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Raypak MVB 1504A User Manual

Raypak MVB 1504A
64 pages
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INSTALLATION & OPERATING
INSTRUCTIONS
CATALOG NO. 3400.542A Effective: 10-04-13 Replaces: 05-21-13 P/N 241512 Rev. 2
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
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Raypak MVB 1504A Specifications

General IconGeneral
BrandRaypak
ModelMVB 1504A
CategoryBoiler
LanguageEnglish

Summary

Safety Warnings

Warning Definitions

Clarifies DANGER, WARNING, CAUTION, and NOTE terms used in the manual.

Specific Safety Advisories

Covers gas, electrical, water safety, and California Proposition 65 warnings.

Before Installation

Product Receipt and Identification

Instructions for checking and identifying the heater model and serial number.

Ratings, Certifications, and Elevation

Lists standards, certifications, and considerations for high-altitude installations.

Component Locations and Data

Component Location Diagrams

Illustrates component placement from side, front, rear, and top views.

Basic Data Table

Provides key specifications and data for various heater models.

General Safety Information

Scald Prevention and Temperature Limits

Discusses risks of hot water over 125°F and recommended temperature settings.

Scald Injury Time/Temperature Chart

Details the relationship between water temperature and burn time.

Installation Procedures

Installation Codes and Requirements

Lists applicable national, state, and local codes for installation.

Equipment Mounting and Clearances

Covers base requirements and indoor installation clearances.

Installation (Continued)

Outdoor Installation Clearances

Provides required clearances for outdoor installations.

Combustion and Ventilation Air Requirements

Details air supply needs for proper combustion and ventilation.

Installation (Continued)

Vent/Air Inlet Termination Clearances

Specifies required distances for vent and air inlet terminations.

Installation (Continued)

Air Filter and Combustion Air Options

Discusses air filter, direct vent, TruSeal, and conventional air supply.

Water Piping and Related Systems

General Water Piping and Relief Valve

Covers general piping, relief valve discharge, and pipe sizing.

Temperature/Pressure Gauge and Hydrostatic Test

Instructions for gauge installation and hydrostatic system testing.

Flushing/Cleaning and Cold Water Operation

Advisories on system cleaning and cold water startup procedures.

Water Piping (Continued)

Cold Water Starts and Bypass Systems

Explains methods for handling cold water startups and bypass systems.

Cold Water Run and 'H' Bypass Adjustment

Details for continuous cold water applications and bypass adjustment.

Hydronic Heating

Pump Selection and Feedwater Regulator

Guidance on pump sizing, feedwater regulator installation, and piping.

Piping Considerations

General piping recommendations and system flow advice.

Applications & Modes

System Components and Mode 1

Discusses air-separation, expansion tanks, valves, and Mode 1 configurations.

Applications & Modes (Continued)

Mode 2 and Mode 3 Operation

Details for Mode 2 (System Loop) and Mode 3 (Boiler Loop) DHW.

Domestic Hot Water Considerations

Specific considerations for domestic hot water applications.

Domestic Hot Water Requirements

Table G: Flow Rate Requirements

Data on flow rates based on water hardness.

Potable Water and Space Heating Guidelines

Guidelines for combined potable water and space heating use.

Pool Heating

Installation Requirements and Pump Interlocks

Specifics for pool heating installations and pump interlocks.

Winterizing Your Heater

Procedure for shutting down the heater in freezing climates.

Pool/Spa Water Chemistry

Importance of water balance and chemical impact on the heater.

Pool Water Chemistry

Table H: Pool Water Chemistry

Recommended water balance levels for pools and spas.

Automatic Chlorinators and Chemical Feeders

Usage guidelines for automatic chemical treatment systems.

Gas Supply

Gas Supply Connection and Pressure

Requirements for gas connection, piping, and pressure.

Electrical Power Connections

Gas Pipe Sizing and Pressure Settings

Tables for maximum equivalent pipe length and manifold gas pressure.

Wiring Codes and Pump Power

Electrical installation standards and pump power wiring.

Electrical Connections

Wiring Diagrams and Power Source Check

Instructions for wiring and checking the power source.

Making the Electrical Connections

Step-by-step guide for making electrical connections.

Field Wiring Connections

Wiring Location and Grounding

Importance of proper wiring location and grounding.

Enable/Disable and Outdoor Sensor Wiring

Instructions for connecting enable/disable functions and outdoor sensors.

Field Wiring Connections (Continued)

Indirect Sensor and Control Signal Wiring

Connecting indirect DHW sensors and optional control signals.

Cascade System Communication Bus

Instructions for connecting multiple boilers in a cascade system.

Cascade System Wiring

Cascade System Pump and Sensor Wiring

Connecting pumps and sensors for cascade systems.

Cascade System Wiring (Continued)

Follower Boiler Wiring and Alarm Connection

Wiring for follower boilers, alarms, and venting categories.

Venting Categories

Classifications of venting systems based on pressure and condensate.

Venting Requirements

Table K: Venting Category Requirements

Summary table of venting category requirements.

Vent Support and Terminal Location

Guidelines for vent stack support and terminal placement.

Extractors, Draft Inducers, and Dampers

Interlocking requirements for venting accessories.

Vent Termination Details

Canadian Vent Termination Rules

Specific vent termination rules for Canada.

U.S. Vent Termination Requirements

Vent termination requirements according to U.S. codes.

Fig. 30: Vent Cap Configurations

Diagrams illustrating different vent cap configurations.

Venting Installation and Configurations

Canadian Vent Termination Rules

Specific vent termination rules for Canada.

