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  5. Installation & Operating Instructions Manual

Raypak 1003A Installation & Operating Instructions Manual

Manual is about: 503A–2003A Types H & WH

Summary of 1003A

  • Page 1

    Installation & operating instructions catalog no. 3400.531a effective: 10-03-13 replaces: 04-09-13 p/n 241511 rev. 2 warning: improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, exposure to hazardous materials* or loss of life. Review the...

  • Page 2

    2 rev. 2 reflects the following: changes to: table a on page 8, table i on page 20, “electrical power connections” on page 20, table j on page 27, table 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 ma...

  • Page 3

    Warnings 4 before installation 5 product receipt 5 model identification 5 ratings and certifications 5 installations at elevation 5 component locations 6 general information 6 general safety 7 time/temperature relationships in scalds 7 installation 8 installation codes 8 equipment base 8 clearances ...

  • Page 4

    4 danger: indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Warning: indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Ca...

  • Page 5

    5 before installation raypak strongly recommends that this manual be re- viewed thoroughly before installing your mvb heater. Please review the general safety information before installing the heater. Factory warranty does not apply to heaters that have been improperly installed or oper- ated. (refe...

  • Page 6

    General information table a: basic data 6 component locations panels omitted for clarity fig. 1: component locations – side top panel, blower and gas train omitted for clarity fig. 4: component locations – top fig. 3: component locations – rear panels omitted for clarity fig. 2: component locations ...

  • Page 7

    7 general safety to meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 210°f. However, water temperatures over 125°f can cause instant severe burns or death from scalds. When supplying general...

  • Page 8

    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 enclosed parking garages must be located at least 18 in. Above the floor. I...

  • Page 9

    9 fig. 6: minimum clearances from combustible surfaces – indoor and outdoor installations lation codes and the requirements of the gas supplier. Three sides must be open in the area under the over- hang. Roof water drainage must be diverted away from heaters installed under overhangs. The combustion...

  • Page 10

    10 u.S. Installations 1 canadian installations 2 a clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) b clearance to window or door that may be opened 4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) c clearance to permanently closed w...

  • Page 11

    11 air filter an air filter is supplied standard with the heater. This filter is shipped loose for field installation. Refer to the air filter kit installation instructions (part no. 241338) for details. Direct vent if outside air is drawn through the intake pipe directly to the unit for combustion:...

  • Page 12

    All air from outdoors the confined space shall communicate with the out- doors in accordance with one of the methods below. The minimum dimension of air openings shall not be less than 3 in. (76 mm) in any direction. Where ducts are used, they shall be of the same cross-sectional area as the net fre...

  • Page 13

    4. Refer to the b149 installation code for additional information water piping general the heater should be located so that any water leaks will not cause damage to the adjacent area or struc- tures. Relief valve piping temperature & pressure gauge the temperature and pressure gauge is shipped loose...

  • Page 14

    14 cold water starts cold water starts, where the inlet water temperature remains below 120°f (49°c) must have cold water start protection. Known protection methods consist of mixing heated outlet water with the inlet water using a bypass to raise the inlet to 120°f (49°c) or higher. Once the system...

  • Page 15

    15 table f: heater rates of flow and pressure drops notes: basis for minimum flow is ∆t . Basis for maximum flow is gpm. Piping all high points should be vented. A heater installed above radiation level must be provided with a low wa- ter cut-off device (sales order option f-10). This heater, when u...

  • Page 16

    16 mode 2 (type h units only) this mode selection is for hydronic heating systems with single or multiple boilers (maximum 4 boilers) in primary/secondary piping configuration with or without outdoor air reset (s4) with indirect dhw on the sys- tem loop (with or without priority). The system tempera...

  • Page 17

    17 mode 3 (type h units only) this mode selection is for hydronic heating systems with single or multiple boilers (maximum 4 boilers) in primary/secondary piping configuration with or without outdoor air reset (s4) with indirect dhw on the boil- er loop (with priority). The system temperature is con...

  • Page 18

    Note: failure of a heat exchanger due to lime scale build-up on the heating surface, low ph or other chemical imbalance is non-warrantable. Note: high chemical concentrates from feeders that are out of adjustment will cause rapid corrosion to the heat exchanger. Such damage is not covered under the ...

  • Page 19

    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 mus...

