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INSTALLATION & OPERATING
Models
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. 3400.53G
INSTRUCTIONS
503–2003
Effective: 04-16-10
L
W
Replaces: 09-12-08
P/N 241288 Rev. 8
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Summary of Contents for Rheem Raypak MVB 503
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 503–2003 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. 8 reflects the following: Changes to: Table D on page 9, Figs 11-12 on page 15, Table I and text changers on page 20, Fig. 18 on page 21, Fig. 21 on page 22, Figs. 22-28 on pages 25-30, Table 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 diagrams on pages 39 and 40, UDB Fault History section on page 48.
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Page 3: Table Of Contents
CONTENTS Outdoor Installation WARNINGS Controls BEFORE INSTALLATION Product Receipt Heater Sequence of Operation 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 UDB Fault History... -
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 H7-2003 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
Component Locations HIGH VOLTAGE ELECTRICAL CONNECTIONS Fig. 3: Component Locations – Rear Panels omitted for clarity Fig. 1: Component Locations – Side Top panel, blower and gas train omitted for clarity Fig. 4: Component Locations – Top General Information MBTUH Vent Size Water Conn. -
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
Equipment Base The temperature of the water in the heater can be reg- ulated by using the Raypak Modulating Temperature Control. To comply with safety regulations, the control The heater should be mounted on a level, structurally is set at 120°F when shipped from the factory (Mode 3 sound surface. -
Page 9: Combustion And Ventilation Air
lation 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 outdoor installations. - Page 10 Fig. 7: 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
Air Filter or sealed single-wall galvanized ducting. The duct will attach directly to the air collar located on the rear of the heater, using three or four sheet metal screws (not An air filter is supplied standard with the heater. This supplied) equally positioned around the circumference filter is shipped loose for field installation. -
Page 12: Water Piping
shall communicate directly, or by ducts, with the (65 cm outdoors or spaces (crawl or attic) that freely com- municate with the outdoors. 2. For heaters using a barometric damper in the vent system there shall be a permanent air supply a. - Page 13 feed valve. Test at standard operating pressure for CAUTION: This heater requires forced water at least 24 hours. circulation when the burner is operating. See Table F and Table G for minimum and maximum flow rates 2. Make sure constant gauge pressure has been and water pump selection.
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Page 14: Hydronic Heating
longer than 7 minutes or where cold water operation is water is kept in a narrow temperature range of no continuous, provisions must be made to mix higher more than 10°F (5°C), a permanent manual bypass temperature outlet water with the colder inlet water can be employed and manually adjusted to achieve an and thereby raise the inlet temperature to at least inlet temperature of 120°F (49°C) or higher as adjust-... - Page 15 Min. Flow Max. Flow 20°F T 30°F T 40°F T Model P (ft) P (ft) P (ft) P (ft) P (ft) 11.3 13.8 1003 12.0 18.6 1253 20.9 10.2 22.2 1503 16.0 25.5 1753 22.5 13.4 13.4 27.2 2003 32.0 18.9 18.9 32.0...
- Page 16 Three-Way Valves NOTE: If local codes require a vacuum relief valve, acquire locally install valve Three-way valves intended to regulate system water manufacturer’s instructions. temperatures by reducing flow in the boiler should not be used. Raypak heaters are high-recovery, low-mass Potable Water and Space Heating heaters which are not subject to thermal shock.
- Page 17 1. Turn on pump. The MVB must be equipped with a field-supplied ex- ternal pump bypass arrangement. This 2. Turn on heater and wait until heater goes to full arrangement blends outlet water with the inlet water to fire. increase the inlet water temperature to a minimum of 120°F (49°C), thereby reducing the likelihood of con- 3.
- Page 18 Pool/Spa Water Chemistry NOTE: For automatic temperature adjustment, a Cold Water Run (CWR) system can be used instead of a manual bypass. See Fig. 10. CAUTION: Corrosive water voids all warranties. Combustion must CAUTION: NOTE: Chemical imbalance can cause severe contaminated by corrosive chemical fumes which damage to your heater and associated equipment.
