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Raypak XTHERM 1005 User's Manual

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2. Ei TWNold SGONTIS THE WAVY O HW Nodo D 43 START UP Pre Start 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 Purge Domestic Hot Water Heaters Purge all air from system before lighting heater This can be normally accomplished by opening a down stream valve XTherm heaters are equipped with an air vent installed in the inlet side of the header to ensure that air is purged from the system It includes an adapter to allow the air vent to be piped in the field to a suitable drain as required by the jurisdiction having authority CAUTION An additional air vent should be installed at the highest point in the system for proper operation If water piping is located higher than the header it should be relocated to the highest point in the installed system Venting System Inspection 1 Check all vent pipe connections and flue pipe ma terial 2 Make sure vent terminations are installed per code and are clear of all debris or blockage 3 Prime condensate
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4. Debris Screen 2 Fig 11 Remove the Debris Screen 9 Install the intake air collar using the six screws removed in step 8 above Intake Air Collar Fig 12 Install the Intake Air Collar 10 Replace all the access panels NOTE Make sure that the air intake piping is installed in a manner that allows full access to the air filter without damage to the filter 11 Install combustion air direct vent in accordance with Fig 27 horizontal or Fig 28 vertical of this manual pages 27 and 28 respectively 12 Provide adequate ventilation of the space occu pied by the heater s by an opening s for ventilation air at the highest practical point com municating with the outdoors The total cross sectional area shall 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 out doors or through vertical duct s The total cross sectional area shall be at least 1 in of free area per 10 000 BTUH 222 mm per kW of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct s In cold climates and to mitigate potential freeze up Raypak highly recommends the installation of a motorized sealed damper to prevent the circula tion of cold air through the heater during the non operating hours TruSeal
5. SPEED EXTRACTOR ALT LOCATION COMMON VENT PIPE VARIABLE SPEED CAT ae EXTRACTOR NJ 4 fs E n A a Ei IC k ee 1 Il l i I ADJUSTABLE VENT pai DAMPER BAFFLE Led la AA La ETa LI 1 T li TP li VENT PIPE SAME I 1 11I q i li Le DIAMETER AS BOILER VENT zunn aaa ammua auaa Iv assa saas asza saus Li ial tol _ VENT DRAIN USE LI TEST PORT TEFLON TUBING ity i RUN TO NEUTRALIZER I HA I ie OR CONDENSATE PUMP ca aera gt 1 tae d sso wai SA al a Note Units rotated 90 for clarity Typical multi unit installations have the heaters installed side by side Extractor is required Fig 24 Typical Common Venting 26 Horizontal Through the Wall and Direct Venting Category IV INSULATED EXHAUST VENTING HEATER UNIT 12 MIN FLUE EXHAUST a VENT CAP TEST WA 12 MIN 12 MIN SSeS N CONDENSATION TRAP Fig 25 Horizontal Through the Wall Venting INSULATED EXHAUST TEST PORT VENTING HEATER UNIT H 12 MIN FLUE EXHAUST a VENT CAP Ai 3 12 MIN CONDENSATION TRAP Fig 26 Alt Horizontal Through the Wall Ve
6. 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 Ill or IV vent system Using improper venting materials can result in personal injury death or property damage 22 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 800 772 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 manufacturer s installation instructions carefully Support of Vent Stack The weight of the vent stack or chimney must not rest on the heater vent connection Support must be pro vided in compliance with applicable codes The vent should also be installed to maintain proper clearances H Exhaust Configuration Vertical Venting Horizontal Through the Wall Venting Combustion Air Supply From Inside Building Non Direct Venting Vertical Venting Horizontal Through the Wall Venting From Outside Building Direct Venting Certified Materials Combustion Air Inlet Material eater Venting Category CAT IV AL29 4C Galvanized Steel PVC ABS CPVC Table L Venting Category Requirements from combustible materials Use insulated vent pipe spacers where the vent passes through com
7. 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 When the system requires water for space heating at temperatures higher than 140 F 60 C a means such as a mixing valve shall be installed to temper the water in order to reduce scald hazard potential Pool Heating When a boiler or water heater is used in a pool heat ing application ensure that all the following installation requirements are met The XTherm must be equipped with a direct coupled Cold Water Run injector pump for pool applications The integral wet rotor injector pump system supplied with all H and model 1005 WH XTherm heaters must not be used for pool service The direct coupled Cold Water Run injector pump package is optional on all H and 1005 WH models and standard on 1505 and 2005 WH and all WHP models The Cold Water Run system must be set to maintain 120 F at the inlet to the pri mary heat exchanger on all XTherm models To complete installation of the heater the system sen sor must be installed in the return water line upstream of the heater The supplied 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 17 CAUTION Power to the heater should b
