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INSTALLATION & OPERATING
Models 2503–4003
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.
CATALOG NO. 3400.56A
INSTRUCTIONS
Effective: 10-08-13
Replaces: 03-28-13
P/N 241510 Rev. 2
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Related Manuals for Raypak 2503
Summary of Contents for Raypak 2503
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 2503–4003 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 Rev. 2 reflects the following: Changes to: “Outdoor Installation” on page 9, Table G on page 18, “Gas Supply Pressure” on page 19, Table J on page 26, Table K on page 29, Warning on page 30, Note on page 30, Table M on page 32, “High Limits” on pages 34-35, Wiring Diagram on page 43, “Blower Check”...
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Page 3: Table Of Contents
CONTENTS Outdoor Installation WARNINGS Controls BEFORE INSTALLATION Product Receipt User Interface Model Identification WIRING DIAGRAMS Ratings and Certifications START-UP Installations at Elevation Pre Start-up Component Locations Start-Up General Information OPERATION Lighting Instructions GENERAL SAFETY Time/Temperature Relationships in To Turn Off Gas To Appliance Scalds TROUBLESHOOTING INSTALLATION... -
Page 4: Warnings
WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. -
Page 5: Before Installation
BEFORE INSTALLATION the upper rear jacket panel of the heater. The model number will have the form H7-2503 or similar depend- ing on the heater size and configuration. The letter(s) Raypak strongly recommends that this manual be re- in the first group of characters identifies the application viewed thoroughly before installing your MVB heater. -
Page 6: Component Locations
Top panel, blower and gas train omitted for clarity VOLTAGE SWITCH Fig. 4: Component Locations – Top General Information Gas Conn. Water MBTUH Input (NPT) Vent Size (in.) Model Conn. Flue Intake (Groove) 2503 2501 4" 2-1/2 2-1/2 3003 3000 4" 2-1/2 2-1/2 3503 3500 4" 2-1/2... -
Page 7: General Safety
GENERAL SAFETY To 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 temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the rec- ommended initial setting for the temperature control is 125°F. -
Page 8: Installation
INSTALLATION Equipment Base The heater should be mounted on a level, structurally Installation Codes sound surface. The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed Installations must follow these codes: in enclosed parking garages must be located at least 18 in. -
Page 9: Combustion And Ventilation Air
loose for field installation. Heaters must not be installed under an overhang unless clearances are in accordance with local instal- lation codes and the requirements of the gas supplier. Three sides must be open in the area under the over- hang. - Page 10 Fig. 8: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening;...
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Page 11: Conventional Combustion Air Supply
NFGC (U.S.) and B149 (Canada), and all local codes. 3. In cold climates, and to mitigate potential freeze- up, Raypak highly recommends the installation of Combustion must a motorized sealed damper to prevent the circula-... - Page 12 gas utilization equipment installed in the combined the enclosure, and space shall be considered in making this determina- b. Not less than the sum of the areas of all vent tion. Each opening shall have a minimum free area of WARNING: Do not use the “one permanent 1 in.
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Page 13: Water Piping
3 in. Verify proper flow rates and ∆T as instructed in non-warrantable failure. When required, Raypak rec- this manual. ommends the boiler be isolated ferom the system piping prior to flushing or cleaning using any cleaning Relief Valve Piping agent. -
Page 14: Hydronic Heating
service life of the appliance and the vent system. A bypass allows part of the heater discharge water to be Cold Water Run mixed with the cooler water returning to the heater inlet to increase the heater inlet temperature above Cold water run differs from cold water start in that the 120°F (49°C). -
Page 15: Applications & Modes
Table F: Heater Rates of Flow and Pressure Drops Feedwater Regulator Air-Separation/Expansion Tank Raypak recommends that a feedwater regulator be in- All heaters should be equipped with a properly sized stalled and set at 12 psi minimum pressure at the expansion tank and air separator fitting as shown in highest point of the system. - Page 16 NOTE: MODE 1 can also be used for process heat- ing applications in conjunction with a buffer/storage tank when operating temperatures above 160°F are required. Care must be given to ensure water hard- ness is no more than 15 grains per gallon for scale free operation.
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Page 17: Domestic Hot Water
Domestic Hot Water When designing the water piping system for domestic hot water applications, water hardness should be con- sidered. Table G indicates the suggested flow rates for soft, medium and hard water. Water hardness is ex- pressed in grains per gallon. Fig. - Page 18 16-25** Grains Per Gallon Model (ºF) (ft wc) (in) (ft wc) (ºF) (ft wc) (in) (ft wc) (ºF) (ft wc) (in) (ft wc) 11.7 15.7 2503 14.4 20.0 11.0 21.7 23.1 3003 12.8 25.6 27.3 16.3 26.8 26.8 3503 18.8 31.0 31.0...
