INSTALLATION & OPERATING INSTRUCTIONS Models 503–2003 Types H & WH L W 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.
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. Additions: Fig. 2 on page 6, Low-lead requirement on page 5, Fig.
CONTENTS WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connection Venting Venting Installation Tips Venting Configurations Outdoor Ins
WARNINGS Pay Attention to These Terms DANGER: WARNING: CAUTION: NOTE: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
BEFORE INSTALLATION the upper rear jacket panel of the heater. The model number will have the form H7-2003 or similar depending on the heater size and configuration. The letter(s) in the first group of characters identifies the application (H = Hydronic Heating, WH = Domestic Hot Water (DHW)). The number which follows identifies the firing mode (7 = electronic modulation).
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 Model No. MBTUH Input Max. Min. Panels omitted for clarity Fig. 2: Component Locations – Front 6 503 500 125 Water Conn. (NPT) 2 Gas Conn. (NPT) Vent Size (in.
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 recommended initial setting for the temperature control is 125°F. This section applies to Hot Water Supply Boilers and Hot Water Heaters ONLY.
Equipment Base The temperature of the water in the heater can be regulated 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). The heater should be mounted on a level, structurally sound surface. The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting.
lation codes and the requirements of the gas supplier. Three sides must be open in the area under the overhang. Roof water drainage must be diverted away from heaters installed under overhangs. The combustion air intake terminal MUST be used for outdoor installations. The elbow is shipped loose to be installed on the rear of the heater at the job site. Heater Side Min.
Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 1 2 t TT * 2 U.S. Installations Canadian Installations A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 ft (1.
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 supplied) equally positioned around the circumference of the duct. The screen assembly should be removed before attaching any air duct to the heater. The screws and duct connection point must be sealed with RTV (not supplied). TruSeal is generally used when damaging contaminants are present in the mechanical room.
shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. (65 cm2). 2. For heaters using a barometric damper in the vent system there shall be a permanent air supply opening(s) having a cross section area of not less than 1 in.2 per 7,000 BTUH (320 mm2 per kW) up to and including 1 million BTUH, plus 1 in.2 per 14,000 BTUH (160 mm2 per kW) in excess of 1 million BTUH.
feed valve. Test at standard operating pressure for at least 24 hours. CAUTION: This heater requires forced water circulation when the burner is operating. See Table F and Table G for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the heater to prevent heater operation without water circulation. 2. Make sure constant gauge pressure has been maintained throughout test. 3. Check for leaks. Repair if found. NOTE: Minimum pipe size for in/out connections is 2 in.
longer than 7 minutes or where cold water operation is continuous, provisions must be made to mix higher temperature outlet water with the colder inlet water and thereby raise the inlet temperature to at least 120°F (49°C) within the 7-minute time limit.
20°F T Model No. gpm 503 44 2.8 753 65 1003 30°F T P (ft) gpm P (ft) 29 1.4 N/A N/A 25 6.4 44 3.1 33 1.9 87 12.0 58 6.0 43 1253 109 20.9 73 10.2 1503 N/A N/A 87 1753 N/A N/A 2003 N/A N/A P (ft) gpm Min. Flow 40°F T T gpm P (ft) 1.1 35 100 11.3 9 33 1.9 40 100 13.8 13 3.7 43 3.7 40 113 18.6 15 54 6.2 54 6.2 40 113 22.2 19 16.0 65 9.5 65 9.5 40 113 25.5 23 102 22.5 76 13.4 76 13.4 40 113 27.2 27 116 32.0 87 18.
Three-Way Valves NOTE: If local codes require a vacuum relief valve, acquire one locally and install per valve manufacturer’s instructions. Three-way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used. Raypak heaters are high-recovery, low-mass heaters which are not subject to thermal shock. See Fig. 16 and instructions on page 17 for adjusting the manual bypass.
1. Turn on pump. The MVB must be equipped with a field-supplied external pump and bypass arrangement. This arrangement blends outlet water with the inlet water to increase the inlet water temperature to a minimum of 120°F (49°C), thereby reducing the likelihood of condensation forming on the heat exchanger. The pump also serves to circulate water through the heater from the main system piping. 2. Turn on heater and wait until heater goes to full fire. 3.
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. CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty. NOTE: Chemical imbalance can cause severe damage to your heater and associated equipment. Chemical imbalance can cause severe damage to the pool heater and associated equipment.
Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier for the correct levels for your water. The heater must be isolated from the gas supply piping system by closing the upstream manual shut-off 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). Relieve test pressure in the gas supply line prior to re-connecting the heater and its manual shut-off valve to the gas supply line.