8. 1 5m vertical runs use 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 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 CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s instructions Failure to install a condensate drain in the venting system will void all warranties on this heater 24 Installation The maximum and minimum venting length for this Category IV appliance shall be determined per the NFGC U S or B149 Canada The diameter of vent flue pipe should be sized accord ing to the NFGC U S and Appendix B of B149 Canada The minimum flue pipe diameter for con ventional venting using Category IV stainless steel AL29 4C vent is 6 in 152mm for Model 1005 and 8 in 203mm for Models 1505 and 2005 The connection from the appliance vent to the stack must be as direct as possible and shall be the same di ameter 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 termi Certified Wank Sice Toral sya Combustion Air Air
9. Site Altitude Above Sea Level Ft barometric dampers blast dampers or draft inducers 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 Attn Service Manager 57 58 59 Y spay HNF FE Registered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A 60
10. 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 gas valve pressure regulator on the heater is nominally preset as noted in Table K During normal operation carbon dioxide should be 8 5 to 9 0 at full fire for natural gas and between 9 5 and 10 0 for propane gas Carbon monoxide should be lt 100ppm Model No High Fire Values Natural Gas Propane Gas oo a e e NOTE Manifold pressures should be 0 2 in WC Table K Manifold Gas Pressure Settings Electrical Power Connections Installations must follow these codes e National Electrical Code and any other national state provincial or local codes or regulations hav ing jurisdiction 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 120VAC 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 for the heater pump or a single 30A rated circuit Model 1505 heaters equipped for hard water require 15A service for the heater and 20A service for the heater pump or a single 40A rated circuit Model 2005 heaters require 20A service for the heater and 20A service for the heater pump or a single 40A service Consult t
11. ANSI Z223 1 NFPA 54 National Fuel Gas Code In accordance with the current CAN CGA 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 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 air is being supplied to the heater See the Maintenance section of this manual for information on checking the filter and establishing service intervals Direct Vent If outside air is drawn through the intake pipe directly to the unit for combustion 1 Convert the unit to draw air through an air intake duct at the rear of the cabinet As shipped XTherm heaters draw combustion air from inside the cabinet 2 Turn off all power to the heater 3 Ensure that the heater is cool to the touch bef
12. CONNECTIONS COMBUSTION AIR AA INLET BASHTRAIN GAS SUPPLY CONNECTION HEAT PUMP a AIR FILTER 1 ACCESS PANEL OPERATING CENTER lt PRESSURE RELIEF i VALVE q Hlo SHIPPED LOOSE BLOWER Ues WATER OUTLET Joel O L 1 OT i amp P GAUGE SHIPPED LOOSE FRONT OF WATER INLET HEATER VARIABLE SPEED INJECTOR PUMP S h HEAT pies zi ASSEMBLY T FLUE OUTLET i H l CONDENSATE DRAIN ee eee BURNER FLAME VIEWING PORT COMPONENT LOCATIONS SIDE PANELS REMOVED FOR CLARITY Fig 1 Component Locations Right Side Fig 3 Component Locations Rear AIR VENT BURNER General Information IGNITER FRONT OF gt HEATER Vent Size FLAME SENSOR MANUAL RESET HI LIMIT COMPONENT LOCATIONS TOP TOP PANEL BLOWER amp GAS TRAIN REMOVED FOR CLARITY Table A Basic Data Fig 2 Component Locations Top 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 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 setting for the temperat
13. Crimp end to be installed into termination cap SIDEWALL VENT TERMINATION OPTION D 15 Fig 33 Termination using Adapter Thimble 32 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 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 The Raypak modulating temperature control is pro vided to maintain the desired system water temperature The control has various modes of opera tion which are described on the following pages The XTherm is designed for use with Primary Secondary pumping only utilizing integral injector pumps to maintain proper flows and tempera tures in the heater Setpoint The intended system supply temperature Deadband Deadband is a band of temperature sens in
14. ELECTRICAL CONNECTIONS Fig 19 Wiring Electrical Connections 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 NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts external connections to the unit Solid conductors should not be used because they can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones on the unit or larger Check the Power Source CIRCUIT BREAKER WHITE GREEN GROUND Fig 20 Wiring Connections 21 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 Check the power source AC 108 VAC Minimum 132 VAC MAX AB 108 VAC Minimum 132 VAC MAX BC lt 1 VAC Maximum 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 NOTE Current draw noted on rating plate does not include pump current Turn off all power to the heater Verify that power has been turned off by testing with a multi meter prior to workin
15. LEAL LO VLLLLLLLL LL A Z H 2 Fig 6 Minimum Clearances from Vent Air Inlet Terminations Indoor and Outdoor Installations Clearance above grade veranda porch deck or balcony Canadian Installations U S Installations 1 ft 30 cm 1 ft 30 cm Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal dis tance of 2 ft 61cm from the centerline of the terminal 4 ft 1 2m below or to side of opening 1 foot 30 cm above opening 3 ft 91 cm Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line ex tended above meter regulator assembly 3 ft 91 cm within a height 15 ft above the me ter regulator assembly Clearance to service regulator vent outlet Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance Clearance to mechanical air supply inlet Clearance above paved sidewalk or paved driveway located on public property 6 ft 1 83m 4 ft 1 2m below or to side of opening 1 ft 30 cm 3 ft 91 cm above opening 3 ft 91 cm above if within 6 ft 1 83m 10 ft 3m horizontally 7 ft 2 13m t 7 ft 2 13m Clearance under veranda porch deck or balcony 12 in 30 cm TT In accordance with the current
