Table of Contents
Advertisement
INSTALLATION
AND OPERATING
INSTRUCTIONS
Models 503-2003
Types H & WH
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of
this or any other appliance. To do so may result in an explosion or fire.
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. Installation and
service must be performed by a qualified installer, service agency or the gas supplier.
* This unit contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans.
WHAT TO DO IF YOU SMELL GAS
•
Do not try to light any appliance.
•
Do not touch any electrical switch; do not use any phone in your building.
•
Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
•
If you cannot reach your gas supplier, call the fire department.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3400.53A
Effective:
8-1-06
Replaces:
6-15-06
P/N 241288 Rev 2
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Raypak 503-2003
Summary of Contents for Raypak 503-2003
- Page 1 INSTALLATION AND OPERATING INSTRUCTIONS Models 503-2003 Types H & WH FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.
-
Page 3: Table Of Contents
Table of Contents WARNINGS...2 SECTION A Before Installation ...3 Product Receipt ...3 Model Identification ...3 Ratings and Certifications...3 Installations at Elevation ...4 Component Locations...4 General Information ...4 SECTION B Hot Water Supply General Safety ...5 Time/Temperature Relationships in Scalds ...6 SECTION C Installation...7 Installation Codes ...7 Equipment Base...7... -
Page 4: Warnings
PAY ATTENTION TO THESE TERMS: DANGER: Indicates 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. CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored. -
Page 5: Section A Before Installation
Raypak repre- sentative. Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durabil- ity of our equipment. -
Page 6: Installations At Elevation
ASME parts not manufactured and/or approved by Raypak will instantly void the ASME and CSA ratings of the vessel and any Raypak warranty on the vessel. Al- tering the ASME or CSA ratings of the vessel also violates national, state, and local approval codes. -
Page 7: Section B Hot Water Supply General Safety
To meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the recommended initial setting for the control is 125°F. -
Page 8: Time/Temperature Relationships In Scalds
Table B: Time to Produce Serious Burn The temperature of the water in the heater can be regu- lated by using the Raypak Modulating Temperature Control. To comply with safety regulations, the control is set at 120°F when shipped from the factory (Mode 3 default setting for Tank Target). -
Page 9: Installation Codes
Installation Codes Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances • National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition (NFGC) • National Electrical Code, ANSI/NFPA 70 - latest edition (NEC) •... - Page 10 SECTION C: Installation Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the terminal Clearance to unventilated soffit...
-
Page 11: Outdoor Installations
SECTION C: Installation Venting not shown for clarity. Heater must be vented per instructions in this manual Fig. 6: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations When installed according to the listed minimum clear- ances from combustible construction, these heaters can still be serviced without removing permanent structural construction around the heater. -
Page 12: Conventional Combustion Air Supply
3. In cold climates, and to mitigate potential freeze- up, Raypak highly recommends the installation of a motorized sealed damper to prevent the circula- tion of cold air through the heater during non- operating hours. -
Page 13: Canadian Installations
b. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in. BTUH (1,100 mm per kW) of total input rat- ing of all equipment in the enclosure. 2. One permanent opening, commencing within 12 in. -
Page 14: Relief Valve Piping
This piping is like a primary/secondary boiler installation with a by- pass acting as the secondary boiler piping. Raypak strongly recommends that thermometer(s) be placed into the heater piping next to the in/out header to facili- tate temperature adjustment. -
Page 15: Temperature & Pressure Gauge
matic valve system, such as a three-way proportional valve or a modulating two-way valve to control the bypass, should 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) continuously. -
Page 16: Hydronic Heating
Feedwater Regulator Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the highest point of the system. Install a check valve or back flow device upstream of the regulator, with a manual shut-off valve as required by local codes. -
Page 17: Pool Heating
Pool Heating When a boiler or water heater is used in a pool heating application, ensure that all the following installation requirements are met. -