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Page 19: Gas Supply
Further advice should be obtained from your pool or The heater must be isolated from the gas supply pip- spa builder, accredited pool shop, or chemical suppli- ing system by closing the upstream manual shut-off er for the correct levels for your water. valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa). -
Page 20: Electrical Power Connections
1 in. NPT 1-1/4 in. NPT 1-1/2 in. NPT 2 in. NPT 2-1/2 in. NPT Model 1103 1253 1503 1753 2003 Natural Gas – 1,000 BTU/ft , 0.60 specific gravity at 0.5 in. WC pressure drop Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. - Page 21 WARNING: Using a multi-meter, check the following voltages at the circuit breaker panel prior to connecting any equipment. Make sure proper polarity is followed and house ground is proven. (See Fig. 19.) Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum FRONT WIRING PANEL LOW VOLTAGE ELECTRICAL CONNECTIONS...
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Page 22: Field Wiring Connection
Venting NOTE: A grounding electrode conductor shall be used connect equipment grounding CAUTION: Proper installation of flue venting is conductors, the equipment enclosures, and the critical for the safe and efficient operation of the grounded service conductor to the grounding heater. - Page 23 Combustion Exhaust Heater Venting Certified Combustion Air Air Supply Configuration Category Materials Inlet Material Vertical Venting From Inside Building (Non-Direct Venting) Horizontal Through- Stainless Steel the-Wall Venting AL29-4C Vertical Galvanized Steel Venting From Outside Building (Direct Venting) Horizontal Through- CPVC the-Wall Venting Table K: Venting Category Requirements Use only the special gas vent pipes listed for use with...
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Page 24: Venting Installation Tips
1. Vent must terminate at least 4 ft below, 4 ft hori- 5. Within 6 ft (1.8 m) of any gas service regulator zontally from or 1 ft above any door, window or vent outlet. gravity air inlet to the building. 6. - Page 25 Vertical Vent Air Inlet Certified Combustion Air Vent Size Height (Ft) Max. Length** (Ft) Model Vent Intake Pipe (in.) Material Material Min. Max. 6” Ø 8” Ø 10” Ø Galvanized Steel, 1003 Category IV PVC, 1253 ABS, (AL29-4C) 1503 CPVC 1753 2003 * Vent length may be extended up to 40 ft.
- Page 26 Common Venting NOTE: For extractor sizing, typical CO levels are 8.5% for natural gas and 9.5% for propane gas and The NFGC does not address sizing guidelines for the flue temperature of 300° F. common venting of multiple Category IV heaters. This is covered in the NFGC under “Engineered Vent Sys- tems”.
- Page 27 Horizontal Through-the-Wall Direct Venting (Category IV) Fig. 25: Horizontal Through-the-Wall Venting Fig. 27: 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 28 Air Inlet Maximum Certified Vent Combustion Air Max. Length** (ft) Model Horizontal Vent Size Intake Pipe Vent Length Material (in.) Material 6” Ø 8” Ø 10” Ø (ft) Galvanized Steel, 1003 Category IV PVC, 1253 (AL29-4C) ABS, CPVC 1503 1753 2003 ** Subtract 10 ft per elbow.
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Page 29: 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 N. 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 30: Controls
NOTE: Condensate can freeze on the vent cap. CAUTION: Risk of electric shock: More than one Frozen condensate on the vent cap can result in a disconnect switch may be required to de-energize blocked flue condition. the equipment before servicing. The Raypak modulating temperature control is pro- vided to maintain the desired system water temperature. - Page 31 Mode 5 – Outdoor reset using primary/secondary pip- ing. The heater is operated as in Mode 2. However, the target temperature is based on outdoor reset. See Fig. MODULATING MODULATING *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig.
- Page 32 RAYPAK MODULATING TEMP CONTROL MODULATING OUTDOOR AIR SENSOR *Maximum 4 times the pipe diameter or 12”, whichever is less. *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig. 34: Mode 7 Primary/Secondary Piping with Fig. 35: Mode 8 Primary/Secondary Piping with External Target Temp External Direct Drive Mode 8 –...
- Page 33 0-10 VDC 0-20 mA* Boiler Target 2-10 VDC 4-20 mA* Boiler Target --- (OFF) --- (OFF) 50°F --- (OFF) 68.9°F 50°F 87.8°F 71.3°F 106.7°F 92.5°F 125.6°F 113.8°F 144.1°F 135°F 163.3°F 156.3°F 182.2°F 177.5°F 201.1°F 198.8°F 220°F 220°F *Requires a 500Ω resistor. *Requires a 500Ω...
- Page 34 Definitions 0-10VDC or 0-20 mA external input signal – When the 0-10VDC signal is selected, an input voltage of 1 VDC corresponds to a boiler target temperature of NOTE: The defined terms are not active in all 50°F (10°C). An input voltage of 10 VDC corresponds modes of control operation.
