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INSTALLATION AND
OPERATION MANUAL
Models 503A–2003A
Types H & WH
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. *This unit contains materials that
have been identified as carcinogenic, or possibly carcinogenic, to humans.
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.
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.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
Effective: 11-3-20
Replaces: 12-15-19
P/N 241511 Rev. 6
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Summary of Contents for Rheem Raypak MVB 503A
- Page 1 INSTALLATION AND OPERATION MANUAL Models 503A–2003A Types H & WH 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. *This unit contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans.
- Page 2 Revision 6 reflects the following changes: Some additional metric and Celsius (SI) values added throughout manual in various tables, text, and figures. Figure 5 and Table C footer revised on page 8. Figure 6 revised on page 9. Truseal™ Direct Vent Combustion Air, and Ducted Combustion Air text revised on page 13.
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Page 3: Table Of Contents
CONTENTS 1. WARNINGS ............. 4 5. CONTROLS ............31 Pay Attention to These Terms ......... 4 Ignition Control Functions ........31 2. GENERAL SAFETY ..........5 6. WIRING DIAGRAM ..........40 Time/Temperature Relationships in Scalds ..... 5 7. START-UP .............. 41 3. -
Page 4: Warnings
1. WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe personal injury, death or DANGER substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, WARNING death or substantial property damage if ignored. -
Page 5: General Safety
2. GENERAL SAFETY Water Temp. Time to Produce Serious Burns 120°F (49°C) More than 5 minutes NOTE: When this water heater supplying 125°F (52°C) 1-1/2 to 2 minutes general purpose hot water for use by individuals, a thermostatically-controlled mixing valve for reducing 130°F (54°C) About 30 seconds point of use water temperature is recommended to reduce... -
Page 6: Before Installation
3. BEFORE INSTALLATION Ratings and Certifications Raypak strongly recommends that this manual be reviewed Standards: thoroughly before installing your MVB heater. Please review the General Safety information before installing • ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Hot the heater. Factory warranty does not apply to heaters Water Boilers that have been improperly installed or operated. -
Page 7: Component Locations
Component Locations COMBUSTION AIR INLET HIGH VOLTAGE BLOWER GAS TRAIN ELECTRICAL CONNECTIONS GAS SUPPLY CONNECTION OPERATING CENTER PRESSURE WATER RELIEF OUTLET VALVE WATER INLET HEAT EXCHANGE ASSEMBLY FLUE OUTLET FRONT OF HEATER F10212 Figure 3. Component Locations – Rear BURNER FLAME VIEWING PORT BURNER FLAME... -
Page 8: Installation
If the heater needs to be secured to the ground, use the 4. INSTALLATION hole pattern shown in Figure 5, following local codes. Additional clearance may be required when using the Installation Codes factory anchor bracket. Installations must follow these codes: Clearances •... - Page 9 Outdoor Installations Min. Clearance from Minimum Service Heater Side Combustible Surfaces Clearance These heaters are design-certified for outdoor installation. in. (mm) in. (mm) Heaters must not be installed under an overhang unless clearances are in accordance with local installation codes Rear 12 (305) 24 (610)
- Page 10 V = VENT X = AIR INLET F10692 Figure 7. Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, deck, or 1' (30 cm) 1' (30 cm) balcony 4' (1.2 m) below or to side of Clearance to window or door that may be opened 3' (91 cm) opening...