16. 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 WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s instructions Failure to install a condensate drain in the venting system will Direct Vent Vertical FLUE EXHAUST 3 MIN VENT CAP INTAKE VENT AN 3 MIN i 1 MIN DLA X lt L ILL A E INSULATED EKHAUST HEATER UNIT Lee sees Sa aa WAA hs ae Ha en lt ALTERNATE COMBUSTION Les AIR INTAKE LOCATION TEST PORT E 12 MIN Z588 f Bs Ki CONDENSATION TRAP Fig 28 Direct Vent Vertical 28 void all warranties on this heater Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent com bustion products to the outdoors The total length of air supply pipe cannot exceed the distances listed in Table 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 Table M The vent cap is not
17. as measured at the 2 pins on the upper left corner of the ignition control 6 Check firing rate control by checking the manifold pressure See Manifold Check on page 46 7 Test safety safety relief valve s in accordance with ASME Heater and Pressure Vessel Code Section IV and Section VIII as applicable APPENDIX 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 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 reasons 1 Installation is in an area containing contaminants listed below which will induce acidic condensation 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 ar eas this may also experience deterioration Products causing contaminated combustion air e spray cans containing chloro fluorocarbons e permanent wave solutions e chlorinated waxes cleaners e chlorine based swimming pool ch
18. 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 owner s responsibility HEAT EXCHANGER WARRANTY 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 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 150 F between the water temperature at intake and heater temperature or operating at heater temperatures exceeding 230 F Secondary Stainless Steel Heat Exchanger Ten 10 years from date of heater installation 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 Raypak s 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 Failure to properly install operate or maintain the heater in accordance with our printed instructions provided Abuse alteration accident fire
19. considered in the overall length of the venting system Care 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 4 inch per foot of hori zontal run to the vent terminal 3 The vent must be insulated through the length of the horizontal run 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 com bustion 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 This type of installation can cause non warrantable problems with components and poor operation of the heater due to the recirculation of flue products Multi ple 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 WARNING No substitutions of flue pipe or vent cap material are allowed Such substituti
20. control damage or failure Attach Manometers to Measure Pressures 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 52 3 Attach 1 24 scale manometer to the manifold pressure tap located on the elbow downstream of the valve Measure point D in Fig 52 4 Attach 1 12 scale manometer near the fan prov ing switch Pull black cap from air pressure switch tee and connect the manometer NOTE Retain caps for reinstallation later TO BURNER wer Fig 52 Gas Pressure Measurement Locations Check Gas Supply Pressure 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 11 0 in WC dynam ic readings full fire input If the gas pressure is greater than 14 0 in WC turn off the main gas shut off valve Start Up NOTE The values in Tables V W and X represent the conditions when the heater is at full firing rate at sea level 45 Turn power on Turn on the heater wait approximately 15 seconds after the blower starts and the igniter should start to glow observable through the observation port located at the front bottom of the heater Look into the sight glass
21. date of heater installation against Thermal Shock excluded however if caused by heater operation at large changes exceeding 150 F between the water temperature at intake and heater temperature or operating at heater temperatures exceeding 230 F Secondary Stainless Steel Heat Exchanger Ten 10 years from date of heater installation 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 Raypak s 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 Failure to properly install operate or maintain the heater in accordance with our printed instructions provided Abuse alteration accident fire flood and the like Sediment or lime build up freezing or other conditions causing inadequate water circulation High velocity flow exceeding heater design rates Failure of connected system devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the heater system Failing to eliminate air from or replenish water in the connected water system Chemical contamination of combustion air or use of chemical additives
22. flood and the like Sediment or lime build up freezing or other conditions causing inadequate water circulation High velocity flow exceeding heater design rates Failure of connected systems devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the heater system Chemical contamination of combustion air or use of chemical additives to water Misuse or neglect including but not limited to freeze ups operating the heater with cabinet door off having flow restrictions or obstructions between the heater outlet and pool spa or not maintaining proper chemical balance pH level must be between 7 2 and 7 8 and total alkalinity between 100 and 150 PPM Total Dissolved Solids TDS must be no greater than 2500 PPM ANOAARWNDN 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 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 descrip
