Raypak 5042004 Relief Valve Piping Temperature & Pressure Gauge, Hydrostatic Test

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CAUTION: This heater requires forced water circulation when the burner is operating. See Table F and Table G for minimum and maximum flow rates and water pump selection. 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 504 and 754 models and 2-1⁄2in NPT for 1104–2004 models. Verify proper flow rates and ∆T as instructed in this manual.

Relief Valve Piping

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.

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 fac- tory-tested and is rated for 160 psi operating pressure. However, Raypak does recommend hydrostatic test- ing of the piping connections to the heater and the rest of the system prior to operation. This is particularly true for hydronic systems using expensive glycol- based anti-freeze. Raypak recommends conducting 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. With bleed valve open, fill heater with water. When water flows from bleed valve, shut off water. Close bleed valve. 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 operating pressure for at least 24 hours.

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

3.Check for leaks. Repair if found.

Cold Water Operation

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.

This heater is equipped with a proprietary condensate 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 manual bypass (see Fig. 16) or an approved low-temperature operation system (Figs. 9 and 10) to prevent problems with con- densation. This piping is similar to a primary/secondary boiler installation, with a bypass acting as the secondary boiler piping. Raypak strong- ly recommends that thermometer(s) be placed into the heater piping next to the in/out header to facilitate tem- perature adjustment. 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 con- densate evaporation system.

Failure to reach or exceed 120°F (49°C) within 7 min- utes may damage or cause failure of the heat exchanger, combustion 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 con- densing beyond the ability of the condensate management system employed in this heater in most installations. Warranty claims will be denied for damage or failures caused by condensation.

Cold water operation issues are applicable to both cold water start and cold water run applications. Cold water operation for 7 minutes or less on initial daily start-up is acceptable. Where cold water starts will last

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Contents Reference Catalog no .54E Effective Replaces 241317 Rev Do so may result in an explosion or firePage Contents Pay Attention to These Terms Installations at Elevation Before InstallationProduct Receipt Model IdentificationGeneral Information Component LocationsTime/Temperature Relationships in Scalds General SafetyWater Time to Produce Serious Temp Burn Installation Codes InstallationIndoor Installations Equipment BaseCombustion and Ventilation Air Outdoor InstallationsIndoor Units Table E Vent/Air Inlet Termination Clearances Conventional Combustion Air Supply InstallationsAir Filter Direct VentWater Piping Canadian InstallationsGeneral Hydrostatic Test Relief Valve Piping Temperature & Pressure GaugeCold Water Operation Pump Selection Hydronic HeatingFeedwater Regulator Cold Water StartsAir-Separation/Expansion Tank PipingModel Input Output 20 ∆T 30 ∆T 40 ∆T Min. Flow GpmDomestic Hot Water Three-Way ValvesPotable Water and Space Heating Pool HeatingPool heating application. Use the following instruc Winterizing Your Heater Pool/Spa Water ChemistryExceed 5 ppm Gas Supply Connection Gas SupplyGas Supply Pressure Automatic Chlorinators Chemical FeedersModel In. NPT 4 in. NPT 2 in. NPT Electrical Power ConnectionsModel Manifold Gas Pressure High Fire ValuesField-Connected Controllers Check the Power SourceMaking the Electrical Connections Venting Field Wiring ConnectionAppliance Categories Support of Vent Stack InstallationsVent Terminal Location Venting Configurations Venting Installation TipsCanadian Installations InstallationMin Max. Length* ft10 Ø TerminationTypical Common Venting Common VentingEngineered Vent Systems Model Vent Size Volume Flue ProductsHorizontal Through-the-Wall Direct Venting Category Horizontal Through-the-Wall Direct Venting Direct Vent-VerticalModel Certified Outdoor InstallationCombustion Air Air Inlet Horizontal Max. Length** ft Vent Freeze Protection ControlsDifferential Graph Operating Modes10 VDC 20 mA Boiler Target Mode 3 Dedicated DHW10 VDC 20 mA DefinitionsPool Heater P, WHP Modes Default Setting Range Boiler H7 Modes Default SettingWater Heater WH1 Modes Default Setting Range Operation Number Field Type Fault DescriptionRank Heater Sequence of Operation High Limit-Manual ResetIgnition Module Code ConditionFlow Switch High Limit-Auto Reset OptionalModulating Temperature Control High & Low Gas Pressure Switches OptionalAir Pressure Switch Blocked Vent SwitchUDB Diagnostic Board Wiring Diagram Models H & WH Wiring Diagram Models P & WHP Pre Start-up START-UPPre Start-up Check Initial Start-upBlower Check Start-UpFinishing Safety InspectionManifold Check Follow-UpPost Start-Up Check Leak Test Procedure Dual-Seat Gas ValveLighting Instructions OperationTo Turn Off Gas To Appliance UDB Fault HistoryStep TroubleshootingSuggested Minimum Maintenance Schedule MaintenancePreventive Maintenance Schedule Weekly Filter MaintenanceSemi-Annually AnnuallyAppendix Filter ReplacementInside Air Contamination Important Instructions for the Commonwealth of Massachusetts Limited Parts Warranty MVB Types H and WH Limited Parts Warranty MVB Types P & WHP Nominal Factory Recommended Settings START-UP Checklist for FAN-ASSISTED Raypak Products

5042004 specifications

The Raypak 5042004 is a highly efficient pool heater designed for residential and commercial applications, providing warmth and comfort for swimming pools and spas. It is a part of Raypak's extensive lineup of pool heating solutions, known for their reliability and energy efficiency. This model caters to different heating needs while maximizing performance and reducing energy consumption.

One of the standout features of the Raypak 5042004 is its use of advanced heat exchanger technology. Constructed with a durable copper fin design, the heat exchanger enhances thermal conductivity, allowing the unit to heat water quickly and effectively. This ensures a consistently enjoyable swimming experience, even in cooler weather conditions. The heater’s aluminum cabinet is designed to withstand harsh weather and resist corrosion, increasing its longevity and reliability.

In addition to its robust construction, the Raypak 5042004 incorporates a user-friendly digital control system. This control system allows users to set their desired temperature with precision, enabling easy adjustments and enhanced control over the heating process. The digital display provides real-time feedback, giving users insight into the system's operation and current water temperature.

Moreover, this model offers a specialized environmentally friendly option. The Raypak 5042004 is designed to run efficiently on both natural gas and propane, which provides flexibility regarding fuel choice based on availability and personal preference. This versatility is paired with low NOx (nitric oxide) emissions, making it compliant with stringent environmental regulations, making it an eco-friendly choice for consumers.

The ease of installation is another characteristic that sets the Raypak 5042004 apart from its competitors. The unit includes versatile piping options and integrated automation features that facilitate quick and hassle-free installation, ultimately saving time and effort for both professional installers and DIY enthusiasts.

In summary, the Raypak 5042004 is a cutting-edge pool heater that combines high efficiency, robust construction, user-friendly controls, and eco-friendly features. Its advanced heating technologies, durable design, and versatile fuel options make it an excellent choice for anyone looking to enhance their swimming experience year-round while being conscious of energy consumption and environmental impact.
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