Raypak 1005 manual

INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 3400.55B Effective: 09-22-09 Replaces: 02-24-09 P/N 241344 Rev . 3 FOR Y OUR 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. T o do so may result in an explosion or fire. WHA T T O DO[...]

2 Rev . 3 reflects the following: Changes to: Fig. 3 on page 6, Fig. 10 on page 1 1, Pool Heater instructions and Fig. 17 on page 17, Fig. 19 on page 21, T able M on page 25, Mode 1 and Mode 4 instructions on page 33, Fig. 35 and Fig. 36 on page 33, Modes 6-8 instructions on page 34, T ables P-R on pages 34-35, “Auto Limit - Auto Reset” instruc[...]

WARNINGS 4 Pay Attention to These T erms 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 6 T ime/T emperature Relationships in Scalds 7 GENERAL SAFETY 7 INST ALLA TION 8 Installation Codes 8 Equipment Base 8 Clearances 8 Combustion[...]

D ANGER: I ndicates 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. CA UTION: Indicates the presence of hazards or uns[...]

BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed thoroughly before installing your XTherm 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.) [...]

General Infor mation T able A: Basic Data 6 AIR FIL TER AC CESS PA NEL Component Locations Fig. 1: Component Locations – Right Side Fig. 2: Component Locations – T op Fig. 3: Component Locations – Rear Model No. MBTUH Input W ater Conn. (NPT) Gas Conn. (NPT) V ent Size (in.) Max. Min. N P Flue Intake 1005 999 250 2-1/2 1-1/4 1 6 6 1505 1500 3[...]

GENERAL SAFETY T o 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 210°F . However , water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water , the rec- ommended initial [...]

Equipment Base The heater should be mounted on a level, structurally s ound surface. The heater is approved for installation on a combustible surface but must NEVER be i nstalled on carpeting. Gas-fueled equipment installed in enclosed parking garages must be located at least 18 in. above the floor . In addition, the heater shall be installed such [...]

9 Fig. 5: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations R oof water drainage must be diverted away from heaters installed under overhangs. Heat er Sid e Min. C le ara nce fr om Com bus tib le Sur face s Minimum Serv ice Clearance Rear 12” 36” Right Side 1” 24” Left Side 1” 1” Top U nobstructed 10” V[...]

U. S. Ins tallations 1 Canad ia n Insta llat ions 2 A Clear ance above gr ade, veranda, p orch , deck, or balco ny 1 ft (30 c m) 1 ft (30 c m) B Clear ance to window or do or that may be o pened 4 ft (1.2 m) be low or to side of openin g; 1 foot (30 c m) a bove op ening 3 ft (91 cm) C Clearance to perma nen tly clos ed wind ow ** D V ertical cleara[...]

Combustion Air Filter This heater is supplied with an integral combustion air filter . This filter will reduce the amount of particulates passed through the combustion system and heat exchanger but will not protect against chemical inside air contamination (See Appendix). The filter must be checked periodically to verify that adequate combus- tion [...]

12. Provide adequate ventilation of the space occu- pi e d b y t h e h e a te r ( s ) b y a n o pe n i n g ( s ) f or ventilation air at the highest practical point com- mu n i c a t i ng wi t h t h e o u t do o r s . Th e t o t a l c ross-sectional area shall be at least 1 in. 2 o f free area per 20,000 BTUH (1 1 1 mm 2 per kW) of total input rati[...]

13 Con v entional Combustion Air Supply U .S. Installations All Air from Inside the Building The confined space shall be provided with TWO per- mane nt op eni ngs c omm unic ati ng di rec tly w ith a n additional room(s) of sufficient volume so that the com- bined volume of all spaces meets the criteria for a room large in comparison (NFGC). The to[...]

R elief V alve Installa tion and Piping The heater is supplied with a Section IV “HV” stamped relief valve sized for the full input of the unit and a “UV” stamped relief valve to protect the section VIII second- ary heat exchanger . The relief valve assembly is shipped loose and must be mounted directly to the heater outlet. No valve shall [...]