23. 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 Risk of electrical shock More than one disconnect switch may be required to de energize the equipment before servicing WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 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 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 NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts external connections to the unit Solid conductors should not be used because they can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones on the unit or larger BEFORE INSTALLATION Raypak strongly recommends that this manual be re viewed thoroughly before installing your X
24. inlet Vent Length ft Intake Pipe Max Length ft in Material Min max eia egeo 10 Category IV ae AL29 4C PVO ose CPVC 1 Vent 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 Table M Category IV Venting nal The horizontal portions of the vent shall also be 10 OR LESS supported for the design and weight of the material employed to maintain clearances and to prevent physi cal damage or separation of joints SUNNE Ske ft 2 MIN NOTE A vent adapter field supplied may be re ul Lo quired to connect the Category IV vent to the heater Termination CAT IV VENT PIPE The vent terminal should be vertical and should termi b nate outside the building at least 2 ft above the highest point of the roof that is within 10 ft The vent cap aa Kai LI should have a minimum clearance of 4 ft horizontally from and in no case above or below unless a 4 ft hori 222S 2222 zontal distance is maintained electric meters gas meters regulators and relief equipment 5588 5555 The distance of the vent terminal from adjacent public walkways adjacent buildings open windows and TEST PORT building openings must be consistent with the NFGC LA U S or B149 Can
25. installation 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 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 LIMITED PARTS WARRANTY ernrpia XTHERM TYPES H AND WH MODELS 1005 2005 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 owner s 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
26. 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 8 Make sure that the high gas pressure switch op tional is set to 3 0 in WC for both natural gas and propane gas Follow Up Safety checks must be recorded as performed Turn heater on After main burner ignition 1 Check manometer for proper readings 2 Cycle heater several times and re check readings 3 Remove all manometers and replace caps and screws gt Check 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 Ais a blee dle valve located upstream of the combination gas valve on the supply manifold NOTE May have to remove HGPS if applicable to conduct this test Test point B is a bleedle valve located between the two automatic gas valve seats Test point C is a bleedle valve located downstream of both automatic gas valve seats and upstream of the manual valve Refer to Fig 54 These tests are to be conducted with the electrical power to the heater turned OFF 1 Manually close the down
27. the Canadian Standards Association CSA for the U S and Canada Each pri mary heat exchanger is constructed in accordance with Section IV and each secondary heat exchanger in accordance with Section VIII of the American Society of Mechanical Engineers ASME Heater Pressure Vessel Code and bears the applicable ASME stamp This heater also complies with the latest edition of the ASHRAE 90 1 Standard 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 Installations at Elevation Rated inputs are suitable for up to 4 500 ft elevation without de rating Consult your local representative or the factory for installations at altitudes over 4 500 ft above sea level No hardware changes are required to the heaters for installations up to 10 000 ft adjust ments may be required Component Locations FLOW SWITCH ELECTRICAL
28. the relief valve outlet and must be routed to a safe point of dis charge Installation must comply with all national state and local codes WARNING The pressure relief valve must be installed at the outlet of the heater No valve is permitted to be installed between the heater and the relief valve Temperature amp Pressure Gauge The temperature and pressure gauge is shipped loose for field installation and must be installed within 12 inches of the boiler outlet if possible in an easily readable location Installation must comply with ASME Section IV as well as all applicable national state and 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 test ing 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 glycol based anti freeze 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 bleed valve open fill heater with water When water flows from bleed valve shut off w
29. to water ANOaABRWN 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 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 Raypak s behalf THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROV IDED I
30. traps in the vent system as nec essary and verify that the traps and drain lines are free of debris or blockage For Your Safety WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance has a hot surface igniter It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 44 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 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 knob will not turn by hand do not try to repair it call a qualified serv ice 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 com bust
