Figure 46 on page 46. Added a note and updated the “Blower Check” section on page 47. Removed “Manifold Check” section on page 47. Removed Table T from page 47.

Added a note to the “Blower Check” on page 47. Added the “Touchscreen Toolbox Menu” figure on page 47. Updated the “User Test” section on page 49. Added the Raymote Troubleshooting sub-section on page 51. Updated “Semi-Annually” and “Annually” section on page 54. Added a note and updated “As Required” section on page 55. Replaced the “Start-Up Checklist” on page 58. Updated Raypak logo on page 59 and 60. Replaced ISO logo on the back cover page.

WARNINGS 4

BEFORE INSTALLATION 5

Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 6

GENERAL SAFETY 7

Time/Temperature Relationships in Scalds 7

INSTALLATION 8

Installation Codes 8 Equipment Base 8 Clearances 8 Combustion and Ventilation Air 9 Conventional Combustion Air Supply 11 Water Piping 13 Hydronic Heating 15 Applications & Modes 16 Domestic Hot Water 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 Maintenance Schedule 53 Preventative Maintenance Schedule 54 Filter Maintenance 55 Filter Replacement 55

APPENDIX 56

Inside Air Contamination 56

IMPORTANT INSTRUCTIONS FOR THE

COMMONWEALTH OF

MASSACHUSETTS 57

START-UP CHECKLIST 59

WARRANTY 60

CONTENTS

DANGER: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored.

WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored.

CAUTION: Indicates the presence of hazards or unsafe practices 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 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.

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.

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.

WARNING: To minimize the possibility of improper operation, serious personal injury, fire, or damage to the heater:

• Always keep the area around the heater free of combustible materials, gasoline, and other flammable liquids and vapors.

• 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.

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: 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.

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.

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.

WARNINGS

Pay Attention to These Terms

WARNING: UL recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications wherein there is a potential for an explosive mixture of fuel gas to accumulate and their installation should be in accordance with the detector manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

WARNING: Both natural gas and propane have an odorant added to aid in detecting a gas leak.

Some people may not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar with the smell of natural gas or propane, ask your local gas supplier. Other conditions, such as “odorant fade,” which causes the odorant to diminish in intensity, can also hide, camouflage, or otherwise make detecting a gas leak by smell more difficult.

BEFORE INSTALLATION

Raypak strongly recommends that this manual be re-viewed thoroughly before installing your MVB heat-

er. Please review the General Safety information before installing the heater. Factory warranty does not apply to heaters that have been improperly installed or operated. (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 www.raypak.com.

Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.

Product Receipt 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.

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.

When ordering parts, you must specify the model and serial number of the heater. When ordering under warranty 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 warranties.

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 Water (DHW), and P = Pool heating). The number which follows identifies the firing mode (7 = electronic modulation). The second group of characters identifies the size of the heater (the four numbers representing the approximate MBTUH input), and, where applica-ble, a letter, indicating the manufacturing series.

Ratings and Certifications Standards:

• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Hot Water Boilers

• CAN 3.1 - latest edition, Industrial and Commercial Gas-Fired Package Boilers

• ANSI Z21.10.3 · CSA 4.3 - latest edition, Gas Wa-ter Heaters

• ANSI Z21.56 · CSA 4.7 - latest edition, Gas-Fired Pool Heaters

• SCAQMD Rule 1146.2

• Low-lead content (<.25%) CSA-certified

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.

Installations at Elevation Rated inputs are suitable for up to 4,500 ft. (1,372 m) elevation without de-rating. Consult your local representative or the factory for installations at altitudes over 4,500 ft. (1,372 m) above sea level. No hardware changes are required to the heaters for installations up to 10,000 ft. (3,048 m) (adjustments may be required).

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. Altering the ASME or CSA ratings of the vessel also violates national, state, and local approval codes.

General Information

Table A: Basic Data

Component Locations

Panels omitted for clarity Fig. 1: Component Locations – Side

Top panel, blower and gas train omitted for clarity 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

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 reach-es 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 appli-ca-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.

