Raypak 2004 User manual

Models 504 thru 2004
Category I with vertical vent
Models 503 thru 2003
Category IV Venting
Up to 87% thermal efficiency!

Raypak’s Next Generation
Modulating Boiler
Time-honored technologies unite with cutting-edge advancements in
Raypak’s new MVB modulating vertical boiler. Never before has a
vertical boiler provided both the installer and building owner such
installation flexibility, ease-of-commissioning, reliability and long-term
performance. Small space, not a problem.The MVB has the smallest
installed footprint of any vertical boiler, only 5.4 square feet.Raypak’s
MVB is built with commercial-grade components and materials. From
our steel channel base to our stainless steel flue wrapper, you can tell
the MVB is built to last. It’s easy to handle and install, but still user
friendly to service. Our compact design fits through a 30” door open-
ing making it the perfect choice for those hard to reach retrofit proj-
ects. Now is the perfect time to take a closer look at Raypak.
Flexibility
Small diameter vents and industry-leading vent length allowances
afford greater vent location options, thus reducing wasted space.Vent
versatility is further enhanced by the self-tuning combustion system
which compensates for unusual chimney and vent configurations.
Category I* -CSA-certified 84% boiler and up to 85% water heater
models available. Our category I solution is the perfect replacement
for your retro-fit applications. This reduces the installed cost by using
existing category I venting or chimney. Installation couldn’t be easier;
all connections are on the back of the unit. Start-up is a snap, it’s as
close to plug-n-play as a boiler can get.
Category IV -CSA-certified 87% efficiency at full fire–the highest
possible for non-condensing boilers
(Up to 88.4% at part load!)
When the job requires high efficiency, our category IV solution meets
your needs.
At the heart of every Raypak MVB is a unique integral evaporator
system - the first defense against harmful condensation. Raypak’s
evaporator system collects and re-evaporates condensate which may
form during initial start-up or brief periods of cold-water operation,
eliminating the need for a boiler condensate drain.This saves you
money on installation costs as well as the headache of dealing with
multiple condensate drains.
True Modulation
Modulation is nothing new to Raypak, we have honed our gas modu-
lation experience for over 50 years. The Raypak MVB will infinitely
track the heating load precisely with it’s built inTempTracker Mod
control, eliminating costly overshooting. Utilizing the latest European
technology for the blower-gas valve package, the optimum fuel-air
ratio is maintained throughout the entire range of the load-tracking
operation. Our smooth 4:1 turndown (503 thru 2003) ensures effi-
ciency is maintained through out the firing rate and actually increases
during part load, right when you want it!The MVB automatically self-
tunes to accommodate the widest range of gas supply pressures.The
high quality integrated blower-gas valve is self-correcting and allows
smooth operation with fluctuating gas supply pressures. The Raypak
MVB is cutting edge technology with atmospheric simplicity.
Key Features
•12 models from 500,000 to 2,000,000 BTUH
•Up to 85% efficiency (Cat. I*);
•Up to 88.4% efficiency (Cat. IV)
•No boiler condensate drain required (proprietary design)
•Lowest minimum required inlet water temperature (120F)
•Modulating gas valve and burner,
up to 4:1 (503 thru 2003) turndown
•Engineered with precisely matched system components
•Smallest installed footprint (5.4 square feet) design fits tight
spaces and easily replaces larger boilers
•Advanced diagnostics and easy component access make
service simple
•All models indoor/outdoor certified
•Complete cabinet protects all controls and wiring
•Meets all current Low NOx regulations, including the new
2010 SCAQMD revisions
•Suitable for altitudes up to 10,000 ft. (derate above 5,000 ft.)
•With all copper and optional bronze waterways, the MVB is
available in boiler and water heater configurations
Category I*-up to 85% efficiency
Category IV-87% efficiency
2*Category I with vertical vent, category III with horizontal venting and no extractor.

1. Control Panel
Fully enclosed controls and wiring protect
against damage or vandalism.Cabinet design
affords easy access to controls for installation
and service.
2.Temp-Tracker Mod Control
This factory-mounted multi-function control
delivers precise load-tracking with selectable
mode displays that are easy to access and read.