15 Leaks must be repaired at once to prevent damage to the heater . NEVER use petroleum-based stop-leak compounds. T o perform hydrostatic test: 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 [...]

T able F: Boiler T emperatures and Minimum Pipe Size at V arying Return T emperatures S ystem R eturn T emp Su pp l y T emp 1 S u p p l y T em p 1 Su pp l y T em p 1 ( °F) (°F) <80' equiv . 80-200 ' equiv . (°F) <80' equiv . 80-200 ' equiv . (°F) <80' equiv . 80-200 ' equiv . 6 0 138 2"NPT 2 1/2"[...]

NO TE: If local codes require a vacuum relief valve, acquire one locally and install per valve manufacturer ’s instructions. Combined P otable Water and Space Heating 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water . 2. T oxic chemicals, such as us[...]

18 T ank u S t f o S . p u S d r a H . p u S d e M / t f o S p m e T n r u t e R p . Med Su p . Hard Sup d e M / t f o S . (°F) T emp 1 (°F) T e mp 1 (°F) < 80' equiv . 80-200 ' equiv . Te mp 1 (°F) T e mp 1 (°F) T e mp 1 (°F) < 80' equiv . 80-200 ' equiv. Sup . Te mp 1 (°F) < 80' equiv. 80-200 ' equiv [...]

Automatic chemical dosing devices are usually more efficient in heater water , unless controlled, they can lead to excessive chlorine level which can damage your heater . Further advice should be obtained from your pool or spa builder , accredited pool shop, or chemical suppli- er for the correct levels for your water . Wa ter Har dness Raypak wate[...]

20 • 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. XTherm heaters are wired for 120V AC single phase power . Models 1005 and 1505, except WH 1505 mod- els equipped with a heater pump for hard water , require 15A service for the heater and 15A service fo[...]

C heck the power source: AC = 108 V AC Minimum, 132 V AC MAX AB = 108 V AC Minimum, 132 V AC MAX BC = <1 V AC Maximum Making the Electrical Connections Refer to Fig. 19-22. 1. V erify 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 p[...]

Field W iring Connection V enting General 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. Category I – A heater which operates with a non-pos- itive vent static pressure and with a vent gas t emperature that avoids excessive conden[...]

T able L: V enting Category Requirements V ent T er minal Location 1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 2. Give special attention to the location of the vent termination to avoid possibility of property dam- age or personal injury . 3. Gases may form a white vapor plume [...]

5. T erminate vent at least 6 ft away from adjacent walls. 6 . DO NOT terminate vent closer than 5 ft below roof overhang. 7. The vent terminal requires a 12 in. vent terminal c learance from the wall. 8. T erminate vent at least 1 ft above grade, including normal snow line. 9. Multiple direct vent installations require a 4 ft clearance between the[...]

T able M: Category IV V enting 1 V ent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. 2 Consult factory for longer vent runs. * Subtract 10 ft per elbow . Max. 4 elbows. ** Adapters supplied by others. T er mination The vent terminal should be vertical and should termi- nate outside the b[...]

Common V enting The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters. This is covered in the NFGC under “Engineered V ent Sys- tems”. T able N provides the volume of flue products at full fire for the calculation of appropriate vent sizing and extractor for common venting. WARNING: V ent connectors [...]

Fig. 25: Horizontal Through-the-W all V enting Fig. 26: Alt. Horizontal Through-the-Wall V enting NO TE: While a drain connection is required in the vent of all XTherm installations, the drain can be ac- complished in several different ways. The figures in this manual show the drain in a vent tee, however , this can also be accomplished using an in[...]

The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure that all j oints 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[...]

C ombustion air supplied from outdoors must be free of particulate and chemical contaminants. T o avoid a blocked flue condition, keep the vent cap clear of snow , ice, leaves, debris, etc. The stainless steel flue direct vent cap must be fur- nished by the heater manufacturer in accordance with its listing (sales order option D-15). Outdoor Instal[...]

