Rheem Raypak MVB 503A User manual
Models 503A–2003A
Types H & WH
INSTALLATION AND
OPERATION MANUAL
WARNING:Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury, exposure to hazardous materials* or loss of
life. Review the information in this manual carefully. *This unit contains materials that
have been identified as carcinogenic, or possibly carcinogenic, to humans.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable 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 appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
the gas supplier.
CONTENTS
1. WARNINGS ............................................................. 4
2. GENERAL SAFETY................................................ 5
3. BEFORE INSTALLATION...................................... 6
4. INSTALLATION....................................................... 8
5. CONTROLS........................................................... 31
6. WIRING DIAGRAM............................................... 40
7. START-UP.............................................................. 41
8. OPERATION.......................................................... 46
9. TROUBLESHOOTING ......................................... 46
10. MAINTENANCE.................................................... 49
11. ILLUSTRATED PARTS LIST............................... 52
ADANGER: Make sure the gas on which the heater will
rating plate.
AWARNING: Should overheating occur or the gas
gas supply at a location external to the heater.
AWARNING: Do not use this heater if any part has
technician to inspect the heater and to replace any part
of the control system and any gas control which has
been under water.
AWARNING: To minimize the possibility of improper
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.
AWARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize the
equipment before servicing.
ACAUTION: This heater requires forced water
circulation when the burner is operating. See minimum
ACAUTION: Operation of this heater in low
temperature systems requires special piping. Harmful
internal condensation will occur if the inlet water
temperature does not exceed 120°F (49°C). Warranty
claims will be denied when condensation occurs.
ACAUTION: If this heater is to be installed above
radiation level, it must be provided with a low water cut-
ACAUTION: If this heater is to be installed in a negative
or positive pressure equipment room, there are special
installation requirements. Consult factory for details.
1. WARNINGS
Pay Attention to These Terms
AWARNING: UL recognized fuel gas detectors are
recommended in all enclosed propane and natural gas
applications wherein there is a potential for an explosive
mixture of fuel gas to accumulate and their installation
should be in accordance with the detector manufacturer’s
recommendations and/or local laws, rules, regulations,
or customs.
AWARNING: Both natural gas and propane have
an odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or recognize
this odorant. If you are unsure or unfamiliar with the
smell of natural gas or propane, ask your local gas
supplier. Other conditions, such as “odorant fade,”
which causes the odorant to diminish in intensity, can
ADANGER
AWARNING
ACAUTION
CAUTION
NOTE
Water temperature over 125°F can
cause instant severe burns or death
from scalds.
Children, disabled, and elderly are
at highest risk of being scalded.
See instruction manual before set-
ting temperature at water heater.
Feel water before bathing or show-
ering.
Temperature limiting valves are
available, see manual.
2. GENERAL SAFETY
NOTE: When this water heater is supplying
general purpose hot water for use by individuals, a
thermostatically-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.
ACAUTION: Hotter water increases the risk of
scalding! There is a hot water scald potential if the
thermostat is set too high.
Time/Temperature
Relationships in Scalds
Table A
®
page 31
Water Temp. Time to Produce Serious Burns
Table A. Time to Produce Serious Burn
3. BEFORE INSTALLATION
Product Receipt
Standards:
AWARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube bundle
headers, or any ASME parts not manufactured and/or
approved by Raypak will instantly void the ASME and
CSA ratings of the vessel and any Raypak warranty
on the vessel. Altering the ASME or CSA ratings of the
vessel also violates national, state, and local approval
codes.
Installations at Elevation
Table B. Basic Data
GAS TRAIN
BLOWER
OPERATING
CENTER
HEAT EXCHANGE
ASSEMBLY
FRONT OF
HEATER
BURNER FLAME
VIEWING PORT
F10210
BURNER
FRONT OF HEATER
IGNITER
FLAME
SENSOR
F10213
GAS SUPPLY
CONNECTION
WATER
OUTLET
COMBUSTION
AIR INLET
HIGH VOLTAGE
ELECTRICAL
CONNECTIONS
WATER INLET
FLUE OUTLET
PRESSURE
RELIEF
VALVE
F10212
Component Locations
Figure 4. Component Locations – Top
Figure 3. Component Locations – Rear
Figure 2. Component Locations – Front
LOW
VOLTAGE
SWITCH
HIGH
VOLTAGE
SWITCH
LOW VOLTAGE
ELECTRICAL
CONNECTIONS
F10211
Figure 1. Component Locations – Side
Model
No.
Input
MBTUH (Kwh) Water
Conn.
