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LED Error Code Listing

Active errors detected are indicated by LED lights on the PIM™. 

Table W: PIM™ LED Error Codes

LED Code

Error Mode

Recommended Troubleshooting

Off

Normal Operation

Red LED

steady ON,

Green Power

LED OFF

ID Card Fault

Check that the proper ID card is securely connected.  Perform a

power and system restart.

Steady ON

Internal Control Failure Perform a power and system reset.  If fault remains, replace PIM™.

1 flash

N/A

N/A

2 flashes

False Flame Error

Check for proper gas valve closure.  Clean burner and electrodes.

3 flashes

Ignition Lockout Fault

Check the gas supply.  See table for more information.

4 flashes

N/A

N/A

5 flashes

Low Voltage Fault

Check the 24 VAC input voltage.  The voltage must be above 18.0

VAC.

6 flashes

N/A

N/A

7 flashes

Hi-Limit Fault

Check for proper water flow.  Check hi-limit and outlet sensor.

8 flashes

Sensor Fault

See VERSA for fault identification.  Check sensor wiring.

9 flashes

N/A

N/A

10 flashes

N/A

N/A

11 flashes

N/A

N/A

12 flashes

N/A

N/A

13 flashes

Hi-Temperature Delta

Fault

Check pump operation.  Confirm proper water flow across heat

exchanger.

14 flashes

Ft-Bus

Communications Fault

Verify VERSA is connected and operating.  Check the cable between

the VERSA and PIM™.

15 flashes

Safety circuit open

Confirm all safeties are functioning normally. Check continuity at J8,

pins 5 and 6 at the PIM™.

Summary of Contents for 2503

Page 1: ...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 applian...

Page 2: ...9 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 on page 46 Additions Motorized Combustion Air Dampers or Louvers on page 11 Fl...

Page 3: ...Hot Water 17 Gas Supply 19 Electrical Power Connections 20 Field Wiring Connection 21 Venting 26 Venting Installation Tips 28 Venting Configurations 28 Outdoor Installation 33 Controls 34 User Interfa...

Page 4: ...cause cancer birth defects or other reproductive harm WARNING Risk of electrical shock More than one disconnect switch may be required to de energize the equipment before servicing CAUTION This heater...

Page 5: ...in kind only per Raypak s standard war ranties Model Identification The model identification number and heater serial number are found on the heater rating plate located on the upper rear jacket pane...

Page 6: ...g 4 Component Locations Top Fig 3 Component Locations Rear HIGH VOLTAGE SWITCH LOW VOLTAGE SWITCH VERSA IC PIM Panels omitted for clarity Fig 2 Component Locations Front Max Min N P Flue Intake 2503 2...

Page 7: ...To determine the water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer NOTE When this water heater is supplying general...

Page 8: ...6 in on the rear and 10 in above the top of the heater is required This will allow 8 Heater Side Minimum Clearance from Combustible Surfaces Minimum Service Clearance Floor 0 0 Rear 12 36 One Side 1 1...

Page 9: ...ater to be serviced without removing any structure around the heater Outdoor Installation These units may be installed outdoors when used with the outdoor air intake hood The outdoor hood must be orde...

Page 10: ...t 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m...

Page 11: ...Motorized Combustion Air Dampers or Louvers When motorized dampers or louvers are communicat ing directly with outside combustion air they must be interlocked with each appliance in the equipment roo...

Page 12: ...UH 740 mm2 per kW of the total input rating of all equipment located in 12 the enclosure and b Not less than the sum of the areas of all vent connectors in the confined space Canadian Installations 1...

Page 13: ...ny that are found Flushing Cleaning of System Piping Many of the chemicals used to perform this function will harm the heat exhcanger as well as some ogas kets and seals within the unit casing a non w...

Page 14: ...d Water Run Cold water run differs from cold water start in that the system water entering the heater remains below 120 F 49 C continuously Typically this is the case in water source heat pump applica...

Page 15: ...g the cooling cycle It is highly recommend ed that the piping be insulated Air Separation Expansion Tank All heaters should be equipped with a properly sized expansion tank and air separator fitting a...

Page 16: ...lower than the WWSD temperature setting if utilized unless an indirect call for heat is present with priority Fig 13 MODE 1 Single Boiler with Primary Secondary Piping Fig 15 MODE 2 Single Boiler with...

Page 17: ...lieu of the Indirect DHW Sensor S5 See the Versa IC manu al for additional details Domestic Hot Water When designing the water piping system for domestic hot water applications water hardness should...

Page 18: ...264 15 7 4 20 0 3003 29 176 11 0 4 12 8 20 255 21 7 4 25 6 19 264 23 1 4 27 3 3503 29 205 16 3 4 18 8 23 264 26 8 4 31 0 23 264 26 8 4 31 0 4003 29 234 25 6 4 28 9 26 264 33 5 4 37 7 26 264 33 5 4 37...

Page 19: ...rate is the same type as specified on the heater s rating plate CAUTION The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in ex...

Page 20: ...EC Class 1 Heater must be electrically grounded as required by the NEC In Canada CSA C22 1 C E C Part 1 The MVB heaters are wired for a 240 VAC single phase power supply Consult the wiring diagram shi...

Page 21: ...ents 4 Observe proper wire colors while making electri cal connections Many electronic controls are polarity sensitive Components damaged by im proper electrical installation are not covered by warran...

Page 22: ...connected to ground Wiring the Outdoor Sensor 1 There is no connection required if an outdoor sen sor is not used in this installation 2 If using an Outdoor Sensor option B 32 connect the sensor wires...

Page 23: ...installation 2 When the Indirect DHW call for heat is active the PIM communicates this to the VERSA The VERSA calculates the optimal operation and sends the firing rate and pump output requests to th...

