Raypak 503-2003 manual

CATALOG NO. 3400.53A Effective: 8-1-06 Replaces: 6-15-06 P/N 241288 Rev 2 INST ALLA TION AND OPERA TING INSTRUCTIONS Models 503-2003 T ypes H & WH FOR YOUR SAFETY Do not store or use gasol ine or other fl ammable vapors and li quids or ot her combust ible ma terials in the vi cinity of this or any other appliance. To do so may result in an expl[...]

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1 WARNINGS................................................................2 SECTION A Before Installation ..............................3 Product R eceipt .......................................................3 Model Identification ................................................3 Ratings and Cer tifications........................................[...]

2 PAY ATTENTION TO T HESE TERMS: DANGE R: Indicates the presence of immediate hazards whic h will cause severe pers onal injury, death or substantial property damage if ignored. WARNING : Indicates the presence of hazards or unsafe practices whic h could cause severe personal injury, death or substantial prop erty damage if igno red . CAUTION: Indi[...]

SECTION C: Installation 3 Raypak strongly recommends th at this manual be re- viewed thoro ughly before i nstalling yo ur MVB heate r. Please review the General Safety information in Sec- tion B before installing the heater. Factory warranty does not a pply to heat ers that ha ve been i mproperly installed or operated. (Refer to the wa rranty at th[...]

SECTION A: Before Installation 4 All Raypak heaters are National Board A pproved, and design-certified and tested by the Canadian Standards Association (CSA) for the U.S. and Canada. Each heater is constructed in accordance with Section IV of the American Society of Mechanical Engineer s (ASME) Heater Pressure Vessel Code and bears the A SME stamp.[...]

SECTION C: Installation 5 To meet commercial hot water use needs, the high lim it safety control on this water heater is adjustable up to 210°F. Howe ver, water temp erat ures over 125°F can cause instant severe burns or deat h from scal ds. When supplying ge neral purp ose hot water, the recomme nded initial setting for the con trol is 125°F. S[...]

SECTION B: General Safety 6 Time/Temperature Relationships in Scalds The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in d etermining the safest water temperature for your applications. Water Temp. Time to Produce Serious Burn 120°F More than 5 m inutes 125°F 1-1/2 t[...]

SECTION C: Installation 7 Installation Codes Installations must follow these cod es: • Local, state, provincial, and national codes, laws, regulations and ordinances • National Fuel Gas Code , ANSI Z223.1/ NFPA 54 – latest edition (NFGC) • National Electri cal Code, ANSI/NFP A 70 - latest edition (NEC) • Standard fo r Controls and Safety [...]

SECTION C: Installation 8 Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Insta llations U.S. Installations 1 Canadian Installations 2 A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm ) 1 ft (30 cm ) B Clearance to window or do or that may be opened 4 ft (1.2m ) below or t o side of openin g; [...]

SECTION C: Installation 9 Venting not shown for clarity. Heater must be vented per instructions in this manual Fig. 6: Minimum Clearances from Combustible Surfaces – Indoor and Ou tdoor Installati ons When installed according to the listed minim um clear- ances from combustible cons truction, these heaters can still be serviced without remov ing [...]

SECTION C: Installation 10 CAUTION: Com bustion air m ust not be contaminat ed by corrosive chemical fumes which can damage the heater and voi d the warra nty. (See Section H.) NOTICE: It is recomm ended that the inta ke vent be insulated to minimize sweating. Optional Construction Air Filter An optional constru ction air f ilter is available for u[...]

SECTION C: Installation 11 b. Where communicating with the outdoors through horizon tal ducts, each o pening shall have a minim um free area of 1 in. 2 per 2,000 BTUH (1,100 mm 2 per kW) of total input rat- ing of all equipment in the en closure. 2. One permanent opening , commencing within 12 in. (305 mm ) of the top of the enclosure , shall be pe[...]

SECTION C: Installation 12 Relief Valve Piping WARNING: Press ure relief valve discharge pipi ng must be pipe d near the floor an d close to a drain to eliminate the potential o f severe burns. Do not pipe to any area where freezing could occur. Refe r to local codes. Hydrostatic Test Unlike many types of heaters, this heater do es not re- quire hy[...]

