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Raypak MVB 2004A User Manual

Raypak MVB 2004A
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 2004A Specifications

General IconGeneral
ModelMVB 2004A
TypeBoiler
Efficiency80%
Fuel TypeNatural Gas
Water Connection Size2" NPT
Input BTU/h200, 000 BTU/h
Input BTU200, 000 BTU/h

Summary

General Safety Warnings and Definitions

Hazard Level Definitions

Defines hazard levels (Danger, Warning, Caution, Note) for safety.

Specific Safety Precautions

Lists critical safety precautions for operation and installation.

Pre-Installation Procedures

Product Receipt and Inspection

Instructions for checking the heater upon receipt and reporting damage.

Model Identification and Ratings

Explains model identification, ratings, and certifications.

Installation Altitude Considerations

Guidance on installations at altitudes above 2,000 ft.

Component Overview and Basic Data

Component Location Diagrams

Figures showing the location of key internal components.

Basic Heater Data Table

Provides basic data like MBTUH input, connections, and vent size.

General Safety and Scald Hazards

Scald Hazard Information

Explains the risk of severe burns from hot water and recommended settings.

Time vs. Temperature Scald Chart

Details how water temperature relates to scald injury time.

Installation Guidelines and Clearances

Installation Codes and Standards

Lists codes and standards that must be followed for installation.

Equipment Base and Mounting

Requirements for the mounting surface and location of the heater.

Indoor Installation Clearances

Specifies minimum clearances for indoor installations.

Outdoor Installation Clearances

Specifies minimum clearances for outdoor installations.

Combustion and Ventilation Air

Requirements for supplying combustion and ventilation air.

Vent/Air Inlet Termination Clearances

Clearances for vent/air inlet terminations per codes.

Water Piping and Cold Water Operation

General Piping and Relief Valve Safety

Locating heater, circulation requirements, and relief valve piping safety.

Cold Water Operation and Starts

Precautions for cold inlet water to prevent condensation and damage.

Hydronic Heating System Setup

Pump Selection and Feedwater Regulator

Guidance on selecting pumps and installing feedwater regulators.

Piping and Expansion Tank

General piping considerations and expansion tank requirements.

Hydronic System Modes

Overview of operating modes for hydronic heating systems.

Domestic Hot Water Considerations

Considerations for water hardness and piping in DHW applications.

Pool and Spa Heating Requirements

Pool Heating Installation and Chemistry

Specific requirements for pool heating, pumps, and water chemistry.

Pool Water Chemistry Chart

Recommended water chemistry levels for pools and spas.

Gas Supply Requirements and Connections

Gas Supply Connection Safety

Instructions for connecting gas supply and pressure testing safety.

Gas Supply Pressure Specifications

Requirements for upstream gas pressure and regulator installation.

Electrical Power Connection Guidelines

Power Connection Codes and Requirements

Codes and guidelines for electrical power connections.

Field Wiring and Controller Connections

Instructions for field wiring, controllers, and making connections.

Venting System Installation and Requirements

General Venting and Appliance Categories

Importance of proper venting and classification of appliance categories.

Vent Terminal Location and Support

Precautions for vent terminal location, support, and clearances.

U.S. and Canadian Venting Codes

Vent termination requirements according to U.S. and Canadian codes.

Vertical and Common Venting

Guidelines for vertical and common venting systems installation.

Horizontal Through-the-Wall Direct Venting (Category III)

Horizontal Venting Installation

Guidelines for installing horizontal through-the-wall direct venting systems.

Vertical Direct Venting Installation

Vertical Direct Vent Installation

Guidelines for installing direct vent vertical systems.

Vertical Direct Vent Termination

Requirements for terminating direct vent vertical systems.

Outdoor Installation Guidelines

Outdoor Installation Precautions

Important precautions when locating and installing heaters outdoors.

Freeze Protection Configuration

How to enable freeze protection and pump operation.

Heater Control System and Safety Devices

Ignition Control Functions

Explanation of ignition module operation and lockout reset.

Manual Reset High Limit Controls

Description of fixed and optional manual reset high limits.

Auto Reset High Limit and Flow Switch

Information on optional auto-reset high limit and flow switch function.

Low Water Cut-Off and Gas Pressure Switches

Function of optional low water cut-off and gas pressure switches.

Blocked Vent Switch

Function and location of the blocked vent pressure switch.

User Interface and Setpoint Adjustment

Overview of user interface and how to adjust the setpoint.

Setup/Adjust Menu Parameters

Setup/Adjust Menu Item Descriptions

Details various settings and their default values in the Adjust menu.

Boiler Menu Parameters

Boiler Menu Item Descriptions

Lists parameters and descriptions found in the Boiler Menu.

Monitor Menu Parameters

Monitor Menu Item Descriptions

Lists parameters and descriptions found in the Monitor Menu.

Toolbox Menu Functions and Outdoor Reset

Toolbox Menu Functions

Describes functions like error lookup, user tests, and defaults.

Outdoor Reset Concept

Explains how outdoor temperature affects setpoint and heating water temp.

Reset Ratio Calculation

Details how reset ratio is calculated and adjusted for heat loss.

Wiring Diagram and Connections

Wiring Diagram Overview

Explains the main wiring diagram and its components.

Start-Up Procedures and Checks

Pre Start-up Checks

Steps before initial start-up: filling, purging, and inspections.

Initial Start-up and Required Tools

Required tools and initial start-up procedure.

Power Supply and Gas Pressure Checks

Verifying power supply and checking gas supply pressure.

Blower and Manifold Checks

Procedures for checking blower suction, CO2, and manifold pressure.

Safety Inspection and Leak Testing

Pre-Start Safety Checks

Checks for thermostats, high limits, flow switches, and pressure settings.

Gas Valve Leak Test Procedure

Detailed procedure for leak testing the dual-seat gas valve.

Post Start-Up Checks

Final checks after start-up, including safety controls and thermostat cycling.

Heater Operation and Shutdown

Lighting Instructions

Step-by-step guide for lighting the heater and initial checks.

Turning Off Gas To Appliance

Procedures for safely shutting off gas to the appliance.

Troubleshooting Error Codes and Faults

MVB Error Codes and Heater Errors

How error codes are displayed and general troubleshooting approach.

Heater Faults and Error Display

Information on faults, error display, and troubleshooting steps.

LED Error Code Listing

Explains LED error codes on the PIM™ and their troubleshooting.

Maintenance Schedules and Procedures

Suggested Maintenance Schedule

Outlines daily, monthly, yearly, weekly, and semi-annual maintenance tasks.

Filter Replacement and Maintenance

Step-by-step instructions for replacing and maintaining the air filter.

Appendix: Air Contamination

Inside Air Contamination Effects

Discusses how contaminants affect condensate and heater materials.

Massachusetts Installation Requirements

MA Installation Rules (CO Detectors, Signage)

Specific MA rules for CO detectors, signage, and exemptions.

MA Gas Pressure Supervision Rules

MA requirements for gas pressure switches and regulators.

Limited Parts Warranty Information

Warranty Scope and Heat Exchanger Coverage

Defines what the warranty covers, excludes, and heat exchanger periods.

Making a Warranty Claim

Steps for initiating a warranty claim and contact information.

Warranty Limitations and Legal Rights

States warranty limitations, liability, and owner's legal rights.