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19

Gas Supply

Gas piping 

must

have a sediment trap ahead of the

heater gas controls, 

and

a manual shut-off valve lo-

cated  outside  the  heater  jacket.  It  is  recommended

that a union be installed in the gas supply piping adja-

cent  to  the  heater  for  servicing.  The  gas  supply

pressure to the heater must not exceed 10.5 in. WC for

natural gas or 13.0 in. WC for propane gas. A pounds-

to-inches regulator must be installed to reduce the gas

supply pressure if it is higher than noted above. This

regulator should be placed a minimum distance of 10

times  the  pipe  diameter  upstream  of  the  heater  gas

controls. Refer to Table H for maximum pipe lengths.

Gas Supply Connection

The heater must be isolated from the gas supply pip-

ing  system  by  closing  the  upstream  manual  shut-off

valve  during  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  its

manual shut-off valve to the gas supply line. 

FAILURE

TO  FOLLOW  THIS  PROCEDURE  MAY  DAMAGE

THE  GAS  VALVE

.  Over-pressurized  gas  valves  are

not covered by warranty. The heater and its gas con-

nections  shall  be  leak-tested  before  placing  the

appliance in operation. Use soapy water for leak test.

DO NOT use an open flame.

DANGER:

Make sure the gas on which the heater

will  operate  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 excess of 1/2 psi

(3.45 kPa). 

Gas Supply Pressure

A  minimum  of  4.0  in.  WC  upstream  gas  pressure

under full load and a maximum gas supply pressure

setpoint of 10.5 in. WC under load and no-load condi-

tions  for  natural  gas.    A  minimum  of  4.0  in.  WC

upstream gas pressure under full load and a maximum

gas supply pressure setpoint of 13.0 in. WC is required

for propane gas.  The gas pressure regulator(s) sup-

plied  on  the  heater  is  for  low-pressure  service.    If

upstream  pressure  exceeds  1/2  psi  at  any  time,  an

intermediate  gas  pressure  regulator,  of  the  lockup

type,  must  be  installed.    This  regulator  should  be

placed a minimum distance of 10 times the pipe diam-

eter upstream of the heater gas controls.

When connecting additional gas utilization equipment

to the gas piping system, the existing piping must be

checked to determine if it has adequate capacity for

the combined load.

The  gas  valve  pressure  regulator  on  the  heater  is

nominally preset as noted in Table I. 

During  normal  operation,  carbon  dioxide  should  be

9.0%  ±  0.2%  at  full  fire  for  natural  gas  and

10.2%  ±  0.2%  for  propane  gas.    Carbon  monoxide

should be ‹100ppm at all firing rates, measured at the

test port, 12” above the flue collar.

Fig. 17: Gas Supply Connection

CAUTION:

Do not use Teflon tape on gas line pipe

thread. A pipe compound rated for use with natural

and  propane  gases  is  recommended.  Apply

sparingly  only  on  male  pipe  ends,  leaving  the  two

end threads bare.

CAUTION:

Support  gas  supply  piping  with

hangers, not by the heater or its accessories. Make

sure  the  gas  piping  is  protected  from  physical

damage and freezing, where required.

Содержание 503A

Страница 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...

Страница 2: ...ble K on page 29 Table M on page 32 Wiring Diagram on page 43 Blower Check on page 46 Table T on page 46 Manifold Check on page 46 Filter Maintenance on page 54 Additions Motorized Combustion Air Damp...

Страница 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...

Страница 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...

Страница 5: ...nly 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 h...

Страница 6: ...cations Top Fig 3 Component Locations Rear Panels omitted for clarity Fig 2 Component Locations Front Model No MBTUH Input Water Conn NPT Gas Conn NPT Vent Size in Max Min N P Flue Intake 503A 500 70...

Страница 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...

Страница 8: ...n in front 1 in on the side at least 24 in on the rear and 10 in above the top of the heater is required This will allow 8 Table C Clearances Indoor Installations INSTALLATION Installation Codes Insta...

Страница 9: ...erhang 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 prop...

Страница 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...

Страница 11: ...g connection section of this manual for proper wiring instructions using Fan Damper dry contacts and external interlock TruSeal Combustion Air In addition to the 3 previous steps combustion air may be...

