Rheem Raypak E-4 User manual

E󰀨ective: 03-25-22
Replaces: 04-09-08
P/N 240691 Rev. 4
INSTALLATION AND OPERATION
MANUAL
E–4 ALARM
ANNUNCIATOR
for Raytherm H, WH, & P
Models 514-4001
IMPORTANT SAFETY INSTRUCTIONS. READ AND FOLLOW ALL
INSTRUCTION. SAVE THESE INSTRUCTIONS.
NOTE: The instructions in this manual are for the use of qualied individuals 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 to be licensed. Persons not qualied shall not attempt to install,
service, or maintain this equipment.
This manual should be maintained in legible condition and kept adjacent to the unit or in a safe place for future
use.

2
Revision 4 reects the following changes:
General document reorganization in conjunction with a reformat using InDesign. Edits for clarity made throughout in text, tables and
gures along with incorporation of additional metric measurement references. Conguration section added on page 4. Updated Figure
4 with drawing 901094.03 Rev. 6.

3
TABLE OF CONTENTS
1. WARNINGS ............................................................ 4
Pay Attention to these Terms .................................. 4
2. CONFIGURATIONS AVAILABLE:........................ 4
3. RECEIVING EQUIPMENT ..................................... 5
4. GENERAL SPECIFICATION ................................. 5
Remote Alarm Panel (E-6 Option)........................... 5
Auxiliary Alarm Board (E-7 Option) ......................... 5
Dimensions and Weight .......................................... 5
Electrical Characteristics ......................................... 5
5. INSTALLATION AND MOUNTING ....................... 5
Mechanical Installation ............................................ 5
6. ELECTRICAL INSTALLATION ............................. 6
120 Vac Feeder Circuits .......................................... 6
Check Your Power Source ...................................... 6
Wiring Power to the E–4 Alarm ............................... 6
Power Test .............................................................. 6
E–4 Alarm Indicator Lights ...................................... 6
Field Wiring Connection Points ............................... 7
Auxiliary Alarm Wiring (Sales Option E-7)............... 7
7. REMOTE ALARM WIRING DIAGRAM ................ 8
8. INSTALLATION VERIFICATION .......................... 9
9. ILLUSTRATED PARTS LIST............................... 10
10. WARRANTY .......................................................... 11

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1. WARNINGS
Pay Attention to these Terms
ADANGER Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial
property damage if ignored.
AWARNING Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or
substantial property damage if ignored.
ACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product
or property damage if ignored.
CAUTION CAUTION used without the warning alert symbol indicates a potentially hazardous 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 not related
to personal injury hazards.
ACAUTION: More than one (1) supply source. This
appliance has provisions to be connected to more than
one (1) supply source. To reduce the risk of electric
shock, disconnect all such connections before servicing.
ACAUTION: Risk of electric shock. More than one (1)
disconnect switch may be required to de-energize the
equipment before servicing.
AWARNING: Improper installation, adjustment,
alteration, service or maintenance may damage the
equipment, create a hazard resulting in asphyxiation,
explosion, re, electric shock, personal injury or property
damage, and will void the warranty.
NOTE: Minimum 18 AWG, 105°C, stranded wire must
be used for all low-voltage (less than 30 volts) external
connections to the unit. Solid conductors should not
be used because they can cause excessive tension on
contact points. Install conduit as appropriate. All high
-voltage wires must be the same size (105°C, stranded
wire) as the wires on the unit or larger.
IMPORTANT NOTICE: These instructions are intended
for use by qualied personnel who are specically
trained and experienced in the installation of this type of
equipment and related system components. Installation
and service personnel may be required by some states
to be licensed. If your state requires certication, be
sure your contractor bears the appropriate license. Only
qualied persons shall attempt to repair this equipment.
Repair must be according to these instructions.
2. CONFIGURATIONS
AVAILABLE:
E-4 with 3" bell
[ ] factory-installed
[ ] eld-installed, P/N 005596
E-4 with 4" bell
[ ] factory-installed
[ ] eld-installed, P/N 005633
E-4 with 3" bell and E-7 auxiliary alarm
[ ] factory-installed
[ ] eld-installed, P/N 005597
E-4 with 4" bell and E-7 auxiliary alarm
[ ] factory-installed
[ ] eld-installed, P/N 005634
E-6 Remote alarm with reset
[ ] eld-installed, P/N 005632
E-7 Auxiliary alarm
[ ] eld-installed, P/N 005635