  • Page 20

    20 the mvb 503a-1503a heaters are wired for 120 vac, 12 amps while the mvb 1753a & 2003a heaters are wired for 120 vac, 18 amps. Consult the wiring dia- gram shipped with the heater. Before starting the heater, check to ensure proper voltage to the heater and pump. Pumps must use a separate power su...

  • Page 21

    Making the electrical connections refer to fig. 18-21. 1. Verify that circuit breaker is properly sized by referring to heater rating plate. A dedicated circuit breaker should be provided. 2. Note: current draw noted on rating plate does not include pump current. 3. Turn off all power to the heater....

  • Page 22

    22 fig. 21: wiring location fig. 22: locator dimples for optional components fig. 23: low voltage field wiring contact closure (including a remote thermostat) across these terminals will enable the mvb unit to run. Caution should be used to ensure neither of the termi- nals becomes connected to grou...

  • Page 23

    23 drive (up) input and a target temperature (down) setpoint. 3. For a 4-20ma application, refer to the versa ic manual (cat. 5000.72). 4. Connect an energy management system or other auxiliary control signal to the terminals marked 0- 10v (+ /-) on the pim™ (see fig. 23). Caution should be used to ...

  • Page 24

    24 versa master master followers fig. 25: mvb cascade system wiring fig. 26: mvb cascade master pumps cascade system pump and sensor wiring 1. On the boiler designated as the master, connect the system pump enable wiring to the terminal block at the rear of the unit. The connections are dry contacts...

  • Page 25

    25 note: this dry contacts closure can come from a room thermostat or a remote relay. No power of any kind should be applied to either of these terminals. 5. Connect the enable/disable wiring to terminals 11 and 12 on the field wiring strip located on the master boiler (see fig. 23). This connection...

  • Page 26

    26 table j: venting category requirements venting general appliance categories heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Category i – a heater which operates with a non-pos- itive vent static pressu...

  • Page 27

    27 vent terminal location 1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 2. Give special attention to the location of the vent termination to avoid possibility of property dam- age or personal injury. 3. Gases may form a white vapo...

  • Page 28

    28 1. Vent must terminate at least 4 ft below, 4 ft hori- zontally from or 1 ft above any door, window or gravity air inlet to the building. 2. The vent must not be less than 7 ft above grade when located adjacent to public walkways. 3. Terminate vent at least 3 ft above any forced air inlet located...

  • Page 29

    29 table k: category iv vertical venting * special vent materials are still required. ** subtract 10 ft per elbow. Max. 4 elbows. T adapters supplied by others. Termination the vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the highest point of the r...

  • Page 30

    30 warning: vent connectors serving any other appliances shall not be connected into any portion of 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...

  • Page 31

    31 fig. 31: horizontal through-the-wall venting fig. 32: alt. Horizontal through-the-wall 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, howev...

  • Page 32

    32 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 prevent the potential accumulation of condensate in the vent pipes. It is required that: 1. The vent must be ins...

  • Page 33

    33 the total length of air supply pipe cannot exceed the distances listed in tables l and m. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in any arrangement that does not exceed the lengths shown in tables l and m. The vent cap is not considered in the overall len...

  • Page 34

    Freeze protection to enable freeze protection, dip switch position 7 (on the pim™) must be turned on (up position). This is the default position. If the water temperature drops below 45˚f on the outlet or inlet sensors, the boiler pump is enabled. The pump is turned off when both the inlet and outle...

  • Page 35

    35 fig. 36: high limit (manual reset) high limit—auto reset (optional) this heater may be equipped with an optional adjust- able auto reset high limit temperature device. The optional adjustable auto reset high limit is located inside the heater junction box. Adjust the setting to approx. 20°f (10°c...

  • Page 36

    36 fig. 40: high/low gas pressure switch blocked vent switch this heater is equipped with a blocked vent pressure switch to prevent the operation of the heater when too much of the vent is blocked. This switch is located on the right side of the heater near the right rear corner. Fig. 41: blocked ve...

  • Page 37

    37 table n: view menu item application description outdoor h mode 1,2,3 outdoor air temperature boil target h mode 1,2,3 current target temperature supply h mode 1,2,3 current system supply temperature boil outlet all current boiler outlet temperature boil inlet all current boiler inlet temperature ...

  • Page 38

    38 table o: setup/adjust menu item application range description default boiler 1 all on off enable or disable the operation of boilers. 4 boiler range, 1 is enabled by default on target h mode 1,2,3 rset setp rset = outdoor reset, setp =setpoint setp tank setp wh off, 50°f to 150°f tank set point t...