31. warranty Tank Model 1005 Model 1505 Model 2005 Return Temp Soft Med Sup Hard Sup Minimum Tubing Size Soft Sup Med Sup Hard Sup Minimum Tubing Size Soft Med Minimum Tubing Size F Temp F Temp F lt 80 equiv 80 200 equiv Temp F Temp F Temp F lt 80 equiv 80 200 equiv Sup Temp F lt 80 equiv 80 200 equiv 60 138 135 2 2 1 2 150 145 143 2 2 1 2 154 2 2 1 2 80 138 135 2 2 1 2 150 145 143 2 2 1 2 154 2 1 2 3 100 138 135 2 1 2 3 150 145 143 2 1 2 3 154 2 1 2 3 120 146 146 2 1 2 3 150 146 146 2 1 2 a 155 2 1 2 3 130 156 156 2 1 2 3 156 156 156 21 2 3 165 2 1 2 3 140 166 166 21 2 3 166 166 166 2 1 2 3 175 2 1 2 3 Approximate high fire heater outlet temperature based on the specified heater pump and the recommended minimum tubing size _Minimum tubing size based on total equivalent feet of supply and return piping between the tank and heater Table H Hot Water Supply Temperatures and Minimum Pipe Size at Varying Return Temperatures Winterizing Your Heater Heaters installed outdoors as pool heaters in freezing climate areas should be shut down for the winter To shut down the heater turn off manual main gas valve and main gas shut off Close isolation valves Drain the heater using the hose bibs located on the bottom of both heat exchangers Disconnect the con
32. 0 Maximum 140 Maximum 140 Maximum 2 3 Total Dissolved Solids 3000 Maximum 3000 Maximum ppm Free Chlorine MUST NOT EXCEED 5 ppm Not for use with salt water pools 3000 Maximum Table I Water Chemistry 18 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 CAUTION The XTherm is not for use with salt water chlorinators damage to heater may occur 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 Water Hardness Raypak water heaters can operate lime scale free using potable water with a hardness not exceeding 25 gpg for models 1005 and 1505 and not exceeding 16 gpg for model 2005 Proper operation is achieved by setting the temperature rise water flow per the guide lines in the installation instructions If the hardness of the water exceeds the maximum level of 25 gpg spe cial measures must be taken to lower it Water should be softened to a hardness level no lower than 5 gpg Water softened as low as 0 to 1 grain per gallon may be under saturated with respect to calcium carbonate resulting in water that is aggressive and corrosive NOTE Soft 0 4 grains per gallon Medium 5 15 grains per gallon Hard 16 25 grains per gallon NOTE Failure of a heat exchanger due to lime sc
33. Combustion Air In addition to the 13 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 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 All ducting must be self supported combustion air if CAUTION Use _ TruSeal damaging airborne contaminants are or may be present in the heater area See the Appendix of this manual regarding air contamination Conventional Combustion Air Supply U S Installations All Air from Inside the Building The confined space shall be provided with TWO per manent openings communicating directly with an 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 total input of all gas utilization equipment installed in the combined space shall be considered in making this determina tion Each opening shall have a minimum free area of 1 in 2 per 1 000 BTUH 2 225 mm per kW of the total input rating of all gas utilization equipment in the con fined space but not less than 100 in 2 645 cm2 One opening shall commence w
34. IN Lowest outlet water temperature that the control is allowed to use as a target temperature BOIL ON Accumulated runtime of heater up to 999 hours then resets to 0 BOIL OUT Actual heater outlet water temperature BOIL START Starting boiler water temperature BOIL SUP Actual system supply water temperature BOIL TARGET Target temperature that the heater is trying to maintain BURNER DELAY Holds control output at ignition setting from the start of the ignition sequence to the specified burner delay time 0 to 3 00 min DEM 1 Indicates 24 VAC signal has been supplied to the H D terminal DEM 2 Indicates 24 VAC Flame Proof signal is pres ent DIFF The operating differential of the heater The heater outlet water temperature is allowed to rise above the BOIL TARGET temperature by of this dif ferential before the heater shuts off For example if the heater target temperature is set to 160 F 71 C and the differential is set to 10 F 5 C on temperature rise the heater will shut off at 165 F 74 C Once the heater shuts off it will not come on again until the tem perature falls to 155 F 68 C EXTERNAL INPUT SIGNAL Selects external input signal range 0 10VDC or 2 10VDC 36 0 10VDC or 0 20 mA external input signal When the 0 10VDC signal is selected an input voltage of 1 VDC corresponds to a boiler target temperature of 50 F 10 C An input voltage of 10 VDC correspond
35. INSTALLATION amp OPERATING INSTRUCTIONS Therm ULTRA HIGH EFFICIENCY Models 1005 2005 Types H WH amp WHP CERTIFIED 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 a DiE A Rheem Company CATALOG NO 3400 55B Effective 09 22 09 Replaces 02 24 09 P N 241344 Rev 3 Rev 3 reflects the following Changes to Fig 3 on page 6 Fig 10 on page 11 Pool Heater instructions and Fig 17
36. MENT 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 instruc tions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting sys tem design or the venting system components and 2 A complete parts list for the venting system design or vent ing system d MANUFACTURER REQUIREMENTS GAS EQUIP MENT 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 sys tems the following requirements shall be satisfied by the manufacturer 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 e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equip ment 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
37. N 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 war ranty 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 su ggest 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 Zip Code Installation Site Daytime Telephone Number Contractor Installer RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 9786 805 278 5300 Fax 800 872 9725 www raypak com 55 D LIMITED PARTS WARRANTY XTHERM TYPES WHP MODELS 1005 2005 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
