Manual MVB RAY PACK

INSTALLATION & OPERATING
INSTRUCTIONS
Models 25034003
Types H & WH
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.
If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3400.56A
Effective: 10-08-13
Replaces: 03-28-13
P/N 241510 Rev. 2
Rev. 2 reflects the following:

Changes to: Outdoor Installation on page 9, Table G on page 18, Gas Supply Pressure on page 19, Table J on
page 26, Table K on page 29, Warning on page 30, Note on page 30, Table M on page 32, High Limits on pages 34-35,
Wiring Diagram on page 43, Blower Check on page 46.
Additions: Motorized Combustion Air Dampers or Louvers on page 11, Flushing/Cleaning of System Piping on
page 13, Extractors, Draft Inducers, and Motorized Flue Dampers on page 27, Fig. 30 on page 30, Fig. 46 on page 45
Deletions: None
CONTENTS
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
Water Piping
Hydronic Heating
Applications & Modes
Domestic Hot Water
Gas Supply
Electrical Power Connections
Field Wiring Connection
Venting
Venting Installation Tips
Venting Configurations
Outdoor Installation
Controls
User Interface
WIRING DIAGRAMS
START-UP
Pre Start-up
Start-Up
OPERATION
Lighting Instructions
To Turn Off Gas To Appliance
TROUBLESHOOTING
MAINTENANCE
Suggested Minimum
Maintenance Schedule
Preventative Maintenance Schedule
Filter Maintenance
Filter Replacement
APPENDIX
Inside Air Contamination
IMPORTANT INSTRUCTIONS FOR
THE COMMONWEALTH OF
MASSACHUSETTS
WARRANTY
START-UP CHECKLIST
4
5
5
5
5
5
6
6
7
7
8
8
8
8
9
11
12
14
15
17
19
20
21
26
28
28
33
34
36
43
44
44
45
49
49
49
49
52
52
53
54
54
55
55
56
57
58
WARNINGS
Pay Attention to These Terms
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.
CAUTION:
Indicates the presence of hazards or unsafe practices which could cause

minor personal injury or product or property damage if ignored.
NOTE:
Indicates special instructions on installation, operation, or maintenance which

are important but not related to personal injury hazards.
DANGER: Make sure the gas on which the heater

will operate is the same type as that specified on the
heater rating plate.
WARNING: 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 also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.
WARNING: Should overheating occur or the gas

supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.
WARNING: 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.
WARNING: To minimize the possibility of improper

operation, serious personal injury, fire, or damage to
the 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.
WARNING - CALIFORNIA PROPOSITION

65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
CAUTION: Operation of this heater in low
temperature systems requires special piping.
Harmful internal condensation will occur if the inlet
water temperature does not exceed 120F. Warranty
claims will be denied when condensation occurs.
WARNING: Risk of electrical shock. More than one

disconnect switch may be required to de-energize
the equipment before servicing.
CAUTION: If this heater is to be installed above

radiation level, it must be provided with a low water
cut-off device at the time of heater installation.
CAUTION: This heater requires forced water

circulation when the burner is operating. See
minimum and maximum flow rates. Severe damage
will occur if the heater is operated without proper
water flow circulation.
CAUTION: If this heater is to be installed in a

negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
4
BEFORE INSTALLATION
the upper rear jacket panel of the heater. The model

number will have the form H7-2503 or similar depending on the heater size and configuration. The letter(s)
in the first group of characters identifies the application
(H = Hydronic Heating, WH = Domestic Hot Water
(DHW)). The number which follows identifies the firing
mode (7 = electronic modulation). The second group
of characters identifies the size of the heater (the four
numbers representing the approximate MBTUH input),
and, where applicable, a letter, indicating the manufacturing series.
Raypak strongly recommends that this manual be reviewed 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 operated. (Refer to the warranty at the back of this
manual.) Installation and service must be performed
by a qualified installer, service agency or gas supplier.
If, after reviewing this manual, you still have questions
which this manual does not answer, please contact
your local Raypak representative or visit our website at
www.raypak.com.
Ratings and Certifications

Standards:
Thank you for purchasing a Raypak product. We hope

you will be satisfied with the high quality and durability
of our equipment.
Product Receipt
On receipt of your heater it is suggested that you visually check for external damage to the shipping crate. If
the crate is damaged, make a note to that effect on the
Bill of Lading when signing for the shipment. Next,
remove the heater from the shipping packaging.
Report any damage to the carrier immediately.
ANSI Z21.13 CSA 4.9 - latest edition, Gas-Fired

Hot Water Boilers
CAN 3.1 - latest edition, Industrial and
Commercial Gas-Fired Package Boilers
ANSI Z21.10.3 CSA 4.3 - latest edition, Gas Water Heaters
Low-lead content (<.25%) CSA-certified
All Raypak heaters are National Board Approved, and

design-certified and tested by the Canadian Standards
Association (CSA) for the U.S. and Canada. Each
heater is constructed in accordance with Section IV of
the American Society of Mechanical Engineers
(ASME) Heater Pressure Vessel Code and bears the
ASME stamp. This heater also complies with the latest
edition of the ASHRAE 90.1 Standard.
On occasion, items are shipped loose. Be sure that

you receive the correct number of packages as indicated on the Bill of Lading.
Claims for shortages and damages must be filed with
the carrier by consignee. Permission to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.
WARNING: 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.
When ordering parts, you must specify the model and

serial number of the heater. When ordering under warranty conditions, you must also specify the date of
installation.
Installations at Elevation
Purchased parts are subject to replacement only

under the manufacturers warranty. Debits for defective replacement parts will not be accepted. Parts will
be replaced in kind only per Raypaks standard warranties.
Rated inputs are suitable for up to 2,000 ft elevation

without de-rating. Consult your local representative or
the factory for installations at altitudes over 2,000 ft
above sea level. No hardware changes are required to
the heaters for installations up to 10,000 ft (adjustments may be required).
Model Identification
The model identification number and heater serial
number are found on the heater rating plate located on
5
Component Locations
RATING PLATE
GAS VALVE
Fig. 3: Component Locations Rear
Panels omitted for clarity

Fig. 1: Component Locations Side
PIM
VERSA IC
HIGH
VOLTAGE
SWITCH
LOW
VOLTAGE
SWITCH
Top panel, blower and gas train omitted for clarity

Fig. 4: Component Locations Top
General Information
Max
Min
Water
Conn.
(Groove)
2503
2501
350
3003
3000
3503
4003
Model
No.
Panels omitted for clarity

Fig. 2: Component Locations Front
MBTUH Input
Gas Conn.
(NPT)
N
4"
2-1/2
2-1/2
10
10
420
4"
2-1/2
2-1/2
10
10
3500
490
4"
2-1/2
2-1/2
12
12
4000
560
4"
2-1/2
2-1/2
12
12
Table A: Basic Data
Vent Size (in.)

Flue Intake
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
210F. However, water temperatures over 125F can
cause instant severe burns or death from scalds.
When supplying general purpose hot water, the recommended initial setting for the temperature control is
125F.
This section applies to Hot Water Supply Boilers and
Hot Water Heaters ONLY. For sanitary rinse applications where outlet temperatures of 180F to 195F are
required, a boiler is recommended since the 210F
limit on water heaters will NOT allow the heater to
maintain these desired sanitary rinse temperatures.
Water temperature over 125F can

cause instant severe burns or death
from scalds.
Children, disabled, and elderly are
at highest risk of being scalded.
Safety and energy conservation are factors to be considered when setting the water temperature on the
thermostat. The most energy-efficient operation will
result when the temperature setting is the lowest that
satisfies the needs of the application.
See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.
Water temperature over 125F can cause instant

severe burns or death from scalds. Children, disabled
and elderly are at highest risk of being scalded.
Temperature limiting valves are

available, see manual.
Feel water before bathing or showering.

Temperature limiting valves are available.
Time/Temperature
Relationships in Scalds
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.
The following chart details the relationship of water

temperature and time with regard to scald injury and
may be used as a guide in determining the safest
water temperature for your applications.
Maximum water temperatures occur just after the

heaters 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 thermometer.
CAUTION: Hotter water increases the risk of
scalding! There is a hot water scald potential if the
thermostat is set too high.
Water
Temp.
Time to Produce Serious

Burn
120F
More than 5 minutes
125F
1-1/2 to 2 minutes
130F
About 30 seconds
135F
About 10 seconds
140F
Less than 5 seconds
145F
Less than 3 seconds
150F
About 1-1/2 seconds
155F
About 1 second
Table courtesy of The Shriners Burn Institute
Table B: Time to Produce Serious Burn
INSTALLATION
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.
Installation Codes
Installations must follow these codes:
Local, state, provincial, and national codes, laws,

regulations and ordinances
National Fuel Gas Code, ANSI Z223.1/NFPA 54
latest edition (NFGC)
National Electrical Code, ANSI/NFPA 70 - latest
edition (NEC)
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1,
(CSD-1) when required
For Canada only: CAN/CSA B149 Natural Gas
and Propane Installation Code and CSA C22.1
C.E.C. Part 1 (C22.1)
CAUTION: 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 under the
appliance. The pan must not restrict air flow.
In addition, the heater shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation or service (circulator replacement, control
replacement, etc.).
If the heater needs to be secured to the ground, use
the hole pattern shown in Fig. 5, following local codes.
Clearances
Indoor Installations
Heater Side
Minimum Clearance
from Combustible
Surfaces
Minimum
Service
Clearance
Floor*
0"
0"
Rear
12"
36"
One Side
1"
1"
Opposite Side
1"
24"
Top
0"
10"
Front
Open
30"
Vent
1"
1"
* DO NOT install on carpeting
Table C: Clearances Indoor Installations
When installed according to the listed minimum clearances from combustible construction, these heaters
can still be serviced without removing permanent
structural construction around the heater. However, for
ease of servicing, a clearance of at least 30 in. in front,
24 in. on one side, at least 36 in. on the rear and 10 in.
above the top of the heater is required. This will allow
Fig. 5: Anchor Hole Locations
loose for field installation.

Heaters must not be installed under an overhang
unless clearances are in accordance with local installation codes and the requirements of the gas supplier.
Three sides must be open in the area under the overhang. Roof water drainage must be diverted away
from heaters installed under overhangs.
Fig. 7: Outdoor Air Intake
Heater Side
Minimum Clearance
from Combustible
Surfaces
Minimum
Service
Clearance
Rear
12"
36"
Front
Open
30"
One Side
Opposite
Side
1"
1"
1"
24"
Unobstructed
10"
12"
12"
Top
Vent
Termination
Fig. 6: Minimum Clearances from Combustible

Surfaces Indoor and Outdoor Installations
Table D: Clearances Outdoor Installations
the heater to be serviced in its installed location without movement or removal of the heater.
Combustion and Ventilation Air
Service clearances less than the minimum may

require removal of the heater to service either the heat
exchanger or the burner components. In either case,
the heater must be installed in a manner that will
enable the heater to be serviced without removing any
structure around the heater.
NOTE: Use of this heater in construction areas

where fine particulate matter, such as concrete or
dry-wall dust, 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.
Indoor Units
These units may be installed outdoors when used with

the outdoor air intake hood. The outdoor hood must
be ordered when ordering the unit, and is shipped
This heater must be supplied with sufficient quantities

of non-contaminated air to support proper combustion
and equipment ventilation. Combustion air can be sup9
Fig. 8: Minimum Clearances from Vent/Air Inlet Terminations Indoor and Outdoor Installations
1
1
2
t
TT
*
U.S. Installations
Canadian Installations
Clearance above grade, veranda, porch,

deck, or balcony
1 ft (30 cm)
1 ft (30 cm)
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)
Clearance to permanently closed window
Vertical clearance to ventilated soffit located

above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the
terminal
5 ft (1.5m)
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
6 ft (1.83m)
Clearance to each side of center line extended above meter/regulator assembly
*
3 ft (91 cm) within a
height 15 ft above the
meter/regulator assembly
Clearance to service regulator vent outlet
6 ft (1.83m)
Clearance to non-mechanical air supply inlet

to building or the combustion air inlet to any
other appliance
4 ft (1.2m) below or to side

of opening; 1 ft (30 cm)
above opening
3 ft (91 cm)
Clearance to mechanical air supply inlet
3 ft (91 cm) above if within

10 ft (3m) horizontally
6 ft (1.83m)
Clearance above paved sidewalk or paved

driveway located on public property
7 ft (2.13m)
7 ft (2.13m) t
Clearance under veranda, porch, deck or

balcony
12 in. (30 cm) TT
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
In accordance with the current CAN/CSA-B149 Installation Codes
Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves
both dwellings
Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and
underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)
Clearances in accordance with local installation codes and the requirements of the gas supplier
Table E: Vent/Air Inlet Termination Clearances
10
plied via conventional means where combustion air is

drawn from the area immediately surrounding the
heater, or via direct vent, where combustion air is
drawn directly from outside. All installations must comply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
opening is communicating with the outdoors

through horizontal duct(s). Damage to the equipment due to inadequate ventilation of the space is
not a warrantable failure.
3. In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of
a motorized sealed damper to prevent the circulation of cold air through the heater during the
non-operating hours.
CAUTION: Combustion air must not be

contaminated by corrosive chemical fumes which
can damage the heater and void the warranty. (See
the Appendix.)
Motorized Combustion Air Dampers or