Vertical Venting (Category I) Installation

General installation guidance for Category I vertical venting.

Venting Installation Tips and Configurations

Tips for vent support, inspection, and configurations.

Venting Details

Table L: Category I Vertical Venting

Specification table for Category I vertical venting.

Vertical Venting Diagram

Illustration of a typical vertical venting setup.

Common Venting

Guidelines for systems that share a common chimney.

Common Venting Procedures

Common Venting Checks and Engineered Systems

Inspection procedures and types of engineered venting systems.

Horizontal Through-the-Wall Direct Venting

Table M: Typical Volume of Flue Products

Table showing flue product volume for different models.

Horizontal Venting Installation

Installation steps and length limitations for horizontal venting.

Horizontal Venting Requirements

Table N: Category III Venting

Specification table for Category III horizontal and direct venting.

Direct Vent-Vertical Installation and Termination

Requirements for direct vertical venting installation and termination.

Outdoor Installation and Freeze Protection

Outdoor Installation Guidelines

Specific instructions and precautions for outdoor unit installations.

Freeze Protection

How to enable and operate the freeze protection feature.

Controls and Ignition Functions

Ignition Control Functions

Explanation of ignition module operation, pre-purge, and lockout.

High Limit—Manual Reset

Description of the fixed and optional manual reset high limit.

Heater Controls

High Limits and Safety Switches

Details on high limits, flow switch, low water cut-off, and gas pressure switches.

User Interface and Setpoints

Blocked Vent Switch and UI Overview

Function of blocked vent switch and user interface buttons.

Adjusting Setpoints and Menu Navigation

How to adjust setpoints and navigate menus for initial adjustment.

Setup/Adjust Menu Parameters

Table P: Setup/Adjust Menu

List of adjustable parameters, ranges, and default settings.

Boiler Menu Parameters

Table Q: Boiler Menu

List of boiler status, temperature, and software information.

Monitor Menu Parameters

Table R: Monitor Menu

List of logged operational data including run times and temperatures.

Control Concepts

Toolbox Menu and Error Code Lookup

Accessing error codes, history, and toolbox functions.

Outdoor Reset Concept

Explanation of temperature control based on outdoor temperature.

Reset Ratio Settings

Reset Ratio Calculation and Settings

Details on Boil START, OUT START, Boil DESIGN, and Reset Ratio settings.

Fig. 45: Reset Ratio Diagram

Diagram illustrating the relationship for reset ratio calculation.

Wiring Diagram

Main Wiring Schematic

Comprehensive wiring diagram for models 504A-2004A.

Start-Up Procedures

Pre Start-up Steps

Initial checks including system filling, air purging, and venting inspection.

Gas Leak Check and Safety

Essential safety steps, including smell test and gas leak prevention.

Required Tools for Initial Start-up

List of tools needed for the initial startup process.

Start-Up Operations

Power Supply and Gas Pressure Checks

Verifying electrical supply voltage and gas supply pressure.

Ignition and Operation Sequence

Step-by-step guide for igniting the burner and initial operation.

Operational Checks

Blower, Manifold, and User Test Checks

Verifying blower operation, manifold pressure, and using the user test function.

Safety Inspection and Leak Test

Comprehensive Safety Inspection Checklist

Detailed checklist for safety inspections of controls and operation.

Dual-Seat Gas Valve Leak Test Procedure

Method for testing the gas valve for leaks using pressure points.

Post Start-Up Checks

Completion Checks and Safety Control Testing

Confirming successful startup and testing safety controls.

Operation

Lighting Instructions

Step-by-step guide for lighting the heater burner.

Turning Off Gas To Appliance

Procedure for safely shutting off the gas supply to the appliance.

Troubleshooting Overview

Introduction to the troubleshooting section and error codes.

Troubleshooting and Error Codes

MVB Fault Text: Error Display

Table listing error items, descriptions, and troubleshooting steps.

LED Error Code Listing

Table X: PIM™ LED Error Codes

List of error codes indicated by PIM LED lights and troubleshooting.

Maintenance Schedule

Suggested Minimum Maintenance Schedule

Overview of recommended daily, monthly, and yearly maintenance tasks.

Maintenance Procedures

Yearly Maintenance and Frequency Breakdown

Details annual service and breakdown by maintenance frequency.

Filter Replacement

Filter Maintenance and Replacement

Instructions for inspecting and replacing the air filter.

Appendix: Inside Air Contamination

Products Causing Contaminated Air

List of common household and industrial products affecting air quality.

Areas with Contaminated Air

Locations where contaminated combustion air commonly exists.

Important Instructions for Massachusetts

Installation Requirements

Specific installation rules for MA, including CO detectors and signage.

Gas Pressure Supervision

Massachusetts requirements for gas pressure monitoring.

Start-Up Checklist

Gas Supply Data Checklist

Checklist items related to gas supply data.

Clearances and Electrical Checklist

Checklist items for clearances and electrical connections.

Component Inspection and Venting Checklist

Checklist items for visual component inspection and venting.

Emissions Settings and Test Information

Checklist items for emissions settings and test information.

Limited Parts Warranty

Scope and Heat Exchanger Warranty

General warranty terms and specific warranty for heat exchangers.

Other Parts Warranty and Exclusions

Warranty for other parts and conditions that void the warranty.

Limited Parts Warranty (Continued)

Parts Replacement and Warranty Claim Process

Process for replacing parts and making a warranty claim.

Exclusive Warranty and Liability Limitation

Legal disclaimers, limitations of liability, and owner rights.