38. O FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE Over pressurized gas valves are not covered by warranty The heater and its gas con nections shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use an open flame MUST BE SUPPLIED BY INSTALLER MANUAL BALL VALVE UNION WRENCHING NIPPLE SEDIMENT TRAP ZERO GOVERNOR ON OFF COMBO VALVE Fig 18 Gas Supply Connection 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 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 2 NPT 2 1 2 NPT KIKA fe e ae KAKAA es 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 Table J Maximum Equivalent Pipe Length 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 upstream pressure exceeds these val ues an intermediate gas pressure regulator of the lockup type must be installed
39. R IN HEADER HYDRONIG r f as r SYSTEM 1 POOL lt SYSTEM RETURN da L Maximum 4 times the pipe diameter or 12 whichever is less Fig 35 Mode 2 Primary Secondary Piping Mode 3 Dedicated DHW operation using UniTemp 80 piping A call for heat is determined by the DHW sensor and the DHW boiler target The heater outlet water is also controlled to the boiler target tempera ture See Fig 36 HEATER RAYPAK MODULATING TEMP CONTROL BOILER OUTLET SENSOR IN SENSOR IN HEADER T HEADER i INLET Fig 36 Mode 3 Dedicated DHW Mode 4 Primary piping with outdoor reset is prohib ited Mode 5 Outdoor reset using primary secondary pip ing The heater is operated as in Mode 2 However the target temperature is based on outdoor reset See Fig 37 RAYPAK MODULATING TEMP CONTROL HEATER we BOILER OUTLET SENSOR IN pa t HEADER FAL BOILER INLET SENSOR IN HEADER Tf ap Te SYSTEM TEMP SENSOR OUTDOOR AIR SENSOR SYSTEM RETURN i Maximum 4 times the pipe diameter or 12 whichever is less Fig 37 Mode 5 Primary Secondary Piping with Outdoor Reset 33 Mode 6 Primary piping is prohibited Mode 7 Designed for an external input signal with primary secondary piping The external input signal c
40. Therm 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 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 visu ally 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 On occasion items are shipped loose Be sure that you receive the correct number of packages as indi cated 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 When ordering parts you must speci
41. accordance with the NFGC U S or B149 Canada The total length of the horizontal through the wall flue system should not exceed 75 equivalent ft in length If horizontal run exceeds 75 equivalent ft an appropri ately 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 75 of straight flue pipe 65 of straight flue pipe and one elbow 55 of straight flue pipe and two elbows 45 of straight pipe and three elbows The vent cap is not considered in the overall length of the venting system 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 horizon tal 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 ex terior 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
42. ada Gas vents supported only by i2 iN flashing and extended above the roof more than 5 ft Soe e should be securely guyed or braced to withstand snow Soe S Tree ae and wind loads L E Z Vis 77 7 Fig 23 Vertical Venting 25 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 heaters NOTE For extractor sizing typical CO levels are 8 5 for natural gas and 9 5 for propane gas and flue temperature of 150 F 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 Sys tems Table N provides the volume of flue products at full fire for the calculation of appropriate vent sizing and extractor for common venting 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 XTherm heater is installed to replace an existing heater the vent 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 EXTRACTOR S PRESSURE SET POINT SLOPE TOWARD APPLIANCE 17 IN 4 MINIMUM Volume of Flue Products NOTE Data for 100 firing rate Table N Volume of Flue Products Data VARIABLE
43. al gas valve field installed near gas inlet connection on back of heater 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 informa tion on the front cover of this manual If you do not smell gas go to next step Turn on all electrical power to the appliance 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 System will try for ignition up to three 49 times one time on optional single try ignition mod ule If flame is not sensed lockout will commence 10 If the appliance will not operate follow the instruc tions To Turn Off Gas To Appliance and call your service technician or gas supplier 11 Replace upper front panel 12 If heater fails to start check the diagnostic board for troubleshooting information and verify the fol lowing a There are no loose connections or that the service switch is off b High temperature limit switch is set above wa ter temperature or manual reset high limit is not tripped c Thermostat is set above water temperature d Gas is on at the meter and the heater e Incoming dynamic gas pressure to the gas valve is NOT less than 4 0 in WC for natural gas or propane gas To Turn Off Gas To Appliance 1 Shut off manual gas
44. ale build up on the heating surface low pH or other chemical imbalance is non warrantable Gas Supply DANGER Make sure the gas on which the heater will operate is the same type as specified on the heater s rating plate Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve lo cated outside the heater jacket It is recommended that a union be installed in the gas supply piping adja cent 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 pounds to inches regulator must be installed to reduce the gas supply pressure if it is higher than noted above This regulator should be placed a mini mum distance of 10 times the pipe diameter upstream 19 of the heater gas controls Refer to Table J on page 20 for maximum pipe lengths 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 The heater must be isolated from the gas supply pip ing 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 T
