Raypak MVB 503-2003 manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 3400.53G Effective: 04-16-10 Replaces: 09-12-08 P/N 241288 Rev . 8 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 .[...]

2 Rev . 8 reflects the following: Changes to: T able D on page 9, Figs 1 1-12 on page 15, T able I and text changers on page 20, Fig. 18 on page 21, Fig. 21 on page 22, Figs. 22-28 on pages 25-30, T able N on page 28, Modes 1,4, 6 and 8 on pages 30-32, Heater Sequence of Operation section on page 36, UDB Diagnostic Board section on page 38, wiring [...]

WARNINGS 4 BEFORE INST ALLA TI ON 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 6 GENERAL SAFETY 7 T ime/T emperature Relationships in Scalds 7 INST ALLA TION 8 Installation Codes 8 Equipment Base 8 Clearances 8 Combustion and V entilation Air 9 Convent[...]

4 D ANGER: I ndicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored. CA UTION: Indicates the presence of hazards or u[...]

5 BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your MVB heater . Please review the General Safety information before installing the heater . Factory warranty does not apply to heaters that have been improperly installed or oper- ated. (Refer to the warranty at the back of this manual.)[...]

General Infor mation T able A: Basic Data 6 HIGH VOL TAGE ELECTRICAL CONNECTIONS Component Locations Panels omitted for clarity Fig. 1: Component Locations – Side T op panel, blower and gas train omitted for clarity Fig. 4: Component Locations – T op Fig. 3: Component Locations – Rear MBTUH In put Gas Conn. (NP T) Vent Si ze (in. ) Mo del No.[...]

7 GENERAL SAFETY T o meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 210°F . However , water temperature s over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water , the rec- ommended initi[...]

Equipment Base The heater should be mounted on a level, structurally s ound surface. The heater is approved for installation on a combustible surface but must NEVER be i nstalled on carpeting. Gas-fueled equipment installed in enclosed parking garages must be located at least 18 in. above the floor . In addition, the heater shall be installed such [...]

9 Fig. 6: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations l ation codes and the requirements of the gas supplier . Three sides must be open in the area under the over- hang. Roof water drainage must be diverted away from heaters installed under overhangs. The combustion air intake terminal MUST be used for o utdoor[...]

10 U. S. Ins tallations 1 Canad ia n Insta llat ions 2 A Clear ance above gr ade, veranda, p orch , deck, or balcony 1 ft (30 c m) 1 ft (30 c m) B Clear ance to window or do or that may be o pened 4 ft (1.2 m) below or to side of openin g; 1 foot (30 c m) a bove op ening 3 ft (91 cm) C Clearance to perma nen tly clos ed wind ow ** D V ertical clear[...]

11 Air Filter An air filter is supplied standard with the heater . This filter is shipped loose for field installation. Refer to the Air Filter Kit Installation Instructions (Part No. 241338) for details. Direct V ent If outside air is drawn through the intake pipe directly to the unit for combustion: 1. Install combustion air direct vent in accord[...]

shall communicate directly , or by ducts, with the o utdoors or spaces (crawl or attic) that freely com- municate with the outdoors. a. Where directly communicating with the out- doors or where communicating to the outdoors through vertical ducts, each open- ing shall have a minimum free area of 1 in. 2 per 4,000 BTUH (550 mm 2 per kW) of total inp[...]

R elief V alve Piping T emperature & Pr essur e 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. Hydros[...]

14 longer than 7 minutes or where cold water operation is continuous, provisions must be made to mix higher t emperature outlet water with the colder inlet water and thereby raise the inlet temperature to at least 120°F (49°C) within the 7-minute time limit. Cold Wa ter Star ts Cold water starts, where the inlet water temperature remains below 12[...]

15 T able F: Heater Rates of Flow and Pressure Drops 20°F T 30° F T 40°F T Min . Flow Ma x . Flow Mode l No. gpm P (ft) gp m P (ft) gp m P ( ft) gp m P ( ft) T gp m P ( ft) T 503 44 2.8 29 1.4 N/A N/A 25 1.1 35 100 11.3 9 753 65 6.4 44 3.1 33 1. 9 33 1.9 40 100 13.8 13 1003 87 12.0 58 6.0 43 3. 7 43 3.7 40 113 18.6 15 1253 109 20.9 73 10. 2 54 6[...]