Louvers:
NOTE: It is recommended that the intake vent be

insulated to minimize sweating.
When motorized dampers or louvers are communicating directly with outside combustion air, they must be
interlocked with each appliance in the equipment
room, to ensure proper operation. See Field Wiring
Connection section of this manual for proper wiring
instructions, using Fan/Damper dry contacts and
external interlock.
Air Filter
An air filter is supplied standard with the heater.
TruSeal Combustion Air

In addition to the 3 previous steps, combustion air may
be ducted directly to the heater by using PVC, CPVC
or sealed single-wall galvanized ducting. The duct will
attach directly to the air collar located on the rear of the
heater, using 3-4 sheet metal screws (not supplied)
equally positioned around the circumference of the
duct. The screen 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 damaging
contaminants are present in the mechanical room.
Fig. 9: Air Filter
Direct Vent
All ducting should be self-supported.
If outside air is drawn through the intake pipe directly

to the unit for combustion:
Conventional Combustion Air
1. Install combustion air direct vent in accordance

with Fig. 33 (horizontal) or Fig. 34 (vertical) of this
manual (pages 31 and 32, respectively).
CAUTION: Use TruSeal combustion air if

damaging airborne contaminants are or may be
present in the heater area. See the Appendix of this
manual regarding air contamination.
2. Ventilation of the space occupied by the heater(s)

is recommended and can be provided by an opening(s) for ventilation air at the highest practical
point communicating with the outdoors. The total
cross-sectional areas should be at least 1 in. of
free area per 20,000 BTUH (111 mm per kW) of
total input rating of all equipment in the room,
when the opening is communicating directly with
the outdoors or through vertical duct(s). The total
cross-sectional area should be at least 1in. of free
area per 10,000 BTUH (222 mm per kW) of total
input rating of all equipment in the room, when the
Supply
U.S. Installations
All Air from Inside the Building
The confined space shall be provided with TWO permanent openings communicating directly with an
additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for a
room large in comparison (NFGC). The total input of all
11
gas utilization equipment installed in the combined

space shall be considered in making this determination. Each opening shall have a minimum free area of
1 in.2 per 1,000 BTUH (2,225 mm2 per kW) of the total
input rating of all gas utilization equipment in the confined space, but not less than 100 in.2 (645 cm2). One
opening shall commence within 12 in. (305 mm) of the
top, and one opening shall commence within 12 in.
(305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than
3 in. (76 mm) in any direction.
the enclosure, and

b. Not less than the sum of the areas of all vent
WARNING: Do not use the one permanent
opening method if the equipment room is under
negative pressure conditions.
connectors in the confined space.
CAUTION: All combustion air must be drawn from

the air outside of the building; the mechanical equipment room must communicate directly with the
outdoors.
All Air from Outdoors
1. Ventilation of the space occupied by the heater

shall 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 required in 2. and 3. (below), but in no case
shall the cross-sectional area be less than 10 in.2
(65 cm2).
The confined space shall communicate with the outdoors 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 free area of the openings to which they
connect.
1. Two permanent openings, one commencing
within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of
the enclosure, shall be provided. The openings
shall communicate directly, or by ducts, with the
outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
2. For heaters using a barometric damper in the vent

system there shall be a permanent air supply
opening(s) having a cross section area of not less
than 1 in.2 per 7,000 BTUH (320 mm2 per kW) up
to and including 1 million BTUH, plus 1 in.2 per
14,000 BTUH (160 mm2 per kW) in excess of 1
million BTUH. This opening(s) shall be either
located at or ducted to a point not more than 18 in.
(450 mm) nor less than 6 in. (152 mm) above the
floor level. The duct can also goose neck through
the roof. The duct is preferred to be straight down
and terminated 18 in. (450 mm) from the floor, but
not near piping. This air supply opening requirement shall be in addition to the air opening for
ventilation air required in 1. (above).
3. For heaters not using a barometric damper in the
a. Where directly communicating with the outdoors or where communicating to the

outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.2
per 4,000 BTUH (550 mm2 per kW) of total
input rating of all equipment in the enclosure.
b. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in.2 per 2,000
BTUH (1,100 mm2 per kW) of total input rating of all equipment in the enclosure.
WARNING: Care must be taken to ensure that the

equipment room is not under negative pressure
conditions.
vent system, and when air supply is provided by
natural air flow from outdoors for a power burner
and there is no draft regulator, drafthood or similar
flue gas dilution device installed in the same
space, in addition to the opening for ventilation air
required in 1., there shall be a permanent air supply opening(s) having a total cross-sectional area
of not less than 1 in.2 for each 30,000 BTUH (74
mm2 per kW) of total rated input of the burner(s),
and the location of the opening(s) shall not interfere with the intended purpose of the opening(s)
for ventilation air referred to in 1. This opening(s)
can be ducted to a point not more than 18 in. (450
2. One permanent opening, commencing within 12

in. (305 mm) of the top of the enclosure, shall be
permitted where the equipment has clearances of
at least 1 in. (25 mm) from the sides and back and
6 in. (152 mm) from the front of the appliance. The
opening shall directly communicate with the outdoors or shall communicate through a vertical or
horizontal duct to the outdoors or spaces that
freely communicate with the outdoors, and shall
have a minimum free area of:
a. 1 in.2 per 3,000 BTUH (740 mm2 per kW) of
the total input rating of all equipment located in
12
mm) nor less than 6 in. (152 mm) above the floor
level. The duct can also goose neck through the
roof. The duct is preferred to be straight down 18
in. (450 mm) from the floor, but not near piping.
Leaks must be repaired at once to prevent damage to

the heater. NEVER use petroleum-based stop-leak
compounds.
To perform hydrostatic test:
4. Refer to the B149 Installation Code for additional

information
1. Connect fill water supply. With bleed valve open,

fill heater with water. When water flows from bleed
valve, shut off water. Close bleed valve. Carefully
fill the rest of the system, making sure to eliminate
any entrapped air by using high-point vents. Close
feed valve. Test at standard operating pressure for
at least 24 hours.
Water Piping
General
The heater should be located so that any water leaks
will not cause damage to the adjacent area or structures.
2. Make sure constant gauge pressure has been

maintained throughout test.
CAUTION: This heater requires forced water

circulation when the burner is operating. See Table F
and Table G for minimum and maximum flow rates.
The pump must be interlocked with the heater to
prevent heater operation without water circulation.
3. Check for leaks. Repair any that are found.
Flushing/Cleaning of System Piping

Many of the chemicals used to perform this function
will harm the heat exhcanger as well as some ogaskets and seals within the unit, casing a
non-warrantable failure. When required, Raypak recommends the boiler be isolated ferom the system
piping prior to flushing or cleaning using any cleaning
agent.
NOTE: Minimum pipe size for in/out connections is

3 in. Verify proper flow rates and T as instructed in
this manual.
Relief Valve Piping

WARNING: Pressure relief valve discharge piping
must be piped near the floor and close to a drain to
eliminate the potential of severe burns. Do not pipe
to any area where freezing could occur. Refer to
local codes.
Cold Water Operation

CAUTION: Damage due to internal condensation
may occur if the heater inlet water temperature does
not exceed 120F (49C) within 7 minutes of startup.
Temperature & Pressure Gauge

The temperature and pressure gauge is shipped
installed on the boiler outlet assembly. Installation
must comply with ASME Section IV as well as all applicable national, state and local codes.
This heater is equipped with a proprietary condensate

evaporation system which will evaporate any condensate that may begin to accumulate inside the primary
heat exchanger with water temperatures as low as
120F (49C).
Hydrostatic Test
Heaters operated with an inlet temperature of less

than 120F (49C) MUST have an approved low-temperature operation system (Figs. 9 and 10) to prevent
problems with condensation. Inlet water temperatures
below 120F (49C) can excessively cool the products
of combustion, resulting in collection of condensate in
the heat exchanger area beyond the capacity of the
condensate evaporation system.
Unlike many types of heaters, this heater does not require hydrostatic testing prior to being placed in
operation. The heat exchanger has already been factory-tested and is rated for 160 psi operating pressure.
However, Raypak does recommend hydrostatic testing of the piping connections to the heater and the rest
of the system prior to operation. This is particularly
true for hydronic systems using expensive glycolbased anti-freeze. Raypak recommends conducting
the hydrostatic test before connecting gas piping or
electrical supply.
Failure to reach or exceed 120F (49C) may damage

or cause failure of the heat exchanger, combustion
chamber, or other parts within the combustion chamber. It can cause operational problems, bad
combustion, sooting, flue gas leakage and reduced
13
service life of the appliance and the vent system. A

bypass allows part of the heater discharge water to be
mixed with the cooler water returning to the heater
inlet to increase the heater inlet temperature above
120F (49C). This precautionary measure should prevent the products of combustion from condensing
beyond the ability of the condensate management system employed in this heater in most installations.
Warranty claims will be denied for damage or failures caused by condensation.
Cold Water Run

Cold water run differs from cold water start in that the
system water entering the heater remains below
120F (49C) continuously. Typically, this is the case in
water source heat pump applications as well as some
others. If the system water is kept in a narrow temperature range of no more than 10F (5C), a permanent
manual bypass can be employed and manually adjusted to achieve an inlet temperature of 120F (49C) or
higher as adjusted at the minimum temperature in this
narrow temperature range (i.e. Range 75F to 85F,
adjust bypass with temperature at 75F (24C)) so that
when temperature is 85F (29C), minimum inlet temperature would be 130F (54C). An injector pump
arrangement may also be utilized to keep the heater
loop at or above 120F (49C). An injector pump
approach has the added value of being able to adjust
to changes in the system water coming back to the
heater.
Cold Water Starts

Cold water starts, where the inlet water temperature
remains below 120F (49C) 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 120F (49C) or higher.
Once the system is heated up and has return water
temperatures of 120F (49C) or higher, the mixing of
outlet water with inlet water is no longer needed and
the bypass can be shut off. If the bypass is not shut off
as the system heats up, the outlet temperature may
continue to climb and trip the high limit, thereby shutting down the heater. Thus an automatic valve system,
such as a three-way proportional valve to control the
bypass, should be used.
Hydronic Heating
*
*Maximum 4 times the pipe diameter or 12, whichever is less.
Fig. 11: Cold Water Run
Pump Selection
*
In order to ensure proper performance of your heater

system, you must install a correctly-sized pump. Raypak requires designing for a T within the range of
16F to 39F (9C to 22C). See Table F for acceptable flow rates for each model (T is the temperature
difference between the inlet and outlet water when the
heater is firing at full rate).
*Maximum 4 times the pipe diameter or 12, whichever is less.
Fig. 10: Cold Water Start
14
SHL
SHL
3"
Pipe
4"
Pipe
GPM
11.7
N/A
14.3
255
21.7
N/A
N/A
N/A
N/A
N/A
N/A
N/A
20 T
MVB
Model
GPM
2503
213
3003
3503
4003
SHL
SHL
3"
Pipe
4"
Pipe
GPM
GPM
142
6.2
10.7
7.4
N/A
N/A
120
25.3
170
10.3
16.6
12.0
131
6.3
N/A
198
15.2
N/A
17.5
153
9.1
N/A
227
23.7
N/A
26.6
174
13.5
30 T
SHL
SHL
3"
Pipe
4"
Pipe
GPM
4.7
35
8.0
5.6
264
131
6.3
39
10.2
7.4
153
9.1
39
14.3
10.5
174
13.5
39
20.1
15.3
39 T
Min Flow
SHL
SHL
3"
Pipe
4"
Pipe
15.7
16
N/A
19.6
264
23.1
19
N/A
27.0
264
26.8
23
N/A
30.6
264
33.5
26
N/A
37.4
Max Flow
P
Notes: Basis for minimum flow is T . Basis for maximum flow is gpm.
Table F: Heater Rates of Flow and Pressure Drops
Feedwater Regulator
Air-Separation/Expansion Tank
Raypak recommends that a feedwater regulator be installed and set at 12 psi minimum pressure at the
highest point of the system. Install a check valve or
back flow device upstream of the regulator, with a
manual shut-off valve as required by local codes.
All heaters should be equipped with a properly sized

expansion tank and air separator fitting as shown in
Fig. 12.
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 adequate system flow in excess of the
connected boiler flow for proper operation. Where
the system flow may drop below the connected
boiler flow a buffer/decoupler may be needed.
Failure to design for adequate flow (i.e. bypasses, 3
way control valves, flow limiting balance devices,
buffer tanks, etc.) will result in boiler short cycling
and may reduce boiler life. Always contact your local
Raypak representative for system design assistance
to avoid these issues.
Fig. 12: Air-Separation/Expansion Tank
Three-Way Valves
Three-way valves intended to regulate system water
temperatures by reducing flow in the boiler should not
be used. Raypak heaters are high-recovery, low-mass
heaters which are not subject to thermal shock.
All high points should be vented. A heater installed

above radiation level must be provided with a low water cut-off device (sales order option F-10). This
heater, when used in connection with a refrigeration
system, must be installed so that the chilled medium is
piped in parallel with the heater with appropriate
valves to pre-vent the chilled medium from entering
the heater.
Applications & Modes