Model No. 503 753 1103 1 in. NPT N 15 5 P 35 15 1253 1-1/4 in. NPT 1-1/2 in. NPT 65 150 130 360 35 55 35 90 N P 65 100 15 1503 25 10 1753 15 N 75 25 15 P N 180 250 60 85 25 2003 Natural Gas – 1,000 BTU/ft3, 0.60 specific gravity at 0.5 in. WC pressure drop Propane Gas – 2,500 BTU/ft3, 1.53 specific gravity at 0.6 in. WC pressure drop 2 in. NPT P 2-1/2 in.
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 Fig. 18: Wiring Electrical Connections Field-Connected Controllers Fig.
Venting NOTE: A grounding electrode conductor shall be used to connect the equipment grounding conductors, the equipment enclosures, and the grounded service conductor to the grounding electrode. CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the heater. General Field Wiring Connection Appliance Categories CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
Combustion Air Supply Exhaust Configuration Heater Venting Category Certified Materials IV Stainless Steel AL29-4C Vertical Venting From Inside Building (Non-Direct Venting) Horizontal Throughthe-Wall Venting Vertical Venting From Outside Building (Direct Venting) Horizontal Throughthe-Wall Venting Combustion Air Inlet Material Galvanized Steel PVC ABS CPVC Table K: Venting Category Requirements Use only the special gas vent pipes listed for use with Category IV gas burning heaters, such as the AL
1. Vent must terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, window or gravity air inlet to the building. 5. Within 6 ft (1.8 m) of any gas service regulator vent outlet. 6. Less than 1 ft (305 mm) above grade level. 2. The vent must not be less than 7 ft above grade when located adjacent to public walkways. 7.
Model Certified Vent Material Vent Size (in.) Vertical Vent 1 Height (Ft) Min. Max. 503 1253 1503 1753 Air Inlet Max. Length** (Ft) 6” Ø 8” Ø 10” Ø 45 100 t N/A N/A 45 85 t * 6 753 1003 15* 15 Combustion Air Intake Pipe Material 75 75 Category IV (AL29-4C) 0 40 75 8 2003 Galvanized Steel, PVC, ABS, CPVC 75 75 * Vent length may be extended up to 40 ft.
Common Venting NOTE: For extractor sizing, typical CO2 levels are 8.5% for natural gas and 9.5% for propane gas and flue temperature of 300° F. The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters. This is covered in the NFGC under “Engineered Vent Systems”. Table M provides boiler discharge vent pressures at vent pressure switch and volumes of flue products at full fire for the calculation of appropriate vent and extractor sizing for common venting.
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.
Model No. 503 753 1003 1253 1503 Certified Vent Material Category IV (AL29-4C) Vent Size (in.) Maximum Horizontal Vent Length (ft) 6 75 Air Inlet Max. Length** (ft) 6” Ø 8” Ø 45 100t Galvanized Steel, PVC, ABS, CPVC 8 1753 Combustion Air Intake Pipe Material 45 10” Ø 85t 2003 ** Subtract 10 ft per elbow. Max. 4 elbows. t Adapters supplied by others.
The total length of air supply pipe cannot exceed the distances listed in Tables L and N. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in any arrangement that does not exceed the lengths shown in Tables L and N. The stainless steel flue direct vent cap must be furnished by the heater manufacturer in accordance with its listing (sales order option D-15). Outdoor Installation The vent cap is not considered in the overall length of the venting system.
NOTE: Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. CAUTION: Risk of electric shock: More than one disconnect switch may be required to de-energize the equipment before servicing. The Raypak modulating temperature control is provided to maintain the desired system water temperature. The control has various modes of operation which are listed on the following pages. Setpoint: The intended system supply temperature.
Mode 5 – Outdoor reset using primary/secondary piping. The heater is operated as in Mode 2. However, the target temperature is based on outdoor reset. See Fig. 33. MODULATING MODULATING * *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig. 31: Mode 2 Primary/Secondary Piping Mode 3 – Dedicated DHW operation using UniTemp 80 piping. A call for heat is determined by the DHW sensor and the DHW boiler target. The heater outlet water is also controlled to the boiler target temperature.
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 External Target Temp Fig. 35: Mode 8 Primary/Secondary Piping with External Direct Drive Mode 8 – This mode is for remote firing control of the heater via an external sequencer such as the Raypak TempTracker MOD+.
0-10 VDC 0-20 mA* Boiler Target 2-10 VDC 4-20 mA* Boiler Target 1 2 50°F 1 2 --- (OFF) 0 0 2 4 68.9°F 8 106.7°F 12 144.1°F 3 6 4 5 10 7 14 6 8 16 9 18 10 *Requires a 500Ω resistor. --- (OFF) 20 0 2 87.8°F 182.2°F 5 10 113.8°F 7 14 156.3°F 18 198.
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 50°F (10°C). An input voltage of 10 VDC corresponds to a boiler target temperature of 220°F (104°C). As the voltage varies between 1 VDC and 10 VDC, the boiler target temperature varies linearly between 50°F (10°C) and 220°F (104°C). If a voltage below 0.