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3. RECEIVING EQUIPMENT
Thank you for selecting the Raypak E-4 Alarm. It is our
sincere hope that you will enjoy its outstanding design and
ease of use. The following information will help familiarize
you with the E-4 and will acquaint you with the installation
procedure.
Check packaging for damaged or missing components.
4. GENERAL SPECIFICATION
The E-4 alarm is a solid-state electronic boiler status
indicator and alarm panel for the Raytherm product
line. It has been engineered to enhance safety, simplify
troubleshooting and minimize equipment downtime.
The E-4 Alarm is comprised of an alarm circuit board, a
NEMA 3R-rated rainproof enclosure, and the following
components:
Standard Indicator Lights:
Power Green, indicates that power is available to the
alarm unit.
Pilot Amber, indicates that the Pilot Valve circuit has
been energized.
Main Gas Green, indicates that the Main Gas Valve has
been energized.
Safety
Shutdown
Red, indicates a safety shutdown has occurred.
Either the 24 or 120 VAC signal is missing from
the safety circuit.
Auxiliary
Alarm
Red, indicates a safety failure after a
predetermined time delay has expired.
(Activated by the Auxiliary Alarm, option E-7, if
present).
Alarm and Bell:
Mechanical
Alarm Bell
Standard bell: 3", optional bell: 4". Upon alarm
activation the mechanical bell rings until the
alarm is acknowledged by pressing the alarm
silence.
Electric
Alarm
Buzzer
Upon alarm activation, the buzzer sounds
a steady tone for ten seconds and then
pulses on and o󰀨 at 2 cycles per second until
acknowledged.
Alarm Silence Switch
Located on the bottom of the enclosure, the alarm silence
switch is a momentary switch used to silence the alarm
bell and buzzer after an alarm condition occurs. Once
acknowledged, the bell and buzzer will cease sounding
until a new alarm condition occurs. The appropriate alarm
indicator light (Safety Shut down or Auxiliary Alarm) will
remain lit until the alarm condition has been cleared.
Table A. Components
Remote Alarm Panel (E-6 Option)
The Remote Alarm Panel (sales order option E-6) provides
a mounting panel and the necessary electrical components
to monitor the E-4 alarm at a remote location. This option is
eld-installed, and includes the following:
Electric
Alarm Buzzer
Provides an audible indication of a fault. See
description above.
Indicator
Light
Red, indicates that a boiler fault has
occurred..
Silence
Switch
Silences the electric alarm buzzers and the
mechanical bell.
Table B. Alarm Panel (E-6 Option)
Auxiliary Alarm Board (E-7 Option)
When installed, the Auxiliary Alarm Board (sales order
option E-7), activates the Auxiliary Alarm light on the E-4
upon a fault in the monitored circuit. The Auxiliary Alarm
provides a user-adjustable time delay from 5 - 60 secs
during which the Auxiliary Alarm veries that the alarm
condition is "locked in". The Auxiliary Alarm can be used
to monitor a ow switch, low water cuto󰀨 switch or any
other circuit that is susceptible to spurious alarms due to
transitory fault conditions.
Dimensions and Weight
• 14" W x 10" H x 7" D
(35.6 cm W x 25.4 cm H x 17.8 cm D)
• 10-1/4 lbs. (4.6 kg)
Electrical Characteristics
• Alarm Module - 120 VAC, 0.25A, 60 Hz
• Monitors - 120 or 24 VAC
5. INSTALLATION AND
MOUNTING
If the E–4 Alarm was not mounted on the boiler by the
factory, care should be taken to select a suitable mounting
location. The E-4 should be mounted on a solid and
permanent surface, typically a wall near the boiler. The
E-4 enclosure is NEMA 3R-rated, rain proof/sleet resistant
and can be mounted outdoors if required. The unit should
be readily accessible for maintenance and installation
purposes, and should be mounted so that the indicating
lights are at a height and location convenient for viewing.
Mechanical Installation
Install the E–4 Alarm within 10 feet of the boiler. The E–4
must be mounted vertically with the conduit holes facing
downward. The conduit holes are sized to accommodate
standard conduit ttings. If additional or larger conduit
ttings are required, the holes must be located on the
bottom of the module.