3. Universal Diagnostics Board
12 LEDs monitor up to 22 safety
circuits and store up to 256 fault codes.
4.Weather-Proof Jacket
Heavy gauge galvanized steel with
a UV-resistant Polytuf powder coat finish is
impervious to weather and corrosion.
5. Combustion Air Fan
Cast aluminum, non-sparking construction.
6.Vent Pressure Switch
Monitors vent pressure and provides safe shut
down if back pressure is excessive.
7. Minimum Clearance Requirements
Only one inch of side clearance is required from
combustible surfaces.
8.Vertical Heat Exchanger
Cylindrical, multi-pass heat exchanger captures
all radiant energy, eliminating the need for
heavy refractory.
9. Rugged All-Bronze Headers
The proven choice for all applications.
10.Tube Sheet Construction
Eliminates the repair & maintenance problems
associated with rolled-tube construction. Easy,
cost-effective component replacement.
11.Viewing Port
Allows easy burner inspection.
1
25
3
10
4
6
9
7
8
11
Cold Water Solutions
Cold Water Start – For applications that
require reliable protection against harmful con-
densation caused by frequent, extended, cold
water start-ups. Raypak’s Cold Water Start pro-
tection system utilizes a proportional three-
way valve to bypass water from the boiler out-
let to the inlet during start-up, when the sys-
tem return water temperature is below the minimum acceptable
level. (See Cat. #1000.19)
Cold Water Run – For applications requir-
ing constant condensation protection. Raypak’s
ColdWater Run system utilizes a variable-
speed pump to inject just the right amount of
water from the main system loop into the boil-
er to maintain the optimum inlet temperature.
This approach allows the full capacity of the
boiler to be utilized to meet the system load,
while at the same time continuously maintaining the optimum inlet
water temperature to prevent condensation.(See Cat. #1000.19)
Multi Boiler Solutions
Y-200 Boiler Sequencer – Provides addi-
tional functionality for multiple-boiler installa-
tions. Controls up to 8 MVB boilers with full
PID logic. LonMark certified interface ensures
seamless compatibility with LonWorks
Building Management Systems (BMS)
(See Cat. #5100.22)
TempTracker Mod+ – Controls up to 16
Raypak MVBs with P or PID logic.Automatic or
manually selectable lead-lag boiler operation.
TempTracker Mod+ monitors and displays sup-
ply water temperatures on all applications
including outdoor temperature when outdoor
reset mode is selected. (See Cat. # 5100.22)
State of the art European combustion technology
Optional Equipment
3

Smallest Installed Footprint
The MVB’s compact design allows for easy installation in the most challenging equip-
ment rooms. It’s easy to handle and install, but still user friendly to service.The MVB has
the smallest installed footprint of any vertical boiler, only 5.4 square feet. The MVB con-
tains all of it’s components to the inside of the cabinet, so there won’t be any fans or
valves hanging off the cabinet that need extra clearance.The compact design fits
through a 30” door opening making it the perfect choice for those hard to reach retrofit
projects.
Model Venting
Category
†
Boilers Water Heaters Input
Min.