Safety and energy conservation are factors to be considered 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.

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.

• Feel water before bathing or showering.

• Temperature limiting valves are available.

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 fau-cet 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 plumber or the local plumbing authority for further information.

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.

See instruction manual before set-ting temperature at water heater.

Feel water before bathing or show-ering.

Temperature limiting valves 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 in determining the safest water temperature for your applications.

Water Temp.

Time to Produce Serious Burn

120°F More than 5 minutes 125°F 1-1/2 to 2 minutes 130°F About 30 seconds 135°F About 10 seconds 140°F Less than 5 seconds 145°F Less than 3 seconds 150°F About 1-1/2 seconds 155°F About 1 second

Table courtesy of The Shriners Burn Institute

Table B: Time to Produce Serious Burn

CAUTION: Hotter water increases the risk of scalding! There is a hot water scald potential if the thermostat is set too high.

Equipment Base The heater should be mounted on a level, structurally sound surface. The heater is approved for installa-tion 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.

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 hole pattern shown in Fig. 5, following local codes.

Additional clearance may be required when using the factory anchor bracket.

Clearances

Indoor Installations

When installed according to the listed minimum clear-ances from combustible construction, these heaters can still be serviced without removing per-manent structural construction around the heater.

However, for ease of servicing, a clearance of at least

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/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)

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.

Fig. 5: Anchor Hole Locations

Heater Side

Minimum Clearance from Combustible

Surfaces

Minimum Service

Clearance

Floor* 0” 0” Rear 12” 24”

Right Side 1” 1” Left Side 1” 1”

Top 0” 10” Front Open 24” Vent 1” 1”

*DO NOT install on carpeting.

Fig. 6: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations ordered when ordering the unit and is shipped loose for field installation. The intake air elbow MUST be installed on the air filter intake at the rear of the unit during installation. The intake elbow MUST be orient-ed with the open end facing downward. Heaters must not be installed under an overhang unless clearances are in accordance with local installation codes and the requirements 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.

Table D: Clearances – Outdoor Installations

24 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 the heater to be 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.

Outdoor Installations

Outdoor installation REQUIRES the use of the com-bustion air intake elbow. The intake 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 supplied 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 comply with the requirements of the NFGC (U.S.) and B149 (Canada), and all local codes.

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.

Heater Side

Min. Clearance from Combustible

Surfaces

Minimum Service

Clearance

Rear 12” 24”

Front Open 24”

Right Side 1” 1”

Left Side 1” 1”

Top Unobstructed 10”

Vent Termination 12” 12”

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can cause non-warrantied damage to the heater. (See the Appendix.)

NOTE: It is recommended that the intake vent be insulated to minimize sweating.

U.S. Installations 1 Canadian Installations 2

A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm)

B Clearance to window or door that may be opened

4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm)

C Clearance to permanently closed window * *

D

Vertical clearance to ventilated soffit located above the terminal within a horizontal dis-tance of 2 ft (61cm) from the centerline of the terminal

5 ft (1.5m) *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner 6 ft (1.83m) *

H Clearance to each side of center line ex-tended above meter/regulator assembly *

3 ft (91 cm) within a height 15 ft above the me-ter/regulator assembly I Clearance to service regulator vent outlet * 6 ft (1.83m)

J Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance

4 ft (1.2m) below or to side of opening; 1 ft (30 cm) above opening 3 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 Installation Codes t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that se rves 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 term inal 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

Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table E: Vent/Air Inlet Termination Clearances

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. (see figure 37 for outdoor installation).

Direct Vent

If outside air is drawn through the intake pipe directly to the unit for combustion:

1. Install combustion air direct vent in accordance with Fig. 35 (horizontal) or Fig. 36 (vertical) of this manual (pages 33 and 34, respectively).