(NPT)
Gas
Conn.
(NPT)
Vent Size
in. (mm)
Max. Min. N P Flue Intake
503A
753A
1003A
1253A
1503A
1753A
2003A
Figure 5
Clearances
Indoor Installations
Heater
Side
Min. Clearance
from Combustible
Surfaces**
in. (mm)
Minimum Service
Clearance
in. (mm)
Table C. Clearances – Indoor Installations
4. INSTALLATION
Installation Codes
Equipment Base
ACAUTION: This heater should be located in an area
where water leakage will not result in damage to the area
adjacent to the appliances or to the structure. When such
locations cannot be avoided, it is recommended that
a suitable catch pan, adequately drained, be installed
31.88"
(81 cm)
0.56" (14 mm)
24.50"
(62 cm)
FRONT OF UNIT F10214
0.75"
(19 mm)
1.125"
(29 mm)
REAR OF UNIT
4 x 0.56" Ø
(14 mm)
Figure 5. Anchor Hole Locations
Outdoor Installations
MUST
MUST
TOP VIEW
24" (610 mm)
SERVICE
CLEARANCE
REAR EXHAUST INSTALLATION
FRONT VIEW
VERTICAL CLEARANCE
(ALL INSTALLATIONS)
10" (254 mm)
SERVICE
CLEARANCE
F10215
1" (25 mm) *
* Must have 12" (305 mm) service clearance on 1 side.
1' (305 mm) *
Figure 6. Minimum Clearances from Combustible
Surfaces – Indoor and Outdoor Installations
Heater Side
Min. Clearance from
Combustible Surfaces
in. (mm)
Minimum Service
Clearance
in. (mm)
Table D. Clearances – Outdoor Installations
A
V = VENT
X = AIR INLET
F10692
V
G
H
A
B
B
V
V
B
BV
AJ
X
IM
VX
K
V
V
B
F
C
OPERABLE FIXED
CLOSED
FIXED
CLOSED
INSIDE
CORNER DETAIL
OPERABLE
D
L
B
E
V
V
Figure 7. Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table E. Vent/Air Inlet Termination Clearances
U.S. Installations1Canadian Installations 2
* *
*
E * *
F * *
G *
*
*
J
K
*
1
2
t
*
Combustion and Ventilation
Inside Air Contamination
Indoor Units
CAUTION:
NOTE: Use of this heater in construction areas where
is present may result in damage to the heater that is not
covered by the warranty. If operated in a construction
environment, a clean source of combustion air must be
provided directly to the heater.
NOTE: It is recommended that the intake vent be
insulated to minimize sweating.
Air Filter
F10676
Figure 8. Air Filter Box
AWARNING: Do not use the “one permanent opening”
method if the equipment room is under negative pressure
conditions.
ACAUTION: All combustion air must be drawn from
the air outside of the building; the mechanical equipment
room must communicate directly with the outdoors.
Canadian Installations
AWARNING: Care must be taken to ensure that
the equipment room is not under negative pressure
conditions.
Conventional Combustion Air Supply
ACAUTION: Use TruSeal combustion air if damaging
airborne contaminants are or may be present in the
heater area. See "Inside Air Contamination"regarding air
contamination.
U.S. Installations
All Air from Inside the Building
TWO
Each opening
All Air from Outdoors
1. Two permanent openings
each opening
2. One permanent opening
Ducted Combustion Air
Figure
30Figure 31
Truseal™ Direct Vent Combustion Air
MUST
Motorized Combustion Air Dampers or
Louvers
Water Piping
General
ACAUTION: This heater requires forced water
circulation when the burner is operating. See Table F and
Table G
must be interlocked with the heater to prevent heater
operation without water circulation.
NOTE: Minimum pipe size for in/out connections is 2
in. NPT for 503A and 753A models and 2-1/2 in. NPT for
instructed in this manual.
Relief Valve Piping
AWARNING: Pressure relief valve discharge piping
eliminate the potential of severe burns. Do not pipe
to any area where freezing could occur. Refer to local
codes.
Temperature & Pressure Gauge
Hydrostatic Test
ACAUTION: Damage due to internal condensation
may occur if the heater inlet water temperature does not
exceed 120°F (49°C) within 7 minutes of start-up.
Cold Water Operation
Warranty claims will be denied for
damage or failures caused by condensation.