Input Output Efficiency Input Output Efficiency
503 IV 500 435 87% 500 435 87% 125
753 IV 750 653 87% 750 653 87% 188
1003 IV 999 869 87% 999 869 87% 250
1253 IV 1250 1088 87% 1250 1088 87% 312
1503 IV 1500 1305 87% 1500 1305 87% 375
1753 IV 1750 1523 87% 1750 1523 87% 438
2003 IV 1999 1739 87% 1999 1739 87% 500
504 I* 500 420 84% 500 420 84% 357ª
754 I* 750 630 84% 750 630 84% 536ª
1104 I* 1100 924 84% 1045 888 85% 786ª
1504 I* 1500 1260 84% 1425 1211 85% 1071ª
2004 I* 1999 1679 84% 1900 1615 85% 1428ª
MBTUH
Models Dimensions (inches) Operating
Weight
(lbs.) Amps‡
MVB
Cat. I* MVB Cat. IV B
Ht. D E F G†
NPT H
NPT K-Ø
Cat. I* K-Ø Cat. IV M Cat I* M Cat IV N
CA Ø P R V
504 503 43 32 35 23-3/4 1 2 8 6 14-1/8 14-1/2 6 35 6 2 600 12
754 753 49 38 41 29-3/4 1 2 10 6 16 14-1/2 6 41 6 2 660 12
1104 1003 55 44 47 35-3/4 1-1/4 2-1/2 10 6 16 14-1/2 6 47 6 2 720 12
1504 1253 61 50 53 41-3/4 1-1/4 2-1/2 12 8 18-1/8 17-3/4 8 53 6 2 780 12
1503 67 56 59 47-3/4 1-1/4 2-1/2 817-3/4 8 59 6 2 840 12
2004 1753 75 62 65 53-3/4 22-1/2 14 8 20-1/8 17-3/4 8 68 9 5 940 18
2003 81 68 71 59-3/4 22-1/2 817-3/4 8 74 9 5 1000 18
PHYSICAL DATA
*Category I with vertical vent, category III with horizontal venting and no extractor.
†Category IV requires sealed vent with condensate drain.Category I uses conventional B vent.
ªBoilers only.
Note: Ratings are for natural or propane gas and for elevations up to 5,000 ft.above sea level. For higher elevations, consult the factory.
*Category I with vertical vent, category III with horizontal venting and no extractor.
†NPT is for Natural Gas. For Propane, NPT= 1” for all water heater/boiler sizes.
‡Current draw is for heater only. (Supply breaker must have a delayed trip.)
4

TOP VIEW
FRONT VIEW FRONT VIEW
PROUDLYMADEIN AMERICA
P/N901889
Note: Current draw (Amps) is for pump only Water hardness grains per gallon
Soft = 0-4 • Medium = 5-15 • Hard = 16-25
Heater
Side From Combustible Surfaces (min.) For Service (recommended)
Floor* 0” 0”
Rear 12” 24”
Right Side 1” 1”
Left Side 1” 1”
Top Indoor
Outdoor 0” Unobstructed 10” Unobstructed
Front Open 24”
Vent Stack Indoor 1” 1”
Vent Cap Outdoor 12” 12”
CLEARANCES
MVB
Model
Water Hardness
Soft Medium Hard
HP Amps HP Amps HP Amps
503/504 1/4 61/4 63/4 11
753/754 1/4 61/2 73/4 11
1003/1104 1/4 61/2 7 1 14
1253 1/2 7 1 14 1 14
1503/1504 3/4 11 1 14 1 14
1753 1 14 1-1/2 15 1-1/2 15
2003/2004 1 14 1-1/2 15 1-1/2 15
*Do not install on carpeting
Note: Local codes may require increased clearances
PUMP
5
All components are contained inside the
cabinet (except PRV) , no external fans or
valves to deal with.

Simple Serviceability
Raypak’s easy-to-understand user interface, including on-board diagnostics and LED operating status lights, tells the technician all he needs to
know.All service/repair components are readily accessible from the front or side for maximum installation flexibility.To enhance serviceability,
the control box is completely removable allowing total access.