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Page 11: Combustion And Ventilation
• remodeling areas Combustion and Ventilation • open pit skimmers Inside Air Contamination Check for areas and products listed above before installing heater. If found: All heaters experience some condensation during start- up. The condensate from flue gas is acidic. Combustion •... -
Page 12: Conventional Combustion Air Supply
shall directly communicate with the outdoors or shall Conventional Combustion Air Supply communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with CAUTION: Use TruSeal combustion air if damaging airborne contaminants are or may be present in the the outdoors, and shall have a minimum free area of: heater area. -
Page 13: Water Piping
more than 18 in. (450 mm) nor less than 6 in. (152 Motorized Combustion Air Dampers or mm) above the floor level. The duct can also “goose Louvers neck” through the roof. The duct is preferred to be straight down 18 in. (457 mm) from the floor, but not When dampers or louvers are communicating directly near piping. - Page 14 To perform hydrostatic test: system, such as a three-way proportional valve to control the bypass, should be used. 1. Connect fill water supply. Fill heater with water. Carefully fill the rest of the system, making sure to eliminate any entrapped air by using high-point COLD WATER vents.
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Page 15: Hydronic Heating
The piping system of a hot water heater connected to Hydronic Heating heating coils located in air handling units where they may be exposed to circulating refrigerated air, must be Pump Selection equipped with flow control valves or other automatic In order to ensure proper performance of your heater means to prevent gravity circulation of the heater water system, you must install a correctly-sized pump. - Page 16 NOTE: See VERSA IC ® manual (241493) for additional Applications and Modes details. ® The VERSA IC Control system is designed for a wide range of applications. The installer/design engineer should MODBUS VERSA refer to the following Modes to determine which best fits ENABLE the intended application and functionality for the unit being 0-10 VDC / 4-20mA...
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Page 17: Domestic Hot Water
Supply sensor (S6) and the Target Max setting when using Mode 2 (Type H Units Only) the Indirect DHW sensor (S5). The Boiler Pump (P1) runs This mode selection is for hydronic heating systems with during all heat calls regardless of priority. The Indirect single or multiple boilers in primary/secondary piping DHW Pump (P3) runs during an indirect call for heat with no “off”... - Page 18 WATER HARDNESS SOFT* MEDIUM HARD* 3-4 Grains Per Gallon 5-15 Grains Per Gallon 16-25** Grains Per Gallon Model ∆T ∆P ∆T ∆P ∆T ∆P °F (°C) (lpm) (ft wc) (in) (ft wc) °F (°C) (lpm) (ft wc) (in) (ft wc) °F (°C) (lpm) (ft wc)
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Page 19: Gas Supply
CAUTION: Combustion air must not be contaminated CAUTION: Do not use Teflon tape on gas line pipe by corrosive chemical fumes which can damage the thread. A pipe compound rated for use with natural and heater and void the warranty. propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare. NOTE: High chemical concentrates from feeders that are out of adjustment will cause rapid corrosion to the CAUTION: Support gas supply piping with hangers,... -
Page 20: Electrical Power Connections
Power for an indirect DHW pump not exceeding 5 amps Gas Supply Pressure should be taken from terminals 4 (Hot), 5 (Com), and 6 (Gnd). Power for a system pump not exceeding 5 amps A minimum of 4.0 in. WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 10.5 should be taken from terminals 7 (Hot), 8 (Com), and 9 in. - Page 21 Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum HIGH VOLTAGE WIRING CIRCUIT BLACK BREAKER WHITE GREEN GROUND F10679 A B C F10219 Figure 19. Wiring Connections Figure 20.
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Page 22: Field Wiring Connection
Field Wiring Connection Wiring the Indirect Sensor 1. An indirect sensor connection is not required if an CAUTION: Label all wires prior to disconnection when indirect water heater is not used in the installation. servicing controls. Wiring errors can cause improper and dangerous operation. - Page 23 FIELD WIRING Wiring the Optional 0–10 Volt Building Control Signal 1. A signal from an energy management system may SYSTEM SUPPLY PUMP be connected to the MVB boiler. This signal should 5A MAX be a 0-10 volt positive DC signal, and an energy (120V) management system can be used to control either the setpoint temperature of a single MVB or a cascade...