2. Ventilation of the space occupied by the heater(s) is recommended and can be provided by an open-ing(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional areas should 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 outdoors or through vertical duct(s). The total cross-sectional area should be at least 1in.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). Damage to the equip-ment due to inadequate ventilation of the space is not a warrantable failure.

3. In cold climates, and to mitigate potential freeze-up, Raypak highly recommends the installation of a motorized sealed damper to prevent the cir-cula-tion of cold air through the heater during the non-operating hours.

Motorized Combustion Air Dampers or Louvers:

When motorized dampers or louvers are communi-cating directly with outside combustion air, they must be interlocked with each appliance in the equipment room, to ensure proper 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 (shipped loose), using 3-4 sheet metal screws (not supplied) equally positioned around the circumference of the duct. The screen assembly should be removed before attaching any air duct. The screws and duct connection point must be sealed with RTV (not supplied). TruSeal is generally used when damaging contaminants are present in the mechanical room.

All ducting MUST be self-supported.

Conventional Combustion Air Supply - U.S. Installations

All Air from Inside the Building

The confined space shall be provided with TWO permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined 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 confined 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 minimum dimension of air openings shall be not less than 3 in. (76 mm) in any direction.

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.

Fig. 8: Air Filter Box

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.

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 the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely com-municate with the outdoors.

a. Where directly communicating with the out-doors or where communicating to the outdoors through vertical ducts, each opening 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.

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 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:

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

WARNING: Do not use the “one permanent opening” method if the equipment room is under negative pressure conditions.

b. Not less than the sum of the areas of all vent connectors in the confined space.

CAUTION: All combustion air must be drawn from the air outside of the building; the mechanical equipment room must communicate directly with the outdoors.

Canadian Installations

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 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 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).

WARNING: Care must be taken to ensure that the equipment room is not under negative pressure conditions.

3. For heaters not using a barometric damper in the 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 sim-ilar 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.

4. Refer to the B149 Installation Code for additional information

Water Piping

General

The heater should be located so that any water leaks will not cause damage to the adjacent area or struc-tures.

Relief Valve Piping 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.

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 factory-tested and is rated for 160 psi operating pres-sure. However, Raypak does recommend hydrostatic testing of the piping connections to the heater and the rest of the system prior to operation. This is par-ticularly true for hydronic systems using expensive glycol-based anti-freeze. Raypak recommends con-ducting the hydrostatic test before connecting gas piping or electrical supply.

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. Fill heater with water.

Carefully fill the rest of the system, making sure to eliminate any entrapped air by using high-point vents. Close feed valve. Test at standard operat-ing pressure for at least 24 hours.

2. Make sure constant gauge pressure has been maintained throughout test.

3. Check for leaks. Repair any that are found.

Flushing/Cleaning of System Piping

Many of the chemicals used to perform this function will harm the heat exchanger as well as some gaskets and seals within the unit, causing a non-warrantable 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 conden-sate 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 low-temperature operation system (Figs. 9, 10 and 11) to prevent problems with condensation. 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 condensate evaporation system.

Failure to reach or exceed 120°F (49°C) may damage or cause failure of the heat exchanger, combus-tion 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 condensing beyond the ability of the condensate management system employed in this heater in most installations.

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. 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.

CAUTION: This heater requires forced water circulation when the burner is operating. See Table F and Table G for minimum and maximum flow rates. The pump must be interlocked with the heater to prevent heater operation without water circulation.

NOTE: Minimum pipe size for in/out connections is 2

in. NPT for 504A and 754A models and 2-1

2 in NPT for 1104A–2004A models. Verify proper flow rates and T as instructed in this manual.

Warranty claims will be denied for damage or fail-ures caused by condensation.

Cold Water Starts

Cold water starts, where the inlet water temperature remains below 120°F (49°C) must have cold water start protection. Known protection 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 outlet temperature may continue to climb and trip the high limit, thereby shut-ting down the heater. Thus an automatic valve system, such as a three-way proportional valve to control the bypass, should be used.