The VERSA IC Control system is designed for a wide
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.
The piping system of a hot water heater connected to

heating coils located in air handling units where they
may be exposed to circulating refrigerated air, must be
equipped with flow control valves or other automatic
means to prevent gravity circulation of the heater
water during the cooling cycle. It is highly recommended that the piping be insulated.
Type H models of MVB have three modes available to

them to address the various applications the units can
be applied to. Type WH units will only have the WH
configuration available to them for use with potable
water applications when directly connected to a hot
water storage tank.
For detailed information on the Versa IC control system, see Catalog 5000.72. This manual can be found
in the document library at www.raypak.com.
15
NOTE: MODE 1 can also be used for process heating applications in conjunction with a buffer/storage
tank when operating temperatures above 160F are
required. Care must be given to ensure water hardness is no more than 15 grains per gallon for scale
free operation.
Fig. 13: MODE 1 - Single Boiler with

Primary/Secondary Piping
Mode 1 (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). The system temperature is
controlled by the System sensor (S3). The Boiler
Pump (P1) runs during any call for heat. The System
Pump (P2) runs whenever the system is enabled for
heating and the outdoor air temperature is lower than
the warm weather shut down (WWSD) temperature
setting (if utilized). The Boiler Pump and System Pump
are delayed off as user defined in the ADJUST
menu.
Fig. 15: MODE 2 - Single Boiler with Indirect

on System Loop

Outdoor Air Reset (S4) with indirect DHW on the system loop (with or without priority). The system
temperature is controlled by the System sensor (S3).
The Indirect DHW sensor (S5) determines the indirect
call/tank setpoint. The system temperature is boosted
to Target Max when using the Indirect DHW sensor
(S5) during an indirect call for heat. Priority mode toggles off the System Pump (P2) when an indirect call for
heat is present. The Boiler Pump (P1) runs during any
call for heat. The Indirect DHW Pump (P3) runs during
an indirect call for heat with no off delay. The Boiler
Pump (P1) and System Pump (P2) delay off as user
defined in the ADJUST menu. The System Pump (P2)
runs whenever the system is enabled for heating and
the outdoor air temperature is lower than the WWSD
temperature setting (if utilized) unless an indirect call
for heat is present with priority.
Fig. 14: MODE 1 - Boiler Cascade with

Primary/Secondary Piping
16
Domestic Hot Water

When designing the water piping system for domestic
hot water applications, water hardness should be considered. Table G indicates the suggested flow rates for
soft, medium and hard water. Water hardness is expressed in grains per gallon.
Fig. 16: MODE 3 - Single Boiler with Indirect

on Boiler Loop

Outdoor Air Reset (S4) with indirect DHW on the boiler loop (with priority). The system temperature is
controlled by the Supply sensor (S3) whenever the
indirect call for heat is not active. The DHW Supply
sensor (S5) determines the indirect call/tank setpoint.
During an indirect call for heat the boiler firing rate is
determined by the water temperature at the Indirect
Supply sensor (S6) and the Target Max setting when
using the Indirect DHW sensor (S5). The Boiler Pump
(P1) runs during all heat calls regardless of priority.
The Indirect DHW Pump (P3) runs during an indirect
call for heat with no off delay. The Boiler Pump (P1)
and System Pump (P2) delay off as user defined in
the ADJUST menu. The system pump (P2) runs
whenever the system is enabled for heating and the
outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect call for
heat is present.
Fig. 17: WH Units - Single Water Heater with Tank

H Units - Single Boiler with Process Tank
WH Direct DHW Configuration

When the unit is ordered as a WH configuration the
only application available to it is direct DHW with single or multiple heaters (Maximum 4 heaters). The tank
temperature is controlled by the System sensor (S3).
The Boiler Pump (P1) runs during any call for heat.
The System Pump (P2) output is active whenever the
system is enabled. The Boiler Pump is delayed off
after the Tank Target temperature is achieved and as
user defined in the ADJUST menu.
NOTE: WH units will operate to a maximum tank
temperature of 160F. For temperatures required
above 160F 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
operation. MODE 1 should be used and configured
for setpoint operation for process heating applications.
NOTE: A Tank Aquastat can be used in lieu of the

Indirect DHW Sensor (S5). See the Versa IC manual for additional details.
NOTE: If local codes require a vacuum relief valve,

acquire one locally and install per valve
manufacturers instructions.
17
MVB
Model
2503
3003
3503
4003
WATER HARDNESS
MEDIUM
5-15 Grains Per Gallon
SOFT
3-4 Grains Per Gallon
HARD*
16-25** Grains Per Gallon
T
(F)
MTS SHL
P
GPM (ft wc) (in) (ft wc)
T
(F)
MTS SHL
P
T
(F)
MTS SHL
P
29
29
29
29
147
176
205
234
20
20
23
26
213
255
264
264
16
19
23
26
264
264
264
264
6.6
11.0
16.3
25.6
4
4
4
4
7.9
12.8
18.8
28.9
11.7
21.7
26.8
33.5
4
4
4
4
14.4
25.6
31.0
37.7
15.7
23.1
26.8
33.5
4
4
4
4
20.0
27.3
31.0
37.7
T = Temperature rise, F
P = Pressure drop through heat exchanger, ft
SHL = System head loss, ft (based on heater and tank connections of no more than 100 eq. ft. of tubing)
gpm = Gallons per minute, flow rate
MTS = Minimum tubing size
*Must utilize optional cupro-nickel tubes. If over 25 grains 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
higher than 130 F. For higher than 130 F operation, a water softener/treatment system must be utilized.
***Care should be given to prevent over-softening of the water as over-softened water can become aggressive. Cupro-nickel tubes are
recommended for water softened below 5 grains per gallon.
Table G: Domestic Water Heater Flow Rate Requirements
Potable Water and Space Heating
Automatic Chemical Feeders
CAUTION: When this heater is used for both

potable water and space heating, observe the
following to ensure proper operation.
All chemicals must be introduced and completely diluted into the water before being circulated through the
heater. High chemical concentrations will result when
the pump is not running (e.g. overnight).
1. All piping materials and components connected to

the water heater for the space heating application
shall be suitable for use with potable water.
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.
2. Toxic chemicals, such as used for boiler treatment,

shall not be introduced into the potable water used
for space heating.
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.
3. If the heater will be used to supply potable water,

it shall not be connected to any heating system or
components previously used with a non-potable
water heating appliance.
CAUTION: Combustion air must not be

contaminated by corrosive chemical fumes which
can damage the heater and void the warranty.
4. When the system requires water for space heating

at temperatures higher than 140F (60C), a
means such as a mixing valve shall be installed to
temper the water in order to reduce scald hazard
potential.
18
Gas Supply
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.
DANGER: Make sure the gas on which the heater

will operate is the same type as specified on the
heaters rating plate.
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve located outside the heater jacket. It is recommended
that a union be installed in the gas supply piping adjacent 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 poundsto-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.
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.
Gas Supply Pressure

A minimum of 4.0 in. WC and a maximum of 10.5 in.
WC upstream gas pressure is required under load and
no-load conditions for natural gas. A minimum of 4.0
in. WC and a maximum of 13.0 in. WC is required for
propane gas. The gas pressure regulator(s) supplied
on the heater is for low-pressure service. If upstream
pressure exceeds these values, an intermediate gas
pressure regulator, of the lockup type, must be
installed.
Gas Supply Connection

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).
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 heater must be isolated from the gas supply piping 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 connections shall be leak-tested before placing the
appliance in operation. Use soapy water for leak test.
DO NOT use an open flame.
The gas valve pressure regulator on the heater is

nominally preset as noted in Table I.
During normal operation, carbon dioxide should be
9.3% 0.2% at full fire for natural gas and
10.7% 0.2% for propane gas. Carbon monoxide
should be 100ppm at all firing rates, measured at test
port, 12" above the flue collar.
Fig. 18: Gas Supply Connection
19
Model
No.
2-1/2 in. NPT
3 in. NPT
pump.
Pumps must use a separate power supply and run the
power through a field-supplied contactor. Use appropriately-sized wire as defined by NEC, CSA and/or
local codes. All primary wiring should be 125% of minimum rating.
4 in. NPT
2503
55
135
160
400
600
--
3003
40
85
120
250
500
--
3503
30
45
80
200
400
600
4003
25
35
65
160
300
400
If any of the original wire as supplied with the heater

must be replaced, it must be replaced with 105C wire
or its equivalent.
Natural Gas 1,000 BTU/ft3, 0.60 specific gravity at 0.5 in.

WC pressure drop
Propane Gas 2,500 BTU/ft3, 1.53 specific gravity at 0.6 in.
WC pressure drop
All high voltage wiring connections to the MVB heater

are made inside the rear wiring box as shown in
Fig. 18. There are three factory supplied pump interlock relays in the rear wiring box to provide an enable
signal via dry contact (5A max) for the Boiler Pump,
System Pump and Indirect DHW Pump as required for
the system depending on the mode selected within the
VERSA IC control system.
Table H: Maximum Equivalent Pipe Length
Model
No.
Manifold Gas Pressure

(High Fire Values)
Natural Gas
Propane Gas
2503
-4.8
-6.4
3003
-6.7
-8.8
3503
-6.8
-9.5
4003
-4.7
-7.4
NOTE: Manifold pressures should be 0.2 in. WC.
Fig. 19: Wiring Electrical Connections
Table I: Manifold Gas Pressure Settings
CAUTION: For proper operation, no more than a

30% drop in gas supply pressure from no-load to fullload conditions is acceptable. Under no
circumstances should the pressure be outside the
listed operational range.
Field-Connected Controllers
It is strongly recommended that all individually-powered control modules and the heater should be
NOTE: Field-supplied isolation relays should be
installed when field-connected controllers are
mounted more than 50 equivalent feet (18 AWG)
from heater. See wiring diagrams.
Electrical Power Connections

Installations must follow these codes:
National Electrical Code and any other national,

state, provincial or local codes or regulations having jurisdiction.
Safety wiring must be NEC Class 1.
Heater must be electrically grounded as required
by the NEC.
In Canada, CSA C22. 1 C.E.C. Part 1.
NOTE: Minimum 18 AWG, 105C, 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 (105C, stranded wire) as the ones on the
unit or larger.
The MVB heaters are wired for a 240 VAC, singlephase power supply. Consult the wiring diagram
shipped with the heater. Before starting the heater,
check to ensure proper voltage to the heater and
20
Check the Power Source
3. Turn off all power to the heater. Verify that power

has been turned off by testing with a multi-meter
prior to working with any electrical connections or
components.
4. Observe proper wire colors while making electrical connections. Many electronic controls are
polarity sensitive. Components damaged by improper electrical installation are not covered by
warranty.
5. Provide overload protection and a disconnect
means for equipment serviceability as required by
local and state code.
Fig. 20: Wiring Connections
6. Install heater controls, thermostats, or building

management systems in accordance with the
applicable manufacturers instructions.
WARNING: 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 Fig. 20.)
7. Conduit should not be used as the earth ground.

NOTE: A grounding electrode conductor shall be
used to connect the equipment grounding
conductors, the equipment enclosures, and the
grounded service conductor to the grounding
electrode.
Check the power source:

AC = 108 VAC Minimum, 132 VAC Maximum
BC = 108 VAC Minimum, 132 VAC Maximum
AB = 216 VAC Minimum, 264 VAC Maximum
Field Wiring Connection

CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper
operation after servicing.
DANGER: SHOCK HAZARD
Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to
components.
Fig. 21: Multi-meter
Making the Electrical Connections

Refer to Fig. 19-22.
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.
21
Fig. 22: Wiring Location
Fig. 23: Locator Dimples for Optional Components
Wiring the Enable/Disable
Wiring the Outdoor Sensor
Connect the Enable/Disable wiring to the field wiring

terminals (shown in Fig. 24). Alternately, any dry 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 terminals becomes connected to ground.
1. There is no connection required if an outdoor sensor is not used in this installation.

