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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 11

Water Piping

Hydronic Heating

Gas Supply

Electrical Power Connections

Field Wiring Connection

Venting

Venting Installation Tips

Venting Configurations

Outdoor Installation

Controls

Heater Sequence of Operation

WIRING DIAGRAMS

START-UP

Pre Start-up

Start-Up

OPERATION

Lighting Instructions

To Turn Off Gas To Appliance

TROUBLESHOOTING

UDB Fault History

MAINTENANCE

Suggested Minimum

Maintenance Schedule

Preventative Maintenance Schedule 49

Filter Maintenance

Filter Replacement

APPENDIX

Inside Air Contamination

IMPORTANT INSTRUCTIONS FOR

THE COMMONWEALTH OF

MASSACHUSETTS

WARRANTY

START-UP CHECKLIST

CONTENTS

Содержание 503-2003

Страница 1: ...pors 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 appliance...

Страница 2: ...d 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 pa...

Страница 3: ...wer Connections 20 Field Wiring Connection 22 Venting 22 Venting Installation Tips 24 Venting Configurations 24 Outdoor Installation 29 Controls 30 Heater Sequence of Operation 36 WIRING DIAGRAMS 39 S...

Страница 4: ...liquids and vapors Heater should never be covered or have any blockage to the flow of fresh air to the heater WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals known to the State of Ca...

Страница 5: ...ly 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 panel of the he...

Страница 6: ...ty Fig 4 Component Locations Top Fig 3 Component Locations Rear MBTUH Input Gas Conn NPT Vent Size in Model No Max Min Water Conn NPT N P Flue Intake 503 500 125 2 1 1 6 6 753 750 188 2 1 1 6 6 1003 9...

Страница 7: ...emperatures occur just after the heater s burner has shut off 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...

Страница 8: ...ations INSTALLATION INSTALLATION Installation Codes Installations must follow these codes Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 N...

Страница 9: ...hang unless clearances are in accordance with local instal Combustion and Ventilation Air Indoor Units This heater must be supplied with sufficient quantities of non contaminated air to support proper...

Страница 10: ...e 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 pav...

Страница 11: ...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 dam aging contaminants a...

Страница 12: ...anical equip ment room must communicate directly with the outdoors Canadian Installations 65 cm2 2 For heaters using a barometric damper in the vent system there shall be a permanent air supply openin...

Страница 13: ...ypass acting as the secondary boiler piping Raypak strong ly recommends that thermometer s be placed into the heater piping next to the in out header to facilitate tem perature adjustment Inlet water...

Страница 14: ...he system water is kept in a narrow temperature range of no more than 10 F 5 C a permanent manual bypass can be employed and manually adjusted to achieve an inlet temperature of 120 F 49 C or higher a...

Страница 15: ...that the chilled medium is piped in parallel with the heater with appropriate valves to pre vent the chilled medium from entering the heater The piping system of a hot water heater connected to heati...

Страница 16: ...PLY SYSTEM RETURN Fig 14 Single Domestic Hot Water Heater and Storage Tank CAUTION When this heater is used for both potable water and space heating observe the following to ensure proper operation So...

Страница 17: ...operation in a pool heating application Use the following instruc tions to set the manual bypass CAUTION Power to the heater should be interlocked with the main system pump to make sure the heater do...

Страница 18: ...ould be shut down for the winter To shut the down heater turn off manual main gas valve and main gas shut off Close isolation valves Drain the heater using the hose bibs located on the bottom of the h...

Страница 19: ...uring 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 i...

Страница 20: ...ring including sensors interlocks enable disable and various options are wired into terminals 1 20 on the front wiring panel as noted in Fig 18 The gas valve pressure regulator on the heater is nomina...

Страница 21: ...ers instructions 7 Conduit should not be used as the earth ground 21 Field Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supp...

Страница 22: ...ZARD CAUTION Proper installation of flue venting is critical for the safe and efficient operation of the heater NOTE For additional information on appliance categorization see appropriate ANSI Z21 Sta...

Страница 23: ...al to the operation of regulators relief valves or other equipment 8 Locate and guard vent termination to prevent acci dental contact by people or pets 9 DO NOT terminate vent in window well stairwell...