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Page 24: Venting - General
0739), Protech System, Inc. (800-766-3473), Z-Flex (800- Alarm Connection 654-5600) or American Metal Products (800-423-4270). Pipe joints must be positively sealed. Follow the vent An alarm annunciator or light may be connected to the alarm contacts on the boiler PIM. The Alarm Contacts manufacturer’s installation instructions carefully. - Page 25 Support of Vent Stack U.S. Installations The weight of the vent stack or chimney must not rest on Refer to the latest edition of the National Fuel Gas Code. the heater vent connection. Support must be provided in WARNING: The Commonwealth of Massachusetts compliance with applicable codes.
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Page 26: Venting Installation Tips
supply inlet to any building or the combustion air inlet The diameter of vent flue pipe should be sized according of any other appliance. to the NFGC (U.S.) and Appendix B of B149 (Canada). The minimum flue pipe diameter for conventional venting 8. - Page 27 portions of the vent shall also be supported for the design Common Venting and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints. Raypak does not support common venting under positive- pressure conditions. Use an external variable-speed NOTE: A vent adapter (field-supplied) may be required extractor to draw the entire common vent to negative...
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Page 28: Horizontal Through-The-Wall Direct Venting (Category Iv)
VARIABLE SPEED EXTRACTOR VENT DRAIN - RUN TO SUITABLE CONDENSATE COLLECTOR PER APPROPRIATE CODES. SLOPE TOWARD ALT. LOCATION EXTRACTOR’S APPLIANCE 1" IN 4' MIN VARIABLE SPEED COMMON VENT PRESSURE (21 mm per m) EXTRACTOR SET POINT PIPE (CAT II) 2X D ADJUSTABLE VENT BAFFLE (IF REQUIRED) VENT PIPE SAME DIAMETER... - Page 29 ALTERNATE COMBUSTION INSULATED AIR INTAKE LOCATION EXHAUST HEATER UNIT VENTING INSULATED EXHAUST 12" MIN (305 mm) VENTING FLUE EXHAUST FLUE EXHAUST VENT CAP VENT CAP HEATER UNIT 12" MIN (305 mm) TEST PORT 36" MIN (.91 m) 12" MIN (305 mm) 6"...
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Page 30: Direct Vent-Vertical
2. The vent must be installed with a slight upward slope WARNING: No substitutions of flue pipe or vent of not more than 1/4 inch per foot of horizontal run cap material are allowed. Such substitutions would (21 mm per m) to the vent terminal. jeopardize the safety and health of inhabitants. -
Page 31: Controls
If the water temperature drops below 45°F (7°C) on FLUE EXHAUST VENT CAP the Outlet or Inlet sensors, the Boiler pump is enabled. The pump is turned off when both the Inlet and Outlet temperatures rise above 50°F (10°C). HEATER UNIT If either the Outlet or Inlet temperature drops below 38°F 3' MIN (3°C), the VERSA starts the burner at the minimum firing... - Page 32 series with the main gas valve, shuts off heater in case of NOTE: Ignition modules are common for all model pump failure or low water flow. sizes. However, model-specific operating parameters are defined by their respective ID cards. High Limit—Manual-Reset This heater is equipped with a fixed-setting manual-reset high limit temperature device as standard. It may also have an additional optional adjustable manual-reset high temperature device.
- Page 33 reset a tripped pressure switch. The LED will go out when the switch is reset. Figure 39. User interface Adjusting the MVB Setpoint To adjust the setpoint on the MVB: Use the MENU button to open the menu options, select Figure 37.
- Page 34 Item Application Description OUTDOOR H MODE 1, 2, 3 Outdoor air temperature Boil Target H MODE 1, 2, 3 Current target temperature SUPPLY H MODE 1, 2, 3 Current system supply temperature Boil OUTLET Current boiler outlet temperature Boil INLET Current boiler inlet temperature Boil ΔT Current temperature difference between boiler outlet and boiler inlet...
- Page 35 Item Application Range Description Default Enable or Disable the operation of boilers in FT Bus. 1 is BOILER 1 ON <> OFF enabled by default TARGET H MODE 1, 2, 3 RSET <> SETP RSET = Outdoor Reset, SETP =Setpoint SETP OFF, 50°F to 160°F TANK SETP...