  • Page 39

    39 boiler menu the boiler view displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information table p: boiler menu item application description ignition all current state of ignition limit temp all current limit temperature aux t...

  • Page 40

    40 monitor menu the monitor menu records and displays critical boiler information, such as, cycle times, run times, and maximum/minimum temperature readings depending on the setup. Table q: monitor menu item application description run time burner 1 all burner run time (hours). Press up/down for 1 s...

  • Page 41

    41 toolbox menu the toolbox menu logs all error codes from the btcii and pim™, as well as other functions. Up to 15 error codes can be logged for a maximum of 24 days. Table r: toolbox menu outdoor reset concept the temperature controller can change the system set point based on outdoor temperature ...

  • Page 42

    42 note: the wiring diagrams in this manual show all standard options. Refer to the large wiring diagram provided with your heater for options installed on your specific unit(s). Reset ratio the control uses the four following settings to determine the reset ratio: boiler start (boil start) the boil...

  • Page 43

    43 wiring diagram - models 503a–2003a.

  • Page 44

    44 start-up pre start-up filling system (heating boilers) fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close ven...

  • Page 45

    45 preparation check power supply with multi-meter at incoming power, check voltage between: hot - common (≈120 vac) hot - ground (≈120 vac) common - ground ( 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 ...

  • Page 46

    46 blower check 1. Check blower suction using the manometer attached to the air pressure tee as shown in fig. 45, with the heater firing at 100% input. The reading should be as noted in table s for both nat- ural and propane gas. 2. When firing at 100%, the desired heater combus- tion co2 is 9.0% ± ...

  • Page 47

    47 follow-up safety checks must be recorded as performed. Turn heater on. After main burner ignition: 1. Check manometer for proper readings. 2. Cycle heater several times and re-check readings. 3. Remove all manometers and replace caps and screws. 4. Check for gas leaks one more time. Leak test pro...

  • Page 48

    48 fig. 46: leak test procedure post start-up check check off steps as completed: 1. Verify that the heater and heat distribution units or storage tank are filled with water. 2. Confirm that the caps on the automatic air vent valves were opened two full turns during the vent- ing procedure. 3. Verif...

  • Page 49

    49 operation lighting instructions 1. Before operation, make sure you have read all of the safety information in this manual. 2. Remove upper front panel. 3. Set the thermostat to the lowest setting. 4. Turn off all electrical power to the appliance. 5. This appliance is equipped with an ignition de...

  • Page 50

    50 2. Note the error code, either through the flash code on the pim™ and/or from the toolbox menu on the user interface, and reference the explanation of the fault along with troubleshooting steps in the mvb fault text section. 3. Press and release the reset key to clear the fault on the user interf...

  • Page 51

    51 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. Perfo...

  • Page 52

    52 maintenance suggested minimum maintenance schedule regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. Daily and monthly maintenance as outlined below may be performed by onsite maintenance staff. Daily 1. Check that the area whe...

  • Page 53

    53 3. Check that area is free from combustible materi- als, gasoline, and other flammable vapors and liquids. 4. Check air filter and replace as necessary. 5. Follow pre-start-up check in the start-up section. 6. Visually inspect burner flame. It should be light blue at full input. Remove and visual...

  • Page 54

    54 6. Perform leakage test on gas valves. (see fig. 46.) 7. Inspect and clean burner using shop air. As required 1. Recondition or replace low water cut-off device (if equipped). 2. Check sediment trap and gas strainers. 3. Check flame failure detection system. (see “post start-up check,” page 46.) ...

  • Page 55

    55 appendix inside air contamination all heaters experience some condensation during start-up. The condensate from flue gas is acidic. Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stai...

  • Page 56

    56 (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 fuel...

  • Page 57

    57 limited parts warranty mvb – types h and wh models 503a-2003a scope raypak, inc. (“raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by raypak will be free from failure under normal use and service for the specified warranty periods and subject ...

  • Page 58: Raypak Products

    58 start-up checklist for fan-assisted raypak products this start-up checklist is to be completely filled out by the service technician starting up the raypak boiler or heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. Additi...

  • Page 59

    59.

  • Page 60: Www.Raypak.Com

    60 www.Raypak.Com raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (805) 278-5468 litho in u.S.A..