2. If using an Outdoor Sensor (option B-32), connect
the sensor wires to the terminals marked OUTDOOR SENSOR (see Fig. 24). Caution should be
used to ensure neither of these terminals
becomes connected to ground.
3. Use a minimum 18 AWG wire for runs of 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 varying weather conditions.
Fig. 24: Low Voltage Field Wiring
22
Drive (UP) input and a Target Temperature

(DOWN) setpoint.
Wiring the Indirect Sensor

1. An indirect sensor connection is not required if an
indirect water heater is not used in the installation.
3. For a 4-20mA application, refer to the VERSA IC

manual (Cat. 5000.72).
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 it can activate the Indirect DHW
pump and Boiler pump as needed. If an optional
Indirect DHW sensor is connected, the PIM will
pass this signal to the VERSA. This allows the
VERSA to optimize the Indirect DHW demand to
maintain the Indirect DHW setpoint. The Indirect
DHW thermostat switch closure is still required
when using the Indirect DHW sensor. If a VERSA
is not present the PIM shall activate the Indirect
DHW pump whenever the Indirect DHW call is
active. The Boiler pump will also be activated
based on the Indirect DHW piping configuration
setting. Consult the VERSA IC manual (Cat.
5000.72) for additional configurations.
4. Connect an Energy Management system or other

auxiliary control signal to the terminals marked 010V (+ /-) on the field wiring terminals (see
Fig. 24). Caution should be used to ensure that the
+0-10V connection does not create a short to
ground.
Wiring the Cascade System

Communication Bus
1. Designate the primary boiler as the master
boiler/boiler1 by leaving dip switch 2 on the
VERSA in the ON position. All other VERSA controls require dip switch 2 to be toggled OFF,
designating them as followers. Follower VERSA
boards are ignored by their corresponding PIM
modules. Use standard 18 AWG wire to connect
the master VERSA to the PIM on the followers.
A total of 3 followers can be connected to the
VERSA on the master. For systems requiring more
than 4 connected boilers, an external sequencer
such as the Raypak Temp Tracker Mod+ Hybrid
can be used.
3. Connect the indirect tank sensor to the terminals

marked INDIRECT DHW SENSOR (see wiring
diagram). Caution should be used to ensure neither of these terminals becomes connected to
ground.
NOTE: Alternately, a thermostat contact closure can
be used in lieu of the sensor for indirect operation.
Connect the thermostat to the terminals marked
INDIRECT DHW OVERIDE.
2. It is recommended that the shortest length cable

possible be used to reach between the boilers. Do
not run unprotected cables across the floor or
where they will become wet or damaged. Do not
run communication cables parallel with, or close to
or against, high voltage (120 volt or greater)
wiring. Raypak recommends that the total maximum length of each set of communication bus
cables not exceed 200 feet.
CAUTION: Sensor and control wiring must NOT be

run in conduit or chases with line voltage.
Wiring the Optional 010 Volt

Building Control Signal
3. Connect the FT_BUS wires to the PIM by pressing down on the slots with a small screwdriver and
then inserting the wires into the holes. See
Fig. 25.
1. A signal from an energy management system may

be connected to the MVB boiler. This signal should
be a 0-10 volt positive DC signal, and an energy
management system can be used to control either
the setpoint temperature of a single MVB or a cascade of up to 4 boilers, or the firing rate of a single
MVB boiler.
2. To enable this remote control function, set dip
switch 5 to the UP position on the PIM. Dip
switch 5 Toggles between an EMS (UP) signal or
a demand signal from the VERSA (DOWN). Dip
switch 2 on the PIM toggles between a Direct
Fig. 25: FT_BUS Wire Connection
23
MASTER
FOLLOWERS
VERSA
MASTER
Fig. 26: MVB Cascade System Wiring
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 rated for pilot duty only (5A maximum).
2. Connect the boiler pump enable wires to the terminal block at the rear of their unit. The connections
are dry contacts rated for pilot duty only (5A maximum).
3. Connect the system supply sensor to terminals 6
and 7 on the field wiring strip located on the Master
PIM (See Fig. 24).
Fig. 27: MVB Cascade Master Pumps
4. Connect the Outdoor sensor (if used) to terminals

8 and 9 on the field wiring strip located on the
Master boiler (See Fig. 24).
24
5. Connect the Enable/Disable wiring to terminals 11

and 12 on the field wiring strip located on the
Master boiler (See Fig. 24). This connection must
be provided through dry contacts closure.
Modbus BMS Communication

The VERSA IC control is equipped as standard with a
communications port for connectivity to building
automation via Modbus protocol. Refer to the VERSA
IC manual (5000.72) for further information.
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.
Alarm Connection
Cascade Follower Pump

and Sensor Wiring
An alarm annunciator or light may be connected to the

alarm contacts on the field wiring terminal strip. The
Alarm Contacts are 3A rated dry contacts on a normally-open relay that close during fault or lockout
conditions, and the maximum voltage across the contacts is 30 VAC or 30 VDC. See the Field Wiring as
shown in Fig. 24.
1. Once the primary boiler has been identified, additional boilers will be designated as follower boilers.
Ensure dip switch 2 on each follower VERSA is set
to the OFF/Down position.
2. For each follower boiler, connect the boiler pump
enable wires to the terminal block at the rear of
each unit. The connections are dry contacts rated
for pilot duty only (5A maximum).
In a cascade system, the alarm output of the master

boiler will be active if either the master boiler or follower(s) have a lockout condition. The alarm output of the
follower boilers will only energize if a lockout condition
occurs on that specific boiler.
3. The System and DHW pump outputs are not used

in the Cascade Follower configuration.
Fig. 28: VERSA Follower
25
Venting
NOTE: For additional information on appliance

categorization, see appropriate ANSI Z21 Standard
and the NFGC (U.S.), or B149 (Canada), or
applicable provisions of local building codes.
General
CAUTION: Proper installation of flue venting is
critical for the safe and efficient operation of the
heater.
CAUTION: Condensate drains for the vent piping

are required for installations of the MVB. Follow vent
manufacturer instructions for installation and location
of condensate drains in the vent. Condensate drain
must be primed with water to prevent gas flue leak
and must be routed to an appropriate container for
neutralization before disposal, as required by local
codes.
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.
WARNING: Contact the manufacturer of the vent

material if there is any question about the appliance
categorization and suitability of a vent material for
application on a Category IV vent system. Using
improper venting materials can result in personal
injury, death or property damage.
Category I A heater which operates with a non-positive vent static pressure and with a vent gas
temperature that avoids excessive condensate production in the vent.
Category II A heater which operates with a non-positive vent static pressure and with a vent gas
temperature that may cause excessive condensate
production in the vent.
CAUTION: Vent piping is hot. Raypak recommends the use of double wall or insulated wall pipe
to prevent personal injury.
Category III A heater which operates with a positive

vent pressure and with a vent gas temperature that
avoids excessive condensate production in the vent.
NOTE: Ensure that clearances are maintained per

Tables C and D.
Category IV A heater which operates with a positive

vent pressure and with a vent gas temperature that
may cause excessive condensate production in the
vent.
See Table J for appliance category requirements.
Combustion
Air Supply
Exhaust
Configuration
Heater Venting
Category
Certified
Materials
II and IV
Stainless Steel
UL listed
Combustion Air
Inlet Material
Vertical
Venting
From Inside Building

(Non-Direct Venting) Horizontal Throughthe-Wall Venting
Vertical
Venting
From Outside Building
(Direct Venting)
Horizontal Throughthe-Wall Venting
Table J: Venting Category Requirements
26
Galvanized Steel
PVC
ABS
CPVC
Use only the special gas vent pipes listed for use with
Category IV gas burning heaters, such as the AL29-4C
stainless steel vents offered by Heat Fab Inc. (800772-0739), Protech System, Inc. (800-766-3473),
Z-Flex (800-654-5600) or American Metal Products
(800-423-4270). Pipe joints must be positively sealed.
Follow the vent manufacturers installation instructions
carefully.
5. The bottom of the vent terminal and the air intake

shall be located at least 12 in. above grade, including normal snow line.
6. Un-insulated single-wall Category IV metal vent
pipe shall not be used outdoors in cold climates for
venting gas-fired equipment without insulation.
7. Through-the-wall vents for Category IV appliances shall not terminate over public walkways or
over an area where condensate or vapor could
create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or
other equipment.
Extractors, Draft Inducers, and Motorized

Flue Dampers
When extractors or inducers are used in the venting
system, they must be interlocked with each connected
appliance, to ensure proper operation. If individual
motorized dampers are used, they must be interlocked
to their respective appliance. See Field Wiring
Connection section of this manual for proper wiring
instructions, using Fan/Damper dry contacts and
external interlock.
8. Locate and guard vent termination to prevent accidental contact by people or pets.
9. DO NOT terminate vent in window well, stairwell,
alcove, courtyard or other recessed area.
10. DO NOT terminate above any door, window, or
gravity air intake. Condensate can freeze, causing
ice formations.
Support of Vent Stack

The weight of the vent stack or chimney must not rest
on the heater vent connection. Support must be provided in compliance with applicable codes. The vent
should also be installed to maintain proper clearances
from combustible materials. Use insulated vent pipe
spacers where the vent passes through combustible
roofs and walls.
11. Locate or guard vent to prevent condensate from

damaging exterior finishes. Use a rust-resistant
sheet metal backing plate against brick or masonry surfaces.
12. DO NOT extend exposed vent pipe outside of
building beyond the minimum distance required
for the vent termination. Condensate could freeze
and block vent pipe.
Vent Terminal Location

NOTE: During winter months check the vent cap
and make sure no blockage occurs from build-up of
snow or ice.
U.S. Installations
Refer to the latest edition of the National Fuel Gas
Code.
1. Condensate can freeze on the vent cap. Frozen

condensate on the vent cap can result in a blocked
flue condition.
Vent termination requirements are as follows:

1. Vent must terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, window or
gravity air inlet to the building.
2. Give special attention to the location of the vent

termination to avoid possibility of property damage or personal injury.
2. The vent must not be less than 7 ft above grade

when located adjacent to public walkways.
3. Gases may form a white vapor plume in winter.

The plume could obstruct a window view if the termination is installed near windows.
3. Terminate vent at least 3 ft above any forced air

inlet located within 10 ft.
4. Prevailing winds, in combination with below-freezing temperatures, can cause freezing of

condensate and water/ice build-up on buildings,
plants or roofs.
4. Vent must terminate at least 4 ft horizontally, and

in no case above or below unless 4 ft horizontal
distance is maintained, from electric meters, gas
meters, regulators, and relief equipment.
27
5. Terminate vent at least 6 ft away from adjacent

walls.
8. Underneath a verandah, porch or deck, unless the

verandah, porch or deck is fully open on a minimum of two sides beneath the floor, and the
distance between the top of the vent termination
and the underside of the verandah, porch or deck
is greater than 1 ft (305 mm).
6. DO NOT terminate vent closer than 5 ft below roof

overhang.
7. The vent terminal requires a 12 in. vent terminal
clearance from the wall.
Venting Installation Tips
8. Terminate vent at least 1 ft above grade, including

normal snow line.
Support piping:
9. Multiple direct vent installations require a 4 ft

clearance between the ends of vent caps located
on the same horizontal plane.
horizontal runsat least every 5 ft (1.5m)

vertical runsuse braces
under or near elbows
WARNING: Examine the venting system at least
once a year. Check all joints and vent pipe
connections for tightness, corrosion or deterioration.
WARNING: The Commonwealth of Massachusetts

requires that sidewall vented heaters, installed in
every dwelling, building or structure used in whole or
in part for residential purposes, be installed using
special provisions as outlined on page 55 of this
manual.
Venting Configurations
Refer to latest edition of the B149 Installation Code.
For heaters connected to gas vents or chimneys, vent

installations shall be in accordance with the NFGC
(U.S.), or B149 (Canada), or applicable provisions of
local building codes.
A vent shall not terminate:
Vertical Venting (Category IV)
CAUTION: This venting system requires the

installation of a condensate drain in the vent piping
per the vent manufacturers instructions. Failure to
install a condensate drain in the venting system will
void all warranties on this heater.
1. Directly above a paved sidewalk or driveway

which is located between two single-family dwellings and serves both dwellings.
2. Less than 7 ft (2.13 m) above a paved sidewalk or
paved driveway located on public property.
Installation
3. Within 6 ft (1.8 m) of a mechanical air supply inlet

to any building.
The maximum and minimum venting length for this

Category IV appliance shall be determined per the
NFGC (U.S.) or B149 (Canada).
4. Above a meter/regulator assembly within 3 ft (915

mm) horizontally of the vertical centre-line of the
regulator.
The diameter of vent flue pipe should be sized according to the NFGC (U.S.) and Appendix B of B149
(Canada). The minimum flue pipe diameter for conventional venting using Category IV, stainless steel UL
listed vent is: 10 in. (254mm) for Models 2503-3003;
and 12 in. (305mm) for Models 3503-4003.
5. Within 6 ft (1.8 m) of any gas service regulator

vent outlet.
6. Less than 1 ft (305 mm) above grade level.
7. Within 3 ft (915 mm) of a window or door which
can be opened in any building, any non-mechanical air supply inlet to any building or the
combustion air inlet of any other appliance.
The connection from the appliance vent to the stack

must be as direct as possible and shall be the same diameter as the vent outlet. The horizontal breaching of
a vent must have an upward slope of not less than 1/4
inch per linear foot from the heater to the vent terminal. 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 physical damage or separation of joints.
28
Model
No.
Certified
Vent
Material
2503
3003
3503
Stainless
Steel
Category IV
(UL listed)
4003
Vent Size
(in.)
Vent Height (eq. ft.)

Min.
Max.
Combustion Air
Intake Pipe
Material
10
5
100
Air Inlet
Max Length** (eq. ft.)
10
12
100
N/A
N/A
100
Galvanized Steel,
PVC, ABS, CPVC
12
* Special vent materials are still required.