Cold Water Starts
must have cold water start
protection
SYSTEM
RETURN
SYSTEM
RETURN
MAIN
SYSTEM
PUMP
SYSTEM
TEMP
PRESSURE
BYPASS
SYSTEM
T & P GAUGE
COLD WATER
TEMP SENSOR
LOCATED IN
INLET HEADER
AB B
A
HEATER
F10677
MAXIMUM 4
TIMES THE
SYSTEM PIPE
DIAMETER, NOT
TO EXCEED 12"
(305 mm)
Figure 9. Cold Water Start
Cold Water Run
T & P GAUGE
HEATER
SYSTEM
TEMP
SENSOR
MAIN
SYSTEM
PUMP
INJECTOR
PUMP TEMP
SENSOR
BOILER
PUMP
INJECTOR
PUMP
SYSTEM
RETURN
SYSTEM
RETURN
F10678
MAXIMUM 4
TIMES THE
SYSTEM PIPE
DIAMETER, NOT
TO EXCEED 12"
(305 mm)
Figure 10. Cold Water Run
Hydronic Heating
Pump Selection
Table F
Feedwater Regulator
Piping
NOTE: Hot water heating systems all have unique levels
of operating diversity that must be accounted for in
the system design. The system should always include
cycling and may reduce boiler life. Always contact
your local Raypak representative for system design
assistance to avoid these issues.
Air-Separation/Expansion Tank
Figure 11
EXPANSION TANK
AIR SEPARATOR
WITH BLEED VALVE
Figure 11. Air-Separation/Expansion Tank
Three-Way Valves
Table F. Heater Rates of Flow and Pressure Drops
MVB
Model
Min Flow Max Flow
GPM (lpm) GPM (lpm) GPM (lpm) GPM (lpm)
°F (°C) GPM (lpm) PT
°F (°C)
503A
753A
1003A
1253A
1503A
1753A
2003A
Figure 13. MODE 1 - Boiler Cascade with Primary/ Secondary Piping
S1a S2a P2a
S3a
S1b S2b
P1b S1c S2c
P1c S1d S2d
P1d
AB C D
MODE 1 CASCADE
A = MASTER B-D = FOLLOWER UNITS
S4a
(MASTER)
PIM
VERSA
PIM
VERSA
PIM
VERSA
PIM
VERSA
P1a
MODBUS
0-10 VDC / 4-20mA
ENABLE
1
CONNECT SYSTEM PUMP
CASCADE FOLLOWER
IN PARALLEL FROM EACH
OUTPUT
F10515
FACTORY INSTALLED SENSOR
FIELD INSTALLED SENSOR 1
Maximum distance 4 system pipe
diameters, not to exceed 12" (305 mm)
Applications and Modes
®
Mode 1 (Type H Units Only)
®
®
ADJUST Figure
12Figure 13
NOTE: MODE 1 can also be used for process heating
when operating temperatures above 160°F are required.
Care must be given to ensure water hardness is no more
than 15 grains per gallon for scale-free operation.
NOTE: See VERSA IC®manual (241493) for additional
details.
S1 S2
P2
S3
S4
MODE 1
P1
VERSA PIM
1
MODBUS
0-10 VDC / 4-20mA
ENABLE
FACTORY INSTALLED SENSOR
FIELD INSTALLED SENSOR
1
Maximum distance 4 system pipe diameters, not to
exceed 12" (305 mm)
F10514
Figure 12. MODE 1 - Single Boiler with Primary/Secondary
Piping
Mode 2 (Type H Units Only)
ADJUST
Figure 14
MODBUS VERSA
AQUASTAT
LOCATED IN
OUTLET PIPE
PIM
S4
S1
P1
S2
S3
P2
S5
P3
1
ENABLE
0–10 / 4–20mA
F10710
FACTORY INSTALLED SENSOR
FIELD INSTALLED SENSOR
1Maximum distance 4 system pipe diameters,
not to exceed 12" (305 mm)
Figure 14. MODE 2 - Single Boiler with Indirect in System
Loop
Mode 3 (Type H Units Only)
not active
ADJUST
Figure 15
NOTE: A Tank Aquastat can be used in lieu of the
Indirect DHW Sensor (S5). See the VERSA IC®manual
(241493) for additional details.
NOTE:
DHW pump (if applicable) outputs from each cascade
member and must be connected in parallel to active
the system pump and DHW pump during "limp-along"
operation respectively. See the VERSA IC®Manual
(241493) for additional details.
