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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 length of

the venting system.

Care must be taken during assembly that all joints are

sealed properly and are 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 be insulated through the length of

the horizontal run.

Termination

The vent cap MUST be mounted on the exterior of the

building. The vent cap cannot be installed in a well or

below grade. The vent cap must be installed at least 1

ft above ground level and above normal snow levels.

The vent cap MUST NOT be installed with any com-

bustion air inlet directly above a vent cap. This vertical

spacing  would  allow  the  flue  products  from  the  vent

cap to be pulled into the combustion air intake installed

above.

This  type  of  installation  can  cause  non-warrantable

problems with components and poor operation of the

heater due to the recirculation of flue products. Multi-

ple  vent  caps  installed  in  the  same  horizontal  plane

must have a 4 ft clearance from the side of one vent

cap to the side of the adjacent vent cap(s).

Combustion air supplied from outdoors must be free of

particulate  and  chemical  contaminants.  To  avoid  a

blocked  flue  condition,  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 D-15).

Outdoor Installation

Outdoor  models  must  be  vented  with  listed

Category IV vent material per the following instructions

and installed with the factory-supplied outdoor vent kit.

A special vent cap and air intake hood are provided in

accordance  with  CSA  requirements.  These  must  be

installed  directly  on  the  vent  pipe  as  illustrated  in

Fig. 29. 

Care  must  be  taken  when  locating  the  heater  out-

doors,  because  the  flue  gases  discharged  from  the

vent  cap  can  condense  as  they  leave  the  cap.

Improper  location  can  result  in  damage  to  adjacent

structures  or  building  finish.  For  maximum  efficiency

and  safety,  the  following  precautions  must  be

observed:

1. Outdoor  models  must  be  installed  outdoors  and

must use the outdoor vent cap and air intake hood

available  from  the  manufacturer  (sales  order

option D-11).

2. Periodically  check  venting  system.  The  heater’s

venting  areas  must  never  be  obstructed  in  any

way and minimum clearances must be observed

to prevent restriction of combustion and ventilation

air. Keep area clear and free of combustible and

flammable materials.

3. Do not locate adjacent to any window, door, walk-

way,  or  gravity  air  intake.  The  vent  must  be

located a minimum of 4 ft horizontally from such

areas.

4. Install above grade level and above normal snow

levels.

5. Vent  terminal  must  be  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.

WARNING: 

No  substitutions  of  flue  pipe  or  vent

cap material are allowed. Such substitutions would

jeopardize the safety and health of inhabitants.

NOTE:

The vent cap and air intake hood must be

furnished by the heater manufacturer in accordance

with its listing (sales order option D-11).

CAUTION:

Use  of  double-wall  vent  pipe  is

recommended to minimize the risk of personal injury.

Summary of Contents for 503A

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: ...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...

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: ...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...

Page 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...

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: ...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...

Page 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...

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: ...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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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: ...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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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: ...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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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 503A 2003A...

Page 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...

Page 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...

Page 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...

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: ...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...

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: ...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...

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: ...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...

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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