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Raypak 503-2003, Installation And Operating Instructions Manual

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Raypak 503-2003 Installation And Operating Instructions Manual Download Page 9

SECTION C: Installation 

 

7 

Installation Codes 

Installations must follow these codes: 

•

 

Local, state, provincial, and national codes, laws, 
regulations and ordinances 

•

 

National Fuel Gas Code, ANSI Z223.1/NFPA 54 – 
latest edition (NFGC) 

•

 

National Electrical Code, ANSI/NFPA 70 - latest 
edition (NEC) 

•

 

Standard for Controls and Safety Devices for Auto-
matically Fired Boilers, ANSI/ASME CSD-1, 
(CSD-1) when required  

•

 

For Canada only: CAN/CSA B149.1 Natural Gas 
and Propane Installation Code and CSA C22.1 
C.E.C. Part 1 (C22.1) 

Equipment Base 

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. Gas-fueled equipment installed in en-
closed parking garages must be located at least 18 in. 
above the floor. 

When such locations cannot be avoided, it is recom-
mended that a suitable catch pan, adequately drained, 
be installed under the appliance. The pan must not re-
strict air flow. 

In addition, the heater shall be installed such that the 
gas ignition system components are protected from 
water (dripping, spraying, rain, etc.) during appliance 
operation or service (circulator replacement, control 
replacement, etc.). 

Clearances 

Indoor Installations 

Heater 

Side 

Minimum Clearance 

 from Combustible  

Surfaces 

Recommended

Service  

Clearance 

Floor* 0” 

0” 

Rear 12” 

24” 

Right Side

1” 

1” 

Left Side 

1” 

1” 

Top 0” 

10” 

Front Open 

24” 

Vent 1” 

1” 

* DO NOT install on carpeting. 

Table C: Clearances – Indoor Installations 

 

 

 

 

 

 

 

 

SECTION C

Installation

Summary of Contents for 503-2003

Page 1: ...or loss of life Review the information in this manual carefully Installation and service must be performed by a qualified installer service agency or the gas supplier This unit contains materials that have been identified as carcinogenic or possibly carcinogenic to humans 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 b...

Page 2: ......

Page 3: ... 7 Equipment Base 7 Clearances 7 Combustion and Ventilation Air 9 Water Piping 11 Gas Supply 17 Electrical Power Connections 19 Venting 21 Controls 28 Wiring Diagrams 38 SECTION D Start up 41 Pre Start up 41 Start Up 42 SECTION E Operation 47 Lighting Instructions 47 To Turn Off Gas To Appliance 47 SECTION F Troubleshooting 49 UDB Fault History 50 SECTION G Maintenance 51 Suggested Minimum Mainten...

Page 4: ...ING To minimize the possibility of improper operation serious personal injury fire or damage to the heater Always keep the area around the heater free of combustible materials gasoline and other flammable liquids and vapors Heater should never be covered or have any blockage to the flow of fresh air to the heater WARNING Risk of electrical shock More than one disconnect switch may be required to d...

Page 5: ...from the factory prior to shipping Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted All returned goods are subject to a restocking charge When ordering parts you must specify the model and serial numbers of the heater When ordering under war ranty conditions you must also specify the date of installation Purchased parts are subject to replaceme...

Page 6: ...e ASME or CSA ratings of the vessel also violates national state and local approval codes Installations at Elevation Rated inputs are suitable for up to 4 500 ft elevation with out de rating Consult the factory for installations at altitudes over 4 500 ft above sea level No hardware changes are required to the heaters for installations up to 10 000 ft adjustments may be required Component Location...

Page 7: ...thermostati cally controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further information Maximum water temperatures occur just after the heater s burner has shut off To determine the water temperature being delivered turn on a hot water faucet place a thermometer in the...

Page 8: ...t 1 second Table courtesy of The Shriners Burn Institute Table B Time to Produce Serious Burn The temperature of the water in the heater can be regu lated 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 To adjust the water temperature follow the instruction for the ...

Page 9: ...ace but must NEVER be installed on carpeting Gas fueled equipment installed in en closed parking garages must be located at least 18 in above the floor When such locations cannot be avoided it is recom mended that a suitable catch pan adequately drained be installed under the appliance The pan must not re strict air flow In addition the heater shall be installed such that the gas ignition system c...

Page 10: ...ance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 4 ft 1 2m below or to side of opening 1 ft 30 cm above opening 3 ft 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 7 ft 2 13m t M Clearance under ...