F10516
S1 S2
P2
S3
S4
MODE 3
FACTORY INSTALLED SENSOR
FIELD INSTALLED SENSOR
S5
P1
P3 S6
PIM
VERSA
MODBUS
0-10 VDC / 4-20mA
ENABLE
1
AQUASTAT
LOCATED IN
OUTLET PIPE
1
1
Maximum distance 4 system pipe diameters,
not to exceed 12" (305 mm)
Figure 15. MODE 3 - Single Boiler with Indirect on Boiler
Loop
Domestic Hot Water
Table G. Domestic Water Heater Flow Rate Requirements
ADJUSTFigure 16
FACTORY INSTALLED SENSOR
FIELD INSTALLED SENSOR
F10521
S1 S2
DIRECT
DHW/PROCESS
S3
P1
HW SUPPLY
HW RETURN
CITY
WATER
VERSA PIM
MODBUS
0-10 VDC / 4-20mA
ENABLE
TANK
P2
Figure 16. WH Units - Single Water Heater with Tank H
Units - Single Boiler with Process Tank
NOTE: If local codes require a vacuum relief valve,
acquire one locally and install per valve manufacturer’s
instructions.
MVB
Model
WATER HARDNESS
SOFT* MEDIUM HARD*
3-4 Grains Per Gallon 5-15 Grains Per Gallon 16-25** Grains Per Gallon
T
°F (°C)
GPM
(lpm)
P
(ft wc)
MTS
(in)
SHL
(ft wc)
T
°F (°C)
GPM
(lpm)
P
(ft wc)
MTS
(in)
SHL
(ft wc)
T
°F (°C)
GPM
(lpm)
P
(ft wc)
MTS
(in)
SHL
(ft wc)
503A
753A
1003A
1253A
1503A
1753A
2003A
**Caution:°°
Potable Water and Space Heating
ACAUTION: When this heater is used for both potable
water and space heating, observe the following to ensure
proper operation.
Automatic Chemical Feeders
NOTE: WH units will operate to a maximum tank
temperature of 160°F (71°C). For temperatures required
above 160°F (71°C) an “H” model boiler must be used
and great care must be given to ensure water hardness
is no more than 15 grains per gallon for scale-free
setpoint operation for process heating applications.
ACAUTION:
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.
ACAUTION: 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.
FAILURE TO FOLLOW THIS
PROCEDURE MAY DAMAGE THE GAS VALVE
MUST BE SUPPLIED
BY INSTALLER
MANUAL BALL
VALVE
WRENCHING
NIPPLE
ELBOW
STREET ELBOW 1'
MANUAL SHUTOFF
VALVE
ZERO GOVERNOR
ON /OFF COMBO VALVE
REAR
JACKET
SEDIMENT
TRAP
UNION
F10691
Figure 17. Gas Supply Connection
Table H. Gas Supply Piping Length
Model
No.
Maximum Equivalent Length, ft. (m)
1 in. NPT 1-1/4 in. NPT 1-1/2 in. NPT 2 in. NPT 2-1/2 in. NPT
NAT PRO NAT PRO NAT PRO NAT PRO NAT PRO
503A
753A
1103A
1253A
1503A
1753A
2003A
ACAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
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
warranty.
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.
Gas Supply
ADANGER: Make sure the gas on which the heater
rating plate.
must
and
Table H
Gas Supply Connection
ACAUTION: 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
ACAUTION: For proper operation, no more than a
30% drop in gas supply pressure from no-load to full-
load conditions is acceptable. Under no circumstances
should the pressure be outside the listed operational
range.
NOTE: During normal operation, carbon dioxide should
for propane gas. Carbon monoxide should be ‹100ppm
Electrical Power Connections
Figure 18.
Figure 18
Figure 22
FIELD WIRING
FACTORY WIRING
SYSTEM
SUPPLY
PUMP
5A MAX
DHW
PUMP
5A MAX
GND
COM
HOT
(120V)
GND
COM
HOT
(120V)
GROUND
COMMON
HOT
(120V)
P/N 902062 REV 1
F10688
9
8
7
6
5
4
3
2
1
Figure 18. Wiring Electrical Connections
Field-Connected Controllers
NOTE: Field-supplied isolation relays should be
more than 50 equivalent feet (18 AWG) from heater. See
wiring diagrams.
NOTE: Minimum 18 AWG, 105°C, stranded wire must
be used for all low voltage (less than 30 volts) external
connections to the unit. Solid conductors should not
be used because they can cause excessive tension on
contact points. Install conduit as appropriate. All high
voltage wires must be the same size (105°C, stranded
wire) as the ones on the unit or larger.
Check the Power Source
AWARNING: Using a multi-meter, check the following
voltages at the circuit breaker panel prior to connecting
any equipment. Make sure proper polarity is followed
and house ground is proven. (See Figure 19.)
This manual suits for next models
6
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