45. an be provided from a BMS an EMS or a sequenc ing control The external input signal changes the boiler target according to a linear scale The control operates the boiler burner to maintain the boiler target at the remote system sensor See Fig 38 EXTERNAL _ 7 CONTROL eee ees a l RAYPAK HEATER MODULATING J TEMP CONTROL BOILER OUTLET SENSOR IN 1 HEADER 4 FA T BOILER INLET SENSOR IN HEADER ee VA SYSTEM TEMP SENSOR MAIN SYSTEM PUMP Maximum 4 times the pipe diameter or 12 whichever is less Fig 38 Mode 7 Primary Secondary Piping with External Target Temp Mode 8 This mode is for remote firing control of the heater via an external sequencer such as the Raypak TemptTracker 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 fir ing rate is controlled by a 0 10 VDC signal from the external sequencer A control signal of 20 5 VDC equates to minimum fire and a signal of 10 VDC equates to 100 firing rate NOTE For Modes 7 and 8 connect to pins 13 and 14 on the low voltage panel See page 21 Use these modes for systems using an external signal EXTERNAL __ a CONTROL RAYPAK MODULATING L TEMP CONTROL i
46. ater 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 2 Make sure constant gauge pressure has been maintained throughout test 3 Check for leaks Repair if found Raypak Integral Cold Water Protection 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 XTherm heaters are equipped with an integral cold water protection system Units equipped with the dual injector pump system are designed to operate with heater inlet water temperatures down to 50 F continu ous Under start up conditions the dual injector system can operate with fluid temperatures down to 32 F Operation at lower temperatures will create unwar rantable damage to the injector pumps XTherm WH and WHP models equipped with single injector pumps are designed for typical domestic hot water and com mercial pool heating operating conditions respectively Contact your local representative or the factory for applications assistance Hydronic Heating Pump Selection The heater is equipped with an integral cold water pro tection system that includes dual modulating injector pumps to pull the required flow from the system loop and a heater pump sized by the factory for the opti mal OT across the primary heat e
47. ation printed on primer cleaner and cement containers 30 PRECAUTIONS Always store primers cleaner and cements in cool dry well ventilated places Do not store them near heat sparks or flames Keep containers closed Use them in well ventilated areas Wear impervious clothing while handling Do not smoke eat or drink while handling Wash thoroughly after handling and before eating Wear eye protection when handling If swallowed drink water do not induce vomiting and call a physician or poison control center immediately If inhaled 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 like Restoration of the original viscosity or removal of gelation by adding solvents or thinners is not recommended Primers and or cement should be NSF and or UPC listed NOTE Cleaners and primers are intended for different functions and should not be considered Verify with vent material interchangeable manufacturer for specific requirements Termination Termination should be accomplished using the adapter thimble as shown in Fig 32 and Fig 33 The adapter thimble is s
48. ave an optional adjustable setting manual reset high temperature device The fixed setting manual reset high limit is located on the In Out header of the heat exchanger on the right side of the heater accessible through the front door for reset as necessary 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 ka 2 Aa 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 adjustable auto reset high limit is located inside the heater junction box Adjust the setting to approx 20 F 10 C above desired outlet temperature For Pool installations the auto limit must be located to sense the water temperature in the main line see Fig 17 Adjust the setting no higher than 110 F ce Fig 43 Adjustable High Limit Auto Reset Flow Switch This standard dual purpose control mounted and wired in series with the main gas valve shuts off the heater in case of pump failure or low water flow i Fig 44 Flow Switch Modulating Temperature Control This heater is equipped with a Raypak modulating temperature control Refer to information starting on page 33 for information on the
49. bustible roofs and walls Vent Terminal Location 1 Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition NOTE During winter months check the vent cap and make sure no blockage occurs from build up of snow or ice Give special attention to the location of the vent termination to avoid possibility of property dam age or personal injury Gases may form a white vapor plume in winter The plume could obstruct a window view if the ter mination is installed near windows Prevailing winds in combination with below freez ing temperatures can cause freezing of condensate and water ice build up on buildings plants or roofs The bottom of the vent terminal and the air intake shall be located at least 12 in above grade includ ing normal snow line Un insulated single wall Category IV metal vent pipe shall not be used outdoors in cold climates for venting gas fired equipment without insulation Through the wall vents for Category IV appli ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimen tal to the operation of regulators relief valves or other equipment 8 Locate and guard vent termination to prevent acci dental contact by people or pets DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area 10 DO NOT terminate above a