16 T hr ee-Way V alv es Three-way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used. Raypak heaters are high-recovery , low-mass h eaters which are not subject to thermal shock. See Fig. 16 and instructions on page 17 for adjusting the manual bypass. Domestic Hot Wa ter When designing the water [...]

17 The MVB must be equipped with a field-supplied ex- te r n a l pu m p an d by p a ss a rr a n g e m e nt . T h i s arrangement blends outlet water with the inlet water to i ncrease the inlet water temperature to a minimum of 120°F (49°C), thereby reducing the likelihood of con- d ensation forming on the heat exchanger . The pump also serves to [...]

18 P ool/Spa Water Chemistr y Chemical imbalance can cause severe damage to the pool heater and associated equipment. Maintain the water chemistry according to the chart below . If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchang- er tubes, reducing heater efficiency and damaging the heater [...]

19 Further advice should be obtained from your pool or spa builder , accredited pool shop, or chemical suppli- er for the correct levels for your water . Automa tic Chlorinator s and Chemical F eeder s All chemicals must be introduced and completely dilut- ed into the pool or spa water before being circulated through the heater . Do not place sanit[...]

20 • Safety wiring must be NEC Class 1. • Heater must be electrically grounded as required by the NEC. • In Canada, CSA C22. 1 C.E.C. Part 1. The MVB 503-1503 heaters are wired for 120 V AC, 12 amps while the MVB 1753 & 2003 heaters are wired for 120 V AC, 18 amps. Consult the wiring diagram shipped with the heater . Before starting the h[...]

C heck the power source: AC = 108 V AC Minimum, 132 V AC MAX AB = 108 V AC Minimum, 132 V AC MAX BC = <1 V AC Maximum Making the Electrical Connections Refer to Fig. 18-21. 1. V erify that circuit breaker is properly sized by referring to heater rating plate. A dedicated circuit breaker should be provided. 2. NOTE: Current draw noted on rating p[...]

22 Field W iring Connection V enting General Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Category I – A heater which operates with a non-pos- it i v e v e n t s ta t i c p r e s su r e a n d w i t h a v en t g a s temperature t[...]

23 Combustion Air Su p ply Exhaust Confi gu rati on H eater Venting Category Certified Materials Com bus tio n Ai r In let Ma te r ia l Vertical Venting From Ins ide Bu ilding (N on-Direct Venting) H orizontal Thro ugh- th e-Wa ll Venting Vertical Venting From Ou tside Building (Direct Venting) H orizontal Thro ugh- th e-Wa ll Venting IV Stainless [...]

24 1 . V ent must terminate at least 4 ft below , 4 ft hori- zontally from or 1 ft above any door , window or g ravity air inlet to the building. 2 . The vent must not be less than 7 ft above grade when located adjacent to public walkways. 3. T erminate vent at least 3 ft above any forced air inlet located within 10 ft. 4. V ent must terminate at l[...]

25 Vert ica l Ve n t Height 1 (Ft) Air In let Max . Lengt h** (Ft) Mode l Certified Vent Material Vent Size (in. ) Min. Ma x . Combustion Air Int ake Pipe Material 6” Ø 8” Ø 10” Ø 503 15 * 753 75 1 0 03 6 7 5 45 100 N/A 1253 40 1503 75 1753 75 20 03 Cate gory IV ( AL29-4C) 8 0 75 Galvanized Steel, PVC , ABS, CPVC N/A 45 85 T able L: Catego[...]

26 C ommon V enting T he NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters. This is covered in the NFGC under “Engineered V ent Sys- tems”. T able M provides boiler discharge vent p ressures at vent pressure switch and volumes of flue products at full fire for the calculation of appropriate vent and [...]

27 Fig. 25: Horizontal Through-the-W all V enting Fig. 26: Alt. Horizontal Through-the-Wall V enting NO TE: While a drain connection is required in the vent of all MVB installations, the drain can be ac- complished in several different ways. The figures in this manual show the drain in a vent tee, however , this can also be accomplished using an in[...]