6
Mount the E–4 Alarm using the mounting bracket and
appropriate 3/8" or 1/4" diameter hardware in four (4)
places.
A minimum of 18 inches (45.7 cm) clearance from the
front, and 6 inches (15.2 cm) clearance on all other sides
is required for service access. The hinged right side of the
box should be installed with su󰀩cient clearance (minimum
3" (7.6 cm) from bolt hole on the right side) to open the
cover.
An electrical distribution sub-panel containing the
disconnect switches and surge suppressors is required at
or near the equipment location(s).
To access the control board, remove the interior panel by
unscrewing the two (2) decal panel fasteners.
Install Conduit As Appropriate.
6. ELECTRICAL
INSTALLATION
120 VAC Feeder Circuits
Install a surge protection device sized appropriately for
your installation at each module.
Install a separate disconnect means for each load. Use
appropriately sized wire for equipment as dened by NEC
and/or local code. All primary wiring should be 125% of
minimum rating.
It is strongly recommended that the E–4 Alarm and the
heater be supplied from the same source power.
Check Your Power Source
Circuit Breaker Panel
• AC = 108 Volts AC Minimum, 132 Volts MAX
• AB = 108 Volts AC Minimum, 132 Volts MAX
• BC = Must be less than 1.0 Volts AC
Figure 1. Breaker Panel and Multi-meter
Wiring Power to the E–4 Alarm
• Observe Polarity
• Observe proper wire colors while making electrical
connections.
• Provide an external surge suppressor capable of
maintaining system integrity.
• Provide overload protection and a disconnect means
for equipment serviceability as required by local and
state code.
• Conduit cannot be used as the ground. (There MUST
be a “WIRED” ground.)
• Very Important: A grounding electrode conductor
shall be used to connect the equipment grounding
conductors, the equipment enclosures, and where the
system is grounded, the grounded service conductor
to the grounding electrode.
Power Test
Check Power
Utilizing a Volt-Ohm-Meter (VOM), monitor the following
on the E–4 Alarm for proper voltage levels. Check at
connector P1 and single-point ground (SPG).
From To Indication
Pin 1 Pin 2 108 VAC to 132 VAC
Pin 2 SPG 108 VAC to 132 VAC
Pin 3 SPG less than 1 VAC
Table C. Power test
E–4 Alarm Indicator Lights
POWER
PILOT
MAIN GAS
SAFETY SHUTDOWN
AUXILIARY ALARM
E–4 BOILER
ALARM PANEL
ALARM RESET LOCATED ON BOTTOM
INDICATOR LIGHTS
Figure 2. Alarm Indicator Light Panel

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Standard Indicator Lights:
Օ Power (Green) Indicates that 120 VAC is being supplied to the E–4 Alarm Board.
Օ Pilot (Amber) Indicates that the pilot valve circuit has been energized.
Օ Main Gas (Green) Indicates that the main gas valve has been energized.
Օ Safety Shutdown
(Red) Indicates that a safety shutdown has occurred. Either the 24 or 120 VAC signal from the safety
circuit that is being monitored by the E-4 is missing. The E-4 does not indicate what component in the
safety chain has been disrupted. Standard troubleshooting techniques must be applied to determine
the cause of the fault.
Օ Auxiliary Alarm
(Red) Indicates that either a safety failure of the boiler or failure in the monitored circuit has occurred
(depending or wiring conguration). The Auxiliary Alarm light is energized by the Auxiliary Alarm Board
(option E-7) after a user-adjustable time delay has expired. The E-7 Alarm may be wired to monitor the
low water cuto󰀨, ow switch or any other component susceptible to spurious alarms.
Figure 3. Indicator Light Meanings
Field Wiring Connection Points
NOTE: Tighten terminal strip clamping screws to 4
in-lbs (0.452 Nm). Breakage from over-torquing is not
covered under warranty.
Use 18 GA stranded copper conductors only.
For supply connections, use wires sized on the basis of
60°C (140°F) ampacity and rated a min. 90°C (194°F).
Also, refer to "7. Remote Alarm Panel Wiring Diagram" on
page 8
Auxiliary Alarm Wiring
(Sales Option E-7)
The E-7 Alarm is available as an option for piggy-back
mounting on the standard board. It provides the
Auxiliary Alarm contacts with an adjustable time delay from
5 - 60 seconds and is designed for local code compliance.
Refer to the E-6 manual (P/N 240706) for installation
instructions.
Figure 4. Field Wiring Connection Points

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7. REMOTE ALARM PANEL WIRING DIAGRAM
T R M P N
D (24V RETURN)
A (MV)
C (PV)
B (MV/PV)
E (FAULT)

9
8. INSTALLATION
VERIFICATION
PROCEDURE
Register
• Before proceeding any further, please verify that
the user registration form has been completed and
mailed.
Mechanical Installation
• Verify that the mechanical installation has been
completed in accordance with the instructions.
System Module Installation
• Verify electrical power wiring connections.
• Verify electrical connection torque requirements.
• Verify Power Test has been completed successfully.

