Raypak Xtherm 1005, Installation & Operating Instructions Manual

Page 1: ...e 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 Models 1005 2005 Types H WH WHP L W ULTRA HIGH EFFICIENCY WARNING I...

Page 2: ...e 1 and Mode 4 instructions on page 33 Fig 35 and Fig 36 on page 33 Modes 6 8 instructions on page 34 Tables P R on pages 34 35 Auto Limit Auto Reset instructions on page 39 wiring diagrams on pages 42 43 Additions PVC Venting Option on pages 30 31 which includes new Figs 30 33 new Fig 39 on page 34 Deletions Vent Table on page 28 identical to Table M on page 25 ...

Page 3: ...ing 17 Gas Supply 19 Electrical Power Connections 20 Field Wiring Connection 22 Venting 22 Venting Installation Tips 24 Venting Configurations 24 Outdoor Installation 29 PVC Venting Option 30 Controls 32 Heater Sequence of Operation 38 WIRING DIAGRAMS 42 Models 1005 1505 42 Model 2005 43 START UP 44 Pre Start up 44 Pre Start up Check 44 Initial Start up 45 Preparation 45 Start Up 45 OPERATION 49 L...

Page 4: ...njury 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 W...

Page 5: ...ification The model identification number and heater serial number are found on the heater rating plate located on the upper rear jacket panel of the heater The model number will have the form H7 2005 or similar depend ing 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 WHP Water Heater for P...

Page 6: ...tions Fig 1 Component Locations Right Side Fig 2 Component Locations Top Fig 3 Component Locations Rear Model No MBTUH Input Water Conn NPT Gas Conn NPT Vent Size in Max Min N P Flue Intake 1005 999 250 2 1 2 1 1 4 1 6 6 1505 1500 375 2 1 2 1 1 4 1 8 8 2005 1999 500 2 1 2 2 1 8 8 ...

Page 7: ...plica tions where outlet temperatures of 180 F to 195 F are required a boiler is recommended since the 210 F limit on water heaters will NOT allow the heater to maintain these desired sanitary rinse temperatures Water temperature over 125 F can cause instant severe burns or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before set ting t...

Page 8: ...odes 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 I...

Page 9: ...ea under the overhang Combustion and Ventilation Air Indoor Units This heater must be supplied with sufficient quantities of non contaminated air to support proper combustion and equipment ventilation Combustion air can be sup 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 ou...

Page 10: ...4 ft 1 2m below or to side of opening 1 ft 30 cm above opening 3 ft 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t M Clearance under veranda porch deck or balcony 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 Natio...

Page 11: ...onal For applications where condensation may form on cold intake air ducting install the con densate drip pan to the bottom of the air filter box using the four screws provided make sure the pan is angled slightly downward toward the rear of the heater as shown in Fig 9 7 Remove the air intake cover panel by removing the 5 phillips head screws holding it in place 2 Turn off all power to the heater...

Page 12: ...single wall galvanized ducting The duct will attach directly to the field installed air collar located on the rear of the heater using three or four sheet metal screws not supplied equally positioned around the circumference of the duct The screws and duct connection point should be sealed with RTV not supplied TruSeal is generally used when damaging contaminants are present in the mechanical room...

Page 13: ...of 1 in 2 per 2 000 BTUH 1 100 mm2 per kW of total input rat ing of all equipment in the enclosure 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 out doors or shall co...

Page 14: ...r 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 sup ply 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 ...

Page 15: ...al T across the primary heat exchanger The system is designed for continuous return temperatures from 50 F to 180 F CAUTION Damage due to internal condensation may occur if the heater inlet water temperature does not exceed 50 F 22 C within 7 minutes of start up Feedwater Regulator Raypak recommends that a feedwater regulator be in stalled and set at 12 psi minimum pressure at the highest point of...