F r eeze Protection The Raypak electronic temperature control includes a f reeze protection feature. In the event the water tem- perature drops below 40°F at any of the heater t emperature sensors, the pump is turned on and will remain on until the temperature at all heater sensors r ises to 45°F . PV C V enting Option V enting of the XTherm with[...]

31 6 ) Apply a liberal coat of cement to pipe leaving no voids. 7) QUICKL Y assemble parts while cement is fluid! If y ou wait too long, re-coat pipes. 8) Push pipe completely into socket of fitting, rotating 1/4 turn to achieve proper orientation until it bot- toms out. 9) Hold pipe and fitting together for 30 seconds, then carefully clean off exc[...]

Controls The Raypak modulating temperature control is pro- vi d e d t o m a i nt a i n t h e d e s i re d s y s t e m w at e r temperature. The control has various modes of opera- tion which are described on the following pages. Th e X T h e r m i s de s i g n e d f o r us e w i t h Primary/Secondary pumping only , utilizing integral injector pumps[...]

33 Fig. 34: Differential Graph Operating Modes Mode 1 – Primary piping is prohibited. Mode 2 – Setpoint operation using primary/secondary piping, used for either hydronics or pool systems. The control operates the heater to satisfy a remote system sensor . The heater is turned off based on boiler max and boiler differential (factory default). S[...]

Recommended Settings for Pool Heater (WHP) Applications Item Modes Recommended Setting Boil T arget 2 78°F Boil Max 2 86°F Boil Min 2 70°F ‘Burner ’ Delay All 0:00 min Boil Mass All 1 (Low) Diff 2 2°F ‘Pump’ Dly All 3:00 min Units All °F Mode N/A 2 T able O: Recommended T emperature Control Setpoints—WHP Models 34 Fig. 38: Mode 7 Pri[...]

35 T able P: T emperature Control Default Setpoints—H7, WH7 & WHP Models Item Modes Default Setting Range B oil T arget 2 1 60°F O FF , 70 to 220°F 3 1 60°F O FF , 70 to 190°F 5, 7 180°F OFF , 70 to 220°F Boil Max 2, 5, 7, 8 200°F OFF , 120 to 225°F 3 180°F OFF , 120 to 190°F Boil Min 2, 3, 5, 7 150°F OFF , 80 to 180°F ‘Burner ?[...]

36 Definitions % OUT - Current percent modulation rate of heater . BOIL DSGN - Design boiler water temperature used in heat loss calculations. BOIL MASS - This setting allows adjustment in the field for high or low thermal masses; High thermal mass (setting=3) provides slower reaction, lower ther- mal mass (setting=1) provides faster reaction. BOIL[...]

37 R ank I tem Field N umber Field T ype F ault Description 0 E 01 E rr E rror E EPROM error 1 F P E rr W arning F lame proof warning 2 BOIL OUT SHr Error Boiler outlet sensor short 3 BOIL OUT OPn Error Boiler outlet sensor open 4 BOIL IN SHr Error Boiler inlet sensor short 5 BOIL IN OPn Error Boiler inlet sensor open 6 SUP SHr Error System sensor [...]

38 Fig. 41: Ignition Module The optional single-try ignition module will lock out after failing to light one time. T o reset it, press and release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case. T urning off the power to the heater WILL NOT reset the single-try ignition[...]

39 T able T : Ignition Module Diagnostic LED Flash Codes Co de Conditi on O n System O K; No fa ults presen t Off Possible c on trol fa ult; Check p ower 1 Fla sh L ow air 2 Flashes Fla me in co mbus tion cha mber ; No call f or he at 3 Flashes Ignition lockou t 4 Flashes Low H SI curren t 5 Flashes L ow 24 VAC 6 Flashes Internal fau lt; Replace c [...]

40 Modulating T emper ature Control This heater is equipped with a Raypak modulating temperature control. Refer to information starting on p age 33 for information on the setting and use of this control. Low W ater Cut-Off (Optional) The optional low water cut-off automatically shuts down the burner whenever water level drops below the level of the[...]