10
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9. ILLUSTRATED PARTS LIST

11
10. WARRANTY
LIMITED WARRANTY
E-4 & Accessories
SCOPE OFWARRANTY :
Raypak, Inc. ("Raypak") warrants to the original owner the Control System to be free from defects in materials and
workmanship under normal use and service for the applicable warranty period. In accordance with the terms of this Limited
Warranty, RAYPAK will furnish a replacement or repair, at our option, any defective part which fails in normal use and service
during the applicable warranty period. The replacement or repair will be warranted for only the unexpired portion of the original
Warranty Period.
APPLICABLEWARRANTY PERIOD
The effective date of warranty coverage is the date of original installation, of the Control System, by a qualified electrician
or by a RAYPAK authorized service technician. The Applicable Warranty Period is one (1) year from the effective date.
WARRANTYEXCLUSIONS
This Limited Warranty does not apply:
1. if the control system is not properly installed by a qualified technician in accordance with manufacturer's installation
instructions, applicable codes, ordinances and good trade practices,
2. to damage or malfunctions resulting from failure to properly install, operate or maintain the system in accordance
with the manufacturer's instructions;
3. if the rating plate(s) or serial number(s) are altered, defaced or removed;
4. if the System is modified in any way or used with any non-factory authorized accessories or components;
5. to damage or failure from abuse, accident, act of nature, fire, flood, freezing or the like;
6. to accessories, rubber or plastic parts, light bulbs or glass parts;
7. if the System is moved from its original installation site; or if the original owner no longer owns the site or the System.
LABOR AND SHIPPING COSTS
This Limited Warranty does not cover labor costs for service, removal or reinstallation of any part nor shipping charges
to or from RAYPAK'S designated repair center or to or from the installation site. All such costs are your responsibility.
HOW TO MAKE A WARRANTY CLAIM
To make a warranty claim, promptly ship (postage prepaid) or carry the defective part to a designated RAYPAK
Service Dealer or Service Station in the United States, supplying proof of purchase and date of installation and the model and
serial numbers. If you cannot locate a dealer, contact RAYPAK'S Service Department at the address/telephone listed below.
Raypak reserves the right at all times to inspect the claimed defect and verify warranty coverage at its factory.
EXCLUSIVE WARRANTY - LIMITATIONOF LIABILITY
This is the only warranty given by RAYPAK. No one is authorized to make any other warranties on Raypak's behalf.
ANY IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT
EXTENDBEYOND THEAPPLICABLEWARRANTY PERIODSPECIFIED ABOVE. RAYPAK'S SOLELIABILITY WITH RESPECT
TOANYDEFECTSHALLBEASSET FORTH IN THIS LIMITED WARRANTY. ANYCLAIMSFORINCIDENTALORCONSEQUENTIAL
DAMAGES (INCLUDING DAMAGE FROM WATER LEAKAGE) ARE EXCLUDED.Some states do not allow limitations on how long
an implied warranty lasts, or for the exclusion of incidental or consequential damages, so the above limitation or exclusion
may not apply to you.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS
WHICH VARY FROM STATE TO STATE.
We suggest you immediately complete the information below and retain this Limited Warranty Certificate in case warranty
service is needed.
RAYPAK,INC. SERVICE DEPARTMENT
2151 Eastman Avenue, Oxnard, CA 93030
Telephone: [phone]
The following information must be provided when you write or call:
_____________________________________________ _______________________________________________
Original Owner Daytime Telephone Number
_________________________________________________________________________________________________
Complete Mailing Address
_____________________________________________ ________________________________________________
City State Zip Code Installation Site
______________________________________________ _______________________________________________
Model Number Contractor/Installer
______________________________________________ _______________________________________________
Date of Installation Serial Number
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone]
Litho in U.S.A.

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] www.raypak.com
NOTES