Page 18: Automatic Chlorinators And Chemical Feeders
SECTION C: Installation To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return wa- ter line, upstream of the heater. This will ensure that the heater will be energized at the right time. Fig. -
Page 19: Pool/Spa Water Chemistry
Raypak water heaters can operate lime/scale-free using potable water with a hardness not exceeding 20 grains per gallon. Proper operation is achieved by setting the temperature rise/water flow per the guidelines in the installation instructions. -
Page 20: Gas Supply Connection
SECTION C: Installation 1” NPT Model 1003 1253 1503 1753 2003 Natural Gas – 1,000 BTU/ft Propane Gas – 2,500 BTU/ft Table H: Maximum Equivalent Pipe Length Gas Supply Connection CAUTION: The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa). -
Page 21: Electrical Power Connections
Manifold Gas Pressure Model (High Fire Values) Natural Gas -0.1 -0.1 1003 -0.2 1253 -0.1 1503 -0.4 1753 2003 NOTE: Manifold pressures should be + 0.2” WC. Table I: Manifold Gas Pressure Settings During normal operation, carbon dioxide should be 8.0 to 9.0% at full fire for natural gas and between 9.0 and 10.0% for propane gas. -
Page 22: Field Wiring Connection
SECTION C: Installation BLACK CIRCUIT BREAKER WHITE GREEN GROUND A B 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. -
Page 23: Venting
Venting CAUTION: Proper installation of flue venting is criti- cal for the safe and efficient operation of the heater. 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. -
Page 24: Vent Terminal Location
SECTION C: Installation Vent Terminal Location NOTICE: During winter months check the vent cap and make sure no blockage occurs from build-up of snow or ice. 1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. -
Page 25: Venting Installation Tips
5. Within 6 ft (1.8 m) of any gas service regulator vent outlet. 6. Less than 1 ft (305 mm) above grade level. 7. Within 3 ft (0.9 m) of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building or the combustion air inlet of any other appliance. -
Page 26: Common Venting
SECTION C: Installation Termination The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the highest point of the roof within 10 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft horizontal dis- tance is maintained) electric meters, gas meters, regulators and relief equipment. - Page 27 SECTION C: Installation Horizontal Through-the-Wall Direct Venting (Category IV) Fig. 22: Horizontal Through-the-Wall Venting Fig. 21: Typical Common Venting Fig. 23: Alt. Horizontal Through-the-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 ways.
- Page 28 SECTION C: Installation Fig. 24: Horizontal Through-the-Wall Direct Venting CAUTION: This venting system requires the installa- tion of a condensate drain in the vent piping per the vent manufacturer’s instructions. Failure to install a condensate drain in the venting system will void all warranties on this heater.
-
Page 29: Direct Vent - Vertical
The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved stainless steel flue direct vent cap must be used (sales order option D-15). The vent terminal must be located NO CLOSER than 12”... -
Page 30: Outdoor Installation
SECTION C: Installation Outdoor Installation Outdoor models are self-venting when installed with the optional factory-supplied outdoor vent kit. Addi- tional vent materials are required as outlined in the Outdoor Vent Kit instructions. A special vent cap and air intake elbow are offered in accordance with CSA requirements. -
Page 31: Operating Modes
The Raypak modulating temperature control is pro- vided to maintain the desired system water temperature. The control has various modes of operation which are listed below. Operating Modes Mode 1 – Setpoint operation using parallel piping. The heater outlet water temperature is controlled to the boiler target setpoint. - Page 32 “VIEW” is dis- played. Pressing the scroll button “scrolls” through the displayed values in the “VIEW” menu. Fig. 28: Modulating Temperature Control Display Default Boiler Water Heater 140 ºF 160 ºF 180 ºF 200 ºF 180 ºF 135 ºF...
-
Page 33: Heater Sequence Of Operation
SECTION C: Installation To make an adjustment to a setting in the control, begin by selecting the “ADJUST” menu. To change from the view menu to the adjust menu, simultaneously press and hold all three buttons for 1 second. name, “ADJUST” will be displayed in the menu field. The menu will automatically revert back to the view menu after 20 seconds of keyboard inactivity. - Page 34 SECTION C: Installation (CFH) of the UDB board. In addition, the amber “Call-for-Heat” LED on the front of the heater will illuminate. 14. The pump contact on the modulating temperature control closes sending 24 VAC to the pump switch located on the front exterior panel of the heater. 15.