Page 24: ...nnections are dry contacts rated for pilot duty only 5A maxi mum 2 Connect the boiler pump enable wires to the termi nal block at the rear of their unit The connections are dry contacts rated for pilo...

Page 25: ...maximum 3 The System and DHW pump outputs are not used in the Cascade Follower configuration Fig 28 VERSA Follower Modbus BMS Communication The VERSA IC control is equipped as standard with a communi...

Page 26: ...r which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent See Table J for appliance category requirements CAUTION Proper...

Page 27: ...lock vent pipe U S Installations Refer to the latest edition of the National Fuel Gas Code Vent termination requirements are as follows 1 Vent must terminate at least 4 ft below 4 ft hori zontally fro...

Page 28: ...er or near elbows Venting Configurations For heaters connected to gas vents or chimneys vent installations shall be in accordance with the NFGC U S or B149 Canada or applicable provisions of local bui...

Page 29: ...than 5 ft should be securely guyed or braced to withstand snow and wind loads Common Venting The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters This is...

Page 30: ...pane gas and flue temperature of 350 F at 100 firing rate meas ured at a test port 12 above the flue collar NOTE Data for 100 firing rate Table L Typical Vent Pressure and Volume of Flue Products Fig...

Page 31: ...allation These installations utilize the heater mounted blower to vent the combustion products to the outdoors Combustion air is taken from inside the room and the vent is installed horizontally throu...

Page 32: ...pproved stainless steel flue direct vent cap must be used sales order option D 15 The vent terminal must be located NO CLOSER than 12 off the wall Subtract 10 ft per elbow Max 4 elbows Table M Categor...

Page 33: ...debris etc The stainless steel flue direct vent cap must be fur nished by the heater manufacturer in accordance with its listing sales order option D 15 Outdoor Installation Units installed outdoors...

Page 34: ...tch may be required to de energize the equipment before servicing NOTE Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Ignition Control F...

Page 35: ...er 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 40 Low Water Cut Off Hig...

Page 36: ...C Control I O Manual Catalog 5000 72 Adjusting the MVB Setpoint To adjust the setpoint on the MVB Use the MENU key to scroll to the SETUP ADJUST menu then use the ITEM key to scroll to the SET POINT i...

Page 37: ...3 Current system supply temperature Boil OUTLET All Current boiler outlet temperature Boil INLET All Current boiler inlet temperature Boil T All Current temperature difference between boiler outlet an...

Page 38: ...rature 220 F TARGET MIN H MODE 1 2 3 OFF 50 F to 190 F Minimum target system temperature 50 F TARGET DIFF H MODE 1 2 3 2 F to 42 F Differential for target system temperature 10 F DHW SENSOR H MODE 1 2...

Page 39: ...fset OPERATOR All Operator Limit Potentiometer PIM setting AUTO DIFF H MODE 1 2 3 Current auto differential PUMP PREPt All Duration of pump prepurge BLOW PREPt All Duration of blower prepurge BLOW PRE...

Page 40: ...oiler outlet temperature Press UP DOWN for 1 sec to clear INLET HI All Records the highest boiler inlet temperature Press UP DOWN for 1 sec to clear INLET LO All Records the lowest boiler outlet tempe...

Page 41: ...degree the outdoor temperature drops the tempera ture of the heating water will increase one degree With the VERSA both ends of the slope are adjustable It is factory set at 70 F water temperature Bo...

Page 42: ...ual temperature where the building is located This temperature is used when completing heat loss calculations for the building Boiler Design Boil DESIGN The Boil DESIGN temperature is the water temper...

Page 43: ...43 WIRING DIAGRAM Models 2503 4003...

Page 44: ...your building Immediately call your gas supplier from a neigh bor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand...

Page 45: ...er wait approximately 15 seconds after the blower starts the igniter should start to glow observable through the observation port located at the front below the gas valve Look into the sight glass loc...

Page 46: ...1 4 3 2 in WC Table S MVB Air Pressure Settings Table T MVB Manifold Pressure Settings User Test Set DIP switch 1 on the VERSA IC control to ON Set USER TEST ON in the ToolBox Menu to start the user...

Page 47: ...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 This will bring gas pressure to the second valve s...

Page 48: ...RSA IC will allow one time operation of the limit and then must be returned to normal operation by turning dip switch 8 back to the OFF position Power to the unit must then be cycled off then on to re...

Page 49: ...ater temperature or manual reset high limit is not tripped c Enable Disable circuit is closed d Gas is on at the meter and the heater e Incoming dynamic gas pressure to the gas valve is NOT less than...

Page 50: ...replace control DELTA T Temperature difference between the inlet and outlet exceeded the set point Check water flow LOW 24VAC Low 24 VAC power Check power supply wiring and transformer BLOW SPEED Blow...

Page 51: ...the gas supply See table for more information 4 flashes N A N A 5 flashes Low Voltage Fault Check the 24 VAC input voltage The voltage must be above 18 0 VAC 6 flashes N A N A 7 flashes Hi Limit Fault...

Page 52: ...c tion deterioration or leakage 4 Visually inspect for proper operation of the con densate drain in the venting If leaks are observed repair at once 5 Check air vents for leakage Yearly Beginning Of E...

Page 53: ...see light blue flame at full input rate Weekly 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 i...

Page 54: ...ing should be 40 75 ohms at 77 F 5 Check flame signal strength Flame signal should be greater than 1 microampere as measured at the 2 pins on the bottom of the PIM 6 Check firing rate control by check...

Page 55: ...ontaminated ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners ch...

Page 56: ...wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth...

Page 57: ...MENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warr...

Page 58: ...utes Vent Size _____________ Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material ____...

Page 59: ...59...

Page 60: ...60 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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