** Subtract 10 ft per elbow. Max. 4 elbows.
Table K: Category IV Vertical Venting
NOTE: A vent adapter (field-supplied) may be required to connect the Category IV vent to the heater.
Termination
The vent terminal should be vertical and should terminate outside the building at least 2 ft above the highest
point of the roof that is within 8 ft for models 2503 and
3003 and 10ft for models 3503 and 4003. The vent
cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft
hori-zontal distance is maintained) 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 consistent with the NFGC
(U.S.) or B149 (Canada). Gas vents supported only by
flashing and extended above the roof more than 5 ft
should be securely guyed or braced to withstand snow
and wind loads.
Common Venting
The NFGC does not address sizing guidelines for the
common venting of multiple Category IV heaters. This
is covered in the NFGC under Engineered Vent Systems. Table L provides boiler discharge vent
pressures at vent pressure switch and volumes of flue
products at full fire for the calculation of appropriate
vent and extractor sizing for common venting.
Fig. 29: Vertical Venting
CAUTION: A listed vent cap terminal suitable for

connection to the Cat IV vent materials, adequately
sized, must be used to evacuate the flue products
from the building.
29
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 UL Listed
stainless steel vent material construction. If it is NOT,
it MUST be replaced.
1 MINIMUM (TYP)
VENT CAPS STACKED VERTICALLY

FLUE GASES MOVING IN PARALLEL
NOTE: For extractor sizing, typical CO2 levels are

9.3% for natural gas and 10.7% for propane gas and
flue temperature of 350F, at 100% firing rate. measured at a test port, 12" above the flue collar.
4-0 MIN.
(TYP)
DISCHARGE
VENT CAPS ALL AT SAME ELEVATION
FLUE GASES MOVING TOWARD EACH OTHER
Model
No.
2 MINIMUM (TYP)
Volume of
Vent Size Vent Pressure
Flue Products
(in.)
(in. WC)
(CFM)
2503
DISCHARGE
4-0 MIN.
(TYP)
0.2
800
3003
0.3
960
3503
0.2
1120
0.3
1280
10
1 MINIMUM (TYP)
VENT CAPS AT STAGGERED ELEVATIONS

FLUE GASES MOVING TOWARD EACH OTHER
12
4003
Fig. 30: Vent Cap Configurations
* NOTE: Data for 100% firing rate.
Table L: Typical Vent Pressure and Volume

of Flue Products
Fig. 31: Typical Common Venting
30
Horizontal Through-the-Wall Direct

Venting (Category IV)
Fig. 32: Horizontal Through-the-Wall Venting
Fig. 34: Horizontal Through-the-Wall Direct Venting

Installation
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 through the wall to the outdoors. Adequate combustion and ventilation air must
be supplied to the equipment room in accordance with
the NFGC (U.S.) or B149 (Canada).
The total length of the horizontal through-the-wall flue
system should not exceed 100 equivalent ft in length.
If horizontal run exceeds 100 equivalent ft, an appropriately sized variable-speed extractor must be used.
Each elbow used is equal to 10 ft of straight pipe. This
will allow installation in one of the four following
arrangements:
Fig. 33: Alt. Horizontal Through-the-Wall Venting
NOTE: While a drain connection is required in the

vent of all MVB installations, the drain can be accomplished in several different ways. The figures in
this manual show the drain in a vent tee, however,
this can also be accomplished using an inline collector for condensing stacks or an inline vertical or
horizontal collector available from several of the
listed vent manufacturers.
100 of straight flue pipe

90 of straight flue pipe and one elbow
80 of straight flue pipe and two elbows
70 of straight pipe and three elbows
The vent cap is not considered in the overall length of

the venting system.
31
Model
No.
Certified
Vent
Material
2503
3003
3503
Category IV
(UL listed - SS)
Vent Size
(in.)
Maximum
Horizontal
Vent Length
(ft)
Combustion Air
Intake Pipe
Material
100
Galvanized Steel,
PVC,
ABS,
CPVC
10
12
4003
Air Inlet
Max. Length**
(ft)
10
12
100
100
** Subtract 10 ft per elbow. Max. 4 elbows.
Table M: Category IV Horizontal Vent & Horizontal Direct Vent
Direct VentVertical
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 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 less than 1/4 inch per foot of horizontal run to the vent terminal.
3. The vent must be insulated through the length of
the horizontal run.
Termination
The flue direct vent cap MUST be mounted on the exterior of the building. The direct vent cap cannot be
installed in a well or below grade. The direct vent cap
must be installed at least 1 ft above ground level and
above normal snow levels. The Raypak-approved
stainless steel 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.
Fig. 35: Direct Vent - Vertical

Installation
WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants.
These installations utilize the heater-mounted blower

to draw combustion air from outdoors and vent combustion products to the outdoors.
32
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 stainless steel flue direct vent cap must be furnished by the heater manufacturer in accordance with
its listing (sales order option D-15).
The vent cap is not considered in the overall length of

the venting system.
Units installed outdoors must be vented with listed

vent material per the following instructions and
installed with the optional 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 during assembly 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:
CAUTION: Use of double-wall vent pipe is

recommended to minimize the risk of personal injury.
1. The vent must be installed with a condensate

drain located in proximity to the heater as directed
by the vent manufacturer.
Care must be taken when locating the heater outdoors, 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:
2. The vent must be installed with a slight upward

slope of not more than 1/4 inch per foot of horizontal run to the vent terminal.
3. The vent must be insulated through the length of
the horizontal run.
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 heaters

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.
This type of installation can cause non-warrantable

problems with components and poor operation of the
heater due to the recirculation of flue products. Multiple 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).
Do not locate adjacent to any window, door, walkway, 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.
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.
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 protected with a rust-resistant sheet metal plate.
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 combustion 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.
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).
WARNING: No substitutions of flue pipe or vent

cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants.
33
NOTE: Condensate can freeze on the vent cap.

Frozen condensate on the vent cap can result in a
blocked flue condition.
WARNING: Turn off the power to the heater before

installation, adjustment or service of any heater
controls. Failure to do so may result in board
damage, heater malfunction, property damage,
personal injury, or death.
CAUTION: This appliance has provisions to be
connected to more than one supply source. To
reduce the risk of electric shock, disconnect all such
connections before servicing.
CAUTION: Risk of electric shock: More than one
disconnect switch may be required to de-energize
the equipment before servicing.
Ignition Control Functions
VENT SUPPORT
When there is a call for heat, and all safeties are

closed, then the combustion air blower starts to purge
air from the combustion chamber. After the pre-purge,
the igniter is energized. The standard ignition module
will lock-out after failing to light 3 times during a call for
heat. To reset the lock-out, press and release the
RESET button located on the user interface. The control will automatically reset after 1 hour. When in
lock-out the control will run the blower through a postpurge cycle.
Fig. 36: Outdoor Venting
Freeze Protection
The single-try ignition module (part of the CSD-1

option) will attempt to light only one time before lockout occurs. To reset the lock-out, press and relase the
RESET button located on the user interface.
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 45F on the
Outlet or Inlet sensors, the Boiler pump is enabled.
The pump is turned off when both the Inlet and Outlet
temperatures rise above 50F.
Turning off the power to the heater WILL NOT reset

the single-try ignition module.
NOTE: Ignition modules are common for all model
sizes. However, model-specific operating parameters are defined by their respective ID cards.
If either the Outlet or Inlet temperature drops below

38F, the VERSA starts the burner at the minimum firing rate. The burner cycle will terminate when both the
Inlet and Outlet temperatures rise above 42F.
High LimitManual Reset

This heater is equipped with a fixed setting manual reset high limit temperature device as standard. It may
also have an additional optional adjustable manual
reset high temperature device.
Controls
WARNING: Installation, adjustment and service of
heater controls, including timing of various operating
functions, must be performed by a qualified installer,
service agency or the gas supplier. Failure to do so
may result in control damage, heater malfunction,
property damage, personal injury, or death.
The optional manual reset high limit is located inside

the cabinet on the upper left corner post. Access the
limit by hinging the control box open to view and make
adjustments.
34
Fig. 39: Flow Switch
Low Water Cut-Off (Optional)

Fig. 37: High Limit (Manual Reset)
The optional low water cut-off automatically shuts

down the burner whenever water level drops below the
level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions
such as power fluctuations or air pockets.
Standard
The fixed setting manual reset high limit is built into the
PIM, it utilizes a dual element sensor located on the
outlet (see Fig. 36). To reset a high limit lock-out, press
and release the RESET button located on the user
interface.
High LimitAuto Reset (Optional)

This heater may be equipped with an optional adjustable auto reset high limit temperature device.
The optional adjustable auto reset high limit is located
inside the cabinet on the upper left corner post.
Access the limit by hinging the control box open to
view and make adjustments. Adjust the setting to
approx. 20F (10C) above desired outlet temperature.
Fig. 40: Low Water Cut-Off
High & Low Gas Pressure Switches

(Optional)
The optional low gas pressure switch mounts
upstream 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
to ensure that sufficient gas pressure is present for
proper valve/regulator performance. The low gas pressure switch automatically shuts down the heater if gas
sup-ply drops below the factory setting of 3.0 in. WC
for natural gas or propane gas.
The high gas pressure switch is standard, and is
mounted downstream of the gas valve. If the gas
pressure regulator in the valve fails, the high gas pressure switch automatically shuts down the burner.
Fig. 38: Adjustable High Limit (Auto Reset)
Flow Switch
Operation of either the High or Low Gas Pressure

Switch will turn on an LED inside the switch housing.
Push the top of the plastic switch housing as shown in
Fig. 40 to reset a tripped pressure switch. The LED
will go out when the switch is reset.
This standard, dual-purpose control, mounted and

wired in series with the main gas valve, shuts off
heater in case of pump failure or low water flow.
35
User Interface
The user interface consists of several Menu options.
Press the MENU button to scroll through the different
menus in the interface. Press the ITEM button to scroll
through available items within a selected menu. And,
the UP and DOWN buttons allow for setting changes
to items in the ADJUST menu. Refer to Fig. 42 for display and key locations.
For detailed descriptions of the various screens, consult the VERSA IC Control I&O Manual (Catalog
#5000.72).
Fig. 41: 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. 43: User Interface
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 SETPOINT item. Adjust the Setpoint using the UP and
DOWN arrow keys. Minimum is 50F, Maximum is the
PIM value, and the default is 180F for H models
and 125F for WH models.
View Menu
Fig. 42: Blocked Vent Switch
The VIEW menu is the default menu. It displays sensor temperatures, the modulation rate of the blower,
heater cascade status, pump operation and CFH information. Some of the items displayed are mode specific
and are only observable when its corresponding mode
is active.
Menu - Initial Adjustment

To change settings use the MENU key to scroll to the
SETUP/ADJUST menu. The ADJUST menu allows
the installer to make adjustments to items shown in
Table N.
Refer to the VERSA IC Control I&O Manual (Catalog
#5000.72) for detailed setup instructions.
36
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
Boil T
All
Current temperature difference between boiler outlet and boiler inlet
DHW SUPPLY
H MODE 2,3
Current indirect DHW supply temperature
TANK DHW
WH
Current tank temperature
BOILER STATUS
All
IDLE, PREP, IGN, MOD RATE %, POST, SOFT

Table N: View Menu
37
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, 50F to 150F
Tank set point temperature
125F
TANK DIFF
WH
2F to 10F
Tank Differential temperature
MODE
H MODE 1,2,3 1,2,3
Piping and application configuration.
SETPOINT
H MODE 1,2,3 50F to PIM value*
Boiler target temperature while a heat demand is present for setpoint operation
180F
OUT START
H MODE 1,2,3 35F to 85F
Outdoor starting temperature - outdoor reset
70F
OUT DESIGN
H MODE 1,2,3 -60F to 45F
Outdoor design temperature - outdoor reset
10F
Boil START
H MODE 1,2,3 35F to 150F
Starting boiler target temperature when the outdoor temperature

is at outdoor start outdoor reset
70F
Boil DESIGN
H MODE 1,2,3 70F to 200F
Design boiler target temperature when the outdoor temperature is

180F
at outdoor design outdoor reset
Boil MASS
All
Thermal mass of the boiler
TARGET MAX
H MODE 1,2,3 100F to PIM value*
Maximum target system temperature
220F
TARGET MIN
H MODE 1,2,3 OFF, 50F to 190F
Minimum target system temperature
50F
TARGET DIFF
H MODE 1,2,3 2F to 42F
Differential for target system temperature
10F
DHW SENSOR
H MODE 1,2,3 OFF <> ON
Selects whether a DHW sensor is used for indirect DHW tank
OFF
DHW DIFF
H MODE 2,3
2F to 10F
Differential for the target indirect DHW tank temperature
6F
IND SUPPLY
H MODE 2,3
OFF, 50F to PIM

value*
Target boiler temperature for the DHW heat exchanger during

indirect DHW operation
180F
OFF <> ON
Selects whether or not Indirect DHW priority is active during indirect DHW operation
OFF
DHW PRIORITY H MODE 2
1<>2<>3
PRI OVR
H MODE 2,3
Au, 0:10hr to 2:00hr
Sets the length of the indirect DHW priority override time
1:00hr
BOIL PURGE
All
0:20min to 10:00min
Sets the length of the boiler pump post purge
20 seconds
SYS PURGE
All
OFF, 0:20min to
20:00min
Sets the length of the system pump post purge
20 seconds
WWSD
H MODE 1,2,3 40F to 100F
The system warm weather shutdown temperature outdoor reset
70F
UNITS
All
deg F <> deg C
Show units using icons in display
deg F
MODBUS
All
OFF<>MNTR<>
TEMP<>RATE
ModBus Operating Mode: Off, Monitor, Temp Control, Rate

Control
OFF
ADDRESS
All
1 to 247
ModBus slave address
DATA TYPE
All
RTU <> ASCI
Modbus data type
RTU
BAUD RATE
All
2400<>9600<>19K2<>
57K6<>115K
19K2
PARITY
All
NONE<>EVEN<>ODD
EVEN
Table O: Setup/Adjust Menu
38
Boiler Menu
The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well
as software and hardware information
Item
Application
Description
IGNITION
All
Current State of Ignition
LIMIT TEMP
All
Current Limit Temperature
AUX TEMP
H MODE 3
Current Auxiliary Temperature
EMS Vdc
All
Current EMS signal in Volts DC
FIRE RATE
All
PIM firing rate
SPEED X1000 BLOWER
All
Blower speed, Revolutions/Minute
HIGH LIMIT
All
High Limit Setting *
H L OFFSET
All
High Limit Offset *
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 PREPr
All
Blower % during prepurge
BLOW POSTt
All
Duration of blower postpurge
BLOW POSTr
All
Blower % during postpurge
MIN RATE
All
Minimum modulation rate % during operation *
START RATE
All
Start modulation rate % during ignition *
MAX RATE
All
Maximum modulation rate % during operation *
FLAME CUR
All
Flame current in micro-amps
IGN TYPE
All
PIM board type
MASS
All
Thermal mass of the boiler
ID CARD
All
Identifies OEM identity card
PIM ID
All
Identifies OEM PIM PCB
SW ID
All
PIM software identification number