- Page 36 Boiler Menu The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information. See Table O. Item Application Description IGNITION Current State of Ignition LIMIT TEMP Current Limit Temperature AUX TEMP H MODE 3 Current Auxiliary Temperature EMS Vdc...
- Page 37 Monitor Menu The Monitor Menu records and displays critical Boiler information, such as, Cycle times, Run times, and Maximum/ Minimum temperature readings depending on the setup. See Table P. Item Application Description RUN TIME Burner 1 Burner run time (hours). Press UP/DOWN for 1 sec to clear. Cycles Burner Number of burner cycles.
- Page 38 Toolbox Menu The Toolbox Menu logs all error codes from the BTCII and PIM, as well as other functions. Up to 15 error codes can be logged for a maximum of 24 days. See Table Q. Item Description Lookup Active Error Look up and display the active error info.
- Page 39 1. Heater Start (Boil START). The Boil START temperature Outdoor Reset Concept is the theoretical heater supply water temperature that the heating system requires when the outdoor The Temperature controller can change the System Set air temperature equals the OUT START temperature Point based on outdoor temperature (Outdoor Reset).
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Page 40: Wiring Diagram
6. WIRING DIAGRAM... -
Page 41: Start-Up
7. START-UP BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell near the floor because some gas is heavier than air and will settle on the floor. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, exposure to hazardous WHAT TO DO IF YOU SMELL GAS: materials or loss of life. -
Page 42: Preparation
Preparation Start-Up WARNING: Do not turn on gas at this time. NOTE: Technician performing initial start-up must carry a calibrated combustion analyzer to ensure desired combustion levels are achieved. Check Power Supply NOTE: The values in Table R represent the conditions With multi-meter at incoming power, check voltage when the heater is at full firing rate at sea level. -
Page 43: Blower Check
Blower Check User Test ® 1. Check blower suction using the manometer attached Set DIP switch #1 on the VERSA IC control to “ON”. On to the air pressure tee as shown in Figure 42, with Touchscreen, click the Menu icon, Tools icon, Systems the heater firing at 100% input. - Page 44 Safety Inspection Leak Test Procedure: Dual-Seat Gas Valve 1. Check all thermostats and high limit settings. Proper leak testing requires three pressure test points in the gas train. Remove the upper front panel and swing 2. During the following safety checks leave manome- the front J-box out of the way to access the gas valve for ters hooked up, check and record.
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Page 45: Post Start-Up Check
7. To test the fixed manual-reset high limit built into the PIM, first set dip switch #8 on the PIM to the ON position. This will activate a Commission Test Mode which will turn on the amber Alarm/Test LED on the PIM. -
Page 46: Operation
8. OPERATION To Turn Off Gas To Appliance 1. Shut off manual gas valve field installed near gas Lighting Instructions inlet connection on back of heater. 1. Before operation, make sure you have read all of the 2. Remove upper front panel. safety information in this manual. 3. -
Page 47: Mvb Fault Text
DANGER: When servicing or replacing components WARNING: Do not use this appliance if any part has that are in direct contact with the water, be certain that: been under water. Improper or dangerous operation may result. Contact a qualified service technician to inspect • There is no pressure in the boiler. (Pull the release the boiler and to repair or replace any part of the boiler on the relief valve. - Page 48 LED Error Code Listing Active errors detected are indicated by LED lights on the PIM. LED Code Error Mode Recommended Troubleshooting Normal Operation Red LED steady Check that the proper ID card is securely connected. Perform a power and ON, Green Power ID Card Fault system restart.