Cold 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 swimming pool heating and water source heat pump applications, as well as some others. 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 and manually adjusted to achieve an inlet temperature of 120°F (49°C) or higher as adjusted at

Fig. 9: Cold Water Start *Maximum 4 times the pipe diameter or 12”, whichever is less.

the minimum temperature in this narrow temperature range (i.e. Range 75°F to 85°F – adjust bypass with temperature 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 utilized to keep the heater loop at or above 120°F (49°C). An injector pump arrangement may be used 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 automatically to changes in the system water coming back to the heater.

“H” Bypass

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) versions and 120°F (49°C) for Hydronic Heating (H7) or Domestic Hot Water (WH7) 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.

For the H-bypass, use the following instructions to set the manual bypass:

1. Turn on pump.

2. Turn on heater and wait until heater goes to full fire.

3. With the heater operating at 100% firing rate, set Valve A (the bypass) to 1

2 open position, and Valve B to fully open position. See Fig. 16.

Fig. 10: Cold Water Run *Maximum 4 times the pipe diameter or 12”, whichever is less.

Table F: Heater Rates of Flow and Pressure Drops

Notes: Basis for minimum flow is T . Basis for maximum flow is gpm.

4. Adjust Valve A until the inlet water temperature is 105°F (40°C) or 120°F (49°C) depending upon heater type.

5. If this process does not raise the inlet water tem-perature to 105°F (40°C) for Pool Heater (P) versions and 120°F (49°C) for Hydronic Heating (H7) or Domestic Hot Water (WH7) versions and Valve A is fully open, then slowly throttle Valve B closed to increase the inlet water temperature to the required temperature.

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 16°F to 39°F (9°C to 22°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).

Feedwater Regulator

Raypak recommends that a feedwater regulator be in-stalled and set at 12 psi minimum pressure at the highest point of the system. Install a check valve or back flow device upstream of the regulator, with a manual shut-off valve as required by local 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 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 NOTE: Hot water heating systems all have unique levels of operating diversity that must be accounted for in the system design. The system should always include adequate system flow in excess of the connected boiler flow for proper operation. Where the system flow may drop below the connected boiler flow a buffer/decoupler may be needed.

Failure to design for adequate flow (i.e. bypasses, 3 way control valves, flow limiting balance devices, buffer tanks, etc.) will result in boiler short cycling and may reduce boiler life. Always contact your local Raypak representative for system design assistance to avoid these issues.

GPM

P

(ft WC) GPM P

(ft WC) GPM P

(ft WC) GPM P

(ft WC) T

(°F) GPM

P

(ft WC) T

(°F)

504A 42 2.7 28 1.4 N/A N/A 25 1.1 34 100 11.3 8 754A 63 6.0 42 2.9 32 1.8 32 1.8 39 100 13.8 13 1104A 92 13.3 62 6.7 47 4.3 47 4.3 39 113 18.6 16 1504A N/A N/A 84 13.3 65 8.4 65 8.4 39 113 22.2 22 2004A N/A N/A 112 26.9 86 16.7 86 16.7 39 113 27.2 30

Max Flow

MVB

Model

20° T 30° T 39° T Min Flow

Fig. 11: “H” Bypass Setting

NOTE: Opening the valve will increase the temperature and closing the valve will decrease the temperature.

NOTE: For automatic temperature adjustment, a Cold Water Run (CWR) system can be used instead of a manual bypass. See Fig. 10.

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.

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 rec-ommended 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 .

Mode 2 (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 with-out Outdoor Air Reset (S4) with indirect DHW on the system loop (with or without priority). The system tem-perature is controlled by the System sensor (S3). The Indirect DHW sensor (S5) determines the indirect call/ tank setpoint. The system temperature is boosted to Target Max when using the Indirect DHW sensor (S5) during an indirect call for heat. Priority mode toggles off the System Pump (P2) when an indirect call for heat is present. The Boiler Pump (P1) runs during any call for heat. The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The Boiler Pump (P1) and System Pump (P2) delay “off” as user defined in the ADJUST menu. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect call for heat is present with priority.