Table P: Boiler Menu
* Fixed values based on ID card
39
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.
Item
Application
Description
RUN TIME Burner 1
All
Burner run time (hours). Press UP/DOWN for 1 sec to clear.
Cycles Burner
All
Number of burner cycles. Press UP/DOWN for 1 sec to clear.
RUN TIME Boiler pump
All
Boiler pump run time (hours). Press UP/DOWN for 1 sec to

clear.
RUN TIME System pump
All
System pump run time (hours). Press UP/DOWN for 1 sec to

clear.
RUN TIME DHW pump
H MODE 2,3
DHW pump run time (hours). Press UP/DOWN for 1 sec to clear.
OUTLET HI
All
Records the highest boiler outlet temperature. Press UP/DOWN

for 1 sec to clear.
OUTLET LO
All
Records the lowest boiler 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 temperature. Press UP/DOWN

for 1 sec to clear.
OUTDOOR HI
H MODE 1,2,3
Records the highest outdoor temperature. Press UP/DOWN for 1

sec to clear.
OUTDOOR LO
H MODE 1,2,3
Records the lowest outdoor temperature. Press UP/DOWN for 1

sec to clear.
SYSTEM HI
All
Records the highest supply temperature. Press UP/DOWN for 1

sec to clear.
SYSTEM LO
All
Records the lowest supply temperature. Press UP/DOWN for 1

sec to clear.
IND HI
H MODE 1,2,3
Records the highest Indirect supply temperature. Press

UP/DOWN for 1 sec to clear.
IND LO
H MODE 1,2,3
Records the lowest Indirect supply temperature. Press

UP/DOWN for 1 sec to clear.
DHW HI
WH
Records the highest DHW temperature. Press UP/DOWN for 1

sec to clear.
DHW LO
WH
Records the lowest DHW temperature. Press UP/DOWN for 1

sec to clear.
Table Q: Monitor Menu
40
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.
Item
Description
Lookup Active Error
Look up and display the active error info.
USER TEST
MAX HEAT
P/N 104901
DEFAULTS
HISTORY
lookup logged error
Select ON to start the function. The setting returns to default after the test is run.
(See Page 47 for details.)
Select ON to start the function. The setting will time out to OFF after 24 hours or can
be set to OFF again by the user. (See VERSA IC Manual for details.)
Software number of the Raypak VERSA
Resets to factory settings. Press UP and DOWN for 1 second to show CLR and load
factory defaults to all settings. This will also clear all history.
Displayed when an error code is present. 1 indicates the most recent error code.
Press UP and DOWN for 1 second to clear the error logs.
Table R: Toolbox Menu
Outdoor Reset Concept
The starting point for most systems is the 1.00

(OD):1.00 (SYS) (Outdoor Temperature: Heating
Water Temperature) ratio. This means that for every
degree the outdoor temperature drops, the temperature of the heating water will increase one degree.
With the VERSA, both ends of the slope are
adjustable. It is factory set at 70F water temperature
(Boil START) at 70F outdoor air (OUT START), and
180F water temperature (Boil DESIGN) at 10F outdoor air (OUT DESIGN).
The Temperature controller can change the System

Set Point based on outdoor temperature (Outdoor
Reset). The temperature controller varies the temperature of the circulating heating water in response to
changes in the outdoor temperature. The heating
water temperature is controlled through the modulation and/or sequencing of the cascade.
The Temperature controller can also control the system circulating pump with an adjustable Outdoor
Cutoff. When the outdoor temperature is above the
Outdoor Cutoff, the pump is turned off and no heating
water is circulated through the system. When the outdoor temperature drops below the Outdoor Cutoff, the
system pump relay is activated and the heating water
circulates through the system. The temperature of the
heating water is controlled by the Reset Ratio, Water
Offset, and changes with the outdoor temperature.
Each building has different heat loss characteristics. A

very well insulated building will not lose much heat to
the outside air, and may need a Reset Ratio of 2.00
(OD):1.00 (SYS) (Outdoor: Water). This means the
outdoor temperature would have to drop 2 degrees to
increase the water temperature 1 degree. On the other
hand, a poorly insulated building may need a Reset
Ratio of 1.00 (OD):2.00 (SYS). This means that for
each degree the outdoor temperature dropped the
water temperature will increase 2 degrees. The
VERSA control Reset Ratio allows for full customization to match any buildings heat loss characteristics.
Reset Ratio/Outdoor Reset

When a building is being heated, heat escapes
through the walls, doors, and windows to the colder
outside air. The colder the outside temperature, the
more heat escapes. If you can input heat into the building at the same rate that it is lost out of the building,
then the building temperatures will remain constant.
The Reset Ratio is an adjustment that lets you achieve
this equilibrium between heat input and heat loss.
A heating curve that relies not only on Outdoor temperature but also on the type of radiation will improve heat
comfort. The user can fine tune these adjustments
based on the specific building need.
41
RESET RATIO
The control uses the four following settings to determine the reset ratio:
Boiler Start (Boil START)
The Boil START temperature is the theoretical boiler supply water temperature that the heating system requires when the outdoor air
temperature equals the OUT START temperature setting. The Boil START is typically set to the desired building temperature.
Outdoor Start (OUT START)
The OUT START temperature is the outdoor air temperature at which the control provides the Boil START water temperature to
the system. The OUT START is typically set to the desired building temperature.
Outdoor Design (OUT DESIGN)
The OUT DESIGN is the outdoor air temperature that is the typical coldest annual 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 temperature required to heat the boiler zones when the outdoor air is as cold as the
OUT DESIGN temperature.
When the outdoor air temperature rises above the WWSD setting, the
control turns on the WWSD segment in the display. When the control is in
Warm Weather Shut Down, the Dem 1 segment is displayed if there is a
heat demand. However, the control does not operate the boiler to satisfy
this demand. The control continues to respond to DHW demands.
OUT
DESIGN
Boil
START
OUT
START
Decreasing Outdoor Temperature
Fig. 44: Reset Ratio
Reset Ratio
The controller uses the following four settings to calculate the Reset Ration (RR):
RESET RATIO =
Increasing Water Temperature
Boil DESIGN
Warm Weather Shut Down (WWSD)
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).
(OUTDOOR START OUTDOOR DESIGN)

(BOILER DESIGN BOILER START)
For example, when using the default values, the RR

is:
RR = (70 - 10) / (180 - 70) = 0.55
Therefore, the RR is 0.55:1 (Outdoor:Water).
42
WIRING DIAGRAM Models 25034003
43
START-UP
BEFORE OPERATING, smell all around the appliance

area for gas. Be sure to smell near the floor because
some gas is heavier than air and will settle on the floor.
NOTE: The following steps must be performed by a

factory-trained technician.
WHAT TO DO IF YOU SMELL GAS:
Pre Start-up
Filling System (Heating Boilers)
Fill system with water. Purge all air from the system.
Lower system pressure. Open valves for normal system operation, and fill system through feed pressure.
Manually open air vent on the compression tank until
water appears, then close vent.
Air Purge (Domestic Hot Water

Heaters)
Purge all air from system before heater operation. This

can be normally accomplished by opening a downstream valve.
The MVB 2503-4003 models have two air vent valves
located on top of the upper headers as standard.
These valves are used to purge air from the heat
exchanger.
Do not try to light any appliance.

Do not touch any electrical switch; do not use any
telephone in your building.
Immediately call your gas supplier from a neighbors telephone. Follow the gas suppliers
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 turn
by hand, do not try to repair it; call a qualified service technician. Forced or attempted repair may
result in a fire or explosion.
Do not use this appliance if any part has been
under water, immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
Check around unit for debris and remove combustible products, i.e. gasoline, etc.
Pre Start-up Check
CAUTION: An air vent valve should be installed at

the highest point in the system for proper operation.
If water piping is located higher than the header, an
air vent valve should be located at the highest point
in the installed system.
1. Verify the heater is filled with water.

2. Check system piping for leaks. If found, repair
immediately.
3. Vent air from system. Air in system can interfere
with water circulation.
4. Purge air from gas line to heater.
Venting System Inspection
Initial Start-up
1. Check all vent pipe connections and flue pipe material.
Required tools
2. Make sure vent terminations are installed per code

and are clear of all debris or blockage.
For Your Safety

This appliance has a hot surface igniter. It is equipped
(1) 12-0-12 (24 scale) U-tube manometer

(2) 6-0-6 (12 scale) U-tube manometer
Screwdrivers (assorted sizes and shapes)
(1) Crescent wrench (8 or 10)
(1) Multi-meter
(1) Amp probe
WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
(Metric Allen wrenches will be required for servicing

the gas valve, but not during start-up)
with an ignition device which automatically lights the

burners. Do not try to light the burners by hand.
NOTE: Digital manometers are not recommended.
44
Preparation
3. If the gas pressure is greater than 14.0 in. WC,

turn off the main gas shut-off valve, upstream of
the heater.
WARNING: Do not turn on gas at this time.
Start-Up
Check Power Supply
NOTE: The values in Tables T and V represent the

conditions when the heater is at full firing rate at sea
level.
With multi-meter at incoming power, check voltage

between:
L1 - Ground (120 VAC)
NOTE: Pressure and combustion data are provided

with the heater.
L2 - Ground (120 VAC)

L1 - L2 (240 VAC)
1. Turn power on.
Attach Manometers to Measure Pressures
2. Turn on the heater, wait approximately 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 below the gas
valve near the front of the unit to check igniter
operation. Gas valve should open in 45-60 seconds.
1. Turn off main gas valve.

2. Attach (1) 12 scale manometer to an upstream
bleedle valve on the gas supply pipe to the heater
(Measure point A in Fig. 45).
3. Attach (1) 24 scale manometer to the manifold
pressure tap located on the shutoff valve downstream of the firing valve (Measure point D in
Fig. 47).
3. The heater ignites at 30% to 40% of full rate (as

indicated on the LCD display of the temperature
controller located behind the front panel).
4. Attach (1) 12 scale manometer on the fan suction

pressure hose. Pull black cap from the air pressure tee as shown in Fig. 46 and connect the
manometer. NOTE: Retain caps for reinstallation
later.
4. If the burner fails to light on the first trial, it will try

for ignition up to three times before going into lockout with the standard ignition module. If the heater
is equipped with the optional single-try ignition
module, it will go into lockout.
5. Wait until the controller indicates 100% on the firing rate display screen (approximately 30
seconds).
MANIFOLD TAP
Fig. 45: Gas Pressure Measurement Locations
Check Gas Supply Pressure

AIR PRESSURE
TEE
1. Slowly turn on main gas shut-off valve.

2. Read the gas supply pressure from the manometer; minimum supply pressure for natural gas is 4.0
in. WC, recommended supply is 7.0 in. WC, minimum supply pressure for propane gas is 4.0 in.
WC, recommended supply is 11.0 in. WC (dynamic readings, full fire input).
Fig. 46: Air Pressure Tee
45
Blower Check
1. Check blower suction using the manometer
attached to the air pressure tee as shown in
Fig. 46, with the heater firing at 100% input. The
reading should be as noted in Table S for both natural and propane gas.
2. When firing at 100%, the desired heater combustion CO2 is 9.3% 0.5% for natural gas and
10.7% 0.5% for propane with CO less than 100
ppm. If this combustion cannot be achieved with
the blower suction within the tolerances specified
in Table S, contact the factory.
Natural Gas
Propane Gas
2503
-4.8
-6.4
3003
-6.7
-8.8
3503
-6.8
-9.5
4003
-4.7
-7.4
Table T: MVB Manifold Pressure Settings
CAUTION: Special manifold and air settings may

be required.
Manifold Check
User Test
1. Check manifold gas pressure at the gas valve outlet pressure tap (connection D in Fig. 45). This
pressure should read per the values in Table T for
natural and propane gas.
Set DIP switch #1 on the VERSA IC control to ON.