Page 16: ...f supply and return piping between the system loop and heater Fig 14 Single Heater with Primary Secondary Piping Fig 15 Dual Heaters Reverse Return with Primary Secondary Piping Fig 16 Single Domestic Hot Water Heater and Storage Tank 16 Domestic Hot Water When designing the hot water piping system for domestic hot water applications water hardness should be considered See Table H on page 18 for t...

Page 17: ...lied electronic operating con trol is configured to operate as the thermostat A separate auto limit is shipped loose to be installed in the system piping downstream of the heater outlet See Fig 17 for the thermostat sensor location CAUTION When this heater is used for both potable water and space heating observe the following to ensure proper operation Set the control in Mode 2 for all single heat...

Page 18: ... protect the heat exchangers These are accessible by removing the lower front door from the heater for the 2 primary drains and the right rear panel for the secondary drain Drain any piping of all water that may experience below freezing temperatures Chemical imbalance can cause severe damage to the pool heater and associated equipment Maintain the water chemistry according to the chart below If t...

Page 19: ...E Failure of a heat exchanger due to lime scale build up on the heating surface low pH or other chemical imbalance is non warrantable DANGER Make sure the gas on which the heater will operate is the same type as specified on the heater s rating plate 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 p...

Page 20: ...Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source 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 If upstre...

Page 21: ...nagement systems in accordance with the applicable manufacturers instructions 7 Conduit should not be used as the earth ground 21 Check the Power Source NOTE Field supplied isolation relays should be installed when field connected controllers are mounted more than a total of 50 equivalent feet 18 AWG from heater WARNING Using a multi meter check the following voltages at the circuit breaker panel ...

Page 22: ...st be pro vided in compliance with applicable codes The vent should also be installed to maintain proper clearances CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause im proper and dangerous operation Verify proper operation after servicing Fig 22 Rear Wiring Location DANGER SHOCK HAZARD CAUTION Proper installation of flue venting is critical for the saf...

Page 23: ...intake Condensate can freeze causing ice formations 11 Locate or guard vent to prevent condensate from damaging exterior finishes Use a rust resistant sheet metal backing plate against brick or mason ry surfaces 12 DO NOT extend exposed vent pipe outside of building beyond the minimum distance required for the vent termination Condensate could freeze and block vent pipe U S Installations Refer to ...

Page 24: ...allation Tips Support piping horizontal runs at least every 5 ft 1 5m vertical runs use braces under or near elbows Venting Configurations 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 Vertical Venting Category IV Installation The maximum and minimum venting length for this ...

Page 25: ...inal 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 Fig 23 Vertical Venting nal The horizontal portions of the vent shall also be supported for the design and weig...

Page 26: ...nt system MUST be verified to be of the correct size and of Category IV AL29 4C vent material construction If it is NOT it MUST be replaced NOTE For extractor sizing typical CO2 levels are 8 5 for natural gas and 9 5 for propane gas and flue temperature of 150 F NOTE Data for 100 firing rate Table N Volume of Flue Products Data Fig 24 Typical Common Venting CAUTION A listed vent cap terminal suita...

Page 27: ...llation 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 out doors 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...

Page 28: ...must be taken during assembly that all joints are sealed properly and are airtight The vent must be installed to prevent the potential ac cumulation of condensate in the vent pipes It is required that 1 The vent must be installed with a condensate drain located in proximity to the heater as directed by the vent manufacturer 2 The vent must be installed with a slight upward slope of not more than 1...

Page 29: ...se as they leave the cap Improper location can result in damage to adjacent structures or building finish For maximum efficiency and safety the following precautions must be observed 1 Outdoor models must be installed outdoors and must use the outdoor vent cap and air intake hood available from the manufacturer sales order option D 11 2 Periodically check venting system The heater s venting areas ...

Page 30: ...aled get fresh air and seek medical attention if ill feelings persist In case of eye and or skin contact immediately flush with plenty of water for 15 minutes and seek medical attention if irritation persists All primers cleaners and cements must meet all local codes Before using primers cleaners and cements stir or shake making sure contents are liquid Do not use if found to be lumpy or jelly lik...