Page 11: ...erminal Three sides must be open in the area under the over hang Roof water drainage must be diverted away from heaters installed under overhangs Heater Side Min Clearance from Combustible Surfaces Recommended Service Clearance Rear 12 24 Right Side 1 1 Left Side 1 1 Top Unobstructed Unobstructed Vent Termination 12 12 Table E Clearances Outdoor Installations The combustion air intake terminal MUS...

Page 12: ...o the heater The screws and duct connection point must be sealed with RTV not supplied TruSeal is generally used when damag ing contaminants are present in the mechanical room All ducting should be self supported CAUTION Use TruSeal combustion air if damaging airborne contaminants are or may be present in the heater area See Section H of this manual regarding air contamination Conventional Combust...

Page 13: ...llion BTUH This opening s shall be either located at or ducted to a point not more than 18 in 450 mm nor less than 6 in 152 mm above the floor level The duct can also goose neck through the roof The duct is preferred to be straight down and ter minated 18 in 450 mm from the floor but not near piping This air supply opening requirement shall be in addition to the air opening for ventila tion air re...

Page 14: ...o the heater piping next to the in out header to facili tate temperature adjustment Inlet water temperatures below 120ºF 49ºC can excessively cool the products of combustion resulting in collection of condensate in the heat exchanger area beyond the capacity of the condensate evaporation system NOTE Vent piping MUST contain a condensate drain which is installed according to the vent manufac turer ...

Page 15: ...re is 85ºF minimum inlet temperature would be 130ºF An injector pump ar rangement may also be utilized to keep the heater loop at or above 120ºF 49ºC An injector pump approach has the added value of being able to adjust to changes in the system water coming back to the heater take off Fig 8 Cold Water Run Temperature Pressure Gauge The temperature and pressure gauge is shipped loose for field inst...

Page 16: ...heater The piping system of a hot water heater connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air must be equipped with flow control valves or other automatic means to prevent gravity circulation of the heater water during the cooling cycle It is highly recommended that the piping be insulated Air Separation Expansion Tank All heaters...

Page 17: ...usly damage the heater Follow these instructions to make sure your heater is properly installed The MVB must be equipped with a field supplied ex ternal 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 thereby reducing the likelihood of condensation form ing on the heat exchanger The pump also serves...

Page 18: ...emperature 5 If this process does not raise the inlet water tem perature to 120 F and Valve A is fully open then slowly throttle Valve B closed to increase the inlet water temperature to 120 F Fig 14 H Bypass Setting Automatic Chlorinators and Chemical Feeders CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty All chemicals...

Page 19: ... in a storage tank or a copper water heater system is 7 2 to 7 8 Total Dissolved Solids Total dissolved solids TDS is the measure of all min erals and solids that are dissolved in the water The concentration of total dissolved solids is usually ex pressed in parts per million ppm as measured in a water sample Water with a high TDS concentration will greatly accelerate lime and scale formation in t...

Page 20: ...cessories Make sure the gas piping is protected from physical damage and freezing where required Gas Supply Pressure A minimum of 4 0 in WC and a maximum of 10 5 in WC upstream gas pressure is required under load and no load conditions for natural gas A minimum of 4 0 in WC and a maximum of 13 0 in WC is required for propane gas The gas pressure regulator s supplied on the heater is for low pressu...

Page 21: ...r and the pump Pumps larger than hp must use a separate power supply and run the power through the optional pump contactor which is located in the rear wiring box see Fig 16 Use appropriately sized wire as defined by NEC CSA and or local codes All primary wiring should be 125 of minimum rating If any of the original wire as supplied with the heater must be replaced it must be replaced with 105 C w...

Page 22: ...polarity sensitive Components damaged by im proper electrical installation are not covered by warranty 5 Provide overload protection and a disconnect means for equipment serviceability as required by local and state code 6 Install heater controls thermostats or building management systems in accordance with the appli cable manufacturers instructions 7 Conduit should not be used as the earth ground...

Page 23: ...ate drains in the vent Condensate drain must be primed with water to prevent gas flue leak and must be routed to an appropriate container for neutrali zation before disposal as required by local codes WARNING Contact the manufacturer of the vent material if there is any question about the appliance categorization and suitability of a vent material for application on a Category IV vent system Using...

Page 24: ...amaging exterior finishes Use a rust resistant sheet metal backing plate against brick or masonry surfaces 12 DO NOT extend exposed vent pipe outside of building beyond the minimum distance required for the vent termination Condensate could freeze and block 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...

Page 25: ...pliance shall be determined per the NFGC U S or B149 1 Canada The diameter of vent flue pipe should be sized accord ing to Part 11 of the NFGC U S and Part 7 and Appendix B of B149 1 Canada The minimum flue pipe diameter for conventional venting using Category IV stainless steel AL29 4C vent is 6 in for Models 503 1003 and 8 in for Models 1253 2003 NOTICE A vent adapter field supplied may be re qu...