Страница 24: ...or door which can be opened in any building any non mechani cal air supply inlet to any building or the combustion air inlet of any other appliance 8 Underneath a verandah porch or deck unless the ver...

Страница 25: ...ained electric meters gas meters regulators and relief equipment The distance of the vent terminal from adjacent public walkways adjacent buildings open windows and building openings must be consisten...

Страница 26: ...mechanical draft systems operating under a positive pressure If an MVB heater is installed to replace an existing heater the vent system MUST be verified to be of the correct size and of Category IV A...

Страница 27: ...tallation 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 thro...

Страница 28: ...el 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 t Adapters supplied by others Table...

Страница 29: ...ondition keep the vent cap clear of snow ice leaves 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...

Страница 30: ...re is above the target temperature by 1 2 of the differential setting See Fig 30 Operating Modes Mode 1 Not supported Setpoint operation using primary piping The heater outlet water temperature is con...

Страница 31: ...or reset See Fig 33 Mode 6 Not supported Designed for an external input signal with primary piping The external input sig nal can be provided from a BMS an EMS or a sequencing control The external inp...

Страница 32: ...he Enable Disable connection at the low voltage terminal strip and the fir ing rate is controlled by a 0 10 VDC signal from the external sequencer A control signal of 0 5 VDC equates to minimum fire a...

Страница 33: ...F 35 to 85 F Outdr Design 4 5 10 F 60 to 32 F Boil Start 4 5 135 F 35 to 150 F Boil Dsgn 4 5 180 F 120 to 220 F WWSD 4 5 70 F 35 to 100 F Units All F F or C Mode N A 2 1 2 3 4 5 6 7 8 External Input S...

Страница 34: ...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 22...

Страница 35: ...enu is the view menu When the temperature control is powered up the con trol turns on all segments in the display for 2 seconds then the software version is displayed for 2 seconds At the end of that...

Страница 36: ...1 The heater pump is powered and begins circulat ing water through the heat exchanger 2 The blower is powered and goes through a 15 sec ond prepurge beginning when air flow is proven by closure of th...

Страница 37: ...ng and use of this control Fig 41 Modulating Temperature Control Fig 42 Low Water Cut Off Low Water Cut Off Optional The optional low water cut off automatically shuts down the burner whenever water l...

Страница 38: ...is equipped with an air pressure switch to prove the operation of the blower before allowing the ignition control to begin a Call for Heat It is located on the right side of the lower flange of the bl...

Страница 39: ...39 WIRING DIAGRAMS Models 503 1503...

Страница 40: ...40 Models 1753 2003...

Страница 41: ...light any appliance Do not touch any electrical switch do not use any telephone in your building Immediately call your gas supplier from a neigh bor s telephone Follow the gas supplier s instructions...

Страница 42: ...tom of the front panel to check igniter operation Gas valve should open in 45 60 seconds 3 The heater ignites at 50 of full rate as indicated on the LCD display of the temperature control located in t...

Страница 43: ...he same gas main check all pressures on the MVB with all other equipment running 4 Check thermostats for ON OFF operation 5 Check high limits for ON OFF operation 6 While in operation check flow switc...

Страница 44: ...pen the bleedle valve at test point A and connect a manometer to it Verify that there is gas pressure and that it is within the proper range NOTE must not exceed 14 0 in WC 3 Open test point B and con...

Страница 45: ...low lighting instructions in the Operation section 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...

Страница 46: ...ff b High temperature limit switch is set above wa ter temperature or manual reset high limit is not tripped c Thermostat is set above water temperature d Gas is on at the meter and the heater e Incom...

Страница 47: ...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...

Страница 48: ...cleared it cannot be recovered MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficienc...

Страница 49: ...burner flame Should 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 s...

Страница 50: ...Manifold Check on page 43 7 Test safety safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV Filter Maintenance Inspect quarterly Replace when tracking pressure exce...

Страница 51: ...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...

Страница 52: ...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...

Страница 53: ...T 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 warrant...

Страница 54: ...ght _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size _________...

Страница 55: ...55...

Страница 56: ...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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