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Page 49: Maintenance
10. MAINTENANCE Sensor Resistance Values Water Sensor / Outdoor Sensor Suggested Minimum Water Temperature °F (°C) Resistance (ohms) Maintenance Schedule 32°F (0°C) 32550 Regular service by a qualified service agency and maintenance must be performed to ensure maximum 41°F (5°C) 25340 operating efficiency. -
Page 50: Preventive Maintenance Schedule
7. Check operation of safety devices. Refer to Semi-Annually manufacturers’ instructions. 1. Recalibrate all indicating and recording gauges. 8. Follow oil-lubricating instructions on pump (if 2. Check flame failure detection system components. required). Over-oiling will damage pump. Water- lubricated circulators do not need oiling. 3. - Page 51 As Required Filter Replacement 1. Recondition or replace low water cut-off device (if 1. Remove the filter box cover by loosening and equipped). removing the two wing nuts holding it in place. 2. Check sediment trap and gas strainers. 3. Check flame failure detection system. ("Post Start- Up Check"...
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Page 52: Illustrated Parts List
11. ILLUSTRATED PARTS LIST 25-S 12-S 23-S 26-S 10-S 14-C 24-S 23-S 11-S 10-S 29-S 13-S 15-M 11-S 16-M 17-S 16-S 12-C 15-S 13-C (OUTDOOR UNITS ONLY) 10-M (ROOFTOP VENTING ONLY) (SIDE WALL VENTING ONLY) - Page 53 HEAT EXCHANGER DETAIL 31-S 18-S 10-H ELECTRONIC COMPONENT DETAILS 30-S 19-S 28-S 21-S 16-J 27-S 11-C 12-J 11-J 20-S 15-C 13-J 14-S 10-J 10-C...
- Page 54 BLOWER DETAIL MODELS 503A–1503A MODELS 1753A–2003A 22-S GAS TRAIN DETAIL 16-G 18-G 17-G 12-G 11-G 10-G 19-G 14-G 15-G 13-G 11-G...
- Page 55 CALL DESCRIPTION 503A 753A 1003A 1253A 1503A 1753A 2003A BURNER ASSEMBLY Adapter Assembly 011749F 011749F 011749F 011749F 011749F 011750F 011750F Adapter Gaskets and Heat Shield 011751F 011751F 011751F 011751F 011751F 011751F 011751F Flame Sensor Probe 011752F 011752F 011752F 011752F 011752F 011752F 011752F Igniter...
- Page 56 CALL DESCRIPTION 503A 753A 1003A 1253A 1503A 1753A 2003A HEAT EXCHANGER Heat Transfer Cupro-Nickel Bronze (Includes 16-S) 014559F 014560F 014561F 014562F 014563F 014564F 014565F Heat Transfer Cupro-Nickel Cast Iron (Includes 16-S) 014566F 014567F 014568F 014569F 014570F 014571F 014572F Heat Transfer Copper Bronze (Includes 16-S) 014573F 014574F 014575F...
- Page 57 CALL DESCRIPTION 503A 753A 1003A 1253A 1503A 1753A 2003A SHEETMETAL Jacket Top 014589F 014589F 014589F 014589F 014589F 014589F 014589F Flue Collector Front (No Opening) (Includes 5-M) 011787F 011788F 011789F 011790F 011791F 011792F 011793F Flue Collector Rear (Opening) (Includes 5-M, 8-M, and 18-S) 011794F 011795F 011796F...
- Page 58 Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with (b) EXEMPTIONS: The following equipment is exempt from 248 regulation 248 CMR 4.00 and 5.00 for installation of through – CMR 5.08(2)(a)1 through 4: the – wall vented gas appliances as follows: The equipment listed in Chapter 10 entitled “Equipment (a) For all side wall horizontally vented gas fueled equipment Not Required To Be Vented”...
- Page 59 LIMITED PARTS WARRANTY MVB – TYPES H AND WH MODELS 503A-2003A 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 60 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This start-up checklist is to be completely filled out by the service technician starting up the Raypak boilers or heaters for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. Additionally this form will be used to record all equipment operation functions and required settings.
- Page 61 NOTES...
- Page 62 NOTES...
- Page 63 NOTES...
- Page 64 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
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