LED status panel
Ignition control
Burner on/off
Pump on/off
MVB Control Panel
Service diagnostic panel
CATEGORY I*
BOILERS
(TYPE H)
MVB
Model
Flow Rates Pressure Drops
Minimum Flow Maximum Flow 20°F 30°F 40°F
GPM ⌬P FT ⌬T °F GPM ⌬P FT ⌬T °F GPM ⌬P FT GPM ⌬P FT GPM ⌬P FT
504 25 1.1 34 100 11.3 8 42 2.7 28 1.4 N/A N/A
754 32 1.7 40 100 13.8 13 63 6.0 42 2.9 32 1.7
1104 46 4.1 40 113 18.6 16 92 13.3 62 6.7 46 4.1
1504 63 8.0 40 113 22.2 22 N/A N/A 84 13.3 63 8.0
2004 84 16.0 40 113 27.2 30 N/A N/A 112 26.9 84 16.0
CATEGORY I*
WATER HEATERS
(TYPE WH)
MVB
Model
Flow Rates Pressure Drops
Minimum Flow Maximum Flow 20°F 30°F
GPM ⌬P FT ⌬T °F GPM ⌬P FT ⌬T °F GPM ⌬P FT GPM ⌬P FT
504 50 2.8 17 100 11.3 8 N/A N/A 28 1.4
754 50 3.5 25 100 13.8 13 64 6.1 42 3.0
1104 60 6.3 30 113 18.6 16 90 12.6 60 6.3
1504 82 12.6 30 113 22.2 22 N/A N/A 82 12.6
2004 109 25.5 30 113 27.2 29 N/A N/A 109 25.5
CATEGORY IV BOILERS
& WATER HEATERS
(TYPE H & WH)
MVB
Model
Flow Rates Pressure Drops
Minimum Flow Maximum Flow 20°F 30°F 40°F
GPM ⌬P FT ⌬T °F GPM ⌬P FT ⌬T °F GPM ⌬P FT GPM ⌬P FT GPM ⌬P FT
503 25†1.1 35 100 11.3 9 43 2.8 29 1.4 N/A N/A
753 33†1.9 40 100 13.8 13 65 6.4 43 3.1 33 1.9
1003 43‡3.7 40 113 18.6 15 87 12.0 58 6.0 43 3.7
1253 54‡6.2 40 113 22.2 19 109 20.9 73 10.2 54 6.2
1503 65‡9.5 40 113 25.5 23 N/A N/A 87 16.0 65 9.5
1753 76‡13.4 40 113 27.2 27 N/A N/A 101 22.5 76 13.4
2003 87‡15.2 40 116 30.2 30 N/A N/A 116 31.9 87 18.9
6
*Category I with vertical vent, category III with horizontal venting and no extractor.
† Minimum flow 50GPM forWH hot water supply.
‡ Use 30° column as minimum flow for hot water supply.
Boiler Only

TempTracker Mod
Raypak’s MVB comes standard withTempTracker Mod.This control can be used for space
heating and hot water supply with six application-specific modes to meet various applica-
tions, including outdoor reset for heating systems. The control monitors and displays inlet
and outlet temperatures on all applications as well as monitor outdoor temperature when
an outdoor reset mode is selected. Only Raypak’s TempTracker Mod allows for a user
definable outdoor reset slope. Boiler adjustable limits prevent over cycling, saving energy
and extending the life of the boiler.Your MVB is never down with a sensor failure thanks
to Raypak’s exclusiveTempTracker software. It can operate with as little as one function-
ing sensor, keeping you up and running until service arrives.
• P or PID logic • 0-10VDC Setpoint/Direct Drive Input
• 4-20ma output -Standard on MVB Cat. I
• Building management direct control -Coming soon on MVB Cat. IV
• LCD Display
Cat. I*
84%
85%
Cat. I*
84%
Cat. IV
87%
MVB
Input Recovery Rates (GPH)
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
500 5,091 2,545 1,697 1,273 1,018 848 727 636 566 509 463 424 392 364 339
750 7,636 3,818 2,545 1,909 1,527 1,273 1,091 955 848 764 694 636 587 545 509
1100 11,200 5,600 3,733 2,800 2,240 1,867 1,600 1,400 1,244 1,120 1,018 933 862 800 747
1500 15,273 7,636 5,091 3,818 3,055 2,545 2,182 1,909 1,697 1,527 1,388 1,273 1,175 1,091 1018
1999 20,353 10,177 6,784 5,088 4,071 3,392 2,908 2,544 2,261 2,035 1,850 1,850 1,566 1,454 1,357
MVB
Input Recovery Rates (GPH)
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