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Page 19: Gas Supply
Gas Supply CAUTION: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with natural DANGER: Make sure the gas on which the heater and propane gases is recommended. Apply will operate is the same type as specified on the sparingly only on male pipe ends, leaving the two heater’s rating plate. -
Page 20: Electrical Power Connections
Model Pumps must use a separate power supply and run the power through a field-supplied contactor. Use appro- priately-sized wire as defined by NEC, CSA and/or 2503 local codes. All primary wiring should be 125% of min- imum rating. 3003... -
Page 21: Field Wiring Connection
Check the Power Source 3. Turn off all power to the heater. Verify that power has been turned off by testing with a multi-meter prior to working with any electrical connections or components. 4. Observe proper wire colors while making electri- cal connections. - Page 22 Fig. 22: Wiring Location Fig. 23: Locator Dimples for Optional Components Wiring the Outdoor Sensor Wiring the Enable/Disable Connect the Enable/Disable wiring to the field wiring 1. There is no connection required if an outdoor sen- terminals (shown in Fig. 24). Alternately, any dry con- sor is not used in this installation.
- Page 23 Caution should be used to ensure nei- than 4 connected boilers, an external sequencer ther of these terminals becomes connected to such as the Raypak Temp Tracker Mod+ Hybrid ground. can be used. NOTE: Alternately, a thermostat contact closure can 2.
- Page 24 MASTER FOLLOWERS VERSA MASTER Fig. 26: MVB Cascade System Wiring Cascade System Pump and Sensor Wiring 1. On the boiler designated as the Master, connect the system pump enable wiring to the terminal block at the rear of the unit. The connections are dry contacts rated for pilot duty only (5A maxi- mum).
- Page 25 5. Connect the Enable/Disable wiring to terminals 11 Modbus BMS Communication and 12 on the field wiring strip located on the Master boiler (See Fig. 24). This connection must The VERSA IC control is equipped as standard with a be provided through dry contacts closure. communications port for connectivity to building automation via Modbus protocol.
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Page 26: Venting
CAUTION: Vent piping is hot. Raypak recom- production in the vent. mends the use of double wall or insulated wall pipe to prevent personal injury. - Page 27 Use only the special gas vent pipes listed for use with 5. The bottom of the vent terminal and the air intake Category IV gas burning heaters, such as the AL29-4C shall be located at least 12 in. above grade, includ- stainless steel vents offered by Heat Fab Inc.
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Page 28: Venting Installation Tips
(Canada). The minimum flue pipe diameter for con- vent outlet. ventional venting using Category IV, stainless steel UL listed vent is: 10 in. (254mm) for Models 2503-3003; 6. Less than 1 ft (305 mm) above grade level. and 12 in. (305mm) for Models 3503-4003. - Page 29 The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the highest point of the roof that is within 8 ft for models 2503 and 3003 and 10ft for models 3503 and 4003. The vent...
- Page 30 FLUE GASES MOVING TOWARD EACH OTHER Volume of Model Vent Size Vent Pressure Flue Products (in.) (in. WC) (CFM) 2” MINIMUM (TYP) 2503 3003 DISCHARGE 1” MINIMUM (TYP) 4’-0” MIN. (TYP) 3503 1120 VENT CAPS AT STAGGERED ELEVATIONS FLUE GASES MOVING TOWARD EACH OTHER...
- Page 31 Horizontal Through-the-Wall Direct Venting (Category IV) Fig. 32: Horizontal Through-the-Wall Venting Fig. 34: Horizontal Through-the-Wall Direct Venting CAUTION: This venting system requires the installation 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 32 1 ft above ground level and installation of a condensate drain in the vent piping above normal snow levels. The Raypak-approved per the vent manufacturer’s instructions. Failure to stainless steel flue direct vent cap must be used (sales install a condensate drain in the venting system will order option D-15).
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Page 33: Outdoor Installation
The total length of air supply pipe cannot exceed the The stainless steel flue direct vent cap must be fur- distances listed in Tables L and M. Each elbow used is nished by the heater manufacturer in accordance with equal to 10 ft of straight pipe. This will allow installation its listing (sales order option D-15). -
Page 34: Controls
NOTE: Condensate can freeze on the vent cap. WARNING: Turn off the power to the heater before Frozen condensate on the vent cap can result in a installation, adjustment or service of any heater blocked flue condition. controls. Failure to do so may result in board damage, heater malfunction, property damage, personal injury, or death. - Page 35 Fig. 39: Flow Switch Low Water Cut-Off (Optional) Fig. 37: High Limit (Manual Reset) The optional low water cut-off automatically shuts down the burner whenever water level drops below the Standard level of the sensing probe. A 5-second time delay pre- vents premature lockout due to temporary conditions The fixed setting manual reset high limit is built into the such as power fluctuations or air pockets.
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Page 36: User Interface
User Interface The user interface consists of several Menu options. Press the MENU button to scroll through the different menus in the interface. Press the ITEM button to scroll through available items within a selected menu. And, the UP and DOWN buttons allow for setting changes to items in the ADJUST menu. - Page 37 Item Application Description OUTDOOR Outdoor air temperature H MODE 1,2,3 Boil Target Current target temperature H MODE 1,2,3 SUPPLY Current system supply temperature H MODE 1,2,3 Boil OUTLET Current boiler outlet temperature Boil INLET Current boiler inlet temperature Boil ∆T Current temperature difference between boiler outlet and boiler inlet DHW SUPPLY Current indirect DHW supply temperature...