Mode 3 (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 with-out Outdoor Air Reset (S4) with indirect DHW on the boiler loop (with priority). The system temperature is controlled 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 priority.

The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The Boiler Pump (P1) and System Pump (P2) delay “off” as user defined in the ADJUST menu. The system pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD tem-perature setting (if utilized) unless an indirect call for heat is present.

Fig. 15: MODE 2 - Single Boiler with Indirect on System Loop

Fig. 16: MODE 3 - Single Boiler with Indirect on Boiler Loop

NOTE: A Tank Aquastat can be used in lieu of the Indirect DHW Sensor (S5). See the Versa IC manual for additional details.

NOTE: MODE 1 can also be used for process heat-ing applications in conjunction with a buffer/storage tank when operating temperatures above 160°F are required. Care must be given to ensure water hard-ness is no more than 15 grains per gallon for scale free operation.

Domestic Hot Water When designing the water piping system for domes-tic 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.

Potable Water and Space Heating

1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water.

2. Toxic chemicals, such as used for boiler treat-ment, shall not be introduced into the potable water used for space heating.

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 heat-ing 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.

CAUTION: When this heater is used for both potable water and space heating, observe the following to ensure proper operation.

T = Temperature rise, °F P = Pressure drop through heat exchanger, ft

SHL = System head loss, ft (based on heater and tank connections of no more than 100 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.

***Care should be given to prevent over-softening of the water as over-softened water can become aggressive. Cupro-nickel 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 25.3 1104A 21 85 11.5 2 1/2 16.2 21 85 11.5 2 1/2 16.2 15 116 19.6 2 1/2 27.8 1504A 27 94 18.4 2 1/2 24.0 24 105 22.5 2 1/2 29.3 22 115 26.5 2 1/2 34.6 2004A 29 117 32.6 2 1/2 40.9 29 117.2 32.6 2 1/2 40.9 29 117 32.6 2 1/2 40.9

SOFT* MEDIUM HARD*

MVB

Model

WATER HARDNESS

NOTE: WH units will operate to a maximum tank temperature of 160°F. For temperatures required above 160°F an “H” model boiler must be used and great care must be given to ensure water hardness is no more than 15 grains per gallon for scale free operation. MODE 1 should be used and configured for setpoint operation for process heating applica-tions.

NOTE: If local codes require a vacuum relief valve, acquire one locally and install per valve manufacturer’s instructions.

Fig. 17: WH Units - Single Water Heater with Tank H Units - Single Boiler with Process Tank

WH – Direct DHW Configuration

When the unit is ordered as a “WH” configuration the only application available to it is direct DHW with sin-gle or multiple heaters (Maximum 4 heaters). The tank temperature is controlled by the System sensor (S3).

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

The System Pump (P2) output is active whenever the system is enabled. The Boiler Pump is delayed “off” after the Tank Target temperature is achieved and as user defined in the ADJUST menu.

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.

NOTE: High chemical concentrates from feeders that are out of adjustment will cause rapid corrosion to the heat exchanger. Such damage is not covered under the warranty.

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can cause unwarrantable damage to the heater.

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.

POOL

THERMOSTAT

FROM

FILTER

TO POOL

CHEMICAL

FEED

AUTO LIMIT

SET TO 110°F

Fig. 18: Single Pool Heater Application *Maximum 4 times the pipe diameter or 12”, whichever is less.

Pool Heating

When a boiler or water heater is used in a pool heating application, ensure that all the following installation requirements are met.

The MVB must be equipped with an external pump and bypass arrangement. This arrangement blends outlet water with the inlet water to increase the inlet water temperature to a minimum of 105°F (40°C) for Pool Heater (P) versions and 120°F (49°C) for Hydronic Heating (H7) or Domestic Hot Water (WH7) versions, thereby reducing the likelihood of conden-sation forming on the heat exchanger. The pump also serves to circulate water through the heater from the main system piping.

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