- Page 35 Rank Item Field Number Field Type Fault Description Error EEPROM error Warning Flame proof warning BOIL OUT Error Boiler outlet sensor short BOIL OUT Error Boiler outlet sensor open BOIL IN Error Boiler inlet sensor short BOIL IN Error Boiler inlet sensor open Error System sensor short Error...
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Page 36: Heater Sequence Of Operation
Heater Sequence of Operation If all limits are satisfied and there is a call for heat: 1. The heater pump is powered and begins circulat- ing water through the heat exchanger. 2. The blower is powered and goes through a 15 sec- ond prepurge beginning when air flow is proven by closure of the blower suction air pressure switch. - Page 37 Modulating Temperature Control This heater is equipped with a Raypak modulating temperature control. Refer to information starting on page 30 for information on the setting and use of this control. Fig. 38: High Limit (Manual Reset) High Limit—Auto Reset (Optional) This heater may be equipped with an optional adjust- able auto reset high limit temperature device.
- Page 38 Blocked Vent 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 This heater is equipped with a blocked vent pressure accessible from the front of the heater (to reset the gas switch to prevent the operation of the heater when too pressure switch) or through the removable access much of the vent is blocked.
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Page 39: Wiring Diagrams
WIRING DIAGRAMS - Models 503–1503... - Page 40 Models 1753–2003...
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Page 41: Start-Up
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. NOTE: The following steps must be performed by a factory-trained technician. -
Page 42: Start-Up
Preparation mum supply pressure for propane gas is 4.0 in. WC, recommended supply is 11.0 in. WC (dynam- ic readings, full fire input). WARNING: Do not turn on gas at this time. 3. If the gas pressure is greater than 14.0 in. WC, Check Power Supply turn off the main gas shut-off valve, upstream of the heater. - Page 43 2. FOR REFERENCE ONLY: Measure the blower Manifold Gas Pressure Setting amp draw with the heater firing at 100% input and High Fire Values (in. WC) Model compare the measured value to the values in Natural Gas Propane Gas Table U. The amp draw is measured with a clamp- on type amp probe clamped to the 14 AWG black -0.1 -0.1...
- Page 44 gas pressure switch (if provided) must be set at 4. Next, close the upstream manual gas valve (field 3.0 in. WC for natural gas and propane gas. supplied) and remove the manometers from the bleedle valves in test point A and test point B. 8.
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Page 45: Operation
Post Start-Up Check 11. Check to see that the high limit control is set above the design temperature requirements of the system. For multiple zones: Check to make sure Check off steps as completed: the flow is adjusted as required in each zone. 1. -
Page 46: To Turn Off Gas To Appliance
To Turn Off Gas To Appliance times (one time on optional single-try ignition mod- ule). If flame is not sensed, lockout will commence. 1. Shut off manual gas valve field installed near gas inlet connection on back of heater. 10. If the appliance will not operate, follow the instruc- tions “To Turn Off Gas To Appliance,”... -
Page 47: Troubleshooting
TROUBLESHOOTING Does the power switch provide Check the switch and/or power to the control panel? line voltage Step 1 Is there a Call For Unit is in standby mode. Heat? Reattach. Step 2 Is Disable connection intact? Check and correct power Is there 120VAC at the blower or connections at main terminal Does the combustion air... -
Page 48: Udb Fault History
MAINTENANCE UDB Fault History To view the fault codes in the UDB history file: Suggested Minimum Maintenance Schedule 1. Press the UP or DOWN buttons on the membrane switch for 2 seconds to access the fault history. Regular service by a qualified service agency and 2. -
Page 49: Preventative Maintenance Schedule
Weekly densate management system or drain, as required by local codes. For low-pressure heaters, test low-water cut-off 3. Check that area is free from combustible materi- device. (With heater in pre-purge, depress the low als, gasoline, and other flammable vapors and water cut-off test button. -
Page 50: Filter Maintenance
Filter Replacement 6. Perform leakage test on gas valves. (See Fig. 48.) 7. Test air switch in accordance with manufacturer’s 1. Remove the filter box cover by loosening and instructions. (Turn panel switch to the “On” posi- removing the two wing nuts holding it in place. tion until blower is proven, then turn the switch to “Off.”... -
Page 51: 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 52: 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 53 LIMITED PARTS WARRANTY MVB – TYPES H AND WH MODELS 503-2003 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 54 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 Boiler or Heater 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 56 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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