- Page 38 Item Application Range Description Default Enable or Disable the operation of boilers. 4 boiler range, 1 is BOILER 1 ON <> OFF enabled by default H MODE 1,2,3 TARGET RSET <> SETP SETP RSET = Outdoor Reset, SETP =Setpoint TANK SETP OFF, 50°F to 150°F 125°F Tank set point temperature...
- Page 39 Boiler Menu The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information Item Application Description IGNITION Current State of Ignition LIMIT TEMP Current Limit Temperature AUX TEMP H MODE 3 Current Auxiliary Temperature EMS Vdc Current EMS signal in Volts DC...
- Page 40 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. 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 41 MAX HEAT be set to OFF again by the user. (See VERSA IC Manual for details.) P/N 104901 Software number of the Raypak VERSA Resets to factory settings. Press UP and DOWN for 1 second to show CLR and load DEFAULTS factory defaults to all settings.
- Page 42 RESET RATIO The control uses the four following settings to determine the reset ratio: Boiler Start (Boil START) The Boil START temperature is the theoretical boiler supply water temperature that the heating system requires when the outdoor air temperature equals the OUT START temperature setting. The Boil START is typically set to the desired building temperature. Outdoor Start (OUT START) The OUT START temperature is the outdoor air temperature at which the control provides the Boil START water temperature to the system.
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Page 43: Wiring Diagrams
WIRING DIAGRAM - Models 2503–4003... -
Page 44: Start-Up
The MVB 2503-4003 models have two air vent valves • Check around unit for debris and remove com- located on top of the upper headers as standard. -
Page 45: Start-Up
Preparation 3. If the gas pressure is greater than 14.0 in. WC, turn off the main gas shut-off valve, upstream of the heater. WARNING: Do not turn on gas at this time. Start-Up Check Power Supply NOTE: The values in Tables T and V represent the With multi-meter at incoming power, check voltage conditions when the heater is at full firing rate at sea between:... - Page 46 1. Check blower suction using the manometer Natural Gas Propane Gas attached to the air pressure tee as shown in Fig. 46, with the heater firing at 100% input. The 2503 -4.8 -6.4 reading should be as noted in Table S for both nat- 3003 -6.7...
- Page 47 Leak Test Procedure: Dual-Seat Gas Safety Inspection Valve 1. Check all thermostats and high limit settings. Proper leak testing requires three pressure test points 2. During the following safety checks leave manome- in the gas train. Remove the upper front panel and ters hooked up, check and record.
- Page 48 8. 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™. The fixed high limit setting is temporarily overridden to match the setpoint potentiometer position on the PIM™.
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Page 49: Operation
OPERATION d. Gas is on at the meter and the heater. e. Incoming dynamic gas pressure to the gas valve is NOT less than 4.0 in. WC for natural Lighting Instructions gas or propane gas. 1. Before operation, make sure you have read all of To Turn Off Gas To Appliance the safety information in this manual. - Page 50 2. Note the error code, either through the flash code WARNING: When servicing or replacing any on the PIM™ and/or from the Toolbox menu on the components of this unit be certain that: user interface, and reference the explanation of •...
- Page 51 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 ON, Check that the proper ID card is securely connected. Perform a ID Card Fault Green Power power and system restart.
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Page 52: Maintenance
MAINTENANCE Sensor Resistance Values Suggested Minimum Water Sensor / Outdoor Sensor Maintenance Schedule Water Temperature (°F) Resistance (ohms) 32550 Regular service by a qualified service agency and 25340 maintenance must be performed to ensure maximum operating efficiency. 19870 15700 Daily and monthly maintenance as outlined below may be performed by onsite maintenance staff. -
Page 53: Preventative Maintenance Schedule
Weekly 3. Check that area is free from combustible materi- als, gasoline, and other flammable vapors and liquids. For low-pressure heaters, test low-water cut-off device. (With heater in pre-purge, depress the low 4. Check air filter and replace as necessary. water cut-off test button. -
Page 54: Filter Maintenance
7. Test safety/safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV. Filter Maintenance • Inspect quarterly NOTE: Use Raypak replacement filters, kit number 014492F. • Replace as needed. The recommended interval is once per year. -
Page 55: Appendix
APPENDIX Areas where contaminated combustion air commonly exists: Inside Air Contamination • dry cleaning/laundry areas • metal fabrication plants All heaters experience some condensation during • beauty shops start-up. The condensate from flue gas is acidic. • refrigeration repair shops Combustion air can be contaminated by certain vapors •... -
Page 56: Important Instructions For The Commonwealth Of
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance (b) EXEMPTIONS: The following equipment is exempt from with regulation 248 CMR 4.00 and 5.00 for installation of 248 CMR 5.08(2)(a)1 through 4: through – the – wall vented gas appliances as follows: 1. - Page 57 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 Wa rranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but a re the owner’s responsibility.
- Page 58 RAYPAK PRODUCTS This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct.
- Page 60 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.