28 The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight. The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that: 1. The vent must be installed with a condensate drain located in proximit[...]

29 The total length of air supply pipe cannot exceed the distances listed in T ables L and N. Each elbow used is e qual to 10 ft of straight pipe. This will allow installation in any arrangement that does not exceed the lengths shown in T ables L and N. T he vent cap is not considered in the overall length of the venting system. Care must be taken [...]

F r eeze Protection The Raypak electronic temperature control includes a freeze protection feature. In the event the temperature drops below 40°F at any of the boiler temperature sen- sors, the pump is turned on and will remain on until the temperature at all boiler sensors rises to 45°F . Controls 30 Fig. 29: Outdoor V enting The Raypak modulati[...]

31 Mode 3 – Dedicated DHW operation using UniT emp 80 piping. A call for heat is determined by the DHW sensor and the DHW boiler target. The heater outlet water is also controlled to the boiler target tempera- ture. See Fig. 32. Mode 4 (Not supported) – Outdoor reset using pri- mary piping. The heater is operated as in Mode 1. However , the tar[...]

32 MODULA TING * Fig. 34: Mode 7 Primary/Secondary Piping with External T arget T emp *Maximum 4 times the pipe diameter or 12”, whichever is less. Mode 8 – This mode is for remote firing control of the heater via an external sequencer such as the Raypak T empT racker MOD+. The Boil Max setting is the heater shutdown temperature (max temperatur[...]

33 T able Q: T emperature Control Default Setpoints Item Modes Default Setting Range Boil T arget 1, 2 160°F OFF , 70 to 220°F 3 160°F OFF , 70 to 190°F 4, 5, 6, 7 180°F OFF , 70 to 220°F Boil Max 1, 2, 4, 5, 6, 7, 8 200°F OFF , 120 to 225°F 3 180°F OFF , 120 to 190°F Boil Min 1, 2, 3, 4, 5, 6, 7 150°F OFF , 80 to 180°F ‘Burner ’ De[...]

34 Definitions % OUT - Current percent modulation rate of heater . BOIL DSGN - Design boiler water temperature used in heat loss calculations. BOIL MASS - This setting allows adjustment in the field for high or low thermal masses; High thermal mass (setting=3) provides slower reaction, lower ther- mal mass (setting=1) provides faster reaction. BOIL[...]

35 R ank I tem Field N umber Field T ype F ault Description 0 E 01 E rr E rror E EPROM error 1 F P E rr W arning F lame proof warning 2 BOIL OUT SHr Error Boiler outlet sensor short 3 BOIL OUT OPn Error Boiler outlet sensor open 4 BOIL IN SHr Error Boiler inlet sensor short 5 BOIL IN OPn Error Boiler inlet sensor open 6 SUP SHr Error System sensor [...]

Fig. 37: Ignition Module The optional single-try ignition module will lock out after failing to light one time. T o reset it, press and release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case. T urning off the power to the heater WILL NOT reset the ignition module. T abl[...]

37 Fig. 38: High Limit (Manual Reset) High Limit—Auto R eset (Optional) This heater may be equipped with an optional adjust- able auto reset high limit temperature device. The optional adjustable auto reset high limit is located inside the heater junction box. Adjust the setting to approx. 20°F (10°C) above desired outlet temperature. Fig. 39: [...]

38 Fig. 43: High/Low Gas Pressure Switch The optional high gas pressure switch connection mounts down-stream of the gas valve. Special ports are located on the backside of the gas valve and accessible from the front of the heater (to reset the gas pressure switch) or through the removable access panels on the rear of the heater (to reset the gas pr[...]

39 WIRING DIA GRAMS - Models 503–1503[...]

40 Models 1753–2003[...]

41 ST ART -UP Pre Star t-up Filling System (Heating Boilers) Fill system with water . Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. Air Pur ge (Domestic Hot Wa ter Heaters) Pu[...]