Страница 12: ...l be provided by an opening s for ventilation air at the highest practical point communicating with the outdoors The total cross sectional area of such an opening s shall be at least 10 of the area re...

Страница 13: ...changer with water temperatures as low as 120 F 49 C Heaters operated with an inlet temperature of less than 120 F 49 C MUST have an approved low tem perature operation system Figs 10 and 11 to preven...

Страница 14: ...water source heat pump applications as well as some others An injector pump arrangement may be used to keep the heater loop at or above 120 F 49 C An injector pump approach has the added value of bei...

Страница 15: ...range of applications The installer design engineer should refer to the following Modes to determine which best fits the intended application and functionality for the unit being installed Type H mode...

Страница 16: ...lower than the WWSD temperature setting if utilized unless an indirect call for heat is present with priority Fig 12 MODE 1 Single Boiler with Primary Secondary Piping Fig 14 MODE 2 Single Boiler with...

Страница 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...

Страница 18: ...ains per gallon a water softener treatment system must be utilized Caution For scale free operation with Hard Water 16 25 grains per gallon of total hardness the operating control must NOT be set high...

Страница 19: ...s supply during any pressure testing of the gas supply system at test pressures in excess of 1 2 psi 3 45 kPa Gas Supply Pressure A minimum of 4 0 in WC upstream gas pressure under full load and a max...

Страница 20: ...to Terminals 1 2 and 3 as noted in Fig 18 All low voltage wiring including sensors interlocks enable disable and var ious options are wired into terminals 1 24 on the front wiring panel as noted in F...

Страница 21: ...Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source NOTE Field supplied isolation relays should...

Страница 22: ...up to 150 feet 4 Mount the outdoor sensor on an exterior surface of the building preferably on the north side in an area that will not be affected by direct sunlight and that will be exposed to varyin...

Страница 23: ...tion 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 the PIM so...

Страница 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...

Страница 25: ...pump outputs are not used in the Cascade Follower configuration Fig 27 VERSA Follower Modbus BMS Communication The VERSA IC control is equipped as standard with a communications port for connectivity...

Страница 26: ...ANSI Z21 Standard and the NFGC U S or B149 Canada or applicable provisions of local building codes WARNING Contact the manufacturer of the vent material if there is any question about the appliance ca...

Страница 27: ...exterior finishes Use a rust resistant sheet metal backing plate against brick or mason ry surfaces 12 DO NOT extend exposed vent pipe outside of building beyond the minimum distance required for the...

Страница 28: ...r 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 vera...

Страница 29: ...The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physi cal damage or separation of joints NOTE A ven...

Страница 30: ...NOT it MUST be replaced NOTE For extractor sizing typical CO2 levels are 9 0 for natural gas and 10 2 for propane gas and flue temperature of 300 F at 100 firing rate meas ured at test port 12 above...

Страница 31: ...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 32: ...t vent cap must be used sales order option D 15 The vent terminal must be located NO CLOSER than 12 off the wall Table M Category IV Horizontal Vent Horizontal Direct Vent Direct Vent Vertical Install...

Страница 33: ...eaves 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 Outdoor models must...

Страница 34: ...e 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 Functions When there is a call for hea...

Страница 35: ...of the gas valve on the inlet flange to the gas valve and is accessible through the removable access panels on the side or front of the heater to reset the gas pressure switch as necessary It is used...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 43: ...43 WIRING DIAGRAM Models 503A 2003A...

Страница 44: ...Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to turn the gas control valve handle Never use tools If the handle will not tur...

Страница 45: ...roximately 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 located just b...

Страница 46: ...ion USER TEST is displayed in the Title Field UP keystrokes are used to advance through the user test The Boil MIN MAX steps for burner operation are only run for enabled boilers Local Heat DHW EMS de...

Страница 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...

Страница 48: ...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 return to nor...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 54: ...sure Vessel Code Section IV Filter Maintenance Inspect quarterly Replace when tracking pressure exceeds 0 5 in WC at 100 fan speed except for models 1003A 1753A and 2003A which need to be replaced whe...

Страница 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...

Страница 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...

Страница 57: ...PLACEMENT 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...

Страница 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 ____...

Страница 59: ...59...

Страница 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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