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INSTALLATION & OPERATING
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.
CATALOG NO. 3400.531A
INSTRUCTIONS
Effective: 10-03-13
Replaces: 04-09-13
P/N 241511 Rev. 2
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Summary of Contents for Raypak 503A
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS 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 Rev. 2 reflects the following: Changes to: Table A on page 8, Table I on page 20, “Electrical Power Connections” on page 20, Table J on page 27, Table K on page 29, Table M on page 32, Wiring Diagram on page 43, “Blower Check” on page 46, Table T on page 46, “Manifold 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
If, after reviewing this manual, you still have questions Ratings and Certifications which this manual does not answer, please contact your local Raypak representative or visit our website at www.raypak.com. Standards: Thank you for purchasing a Raypak product. We hope •... -
Page 6: Component Locations
Fig. 4: Component Locations – Top General Information MBTUH Vent Size Water Conn. Model Input (in.) Conn. (NPT) (NPT) Max. Min. Flue Intake 503A 753A 1003A 2-1/2 1-1/4 1 1253A 1250 2-1/2 1-1/4 1 1503A 1500 2-1/2 1-1/4 1 1753A 1750 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
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 elbow 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
3. In cold climates, and to mitigate potential freeze- top, and one opening shall commence within 12 in. up, Raypak highly recommends the installation of (305 mm) of the bottom of the enclosure. The mini- a motorized sealed damper to prevent the circula-... - Page 12 Canadian Installations All Air from Outdoors The confined space shall communicate with the out- CAUTION: All combustion air must be drawn from doors in accordance with one of the methods below. the air outside of the building; the mechanical equip- The minimum dimension of air openings shall not be ment room must communicate directly with the less than 3 in.
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Page 13: Water Piping
NOTE: Minimum pipe size for in/out connections is not exceed 120°F (49°C) within 7 minutes of start- 2 in. NPT for 503A and 753A models and 2- ⁄ in NPT for 1003A–2003A models. Verify proper flow rates and ∆T as instructed in this manual. -
Page 14: 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 *Maximum 4 times the pipe diameter or 12”, whichever is less. -
Page 15: Applications & Modes
Raypak heaters are high-recovery, low-mass ter cut-off device (sales order option F-10). This heaters which are not subject to thermal shock. - 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 T (ºF) T (ºF) GPM Model (ºF) (ft wc) (in) (ft wc) (ft wc) (in) (ft wc) (ft wc) (in) (ft wc) 503A 10.4 25.7 753A 17.3 11.4 25.3 1003A 11.5 2 1/2 16.2 11.5 2 1/2 16.2 19.6...
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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
Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. WC pressure drop Table H: Maximum Equivalent Pipe Length The MVB 503A-1503A heaters are wired for 120 VAC, Manifold Gas Pressure 12 amps while the MVB 1753A & 2003A heaters are... -
Page 21: Field Wiring Connection
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 Fig. - Page 22 Fig. 21: Wiring Location Fig. 22: Locator Dimples for Optional Components NOTE: A grounding electrode conductor shall be contact closure (including a remote thermostat) across used connect equipment grounding these terminals will enable the MVB unit to run. conductors, the equipment enclosures, and the Caution should be used to ensure neither of the termi- grounded service conductor to the grounding nals becomes connected to ground.
- Page 23 INDIRECT DHW SENSOR (see wiring than 4 connected boilers, an external sequencer diagram). Caution should be used to ensure nei- such as the Raypak Temp Tracker Mod+ Hybrid ther of these terminals becomes connected to can be used. ground.
- Page 24 MASTER FOLLOWERS VERSA MASTER Fig. 25: 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. 23). 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
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 29: Common Venting
Adapters supplied by others. Table K: Category IV Vertical Venting listed - SS vent is: 6 in. (254mm) for Models 503A - 1003A; and 8 in. (305mm) for Models 1253A - 2003A. The connection from the appliance vent to the stack 1”... - Page 30 12" above the flue collar. Vent Volume of Vent Model Pressure Flue Products Size (in.) (in. WC) (CFM) 503A 753A 1003A 1253A 1503A 1753A 2003A * NOTE: Data for 100% firing rate. Table L: Typical Vent Pressure and Volume Fig. 29: Vertical Venting of Flue Products Fig.
- Page 31 Horizontal Through-the-Wall Direct Venting (Category IV) Fig. 31: Horizontal Through-the-Wall Venting Fig. 33: 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: Flow Switch
Low Water Cut-Off (Optional) The optional low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay pre- vents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig. -
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.
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Page 42: Reset Ratio
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. -
Page 43: Wiring Diagram
WIRING DIAGRAM - Models 503A–2003A... -
Page 44: 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 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 S and T 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. 45, with the heater firing at 100% input. The 503A -4.7 -5.3 reading should be as noted in Table S for both nat- 753A -4.6...
- 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: Preventive 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 NOTE: Use Raypak replacement filters, kit number 012553F (12”X12”) for models 503A-1003A and kit number 012552F (16”X16”) for models 1253A- 2003A. • Inspect quarterly Fig. -
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.