SECTION C: Installation

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.

Hydrostatic Test

Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in operation. The heat exchanger has already been fac- tory-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 glycol-based antifreeze. Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply.

Leaks must be repaired at once to prevent damage to the heater. NEVER use petroleum-based stop-leak compounds.

To perform hydrostatic test:

1.Connect fill water supply. With field-installed bleed valve open, fill heater with water. When wa- ter 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 us- ing high-point air vents. Close feed valve. Test at standard operating pressure for at least 24 hours.

2.Make sure constant gauge pressure has been main- tained throughout test.

3.Check for leaks. Repair if found.

Cold Water Operation

CAUTION: Damage due to internal condensation may occur if the heater inlet water temperature does not exceed 120˚F (49ºC) within 7 minutes of start-up.

This heater is equipped with a proprietary condensate evaporation system which will evaporate any conden- sate that may begin to accumulate inside the primary heat exchanger with water temperatures as low as 120ºF (49ºC).

Heaters operated with an inlet temperature of less than 120ºF (49ºC) MUST have a manual bypass (see Fig.

14)or an approved low-temperature operation system to prevent problems with condensation. This piping is

like a primary/secondary boiler installation with a by- pass acting as the secondary boiler piping. Raypak strongly recommends that thermometer(s) be placed into the heater piping next to the in/out header to facili- tate temperature adjustment. Inlet water temperatures below 120ºF (49ºC) 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.

NOTE: Vent piping MUST contain a condensate drain which is installed according to the vent manufac- turer’s instructions and plumbed to an appropriate condensate management system (field supplied).

Failure to reach or exceed 120ºF (49ºC) within 7 min- utes may damage or cause failure of the heat exchanger, combustion chamber, or other parts within the combus- tion chamber. It can cause operational problems, bad combustion, sooting, flue gas leakage and reduced ser- vice life of the vent system. A bypass allows part of the heater discharge water to be mixed with the cooler wa- ter returning to the heater inlet to increase the heater inlet temperature above 120ºF (49ºC). This precaution- ary 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 operation issues are applicable to both cold water start and cold water run applications. Cold water operation for 7 minutes or less on initial daily start-up is acceptable. Where cold water starts will last longer than 7 minutes or where cold water operation is con- tinuous, provisions must be made to mix higher temperature outlet water with the colder inlet water and thereby raise the inlet temperature to at least 120ºF (49ºC) within the 7-minute time limit.

Cold Water Starts

Cold water starts, wherein the inlet water temperature remains below 120ºF (49ºC) for more than 7 minutes, must have cold water start protection. Known pro- tection methods consist of mixing heated outlet water with the inlet water with a bypass to raise the inlet to 120ºF (49ºC) or higher. Once the system is heated up and has return water temperatures of 120ºF (49ºC) 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 auto-

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Raypak 503-2003 manual Relief Valve Piping Hydrostatic Test, Cold Water Operation, Cold Water Starts
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503-2003 specifications

The Raypak 503-2003 is a notable entry in the world of water heating solutions, renowned for its efficiency and reliability in both residential and commercial settings. This model is designed to provide exceptional performance while maintaining ease of use and minimization of environmental impact.

One of the standout features of the Raypak 503-2003 is its advanced heating technology. The unit utilizes a durable, copper heat exchanger which ensures quick and efficient heating of water. This heat exchanger is known for its ability to transfer heat effectively, leading to reduced energy consumption and lower utility bills. The design also allows for a seamless operation, ensuring that the system heats water swiftly without sacrificing performance.

In addition to its efficient heating capabilities, the Raypak 503-2003 is equipped with innovative controls. The digital control panel allows users to easily set and adjust the desired water temperature. This feature provides a level of convenience that simplifies operation while enhancing user experience. Furthermore, the smart technology employed in the unit ensures that it operates within optimal parameters, avoiding unnecessary energy expenditure.

Durability is another hallmark of the Raypak 503-2003. Built with heavy-duty components, this water heating solution is designed to withstand the rigors of continuous use. The rugged construction ensures longevity, making it a cost-effective investment for homeowners and businesses alike. Moreover, the unit is designed to be resistant to corrosion and wear, further extending its lifespan and reliability.

The energy efficiency of the Raypak 503-2003 is a crucial characteristic that sets it apart from competitors. Rated with a high efficiency score, this model contributes to lower emissions and is environmentally friendly. It adheres to various energy standards, making it a suitable choice for those looking to reduce their carbon footprint while enjoying reliable water heating.

Noise reduction is another important feature of the Raypak 503-2003. Designed with quiet operation in mind, the unit operates with minimal noise pollution, allowing for a pleasant environment in both residential and commercial spaces.

In summary, the Raypak 503-2003 combines advanced heating technology, user-friendly controls, durability, and energy efficiency into a robust water heating system. This makes it an excellent choice for those in need of dependable and sustainable heating solutions. Whether for daily home use or for larger commercial applications, the Raypak 503-2003 stands out as a leader in its class.
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