Set USER TEST = ON in the 'ToolBox' Menu to start
the user test function.
2. If the pressure reading differs by more than 0.2

in. WC, STOP Call the factory for directions
on what to do next!
Model

(High Fire Values)
Model
No.
Air Pressure Setting

(in. WC)
Setting
Tolerance
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 demands must be present
for burner operation.
Number
Field
Output Action
.2 in. WC
SYS
System Pump relay turns on.
-4.3
.2 in. WC
DHW
DHW Pump relay turns on.
-4.1
-4.3
.2 in. WC
-4.1
-4.3
.2 in. WC
PMP 1
System and Boiler Pump relays turn on.
Boil 1
Ignite Boiler Burner.
Min 1
Hold Boiler at Min Fire.
Max 1
Ramp Boiler to Max Fire and hold.
Nat. Gas
Propane
2503
-4.1
-4.3
3003
-4.1
3503
4003
Table S: MVB Air Pressure Settings
Table U: User Test Fields
46
On the first press of the Up button, the test step is

held and "HOLD" is flashed at 1Hz.
On the second press of the Up button, the test
step is incremented.
If boiler outlet temperature reaches the PIM HiLimit, the boiler will be ramped down to keep the
temperature in a safe range.
Press of the Up button from Boiler Max will End
the User Test function.
Leak Test Procedure: Dual-Seat Gas

Valve
Safety Inspection
1. Check all thermostats and high limit settings.
Proper leak testing requires three pressure test points

in the gas train. Remove the upper front panel and
swing the front J-box out of the way to access the gas
valve for this test.
2. During the following safety checks leave manometers hooked up, check and record.
3. If other gas-fired appliances in the room are on the
same gas main, check all pressures on the MVB
with all other equipment running.
Test point A is a bleedle valve located upstream of the

combination gas valve on the supply manifold.
4. Check thermostats for ON-OFF operation.
Test point B is a bleedle valve located between the two

automatic gas valve seats.
5. Check high limits for ON-OFF operation.
Test point C is a bleedle valve located downstream of

both automatic gas valve seats and upstream of the
manual valve. Refer to Fig. 47.
6. While in operation, check flow switch operation.

7. Check the low gas pressure switch (if provided).
(For proper adjustment, use the attached
manometers, if available, to set pressure. The
scales on the switch are approximate only.) Low
gas pressure switch (if provided) must be set at
3.0 in. WC for natural gas and propane gas.
These tests are to be conducted with the electrical

power to the heater turned OFF.
1. Manually close the downstream leak test valve.
2. Open 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).
8. Make sure that the high gas pressure switch is set

to 3.0 in. WC for both natural gas and propane
gas.
3. Open test point B and connect a rubber tube to it.

Connect the other end of the tube to a manometer
and look for a build-up of pressure. Increasing
pressure indicates a leaking gas valve which must
be replaced.
Finishing
1. Record all data on the Start-up Checklist located
at the back of this manual.
2. Disconnect the manometers and reconnect the
cap on the fan pressure tee and reinsert the sealing screws into the bleedle valves.
4. Next, close the upstream manual gas valve (field

supplied) and remove the manometers from the
bleedle valves in test point A and test point B.
Connect a rubber tube from the test point A bleedle valve to the test 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 seat.
3. Start-up is complete and the heater should be

operating properly.
Follow-Up
Safety checks must be recorded as performed.
Turn heater on. After main burner ignition:
5. Open the bleedle valve at test point C and connect

a second rubber tube to it. Connect the other end
of the tube to a manometer and look for a build-up
of pressure. Increasing pressure indicates a leaking gas valve which must be replaced.
1. Check manometer for proper readings.

2. Cycle heater several times and re-check readings.
3. Remove all manometers and replace caps and
screws.
6. Remove rubber tube and manometers. Close

each bleedle valve as the tubes are removed.
4. Check for gas leaks one more time.
7. After no leakage has been verified at all valve

seats and test valve, open downstream leak test
valve and restore electrical power to the heater.
47
8.
To test the fixed manual reset high limit built into

the PIM, first set dip switch #8 on the PIM to
the ON position. This will activate a Commission
Test Mode which will turn on the amber Alarm/Test
LED on the PIM. The fixed high limit setting is
temporarily overridden to match the setpoint
potentiometer position on the PIM. The high
limit can now be adjusted by the potentiometer to
assist in commission testing and verification of
high limit functionality. The VERSA IC will 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 normal operation.
9.
Test ignition system safety device:

a.
Close manual gas valve. Turn power on.
b.
Close Enable/Disable circuit to call for heat.
c.
The burner should attempt three trials for ignition for the standard model and then lock out.
Single try ignition modules will try only once
and then lock out.
d.
Open manual gas valve. Reset the ignition

control by pressing for one second and then
releasing the reset button on either the user
interface or at the PIM to clear the ignition
fault.
Fig. 47: 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 venting procedure.
3.
Verify that air has been purged from the system.
4.
Verify that air has been purged from the gas piping, and that the piping has been checked for
leaks.
5.
Confirm that the proper start-up procedures were

followed.
6.
Inspect burner to verify flame.
7.
Test safety controls: If heater is equipped with a

low water cut-off or additional safety controls, test
for operation as outlined by manufacturer. Burner
should be operating and should go off when controls are tested. When safety devices are restored,
burners should re-ignite after pre-purge time
delay.
10. To restart system, follow 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 flow is adjusted as required in each zone.
12. Check that the heater is cycled with the thermostat. Raise the setting on the thermostat to the
highest setting and verify that the heater goes
through the normal start-up cycle. Reduce to the
lowest setting and verify that the heater goes off.
13. Observe several operating cycles for proper operation.
14. Set the heater thermostat to desired temperature.
15. Review all instructions shipped with this heater
with owner or maintenance person, return to envelope and give to owner or place the instructions
inside front panel on heater.
48
OPERATION
d. Gas is on at the meter and the heater.
Lighting Instructions
e. Incoming dynamic gas pressure to the gas

valve is NOT less than 4.0 in. WC for natural
gas or propane gas.
1. Before operation, make sure you have read all of

the safety information in this manual.
To Turn Off Gas To Appliance
2. Remove upper front panel.
1. Shut off manual gas valve field installed near gas

inlet connection on back of heater.
3. Set the thermostat to the lowest setting.
2. Remove upper front panel.
4. Turn off all electrical power to the appliance.
3. Adjust setpoint to lowest setting.
5. This appliance is equipped with an ignition device

which automatically lights the burner. Do not try to
light the burner by hand.
4. Turn off all electrical power to the appliance if service is to be performed.

5. Replace access panel.
6. Turn on main manual gas valve field installed near

gas inlet connection on back of heater.
TROUBLESHOOTING
7. Wait 5 minutes to clear out any gas. Then smell for

gas, especially near the floor. If you then smell
gas, STOP! Follow the steps in the safety information on the front cover of this manual. If you do not
smell gas, go to next step.
MVB Error Codes

If any of the sensors detect an abnormal condition or
an internal component fails during the operation of the
MVB, the display may show the error. This code may
either be the result of a temporary condition in which
case the display will revert to its normal readout when
the condition is corrected, or it may be the result of a
condition that the controller has evaluated as not safe
to restart the unit. In this case, the unit control will be
locked out, requiring the maintenance person to manually reset the control by pressing and releasing the
RESET key.
8. Turn on all electrical power to the appliance.

9. Set thermostat to desired setting. The appliance
will operate. The igniter will glow after the prepurge time delay (15 seconds). After igniter
reaches temperature (30 seconds) the main valve
should open. System will try for ignition up to three
times (one time on optional single-try ignition module). If flame is not sensed, lockout will
commence.
Heater Errors
10. If the appliance will not operate, follow the instructions To Turn Off Gas To Appliance, and call your
service technician or gas supplier.
When an error condition occurs, the controller will display an error code on the display module. These error
codes and several suggested corrective actions are
included in the MVB Fault Text section on the following
page.
11. Replace upper front panel.

12. If heater fails to start, verify the following:
Heater Faults
a. There are no loose connections or that the

service switch is off.
1. When a fault condition occurs, the controller will

flash a red light on the PIM and display the error
code on the user interface. The alarm output will
also be activated. Most fault conditions will also
cause the boiler pump to run in an attempt to cool
the unit.
b. High temperature limit switch (optional) is set

above water temperature or manual reset high
limit is not tripped.
c.
Enable/Disable circuit is closed.
49
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.
WARNING: When servicing or replacing any

components of this unit be certain that:
The gas is off.
All electrical power is disconnected.
3. Press and release the RESET key to clear the

fault on the user interface and resume operation.
Be sure to observe the operation of the unit for a
period of time to ensure correct operation and no
reoccurrence of fault code(s).
WARNING: Do not use this appliance if any part

has been under water. Improper or dangerous
operation may result. Contact a qualified service
technician to inspect the boiler and to repair or
replace any part of the boiler that has been under
water prior to placing the boiler back in operation.
DANGER: When servicing or replacing components

that are in direct contact with the water, be certain
that:
There is no pressure in the boiler. (Pull the release
on the relief valve. Do not depend on the pressure
gauge reading).
The boiler water is not hot.
The electrical power is off.
CAUTION: Wiring errors can cause improper and

dangerous operation. Verify proper operation after
servicing. See wiring diagram.
CAUTION: If overheating occurs or the gas supply
fails to shut off, do not turn off electrical power to the
circulating pump. This may aggravate the problem
and increase the likelihood of boiler damage.
Instead, shut off the gas supply to the boiler at the
gas service valve.
MVB Fault Text

Error Display
If there is an active error, then it is displayed as the first item in the Toolbox Menu and it is the default display for
the control until the error is resolved.
Error Item
Description and Troubleshooting
OUTLET SEN
Check the outlet water sensor and its wiring.
LIMIT SEN
Check the high limit sensor and its wiring.
INLET SEN
Check the inlet sensor and its wiring.
GAS PRESS
Check PIM wiring.
IGNITION
Reset control, push and release RESET button
LIMIT TRIP
Boiler temperature tripped the high limit.
FLAME
False flame detected. Shut off gas supply, recycle power.
ID CARD
Identity card, check ID card and wiring.
IGN CTRL
Internal control fault. Reset power, 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
Blower speed out of range. Check blower wiring and blower.

Table V: Error Display
50
LED Error Code Listing

Active errors detected are indicated by LED lights on the PIM.
LED Code
Error Mode
Off
Normal Operation
Red LED
steady ON,
ID Card Fault
Green Power
LED OFF
Recommended Troubleshooting
Check that the proper ID card is securely connected. Perform a

power and system restart.
Steady ON
Internal Control Failure Perform a power and system reset. If fault remains, replace PIM.
1 flash
N/A
N/A
2 flashes
False Flame Error
Check for proper gas valve closure. Clean burner and electrodes.
3 flashes
Ignition Lockout Fault
Check 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
Check for proper water flow. Check hi-limit and outlet sensor.
8 flashes
Sensor Fault
See VERSA for fault identification. Check sensor wiring.
9 flashes
N/A
N/A
10 flashes
N/A
N/A
11 flashes
N/A
N/A
12 flashes
N/A
N/A
13 flashes
Hi-Temperature Delta
Fault
Check pump operation. Confirm proper water flow across heat

exchanger.
14 flashes
Ft-Bus
Communications Fault
Verify VERSA is connected and operating. Check the cable between

the VERSA and PIM.
15 flashes
Safety circuit open
Confirm all safeties are functioning normally. Check continuity at J8,

pins 5 and 6 at the PIM.
Table W: PIM LED Error Codes
51
MAINTENANCE
Sensor Resistance Values

Water Sensor / Outdoor Sensor
Suggested Minimum
Maintenance Schedule
Water Temperature (F)
Resistance (ohms)
32
32550
41
25340
50
19870
59
15700
68
12490
Daily and monthly maintenance as outlined below may

be performed by onsite maintenance staff.
77
10000
Daily
86
8059
95
6535
104
5330
113
4372
122
3605
2. Check for and remove any obstruction to the flow

of combustion or ventilation air to heater.
131
2989
Monthly
140
2490
149
2084
158
1753
167
1481
176
1256
2. Visually inspect burner flame.
185
1070
194
915
3. Visually inspect venting system for proper function, deterioration or leakage.
203
786
212
667
Regular service by a qualified service agency and

maintenance must be performed to ensure maximum
operating efficiency.
1. Check that the area where the heater is installed

is free from combustible materials, gasoline, and
other flammable vapors and liquids.
1. Check for piping leaks around pumps, mixing

valves, relief valves, and other fittings. If found,
repair at once. DO NOT use petroleum-based
stop-leak compounds.
4. Visually inspect for proper operation of the condensate drain in the venting. If leaks are observed
repair at once.
Table X: Approximate Sensor Resistance Values
5. Check air vents for leakage.
Yearly (Beginning Of Each Heating

Season)
Schedule annual service by qualified service agency.
1. Visually check top of vent for soot. Call service
person to clean. Some sediment at bottom of vent
is normal.
2. Visually inspect venting system for proper function, deterioration or leakage. Ensure that
condensate drain is inspected and ensure that
condensate is being directed to appropriate condensate management system or drain, as required
by local codes.
52
3. Check that area is free from combustible materials, gasoline, and other flammable vapors and
liquids.
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 ignition fault light should come on. Depress reset
button on front of heater control panel to reset).
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 visually inspect hot
surface igniter and sensor for damage, cracking or
debris build-up.
Monthly
1. Check flue, vent, stack, or outlet dampers.
2. Test blower air pressure. (See Blower Check on
page 42.)
7. Check operation of safety devices. Refer to manufacturers instructions.
3. Test high and low gas pressure interlocks (if

equipped). (See Safety Inspection on page 47.)
8. Follow oil-lubricating instructions on pump (if required). Over-oiling will damage pump.
Water-lubricated circulators do not need oiling.
Semi-Annually
9. To avoid potential of severe burn, DO NOT REST

HANDS ON OR GRASP PIPES. Use a light touch;
return piping will heat up quickly.
1. Recalibrate all indicating and recording gauges.