SECTION C: Installation 13 matic valve system, such as a three-way prop ortional valve or a modulating two-way valve to control the bypass, shou ld be utilized. Fig. 7: Cold Water Start Cold Water Run Cold water run differs from cold water start in that the system water entering the heater remains below 120ºF (49ºC) continuous ly. Typically, this[...]

SECTION C: Installation 14 Hydronic Heating Pump Selection In order to ensure proper perf ormance of your heater system, you must install a correctly-sized pump. Ray- pak recomm ends designi ng for a ∆ T within the range of 10°F to 40°F. See Table F for acce ptable flow rates for each m odel ( ∆ T is t he tem perature difference be- tween the[...]

SECTION C: Installation 15 Fig. 12: Sing l e Domestic Hot Water Heater and Storage Tank Potable Water and Space Heating CAUTION: Whe n this heater is used for both pota ble water and space heating, observe the following to en- sure prope r operation. 1. All piping materials and components conne cted to the water heater for the space heating appli c[...]

SECTION C: Installation 16 To complete the installation of the poo l heater, the pool thermostat needs to be installed in the main return wa- ter line, upstream of the heater. This will ensu re that the heater will be energized at the right ti me. Fig. 13: Single Pool He ater Application Adjustment of the manual bypass valve is critical to proper o[...]

SECTION C: Installation 17 NOTE: There are 2 separate drains on the MVB that must BOTH be drained to protect the heat exchanger. These are bot h accessible by rem oving the lower front door from the heater. Drain any piping of all water that may experience below-freezing temperatures. Pool/Spa Water Chemistry NOTICE: Chemical imbalance can ca use s[...]

SECTION C: Installation 18 Gas Supply Connection CAUTION: The heater must be disconnect ed from the gas supply during any pressure testi ng of the gas supply system at test pre ssures in excess of 1/2 psi (3.45 kPa). The heater m ust be is olated from the gas su pply pipi ng system by closing the upstream manual sh ut-off valve during any pressure [...]

SECTION C: Installation 19 Manifold Gas Pressure (High Fire Values) Model No. Natural Gas Propane Gas 503 -0.1 -0.1 753 -0.1 -0.1 1003 -0.2 -0.2 1253 -0.1 -0.1 1503 -0.4 -0.3 1753 0.4 0.4 2003 0.6 0.6 NOTE: Manifold pressures should be + 0.2” WC. Table I: Manifold Gas Pressure Settings During norm al operation, carbon di oxide should be 8. 0 to 9[...]

SECTION C: Installation 20 CIRCUIT BREAKER WHITE GROUND BLACK GREEN AB C Fig. 17: Wiring Connections Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum Fig. 18: Multi-meter Making the Electrical Connections Refer to Fig. 1 6-19. 1. Verify that circuit breaker is properly sized by refer[...]

SECTION C: Installation 21 Venting CAUTION: Proper installation of flue venting is criti- cal for the safe and efficien t operation of the heater. General Appliance Categories Heaters are divided in to four categories based on the pressure produced in the exhaust and the lik elihood of condensate pr oduction in t he vent. Category I – A heater wh[...]

SECTION C: Installation 22 Vent Terminal Location NOTICE: During winter mont hs check the vent cap and make s ure no blockage occ urs from build-up of snow or ice. 1. Condensate can freeze on the vent ca p. Frozen condensate on t he vent cap can result in a blocked flue condition. 2. Give special attention to th e location of the vent termination t[...]

SECTION C: Installation 23 5. Within 6 ft (1.8 m) of a ny gas service re gulator vent outlet. 6. Less than 1 ft (305 mm) above grade lev el. 7. Within 3 ft (0.9 m) of a window or door which can be opened in any bu ilding, any non-mechanical air supply inlet to any bu ilding or the combustio n air inlet of any other applianc e. 8. Underneat h a vera[...]

SECTION C: Installation 24 Termination The vent term inal should be vert ical and shoul d termi- nate outside the building at least 2 ft above the highest point of t he roof withi n 10 ft. The ve nt cap sho uld have a minim um clearance of 4 ft horiz ontally from and in no case above or below (unl ess a 4 ft horizontal di s- tance is maintained) el[...]

