Raypak 2503 Installation & Operating Instructions Manual Download Page 56

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(b) EXEMPTIONS: The following equipment is exempt from

248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled "Equipment

Not Required To Be Vented" in the most current edition of

NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled

equipment installed in a room or structure separate from the

dwelling, building or structure used in whole or in part for res-

idential purposes.

(c)  MANUFACTURER  REQUIREMENTS  -  GAS  EQUIP-

MENT  VENTING  SYSTEM  PROVIDED.  When  the

manufacturer  of  Product  Approved  side  wall  horizontally

vented gas equipment provides a venting system design or

venting system components with the equipment, the instruc-

tions  provided  by  the  manufacturer  for  installation  of  the

equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting sys-

tem design or the venting system components; and

2. A complete parts list for the venting system design or vent-

ing system.

(d)  MANUFACTURER  REQUIREMENTS  -  GAS  EQUIP-

MENT  VENTING  SYSTEM  NOT  PROVIDED.  When  the

manufacturer  of  a  Product Approved  side  wall  horizontally

vented gas fueled equipment does not provide the parts for

venting  the  flue  gases,  but  identifies  "special  venting  sys-

tems",  the  following  requirements  shall  be  satisfied  by  the

manufacturer:

1. The referenced "special venting system" instructions shall

be  included  with  the  appliance  or  equipment  installation

instructions; and

2. The "special venting systems" shall be Product Approved

by  the  Board,  and  the  instructions  for  that  system  shall

include a parts list and detailed installation instructions.

(e)  A  copy  of  all  installation  instructions  for  all  Product

Approved  side  wall  horizontally  vented  gas  fueled  equip-

ment,  all  venting  instructions,  all  parts  lists  for  venting

instructions,  and/or  all  venting  design  instructions  shall

remain with the appliance or equipment at the completion of

the installation.

GAS PRESSURE SUPERVISION

The  Commonwealth  of  Massachusetts  requires  listed  high

and low gas pressure switches (manual reset) for any model

with a maximum firing input greater than 1,000,000 Btu/Hr in

accordance with 248 CMR 7.04(11)(d).  

A gas  pressure  regulator  (field  supplied)  is  required  in  the

gas train ahead of the heater, for heaters having input rates

greater than 1,000,000 Btu/Hr, in accordance with 248 CMR

7.04 Figure 3B requirements.

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:

(a) For all side 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  and  where  the

side wall exhaust vent termination is less than seven (7) feet

above finished grade in the area of the venting, including but

not limited to decks and porches, the following requirements

shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS.

At the time of installation of the side wall horizontal vented

gas fueled equipment, the installing plumber or gasfitter shall

observe that a hard wired carbon monoxide detector with an

alarm  and  battery  back-up  is  installed  on  the  floor  level

where the gas equipment is to be installed. In addition, the

installing  plumber  or  gasfitter  shall  observe  that  a  battery

operated  or  hard  wired  carbon  monoxide  detector  with  an

alarm  is  installed  on  each  additional  level  of  the  dwelling,

building or structure served by the side wall horizontal vent-

ed gas fueled equipment. It shall be the responsibility of the

property owner to secure the services of qualified licensed

professionals  for  the  installation  of  hard  wired  carbon

monoxide detectors

a.  In  the  event  that  the  side  wall  horizontally  vented  gas

fueled equipment is installed in a crawl space or an attic, the

hard wired carbon monoxide detector with alarm and battery

back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can

not be met at the time of completion of installation, the owner

shall  have  a  period  of  thirty  (30)  days  to  comply  with  the

above  requirements;  provided,  however,  that  during  said

thirty (30) day period, a battery operated carbon monoxide

detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each

carbon  monoxide  detector  as  required  in  accordance  with

the  above  provisions  shall  comply  with  NFPA  720  and  be

ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be

permanently mounted to the exterior of the building at a min-

imum height of eight (8) feet above grade directly in line with

the  exhaust  vent  terminal  for  the  horizontally  vented  gas

fueled heating appliance or equipment. The sign shall read,

in print size no less than one-half (1/2) inch in size, "GAS

VENT  DIRECTLY  BELOW.  KEEP  CLEAR  OF  ALL

OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side

wall  horizontally  vented  gas  fueled  equipment  shall  not

approve the installation unless, upon inspection, the inspec-

tor  observes  carbon  monoxide  detectors  and  signage

installed  in  accordance  with  the  provisions  of  248  CMR

5.08(2)(a)1 through 4.

Important Instructions for the Commonwealth of Massachusetts

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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