42 Prepar ation Check P ow er Suppl y With multi-meter at incoming power , check voltage between: Hot - Common (≈120 V AC) Hot - Ground (≈120 V AC) Common - Ground (< 1 V AC) Attach Manometers to Measure Pr essur es 1. T urn off main gas valve. 2. Attach (1) 12” scale manometer to an upstream bleedle valve on the gas supply pipe to the hea[...]

43 2. FOR REFERENCE ONL Y : Measure the blower amp draw with the heater firing at 100% input and compare the measured value to the values in T able U. The amp draw is measured with a clamp- on type amp probe clamped to the 14 AWG black power wire going into the blower . 3. When firing at 100%, the desired heater combus- tion CO2 is between 8.5 and [...]

44 g as pressure switch (if provided) must be set at 3.0 in. WC for natural gas and propane gas. 8. Make sure that the high gas pressure switch (op- t ional) is set to 3.0 in. WC for both natural gas and propane gas. F ollow-Up Safety checks must be recorded as performed. T urn heater on. After main burner ignition: 1. Check manometer for proper re[...]

45 P ost Star t-Up Check Check off steps as completed: 1. V erify that the heater and heat distribution units or storage tank are filled with water . 2. Confirm that the automatic air vent (if used) was opened two full turns during the venting proce- dure. 3. V erify that air has been purged from the system. 4. V erify that air has been purged from[...]

46 t imes (one time on optional single-try ignition mod- ule). If flame is not sensed, lockout will commence. 1 0. If the appliance will not operate, follow the instruc- tions “T o T urn Off Gas T o Appliance,” and call your s ervice technician or gas supplier . 1 1. Replace upper front panel. 12. If heater fails to start, verify the following:[...]

47 TR OUBLESHOO TING Ste p 8 Ste p 7 Ste p 6 Ste p 9 Step 1 Step 2 Step 3 Step 4 Step 5 Is there a Call For Heat? Is Disable connection intact? Does the combustion air blower come on? Is 4-20mA present at the quick disconne ct s on the black and blue wir es of the tem p erature controlle r ? Is 24VAC at the NC side of the air p ressure swit ch? Doe[...]

48 UDB F ault Histor y T o view the fault codes in the UDB history file: 1. Press the UP or DOWN buttons on the membrane s witch for 2 seconds to access the fault history . 2. Press either button to scroll through the recorded faults in history . 3. The most recent fault recorded will be the first fault displayed (the last 16 faults are stored in t[...]

49 densate management system or drain, as required by local codes. 3. Check that area is free from combustible materi- als, gasoline, and other flammable vapors and liquids. 4. Check air filter and replace as necessary . 5. Follow pre-start-up check in the Start-up section. 6. Visually inspect burner flame. It should be light blue at full input. Re[...]

50 6 . Perform leakage test on gas valves. (See Fig. 48.) 7. T est air switch in accordance with manufacturer ’s instructions. (T urn panel switch to the “On” posi- t ion until blower is proven, then turn the switch to “Off.” 8. Inspect and clean burner using shop air . As R equir ed 1. Recondition or replace low water cut-off device (if [...]

51 APPENDIX Inside Air Contamination All heaters experience some condensation during start-up. The condensate from flue gas is acidic. Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high effi- [...]

52 (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1 . The equipment listed in Chapter 10 entitled "Equipment Not Required T o Be V ented" in the most current edition of NFP A 54 as adop ted by the Board; and 2 . Product Approved side wall horizontally vented gas fueled equipment installed in a room o[...]

53 LIMITED PARTS WARRANTY MVB – TYPES H AND WH MODELS 503-2003 SCOP E R aypak , Inc . (“ Ray pak”) w arr ants to th e or ig in al ow ner t hat a ll par ts o f th is h eat er w hic h are ac tu al ly man uf ac tur ed by R ay pak w ill b e fr e e f ro m f ailur e un der n orm al us e a nd s ervic e for t he s p ec if ie d wa rr a nty per iods an[...]

54 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This s tart-up checklis t is to be co mpletely filled o ut by t he service techn ician s tarting up th e Rayp ak Boiler or H eater for the first time. All in formation may be us ed for w arra nty purpos es an d to ensure that the ins tallation is corre ct. Additionally this form wi ll be use d [...]

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w w w .r a y pak .co m Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.[...]