SECTION C: Installation 25 Fig. 21: Typical Common Ventin g Horizontal Through-the-Wall Direct Venting (Category IV) Fig. 22: Horizontal Through-the-Wall Venting Fig. 23: Alt. Horizontal Through-t he-Wall Venting NOTE: While a drain connection is required in the vent of all MVB installations, the drain can be ac- complished in several different way[...]

SECTION C: Installation 26 Fig. 24: Horizontal Through-the-Wall Direct Venting CAUTION : This venting system requires the installa- tion of a condensate drain in t he vent piping pe r the vent ma nufacturer’s i nstructions . Failure t o install a condensate drain in th e venting system will void all warranties on this heater. Installation These i[...]

SECTION C: Installation 27 3. The vent must be insulated th rough the length of the horizontal run. Termination The flue direct vent cap MU ST be mounte d on the ex- terior of the building. The direct vent ca p cannot be installed in a wel l or below gra de. The direct vent ca p must be installe d at least 1 ft ab ove ground level an d above normal[...]

SECTION C: Installation 28 Outdoor Installation Outdoor models are self-ven ting when in stalled with the optional fa ctory-suppl ied outdoor ve nt kit. Addi- tional ve nt materials are requi red as outl ined in the Outdoor Vent Kit instructions. A special vent cap and air intake elbow ar e offere d in accordance wit h CSA requirements. These must [...]

SECTION C: Installation 29 The Raypak modulating t emperature co ntrol is pr o- vided to maintain the desired system water temperature. The control has various m odes of ope ration whic h are listed below. Operating Modes Mode 1 – Setpoint operat ion using paralle l piping. The heater outlet water temperature is controlled to the boiler targ et s[...]

SECTION C: Installation 30 system operation by means of three push buttons (Item, ▲ , ▼ ). Item advances the display, while ▲ , ▼ are used in the adjust menu. Fig. 27: Modulating Te mperature Control User Interface All items displayed by the control are organized in to two menus, the view m enu and t he adjust menu. T he active menu i s dis[...]

SECTION C: Installation 31 To make an adjust ment to a sett ing in the contr ol, begin by selecting t he “ADJUST” m enu. To cha nge from the view menu t o the adjust menu , simultaneously press and hold all three buttons for 1 second. The menu name, “ADJUST” will be displayed in the menu field. The menu will automatically revert back to the[...]

SECTION C: Installation 32 (CFH) of the UDB board. In addition, the a mber “Call-for-Heat” LED on the front o f the heater will illuminate. 14. The pum p contact on t he modulati ng temperature control closes sen ding 24 VAC to the pum p switch located on the front e xterior panel of the heater. 15. When the pump switch is closed, 24 VAC is sen[...]

SECTION C: Installation 33 pump relay and the blower receives power but does not energize at this time and terminal L1 the ignition module is powere d. 3. The 120/24 V AC transform er sends a 24 VAC hot power signal t o the 24V Ter minal Block. 4. 24 VAC is sent from the 2 4V Terminal Block to pin L1 of the Low Water Cut Off, the 24 VAC terminal of[...]

SECTION C: Installation 34 When the 24 VAC signal is sent from the flow switch to P4-9, the same signal then de-energizes the coil of the time delay relay to remove a heat demand fr om the modulat ing tem perature cont rol and restart the ignition se quence after the five- second time del ay. Upon igniti on lockout, t he module ene rgizes the locko[...]

SECTION C: Installation 35 Fig. 29: Ignition Module The standard single-try ignitio n module will lock out after failing to light one time. To reset it, press and release the small, recessed black push button located inside of t he cut-out o n the lower right-han d corner of the ignition mo dule case. Turning off the power to the heater WILL NOT re[...]

SECTION C: Installation 36 Fig. 32: Flow Switch Modulating Temperature Control The heater is e quipped wi th a Raypak modulati ng tem- perature cont rol. Refer t o inform ation starting on page 28 for information on the setting and use of this con trol. Fig. 33: Modulating Te mperature Control Low Water Cut-Off (Optional) The optional low water cu [...]

SECTION C: Installation 37 Fig. 36: Air Pres sure Switch Blocked Vent Switch This heater is equippe d with a bloc ked vent pressure switch to preven t the operation o f the heater when too much of the vent is bloc ked. This s witch is locat ed on the right side of the heater near the right rear corner. Fig. 37: Blocked Ven t Sw itch UDB Diagnostic [...]