2. Check flame failure detection system components.
10. Check blower and blower motor.
3. Check firing rate control by checking the manifold

pressure. (See Manifold Check on page 46.)
11. Check for piping leaks around pumps, relief valves

and other fittings. Repair, if found. DO NOT use
petroleum-based stop-leak.
4. Check piping and wiring of all interlocks and shutoff valves.
Periodically
5. Check air filter and replace as necessary.
1. Check relief valve. Refer to manufacturers

instructions on valve.
Annually
2. Test low water cut-off (if equipped). Refer to manufacturers instructions.
1. Test flame failure detection system and pilot turndown.
Preventive Maintenance
Schedule
2. Test high limit and operating temperature. (See

Post Start-Up Check, page 48.)
3. Check flame sensor.
The following procedures are recommended and are

good practice for all MVB installations.
4. Conduct a combustion test at full fire. Carbon dioxide should be 9.3% at full fire for natural gas, and
10.7% for propane gas. Carbon monoxide should
be < 100 ppm.
Daily
1. Check gauges, monitors and indicators.
5. Check valve coil for 60 cycle hum or buzz. Check

for leaks at all valve fittings using a soapy water
solution (while heater is operating). Test other
operating parts of all safety shut-off and control
valves and increase or decrease settings
(depending on the type of control) until the safety
circuit opens. Reset to original setting after each
device is tested.
2. Check instrument and equipment settings. (See

Post Start-Up Check on page 48.)
3. Check burner flame. (Should see light blue flame
at full input rate).
53
6. Perform leakage test on gas valves. (See Fig. 47.)

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.)
4. Check igniter. (Resistance reading should be 4075 ohms at 77F).
5. Check flame signal strength. (Flame signal should
be greater than 1 microampere as measured at
the 2 pins on the bottom of the PIM).
6. Check firing rate control by checking the manifold
pressure. (See Manifold Check on page 46.)
7. Test safety/safety relief valves in accordance with
ASME Heater and Pressure Vessel Code
Section IV.
Filter Maintenance
Inspect quarterly
NOTE: Use Raypak replacement filters, kit number

014492F.
Replace as needed. The recommended interval is

once per year.
54
APPENDIX
Areas where contaminated combustion air commonly

exists:
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
stainless steel, which is commonly used in high efficiency systems. The heater can be supplied with
corrosion-resistant, non-metallic intake air vent material. You may, however, choose to use outside
combustion air for one or more of these reasons:
1. Installation is in an area containing contaminants

listed below which will induce acidic condensation.
Check for areas and products listed above before installing heater. If found:
2. You want to reduce infiltration into your building

through openings around windows and doors.
3. You are using AL29-4C stainless steel vent pipe,

which is more corrosion-resistant than standard
metallic vent pipe. In extremely contaminated areas, this may also experience deterioration.
Products causing contaminated combustion air:
spray cans containing chloro/fluorocarbons

permanent wave solutions
chlorinated waxes/cleaners
chlorine-based swimming pool chemicals
calcium chloride used for thawing
sodium chloride used for water softening
refrigerant leaks
paint or varnish removers
hydrochloric acid/muriatic acid
cements and glues
antistatic fabric softeners used in clothes dryers
chloride-type bleaches, detergents, and cleaning
solvents found in household laundry rooms
adhesives used to fasten building products
similar products
55
dry cleaning/laundry areas

metal fabrication plants
beauty shops
refrigeration repair shops
photo processing plants
auto body shops
plastic manufacturing plants
furniture refinishing areas and establishments
new building construction
remodeling areas
open pit skimmers
remove products permanently, OR

install TruSeal direct vent.
Important Instructions for the Commonwealth of Massachusetts

The Commonwealth of Massachusetts requires compliance
with regulation 248 CMR 4.00 and 5.00 for installation of
through the wall vented gas appliances as follows:
(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
(a) For all side 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 and where the
side wall exhaust vent termination is less than seven (7) feet
above finished grade in the area of the venting, including but
not limited to decks and porches, the following requirements
shall be satisfied:
2. Product Approved side wall horizontally vented gas fueled

equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the
manufacturer of Product Approved side wall horizontally
vented gas equipment provides a venting system design or
venting system components with the equipment, the instructions provided by the manufacturer for installation of the
equipment and the venting system shall include:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS.

At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level
where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery
operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the
property owner to secure the services of qualified licensed
professionals for the installation of hard wired carbon
monoxide detectors
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the
manufacturer of a Product Approved side wall horizontally
vented gas fueled equipment does not provide the parts for
venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the
manufacturer:
a. In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an attic, the
hard wired carbon monoxide detector with alarm and battery
back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the
above requirements; provided, however, that during said
thirty (30) day period, a battery operated carbon monoxide
detector with an alarm shall be installed.
1. The referenced "special venting system" instructions shall

be included with the appliance or equipment installation
instructions; and
2. The "special venting systems" shall be Product Approved
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
2. APPROVED CARBON MONOXIDE DETECTORS. Each

carbon monoxide detector as required in accordance with
the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified.
(e) A copy of all installation instructions for all Product

Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting
instructions, and/or all venting design instructions shall
remain with the appliance or equipment at the completion of
the installation.
3. SIGNAGE. A metal or plastic identification plate shall be

permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with
the exhaust vent terminal for the horizontally vented gas
fueled heating appliance or equipment. The sign shall read,
in print size no less than one-half (1/2) inch in size, "GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS".
GAS PRESSURE SUPERVISION

The Commonwealth of Massachusetts requires listed high
and low gas pressure switches (manual reset) for any model
with a maximum firing input greater than 1,000,000 Btu/Hr in
accordance with 248 CMR 7.04(11)(d).
4. INSPECTION. The state or local gas inspector of the side

wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
A gas pressure regulator (field supplied) is required in the

gas train ahead of the heater, for heaters having input rates
greater than 1,000,000 Btu/Hr, in accordance with 248 CMR
7.04 Figure 3B requirements.
56
LIMITED PARTS WARRANTY

MVB TYPES H AND WH
MODELS 2503-4003
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 to the conditions set forth in this Warranty. Labor
charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the
owners responsibility.
HEAT EXCHANGER WARRANTY
Domestic Hot Water

Five (5) years from date of heater installation. Includes copper heat exchanger with bronze waterways.
Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze waterways.
Space Heating (Closed Loop System)
Ten (10) years from date of heater installation. Includes both cupro-nickel and copper heat exchanger with bronze water-ways.
Thermal Shock Warranty
Twenty-five (25) years from date of heater installation against Thermal Shock (excluded, however, if caused by heater operation at large
changes exceeding 150F between the water temperature at intake and heater temperature, or operating at heater temperatures exceeding 230F).
ANY OTHER PART MANUFACTURED BY RAYPAK
One (1) year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypaks records,
whichever comes first.
SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE
VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.
ADDITIONAL WARRANTY EXCLUSIONS
This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;
2. Abuse, alteration, accident, fire, flood and the like;
3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;
4. High velocity flow exceeding heater design rates;
5. Failure of connected systems devices, such as pump or controller;
6. Use of non-factory authorized accessories or other components in conjunction with the heater system;
7. Failing to eliminate air from, or replenish water in, the connected water system;
8. Chemical contamination of combustion air or use of chemical additives to water.
PARTS REPLACEMENT
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 warranty conditions found satisfied. The replacement part will be warranted for
only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak
will apply any such warranty as may be provided to it by the parts manufacturer.
TO MAKE WARRANTY CLAIM
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service
Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be
received from Raypak before replacement of any part.
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY
This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypaks behalf. THIS WARRANTY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAKS SOLE LIABILITY AND THE SOLE REMEDY AGAINST
RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK
SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE,
FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states
do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above
limitation or exclusion may not apply to you.
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that
you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective
date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of manufacture plus
thirty (30) days.
Original Owner
Model Number
Mailing Address
Serial Number
Date of Installation
City
State
Daytime Telephone Number

RAYPAK, INC
Zip Code
Installation Site
Contractor/Installer
2151 Eastman Avenue Oxnard, CA 93030-9786
(805) 278-5300
57
Fax (800) 872-9725
www.raypak.com
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.
Additionally this form will be used to record all equipment operation functions and required settings.
GAS SUPPLY DATA
Regulator Model & Size

Gas Line Size (in room)
Length of Gas Line
Low Gas Pressure Setting
High Gas Pressure Setting
Gas Shut-Off Valve Type
( Ball, Lube cock)
Sediment Trap
Port
_________ / ______CFH
________________In. NPT
________________Eq Ft
________________In. WC
________________In. WC
________________
________________Y/N
_______Std______Full
VISUAL INSPECTION OF COMPONENTS
Verify inspection was done and condition of components are in

good working order with a yes
Wiring Harness
_________________ Y/N
Burner/s (flame)
_________________ Y/N
Refractory (visual)
_________________ Y/N
Remote flame sense
_________________ Y/N
Covers in place for outdoor
_________________ Y/N
VENTING
Vent Size: _____________

Category: _________
Vent Material:
Vent Termination Type:
Combustion Air Openings:
Ventilation air
Stack Height:_______
sketch vent on reverse side ***
__________________
__________________
Low __________ in2
High __________ in2
EMISSIONS SETTINGS AND TEST INFORMATION

(AT FULL FIRE)
Blower Pressure Setting

Supply Gas Pressure
Verify stable pressure static &
Pilot Gas Pressure
_________________In. WC
_________________In. WC
dynamic condition
_________________In. WC
_________________In. WC
CLEARANCES
Front Clearance
Right Side Clearance
Left Side Clearance
Rear Clearance
Overhead Clearance
ELECTRICAL
Voltage Supply (VAC)

Voltage -24 VAC
Voltage Com to Ground
Hot Surface Igniter
Auto High Limit Setting
Manual Reset High Limit Setting
Operating Control Setting
_______________In.
_______________In.
_______________In.
_______________In.
_______________In.
No Load______ Load_____
_______________VAC
_______________VAC
_______________Ohms
_______________deg F
_______________deg F
_______________deg F
Sketch plumbing on reverse side
WATER SUPPLY
Flow Rate in GPM or Delta T

Measure flow rate at full fire
Pump Economaster setting
Low Water Cutoff
Number of Tanks and Size
Plumbing Size
Pump Size: _________(boiler)
Impeller trim____________
Louvers __________________
_______________If Avail
_______________Minutes
_______________Test
Qty____ _______Gallons
_______________
Pump HP: ______
Pump Model___________
Screens________________
Nominal Factory Recommended Settings
See manual or card tag

The following measurements must be obtained with a Combustion Analyzer.

Free Oxygen
CO
CO2
_________________%
_________________PPM
_________________%
Model Number: ______________________________

*** Note: draw venting with details, such as extractors,
barometric dampers, blast dampers or draft inducers
See manual
Less than 150 PPM
See manual
Serial Number: _______________________________
Site Altitude Above Sea Level __________________Ft.
Job Name _______________________________________________________________________________________

Address _________________________________________________________________________________________
Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; Roof______; Below Grade______
Mechanical Contractor / Installer _______________________________________________________________________
Date and Time of Start-up _____________Print Name and Signature of Start-up Technician_________________________
Information must be faxed to: (805) 278-5471 in order to ensure warranty consideration
58
Attn: Service Manager
59
www.raypak.com
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468
Litho in U.S.A.
60

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INSTALLATION & OPERATING

CATALOG NO. 3400.56A

P/N 241510 Rev. 2

Rev. 2 reflects the following:

Indicates the presence of immediate hazards which will cause severe

Indicates the presence of hazards or unsafe practices which could cause

Indicates the presence of hazards or unsafe practices which could cause

Indicates special instructions on installation, operation, or maintenance which

DANGER: Make sure the gas on which the heater

WARNING: Both natural gas and propane have an

WARNING: Should overheating occur or the gas

WARNING: UL recognized fuel gas detectors are

WARNING: To minimize the possibility of improper

Always keep the area around the heater free of

Heater should never be covered or have any

WARNING - CALIFORNIA PROPOSITION

WARNING: Risk of electrical shock. More than one

CAUTION: If this heater is to be installed above

CAUTION: This heater requires forced water

CAUTION: If this heater is to be installed in a

the upper rear jacket panel of the heater. The model

Ratings and Certifications

Thank you for purchasing a Raypak product. We hope

ANSI Z21.13 CSA 4.9 - latest edition, Gas-Fired

All Raypak heaters are National Board Approved, and

On occasion, items are shipped loose. Be sure that

WARNING: Altering any Raypak pressure vessel

When ordering parts, you must specify the model and

Purchased parts are subject to replacement only

Rated inputs are suitable for up to 2,000 ft elevation

Fig. 3: Component Locations Rear

Panels omitted for clarity

Top panel, blower and gas train omitted for clarity

Panels omitted for clarity

Table A: Basic Data

Vent Size (in.)

Water temperature over 125F can

See instruction manual before setting temperature at water heater.

Water temperature over 125F can cause instant

Temperature limiting valves are

Feel water before bathing or showering.

NOTE: When this water heater is supplying general

The following chart details the relationship of water

Maximum water temperatures occur just after the

Time to Produce Serious

More than 5 minutes

Less than 5 seconds

Less than 3 seconds

About 1-1/2 seconds

Table courtesy of The Shriners Burn Institute

Table B: Time to Produce Serious Burn

Local, state, provincial, and national codes, laws,

CAUTION: This heater should be located in an

* DO NOT install on carpeting

Table C: Clearances Indoor Installations

Fig. 5: Anchor Hole Locations

loose for field installation.

Fig. 7: Outdoor Air Intake