Page 26: ...enting Common Venting 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 Sys tems Table L provides boiler discharge vent pressures at vent pressure switch and volumes of flue products at full fire for the calculation of appropriate vent sizing for common venting WARNING Vent connectors serving any oth...

Page 27: ...ll Venting NOTE While a drain connection is required in the vent of all MVB installations the drain can be ac complished in several different ways The figures in this manual show the drain in a vent tee however this can also be accomplished using an inline collec tor for condensing stacks or an inline vertical or horizontal collector available from several of the listed vent manufacturers ...

Page 28: ... 75 of straight flue pipe 65 of straight flue pipe and one elbow 55 of straight flue pipe and two elbows 45 of straight pipe and three elbows The vent cap is not considered in the overall length of the venting system The vent must be installed to prevent flue gas leakage Care must be taken during assembly to ensure that all joints are sealed properly and are airtight The vent must be installed to ...

Page 29: ... airtight The vent must be installed to prevent the potential ac cumulation of condensate in the vent pipes It is required that 1 The vent must be installed with a condensate drain located in proximity to the heater as directed by the vent manufacturer 2 The vent must be installed with a slight upward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal 3 The vent must ...

Page 30: ...e at least 3 ft above any forced air inlet located within 10 ft 6 Adjacent brick or masonry surfaces must be pro tected with a rust resistant sheet metal plate NOTICE Condensate can freeze on the vent cap Fro zen condensate on the vent cap can result in a blocked flue condition NOTICE The vent cap and air intake hood must be furnished by the heater manufacturer in accordance with its listing sales...

Page 31: ...gh thermal mass setting 3 provides slower reaction lower ther mal mass setting 1 provides faster reaction BOIL MAX Highest outlet water temperature that the control is allowed to use as a target temperature BOIL MIN Lowest outlet water temperature that the control is allowed to use as a target temperature BOIL ON Accumulated runtime of heater up to 999 hours then resets to 0 BOIL OUT Actual heater...

Page 32: ...ode and VIEW is dis played Pressing the scroll button scrolls through the displayed values in the VIEW menu Fig 28 Modulating Temperature Control Display Default Item Modes Boiler Water Heater Range BOIL TARGET 1 2 3 4 5 140 ºF 180 ºF 160 ºF OFF 70 220 ºF OFF 70 200 ºF OFF 70 220 ºF BOIL MAX 1 2 4 5 6 3 200 ºF 180 ºF 120 225 ºF OFF 120 200 ºF OFF BOIL MIN 1 5 135 ºF 135 ºF OFF 80 180 ºF BURNER DEL...

Page 33: ...ill send a 24 VAC signal to pin P3 4 of the UDB board to indicate a safety fault 6 A 24 VAC signal is sent from the NO contacts of the Low Water Cut Off to the common terminal of the Blocked Vent Switch During a blocked vent condition a 24 VAC signal is sent from the NO open contacts of the Blocked Vent Switch to pin P3 5 of the UDB board to indi cate a safety fault 7 During normal operation of th...

Page 34: ...C is sent to the heater interlock connection on the ignition module If air pressure is insufficient or lost during heater operation a 24 VAC signal is sent from the NC contacts of the air pressure switch to pin P4 10 of the UDB board to indicate insufficient air pressure When the 24 VAC signal is sent to P4 10 the same signal then de energizes the coil of the time delay relay to remove a heat dema...

Page 35: ...mmon terminal of the High Gas Pressure Switch if equipped During a high gas pressure condition 24 VAC is sent from the NO contacts of the High Gas Pres sure Switch to Pin P3 7 of the UDB board to indicate a safety fault 8 24 VAC is sent from the NC contacts of the High Gas Pressure Switch to energize the alarm relay coil and to the common terminal of the Auto Reset High Limit if equipped If the Au...

Page 36: ...ce after the five second time delay 22 After receiving 24 VAC at the heater interlock power then travels to the P Switch terminal of the ignition module The ignition module employs a 15 second pre purge before the next sequence 23 After 15 seconds of combustion chamber pre purge pin S1 sends 120 VAC to the Hot Surface Igniter The Hot Surface Igniter will be energized for ap proximately 30 seconds ...

Page 37: ... is equipped with a fixed setting manual re set high limit temperature device as standard or it may have an optional adjustable setting manual reset high temperature device The fixed setting manual reset high limit is located on the In Out header of the heat exchanger on the right side of the heater accessible through the front door for reset as necessary The optional adjustable manual reset high ...