SECTION C: Installation 38 Wiring Diagrams Models 503-1503[...]

SECTION C: Installation 39 Models 1753-2003[...]

SECTION C: Installation 40[...]

41 Pre Start-up Filling System (Heating Boilers) Fill system with water. Purg e all air from the system. Lower the system pr essure. Open valves fo r normal system operation, and fill system through feed pressure. Manually ope n air vent on the com pression tank unti l water appears, then cl ose vent. Air Purge (Domestic Hot Water Heaters) Purge al[...]

SECTION D: Start up 42 of the control s ystem and any gas control wh ich has been under water. • Check around unit for debris and rem ove combust i- ble products, i .e. gasoline , etc. Pre Start-up Check 1. Verify heater is filled with water. 2. Check system piping for leaks. If found, repai r immediately. 3. Vent air from system. Air in system c[...]

SECTION D: Start up 43 5. Check blowe r motor am p draw and t he manom eter attached to fan pressure s witch with the blower running at 100 % speed. The readi ng should be as noted in Ta bles P an d Q for bot h natural g as and propane ga s. If not, a djust the air s hutter on the blower to attain the correct values. 6. Measure the blower amp draw [...]

SECTION D: Start up 44 Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check a nd record. 3. If othe r gas-fired a ppliances in t he room are o n the same gas main, chec k all pressures on the MVB with all ot her equipm ent runni ng. 4. Check thermostats for ON-[...]

SECTION D: Start up 45 Fig. 40: Leak T est Procedure Post Start-Up Check Check off steps as completed: 1. Verify t hat the heater and heat distributi on units or storage tank are filled with water. 2. Confirm that the automatic air vent (if used) was opened two f ull turns during the venti ng procedure. 3. Verify that air has been purge d from the [...]

SECTION D: Start up 46[...]

SECTION D: Start up 47 Lighting Instructions 1. Before lighting, make sure you have read all of the safety information in this manual. 2. Remove up per front panel . 3. Set the thermostat to the lowest setting. 4. Turn off all electrical power to the appliance. 5. This appliance is equ ipped with an ignition dev ice which automatically lig hts the [...]

SECTION E: Operation 48[...]

SECTION D: Start up 49 SECTION F Troubleshooting 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 disconnects on the black and blue wires of the tem p erature controlle r ? Is 24VAC at the NC side of the a[...]

SECTION F: Troubleshooting 50 UDB Fault History To view the fault codes in the UDB history file: 1. Press and hold t he switch labeled “SW1” for 5 seconds to access the fault history. LED 17 will begin to flash when the histo ry has been accessed. See Fig. 38 on page 37. 2. Press the switch labeled “SW2” to scroll through the recorded fault[...]

51 Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and mainte- nance must be performed to ensure maximum operating efficiency. Maintenance as outlined below may be performed by the owner. Daily 1. Check that the area where the heater is installed is free from combustible materials, gasoline, and other flam- mabl[...]

SECTION G: Maintenance 52 11. Check for piping leaks aroun d pumps, relief valves and other fittings. Repair, if found. DO NOT use pe- troleum-based stop-leak. Periodically 1. Check relief valve. Refer to manufacturer’s instruc- tions on valve. 2. Test low water cut-off (if equipped). Refer to manu- facturer’s instructions. Preventive Maintenan[...]

53 Inside Air Contamination All heaters experience some conde nsation during start- up. The conde nsate from flue gas is acidic. Combusti on air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acid- ity levels attack many materials including stainless steel, which is commonly used i n high efficien[...]

LIMITED PARTS WA RRANTY MVB – TYPES H AND WH MODELS 503-2003 SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all part s of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warr anty periods and subject to the c onditions set forth in th is Wa rran [...]

NOTES: _____________ ____________ _______________ ____________ _______________ ____________ ______________ _____________ ____________ _______________ ____________ _______________ ____________ ______________ _____________ ____________ _______________ ____________ _______________ ____________ ______________ _____________ ____________ _______________ [...]

www .raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnar d, CA 93030 (805) 278-5300 F ax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Onta rio, Canada L4T 1G2 (905) 677-7999 Fax (9 05) 677-8036[...]