- Page 35 pump relay and the blower receives power but does not energize at this time and terminal L1 the ignition module is powered. 3. The 120/24 VAC transformer sends a 24 VAC hot power signal to the 24V Terminal Block. 4. 24 VAC is sent from the 24V Terminal Block to pin L1 of the Low Water Cut Off, the 24 VAC terminal of the ignition control module, the green LED on the front of the heater to signify “Power...
-
Page 36: Ignition Module
SECTION C: Installation 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 from the modulating temperature control and restart the ignition sequence after the five- second time delay. -
Page 37: Flow Switch
Fig. 29: Ignition Module The standard single-try ignition 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 the cut-out on the lower right-hand corner of the ignition module case. - Page 38 SECTION C: Installation Fig. 32: Flow Switch Modulating Temperature Control The heater is equipped with a Raypak modulating tem- perature control. Refer to information starting on page 28 for information on the setting and use of this control. Fig. 33: Modulating Temperature Control...
-
Page 39: Blocked Vent Switch
Fig. 36: Air Pressure Switch Blocked Vent Switch This heater is equipped with a blocked vent pressure switch to prevent the operation of the heater when too much of the vent is blocked. This switch is located on the right side of the heater near the right rear corner. Fig. -
Page 40: Wiring Diagrams
SECTION C: Installation Wiring Diagrams Models 503-1503... - Page 41 SECTION C: Installation Models 1753-2003...
- Page 42 SECTION C: Installation...
-
Page 43: Section D Start-Up
Raypak offers an optional air vent for the MVB heaters which can be screwed directly into the inlet side of the header to ensure that air is purged from the system. -
Page 44: Pre Start-Up Check
SECTION D: Start up of the control system and any gas control which has been under water. • Check around unit for debris and remove combusti- ble products, i.e. gasoline, etc. Pre Start-up Check 1. Verify heater is filled with water. 2. - Page 45 5. Check blower motor amp draw and the manometer attached to fan pressure switch with the blower running at 100% speed. The reading should be as noted in Tables P and Q for both natural gas and propane gas. If not, adjust the air shutter on the blower to attain the correct values.
-
Page 46: Safety Inspection
SECTION D: Start up Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record. 3. If other gas-fired appliances in the room are on the same gas main, check all pressures on the MVB with all other equipment running. - Page 47 Fig. 40: Leak Test Procedure Post Start-Up Check Check off steps as completed: 1. Verify 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 procedure. 3.
- Page 48 SECTION D: Start up...
-
Page 49: Section E Operation
Lighting Instructions 1. Before lighting, make sure you have read all of the safety information in this manual. 2. Remove upper front panel. 3. Set the thermostat to the lowest setting. 4. Turn off all electrical power to the appliance. 5. - Page 50 SECTION E: Operation...
-
Page 51: Section F Troubleshooting
Does the power switch provide power to the control panel? Step 1 Is there a Call For Heat? Is Disable connection intact? Step 2 Does the combustion air Step 3 blower come on? Is 4-20mA present at the quick disconnects on the black and blue wires of the temperature controller? Does F2 on ignition module have AC power? -
Page 52: Udb Fault History
SECTION F: Troubleshooting UDB Fault History To view the fault codes in the UDB history file: 1. Press and hold the switch labeled “SW1” for 5 seconds to access the fault history. LED 17 will begin to flash when the history has been accessed. See Fig. -
Page 53: Section G Maintenance
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 Check that the area where the heater is installed is free from combustible materials, gasoline, and other flam- mable vapors and liquids. -
Page 54: Preventive Maintenance Schedule
SECTION G: Maintenance 11. Check for piping leaks around pumps, relief valves and other fittings. Repair, if found. DO NOT use pe- troleum-based stop-leak. Periodically Check relief valve. Refer to manufacturer’s instruc- tions on valve. Test low water cut-off (if equipped). Refer to manu- facturer’s instructions. -
Page 55: Section H 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 acid- ity levels attack many materials including stainless steel, which is commonly used in high efficiency sys- tems. - Page 56 SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
- Page 57 NOTES: _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________...
- Page 58 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036...
Need help?
Do you have a question about the 503-2003 and is the answer not in the manual?
Questions and answers