Page 38: ...ce The low gas pressure switch automatically shuts down the heater if gas sup ply drops below the factory setting of 3 0 in WC for natural gas or LP gas 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 acces sible from the front of the heater to reset the gas pressure switch or through the removable ...

Page 39: ...is switch is located on the right side of the heater near the right rear corner Fig 37 Blocked Vent Switch UDB Diagnostic Board This heater is equipped with a diagnostic board which will indicate faults as they occur It has the ability to retain up to 256 faults in history Refer to the Trouble shooting section for instructions on accessing reviewing and clearing these faults Fig 38 UDB Diagnostic ...

Page 40: ...SECTION C Installation 38 Wiring Diagrams Models 503 1503 ...

Page 41: ...SECTION C Installation 39 Models 1753 2003 ...

Page 42: ...SECTION C Installation 40 ...

Page 43: ...you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance has a hot surface igniter It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell near the floor because some gas...

Page 44: ...und failure Failure to do this may burn out 120V 24V transformer or may cause other safety control damage or failure Attach Manometers to Measure Pressures 1 Turn off main gas valve 2 Attach 1 12 scale manometer to an upstream bleedle valve on the gas supply pipe to the heater Measure point A in Fig 39 3 Attach 1 24 scale manometer to the manifold pressure tap located on the valve Measure point C ...

Page 45: ...ssure Requirements Manifold Adjustment 1 Turn off unit 2 Open manual firing valves 3 Turn on the unit wait approximately 15 seconds and the igniter should glow observable through the observation port located at the front bottom of the heater Look into sight glass located at the bottom of the front panel to check igniter operation Gas valve should open in 45 60 seconds 4 If burner does not light on...

Page 46: ...leedle valve located between the two automatic gas valve seats Test point C is a bleedle valve located downstream of both automatic gas valve seats and upstream of the manual valve Refer to Fig 40 These tests are to be conducted with the electrical power to the heater turned OFF 1 Manually close the downstream leak test valve 2 Open the bleedle valve at test point A and connect a manometer to it V...

Page 47: ...urner should re ignite after pre purge time delay NOTE Ignition control may have to be reset after this portion of the test 9 Test ignition system safety device a Open manual gas valve Turn power on b Set thermostat to call for heat c When the heater is in operation pull cap off of tee in air switch hose The burner should go off almost immediately d Reattach cap on tee Burner should re ignite afte...

Page 48: ...SECTION D Start up 46 ...

Page 49: ...igniter reaches temperature 30 seconds the main valve should open System will try for ignition one time three times on optional 3 try ignition module If flame is not sensed lockout will commence 10 If the appliance will not operate follow the in structions To Turn Off Gas To Appliance and call your service technician or gas supplier 11 Replace upper front panel 12 If heater fails to start verify t...

Page 50: ...SECTION E Operation 48 ...

Page 51: ...pressure switch Correct the shutter setting or blower amp draw NO Check the switch and or line voltage YES Does the power switch provide power to the control panel Unit is in standby mode Reattach NO NO YES YES NO Is diagnostic board indicating open safeties Check and correct power connections at main terminal block circuit breaker panel or blower relay NO NO YES NO YES Is 24VAC at PS on ignition ...

Page 52: ...ault number 4 The faults are recorded and displayed on a last in first out basis The last fault recorded will be the first fault displayed There is no time or date stamp associated with these faults 5 Continue to push SW2 to view subsequent faults 6 When the history of faults has been exhausted pushing SW2 again will roll the fault history over and it will start again 7 To exit the fault history p...

Page 53: ...service agency 1 Visually check top of vent for soot Call service person to clean Some sediment at bottom of vent is normal 2 Visually inspect venting system for proper function deterioration or leakage Ensure that condensate drain is inspected and ensure that condensate is being di rected to appropriate condensate management system or drain as required by local codes 3 Check that area is free fro...

Page 54: ...t dampers 2 Test blower air pressure See Blower Adjustment on page 42 3 Test high and low gas pressure interlocks if equipped See Safety Inspection on page 44 Semi Annually 1 Recalibrate all indicating and recording gauges 2 Check flame failure detection system components 3 Check firing rate control by checking the manifold pressure See Manifold Adjustment on page 43 4 Check piping and wiring of a...

Page 55: ...r eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners chlorine based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varnish removers hydrochloric acid muriatic acid cements and glues antista...

Page 56: ...er 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 warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts not manufactured by it but Raypak wi...

Page 57: ...________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________...

Page 58: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Raypak Canada Limited 2805 Slough St Mississauga Ontario Canada L4T 1G2 905 677 7999 Fax 905 677 8036 ...

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