Page 31: ...C and they will re harden during curing 10 Allow connections a sufficient time to cure before disturbing follow manufacturer instructions 11 A special sidewall vent adapter termination must be used as supplied by Raypak per our listing 12 Rooftop installations must use a category IV listed vent cap Fig 30 PVC Vent Adapter Rear panel and vent limit switch removed for clarity VENT TEMPERATURE LIMIT ...

Page 32: ... the water temperature is below the target temperature by 1 2 of the differential setting and will open when the water temperature is above the target temperature by 1 2 of the differential setting See Fig 34 32 CAUTION Risk of electric shock More than one disconnect switch may be required to de energize the equipment before servicing CAUTION This appliance has provisions to be connected to more t...

Page 33: ...also controlled to the boiler target tempera ture See Fig 36 RAYPAK MODULATING TEMP CONTROL BOILER INLET SENSOR IN HEADER BOILER OUTLET SENSOR IN HEADER HYDRONIC SYSTEM TEMP SENSOR POOL SYSTEM TEMP SENSOR Maximum 4 times the pipe diameter or 12 whichever is less Fig 35 Mode 2 Primary Secondary Piping RAYPAK MODULATING TEMP CONTROL Fig 36 Mode 3 Dedicated DHW Mode 4 Primary piping with outdoor rese...

Page 34: ...ates the boiler burner to maintain the boiler target at the remote system sensor See Fig 38 Mode 8 This mode is for remote firing control of the heater via an external sequencer such as the Raypak TempTracker MOD The Boil Max setting is the heater shutdown temperature max temperature The heater is enabled via dry contact at the Enable Disable connection at the low voltage terminal strip and the fi...

Page 35: ...70 F 35 to 85 F Outdr Design 5 10 F 60 to 32 F Boil Start 5 135 F 35 to 150 F Boil Dsgn 5 180 F 120 to 220 F WWSD 5 70 F 35 to 100 F Units All F F or C Mode N A 2 1 2 3 4 5 6 7 8 External Input Signal 7 2 to 10 VDC 2 to 10 VDC or 0 to 10 VDC Offset 7 0 F 10 F to 10 F 0 10 VDC 0 20 mA Boiler Target 0 0 OFF 1 2 50 F 2 4 68 9 F 3 6 87 8 F 4 8 106 7 F 5 10 125 6 F 6 12 144 1 F 7 14 163 3 F 8 16 182 2 ...

Page 36: ... voltage of 10 VDC corresponds to a boiler target temperature of 220 F 104 C As the voltage varies between 1 VDC and 10 VDC the boiler target temperature varies linearly between 50 F 10 C and 220 F 104 C If a voltage below 0 5 VDC is received the boiler target temperature is displayed as indicating that there is no longer an internal heat demand A 0 20 mA signal can be converted to a 0 10 VDC sign...

Page 37: ... menu field The default menu is the view menu When the temperature control is powered up the con trol turns on all segments in the display for 2 seconds then the software version is displayed for 2 seconds At the end of that 4 second period the control enters the normal operating mode and VIEW is displayed Pressing the scroll button scrolls through the dis played values in the VIEW menu To make an...

Page 38: ... Operation If all limits are satisfied and there is a call for heat 1 The internal heater primary pump will start and begin circulating water in the heater s primary heat exchanger and the injector pump s will be pow ered and enabled 2 The blower is powered and goes through a 15 sec ond prepurge from when air flow is proven by closure of the blower suction air pressure switch 3 The igniter will be...

Page 39: ...cessary The optional adjustable manual reset high limit is lo cated inside the heater junction box Push the reset button and adjust the setting to approx 40 F 20 C above desired outlet temperature Fig 42 High Limit Manual Reset High Limit Auto Reset Optional This heater may be equipped with an optional adjust able auto reset high limit temperature device For H and WH systems the optional adjustabl...