500 5,091 2,545 1,697 1,273 1,018 848 727 636 566 509 463 424 392 364 339
750 7,636 3,818 2,545 1,909 1,527 1,273 1,091 955 848 764 694 636 587 545 509
1045 10,640 5,320 3,547 2,660 2,128 1,773 1,520 1,330 1,182 1,064 967 887 818 760 709
1425 14,682 7,341 4,894 3,670 2,936 2,447 2,097 1,835 1,631 1,468 1,335 1,223 1,129 1,049 979
1900 19,576 9,788 6,525 4,894 3,915 3,263 2,797 2,447 2,175 1,958 1,780 1,631 1,506 1,398 1,305
MVB
Input Recovery Rates (GPH)
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
500 5,273 2,636 1,758 1,318 1,055 879 753 659 586 527 479 439 406 377 352
750 7,909 3,955 2,636 1,977 1,582 1,318 1,130 989 879 791 719 659 608 565 527
999 10,535 5,267 3,512 2,634 2,107 1,756 1,505 1,317 1,171 1,053 958 878 810 752 702
1250 13,182 6,591 4,394 3,295 2,636 2,197 1,883 1,648 1,465 1,318 1,198 1,098 1,014 942 879
1500 15,818 7,909 5,273 3,955 3,164 2,636 2,260 1,977 1,758 1,582 1,438 1,318 1,217 1,130 1,055
1750 18,455 9,227 6,152 4,614 3,691 3,076 2,636 2,307 2,051 1,845 1,678 1,538 1,420 1,318 1,230
1999 21,080 10,540 7,027 5,270 4,216 3,513 3,011 2,635 2,342 2,108 1,916 1,757 1,622 1,506 1,405
7

MVB
HEAT EXCHANGERJACKETOTHER GAS TRAIN SAFETIES OPERATING CONTROLS
ASME, National Board Registered, 160 PSI • HLW Stamp N/A
• H Stamp N/A 
Heat ExchangerTubes • Copper 
• Cupro Nickel 
Bronze Headers 
Cast Iron Headers N/A 
Pressure ReliefValve • 60 PSI 
• 125 PSI 
• 30, 45, 75, 150 PSI 
Temperature & Pressure Gauge 
Pump • 120V, Single-Phase 
Indoor/Outdoor Certified 
VentTerminal • Outdoor 
• Through-the-Wall 
Fully-Enclosed Controls 
Combustible Floor Rated 
120V Power Supply with 120V/24VTransformer 
On/Off Switch 
Programmable PumpTime Delay, Single-Phase • Included inTempTracker Mod Controller 
Terminal Block Connections • Enable / Disable 
• External Interlocks 
• 0-10VDC Setpoint/Direct Drive Input (cat. I) 
12 Diagnostic Lights with 256-Event History 
Status Display Lights (4) 
Temperature Controller with 3Water Sensors • TempTracker Mod (up to 4:1 Turndown, cat. IV) 
• Outdoor Reset Sensor N/A 
Multiple Boiler Controller • TempTracker Mod+, up to 16 boilers 
• Y-200, up to 40 boilers (LonWorks optional) 
Hot Surface Ignition System • 1-try (standard on cat. IV) 
• 3-try (standard on cat. I) 
High/Low Gas Pressure Switches 
BlockedVent and Air Pressure Switches 
High Limit Switch • Manual Reset, Fixed 
• Manual Reset,Adjustable 
• Automatic Reset,Adjustable 
LowWater Cut-Off, 24V • With Manual Reset andTest Buttons 
Flow Switch 
Modulating Combination GasValve 
CombustionAir Blower 
TruSeal Direct-Vent Ready 
Additional SafetyValve • Motorized (externally mounted) 
• Solenoid (externally mounted) 
CSA-Certified Efficiency • Cat. IV - 87% at Full Fire 
• Cat. I - 84% to 85% (see MBTUH table) 
Air Filter 
Alarm System 
CSD-1 / GE GAP Control System 
Low NOx • Meets all current requirements 
ColdWater Start • Prevents internal condensation on start-up 
ColdWater Run • Prevents condensation in continuous low-temp operation 
Water Heaters
(TypeWH) Boilers
(Type H)
  = Standard   = Optional
Raypak, Inc. • 2151 EastmanAvenue, Oxnard, CA 93030 • phone:[phone] • fax: [phone] • www.raypak.com
Cat. No. 3400.11E Effective 07-01-08 Replaces 11-1-07