41 Air Pressur e Switch This heater is equipped with an air pressure switch to prove the operation of the blower before allowing the ignition control to begin a trial for ignition. It is located on the right side of the lower flange of the blower mounting assembly , directly behind the junction box. Block ed V ent Switch This heater is equipped wit[...]

42 WIRING DIA GRAMS - Models 1005 & 1505[...]

43 Model 2005[...]

44 ST ART -UP Pre Star t-up Filling System (Heating Boilers) Fill system with water . Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. Air Pur ge (Domestic Hot Wa ter Heaters) Pu[...]

45 Check Gas Supply Pressur e 1. Slowly turn on main gas shut-off valve. 2. Read the gas supply pressure from the manome- ter; minimum supply pressure for natural gas is 4.0 in. WC, recommended supply is 7.0 in. WC, mini- mum supply pressure for propane gas is 4.0 in. WC, recommended supply is 1 1.0 in. WC (dynam- ic readings, full fire input). 3. [...]

46 4. When firing at 100%, the desired heater combus- tion CO2 is between 8.5 and 9.0% for natural gas and 9.5 and 10.0% for propane with CO less than 100 ppm. If this combustion cannot be achieved with the net blower suction within the tolerances specified in T able U, contact the factory . The refer- ence amp draw reading may help to indicate if [...]

47 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 switch tee and reinsert the sealing screws into the bleedle valves. 3. Start-up is complete and the heater should be operating properly . Safety Inspection 1. Check all thermostat[...]

48 d le 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 g as pressure to the second valve seat. 5. Open the bleedle valve at test point C and connect a second rubber tube to it. Connect the other end of th[...]

49 1 1. 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 thermo- s tat. Raise the setting on the thermostat to the highest setting and verify that the heater goes [...]

50 TR OUBLESHOO TING Ste p 8 Ste p 7 Ste p 6 Ste p 9 S tep 1 Step 2 Step 3 Step 4 Step 5 I s there a Call For Heat? Is Disable conn ection int act? Does the combustion air blower come on? Is 4-20mA present at the quick disconne ct s on the black and blue wir es of the tem p erature controlle r ? Is 24VAC at the NC side of the air pressure switch? D[...]

51 UDB F ault Histor y T o view the fault codes in the UDB history file: 1. Press the UP or DOWN buttons on the membrane s witch for 2 seconds to access the fault history . 2. Press either button to scroll through the recorded faults in history . 3. The most recent fault recorded will be the first fault displayed (the last 16 faults are stored in t[...]

52 2 . Visually inspect venting system for proper func- tion, deterioration or leakage. Ensure that condensate drain is inspected and ensure that condensate is being directed to appropriate con- d ensate management system or drain, as required by local codes. 3. Check that area is free from combustible materi- als, gasoline, and other flammable vap[...]

53 4 . Conduct a combustion test at full fire. Carbon diox- ide should be 8.5 to 9.0% at full fire for natural gas, and between 9.5 to 10.0% for propane gas. Carbon monoxide should be < 100 ppm. 5. Check valve coil for 60 cycle hum or buzz. Check f or leaks at all valve fittings using a soapy water solution (while heater is operating). T est oth[...]

54 (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 T o Be V ented" in the most current edition of NFP A 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or s[...]

55 LIMITED P ARTS W ARRANTY XTHERM – TYPES H AND WH MODELS 1005-2005 S COPE 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 War[...]

56 LIMITED P ARTS W ARRANTY XTHERM – TYPES WHP MODELS 1005-2005 SCOPE R aypak, 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[...]

57 START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS This s tart-up checklis t is to be co mplete ly filled o ut by t he service techn ician s tarting up th e Rayp ak Boiler or H eater for the first time. All in formation may be us ed for w arra nty purpos es an d to ensure that the ins tallation is corre ct. Additionally this form wi ll be use d[...]

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60 w w w .r a y pak .c o m Raypak, Inc., 2151 Eastman A venue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.[...]