Page 40: ... is used to ensure that sufficient gas pressure is present for proper valve regulator performance The low gas pres sure switch automatically shuts down the heater if gas supply drops below the factory setting of 3 0 in WC for natural gas or propane gas The optional high gas pressure switch connection mounts down stream of the gas valve Special ports are located on the backside of the gas valve and...

Page 41: ...indicate faults as they occur Refer to the Trouble shooting section for instructions on accessing reviewing and clearing these faults Condensate Float Switch This heater is equipped with a condensate float switch to prevent operation when the condensate water level is too high The heater shutting down from the conden sate float switch is indicative of a blocked drain or problem with the condensate...

Page 42: ...42 WIRING DIAGRAMS Models 1005 1505 ...

Page 43: ...43 Model 2005 ...

Page 44: ...he floor WHAT TO DO IF YOU SMELL GAS 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 neigh bor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas con trol knob Never use tools If the kno...

Page 45: ...ir ing rate display screen approximately 30 seconds Initial Start up Required tools 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 Metric Allen wrenches will be required for servicing the gas valve but not during start up Preparation Check Power Supply With multi meter at incoming powe...

Page 46: ...sure at point B in Fig 53 with the heater firing at 100 input The tracking pressure pro vides feedback to the gas regulator to compensate for various air ducting arrangements and changes in the pressure drop across the combustion air fil ter Initial readings with a clean air filter installed must be recorded on the Start up Checklist locat ed at the back of this manual When the tracking pressure i...

Page 47: ...eck for gas leaks one more time Leak Test Procedure Dual Seat Gas Valve Proper leak testing requires three pressure test points in the gas train Remove the access panel on the rear of the heater to access the gas valve for this test Test point A is a blee dle valve located upstream of the combination gas valve on the supply manifold Test point B is a bleedle valve located between the two automatic...

Page 48: ...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 con trols are tested When safety devices are restored burners should re ignite after pre purge time dela...

Page 49: ...oor If you then smell gas STOP Follow the steps in the safety informa tion on the front cover of this manual If you do not smell gas go to next step 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 pre purge time delay 15 seconds After igniter reaches temperature 30 seconds the main valve should open Syst...

Page 50: ...ct the shutter setting or blower amp draw NO Check the switch and or line voltage YES Does the power switch provide power to the control panel Unit is in standby mode Reattach NO NO YES YES NO Is diagnostic board indicating open safeties Check and correct power connections at main terminal block circuit breaker panel or blower relay NO NO YES NO YES Is 24VAC at PS on ignition module Is connecting ...

Page 51: ...the history has been cleared it cannot be recovered MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency Maintenance as outlined below may be performed by the owner Daily 1 Check that the area where the heater is installed is free from combustible materials gasoline and other flamma...

Page 52: ...nufacturer s instructions on valve 2 Test low water cut off if equipped Refer to manu facturer s instructions 3 Reset fault history after any testing Preventive Maintenance Schedule The following procedures are recommended and are good practice for all XTherm installations Daily 1 Check gauges monitors and indicators 2 Check instrument and equipment settings See Post Start Up Check on page 48 3 Ch...

Page 53: ...ombustion 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 effi ciency systems The heater can be supplied with corrosion resistant non metallic intake air vent materi al You may however choose to use outside combustion air for one or more of these reaso...

Page 54: ... 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 sh...

Page 55: ...f 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 unex pired portion of the original warranty Raypak makes no warranty what...

Page 56: ... between 100 and 150 PPM Total Dissolved Solids TDS must be no greater than 2500 PPM 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 unex pired portion...

Page 57: ...ff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material __________________ Plumbing Size _______________ Vent Termination Type __________________ Pump Size _________ boiler Pump HP ______ Combustion Air Openings Low __________ in2 Impeller trim____________ Pump Model___________ Ventilation air High __________ in2 Louvers _...

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Page 60: ...60 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...