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INSTALLATION & OPERATING
INSTRUCTIONS
Models 503–2003
L
Types H & WH
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.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other comb
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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. 8 on page 11, Caution on
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CONTENTS WARNINGS 4 Outdoor Installation 29 BEFORE INSTALLATION 5 Controls 30 Product Receipt 5 Heater Sequence of Operation 36 Model Identification 5 WIRING DIAGRAMS 39 Ratings and Certifications 5 START-UP 41 Installations at Elevation 5 Pre Start-up 41 Component Locations 6 Start-Up 42 General Information 6 OPERATION 45 GENERAL SAFETY 7 Lighting Instructions 45 Time/Temperature Relationships in To Turn Off Gas To Appliance 46 Scalds 7 TROUBLESHOOTING 47 INSTALLATION 8 UDB Fault History 48 Ins
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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. Indicates special ins
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the upper rear jacket panel of the heater. The model BEFORE INSTALLATION 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. (H = Hydronic Heating, WH = Domestic Hot Water Please review the General Safety information before (DHW)). The number which follows identifies the firing
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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 Gas MBTUH Vent Size Water Conn. Model Input (in.) Conn. (NPT) No. (NPT) Max. Min. N P Flue Intake 503 500 125 2 1 1 6 6 753 750 188 2 1 1 6 6 1003 999 250 2-1/2 1-1/4 1 6 6 1253 1250 312 2-1/2 1-1/4 1 8 8 1503 1500 375 2-1/2 1-1/4 1 8 8
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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. This section applies to Hot Water Supply Boilers and Hot Water Heaters ONLY. For sanitary rinse applica- tions
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The temperature of the water in the heater can be reg- Equipment Base 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. The heater is approved for installation default setting for Tank Target). on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed To adjust the water temperatu
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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. The elbow is shipped loose to be installed on the rear of the heater at the job site. Min. Clearance Minimum Heater from Combustible Service Side Surfaces Clearance Rear 12” 24” Front Open 24” Right Side 1” 1” Left Side 1” 1” Top
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Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 2 U.S. Installations Canadian Installations Clearance above grade, veranda, porch, A 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; 1 foot (30 cm) B 3 ft (91 cm) opened above opening C Clearance to permanently closed window ** Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- D 5
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or sealed single-wall galvanized ducting. The duct will Air Filter 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. Refer to the of the duct. The screen assembly should be removed Air Filter Kit Installation Instructions (Part No. 241338) before attaching any air duct to the h
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2 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. Where directly communicating with the out- opening(s) having a cross section area of not less 2 2 doors or where communicating to the than 1 in. per 7,000 BTUH (320 mm per kW) up 2 outdoors through vertical ducts, each open- to and including 1 million BTUH
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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. The pump must be maintained throughout test. interlocked with the heater to prevent heater operation without water circulation. 3. Check for leaks. Repair if found. NOTE: Minimum pipe size for in/out connections i
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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- 120°F (49°C) within the 7-minute time limit. ed at the minimum temperature in this na
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20°F T 30°F T 40°F T Min. Flow Max. Flow Model No. gpm P (ft) gpm P (ft) gpm P (ft) gpm P (ft) T gpm P (ft) T 503 44 2.8 29 1.4 N/A N/A 25 1.1 35 100 11.3 9 753 65 6.4 44 3.1 33 1.9 33 1.9 40 100 13.8 13 1003 87 12.0 58 6.0 43 3.7 43 3.7 40 113 18.6 15 1253 109 20.9 73 10.2 54 6.2 54 6.2 40 113 22.2 19 1503 N/A N/A 87 16.0 65 9.5 65 9.5 40 113 25.5 23 1753 N/A N/A 102 22.5 76 13.4 76 13.4 40 113 27.2 27 2003 N/A N/A 116 32.0 87 18.9 87 18.9 40 116 32.0 30 Notes: Basis for minimum flow is ∆T . B
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Three-Way Valves NOTE: If local codes require a vacuum relief valve, acquire one locally and install per 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. See Fig. 16 and instructions on page 17 for adjusting the CAUTION: When this heater is used for both manual bypass. potabl
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1. Turn on pump. The MVB must be equipped with a field-supplied ex- ternal pump and 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. With the heater operating at 100% firing rate, set 1 densation forming on the heat exchanger. The pump Valve A (the bypass) to ⁄2 open position, and Valve also serves
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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 NOTE: Chemical imbalance can cause severe contaminated by corrosive chemical fumes which damage to your heater and associated equipment. can damage the heater and void the warranty. Winterizing Your Heater Chemical imbalance can cause severe damage to the pool heat
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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 Automatic Chlorinators and 1/2 psi (3.45 kPa). Relieve test pressure in the gas Chemical Feeders supply line prior to re-connecting the heate
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1 in. NPT 1-1/4 in. NPT 1-1/2 in. NPT 2 in. NPT 2-1/2 in. NPT Model No. N P N P N P N P N P 503 15 35 65 150 130 360 753 5 15 65 100 75 180 250 1103 35 55 35 90 125 300 300 1253 15 25 25 60 85 225 200 300 1503 10 15 15 25 60 150 150 275 1753 45 110 115 230 2003 35 90 85 210 3 Natural Gas – 1,000 BTU/ft , 0.60 specific gravity at 0.5 in. WC pressure drop 3 Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. WC pressure drop Table I: Maximum Equivalent Pipe Length The gas valve pressure