Rank Item Field Number Field Type Fault Description 1 FP Err Warning Flame proof warning BOIL OUT OPn Error Boiler outlet sensor open BOIL IN OPn Error Boiler inlet sensor open SUP OPn Error System sensor open OUTDR OPn DHW OPn 0 E01 2 BOIL OUT 4 BOIL IN 3 5 6 7 SUP 8 OUTDR 10 DHW 9 11 Err Error SHr Error SHr Error SHr Error SHr Error SHr WWSD - Selects the outdoor temperature that shuts the heater off, no matter what the demand.
Heater Sequence of Operation If all limits are satisfied and there is a call for heat: 1. The heater pump is powered and begins circulating water through the heat exchanger. 2. The blower is powered and goes through a 15 second prepurge beginning when air flow is proven by closure of the blower suction air pressure switch. 3. The igniter is powered, and once proven, heats up for 20 seconds. Fig. 37: Ignition Module 4. The gas valve is then energized for a 4 second trial for ignition period.
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 adjustable auto reset high limit temperature device. Fig.
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 accessible from the front of the heater (to reset the gas pressure switch) or through the removable access panels on the rear of the heater (to reset the gas pressure switch), as necessary. If the gas pressure regulator in the valve fails, the high gas pressure switch automatically shuts down the burner.
WIRING DIAGRAMS - Models 503–1503 39
Models 1753–2003 40
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. WHAT TO DO IF YOU SMELL GAS: Pre Start-up • • Filling System (Heating Boilers) • Fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal system operation, and fill system through feed pressure.
Preparation mum supply pressure for propane gas is 4.0 in. WC, recommended supply is 11.0 in. WC (dynamic 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, turn off the main gas shut-off valve, upstream of the heater.
2. FOR REFERENCE ONLY: Measure the blower amp draw with the heater firing at 100% input and compare the measured value to the values in Table U. The amp draw is measured with a clampon type amp probe clamped to the 14 AWG black power wire going into the blower. Model 503 753 3. When firing at 100%, the desired heater combustion CO2 is between 8.5 and 9.0% for natural gas and 9.5 and 10.0% for propane with CO less than 100 ppm.
gas pressure switch (if provided) must be set at 3.0 in. WC for natural gas and propane gas. 4. Next, close the upstream manual gas valve (field supplied) and remove the manometers from the bleedle valves in test point A and test point B. Connect a rubber tube from the test point A bleedle valve to the test point B bleedle valve and open the upstream manual gas valve. Make sure that test point A & B bleedle valves have been opened so as to allow gas to flow.
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 the flow is adjusted as required in each zone. Check off steps as completed: 1. 2. 3. 4. 5. 6. 7. 8. 9. Verify that the heater and heat distribution units or storage tank are filled with water. 12. Check that the heater is cycled with the thermostat.
To Turn Off Gas To Appliance times (one time on optional single-try ignition module). 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 instructions “To Turn Off Gas To Appliance,” and call your service technician or gas supplier. 2. Remove upper front panel. 3. Set the thermostat to lowest setting. 11. Replace upper front panel. 4.
TROUBLESHOOTING Step 1 Does the power switch provide power to the control panel? Check the switch and/or line voltage NO Is there a Call For Heat? YES NO Unit is in standby mode. YES Step 2 NO Is Disable connection intact? Reattach. YES Step 3 Does the combustion air blower come on? Is there 120VAC at the blower or blower relay? NO Check and correct power connections at main terminal block, circuit breaker panel or blower relay.
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 maintenance must be performed to ensure maximum operating efficiency. 2. Press either button to scroll through the recorded faults in history. 3.
Weekly densate management system or drain, as required by local codes. For low-pressure heaters, test low-water cut-off device. (With heater in pre-purge, depress the low water cut-off test button. Appliance should shut-off and ignition fault light should come on. Depress reset button on front of heater control panel to reset). 3. Check that area is free from combustible materials, gasoline, and other flammable vapors and liquids. 4. Check air filter and replace as necessary. Monthly 5.
Filter Replacement 6. Perform leakage test on gas valves. (See Fig. 48.) 7. Test air switch in accordance with manufacturer’s instructions. (Turn panel switch to the “On” position until blower is proven, then turn the switch to “Off.” 1. Remove the filter box cover by loosening and removing the two wing nuts holding it in place. 8. Inspect and clean burner using shop air. As Required 1. Recondition or replace low water cut-off device (if equipped). 2. Check drip leg and gas strainers. 3.
APPENDIX Areas where contaminated combustion air commonly exists: 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 acidity levels attack many materials including stainless steel, which is commonly used in high efficiency systems. The heater can be supplied with corrosion-resistant, non-metallic intake air vent material.
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows: (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1.
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.
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.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.