50. ce Igniter Ohms Verify inspection was done and condition of components are in Auto High Limit Setting _deg F good working order with a yes Manual Reset High Limit Setting deg F Wiring Harness Y N Operating Control Setting deg F Burner s flame Y N Refractory visual Y N Sketch plumbing on reverse side Remote flame sense Y N WATER SUPPLY Covers in place for outdoor Y N Flow Rate in GPM or Delta T If Avail Measure flow rate at full fire VENTING Pump Economaster setting Minutes Vent Size Stack Height Low Water Cutoff 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 Screens EMISSIONS SETTINGS AND TEST INFORMATION Nominal Factory Recommended Settings AT FULL FIRE Blower Pressure Setting In WC See manual or card tag Supply Gas Pressure In WC See manual or card tag Verify stable pressure static amp dynamic condition Pilot Gas Pressure In WC See manual or card tag Manifold Gas Pressure In WC See manual or card tag Tracking Pressure clean filter In WC The following measurements must be obtained with a Combustion Analyzer NOX PPM Less than 20 PPM If required by Certifying Agency Free Oxygen See manual PPM Less than 150 PPM CO2 See manual Model Number Serial Number Note draw venting with details such as extractors
51. check the track ing pressure 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 is more negative than 0 6 in WC for 1005 and 1505 models or 0 8 in WC on 2005 models and there are no obstructions to the air intake replace the combustion air filter If the air intake is obstructed shut the unit off clear the obstruction re start and check the tracking pres sure as previously noted Fig 53 Air Pressure Measurement Locations FOR REFERENCE ONLY Measure the blower amp draw with the heater firing at 100 input and compare the measured value to the values in Table V The amp draw is measured with a clamp on type amp probe clamped to the 14 AWG black power wire going into the blower 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 Table U contact the factory The refer ence amp draw reading may help to indicate if there is a problem with the system or if blower adjustm
52. cor UA AAA il HEATER A J OUTDOOR AIR mi hy SENSOR T T BOILER OUTLET SENSOR IN aen HEADER HEADER SYSTEM TEMP SENSOR x 4 MAIN SYSTEM SYSTEM RETURN PUMP Maximum 4 times the pipe diameter or 12 whichever is less Fig 39 Mode 8 Primary Secondary Piping with External Direct Drive Pool Heater WHP Applications oi Setting Boil Target Boil Target TF Pane fe eae el a a Table O Recommended Temperature Control Setpoints WHP Models 34 tem Moas Default Seting Rase Boil Max Tom 2 Wed 9h ai si Ma S RO C asn f o O r O o E SY zoom O wo or sow Table P Temperature Control Default Setpoints H7 WH7 amp WHP Models O E OS G a Requires a 5000 resistor Requires a 5000 resistor Table Q 0 10 VDC or 0 20 mA External Input Signal Table R 2 10 VDC or 4 20 mA External Input Signal Ca E Ci 35 Definitions NOTE The defined terms are not active in all modes of control operation 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 MAX Highest outlet water temperature that the control is allowed to use as a target temperature BOIL M
53. d to be straight down 18 in 450 mm from the floor but not near piping Refer to the B149 Installation Code for additional information Water Piping General The heater should be located so that any water leaks will not cause damage to the adjacent area or struc tures CAUTION This heater must be installed with a Primary Secondary piping arrangement for the integral pumping system to function properly NOTE Minimum pipe size for the heater inlet outlet connections is dependent on the equivalent length of piping between the load loop and the heater loop the operating conditions and the size of the heater See Table G on page 16 Relief Valve Installation and 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 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 be installed between the heater and the relief valves The relief valves shall be mounted with their spindles vertical see Fig 1 2 and 3 on page 6 Relief valve discharge piping shall pro vide no less than the cross sectional area of
54. densate hose from the secondary heat exchanger and drain the condensate trap NOTE There are 3 separate drains on the XTherm that must ALL be drained to 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 NOTE Chemical imbalance can cause severe damage to your heater and associated equipment Chemical imbalance can cause severe damage to the pool heater and associated equipment Maintain the water chemistry according to the chart below If the mineral content and dissolved solids in the water become too high scale forms inside the heat exchang er tubes reducing heater efficiency and damaging the heater If the pH drops below 7 2 this will cause corro sion of the heat exchanger and severely damage the heater Heat exchanger damage resulting from chem ical imbalance is not covered by the warranty For your health and the protection of your pool equip ment it is essential that your water be chemically balanced The following levels must be used as a guide for balanced water Occasional chemical shock dosing of the pool or spa should not damage the heater providing the water is balanced Pool Spa Water Chemistry CAUTION Corrosive water voids all warranties 200 400 Calcium Hardness ppm 200 300 150 200 Salt ppm 14
55. e interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation Improper flow control can damage the heater Uncontrolled flow too high or restricted flow too low can seriously damage the heater Follow these instructions to make sure the heater is properly installed AUTO LIMIT SET AT 110 F Maximum 4 times the pipe diameter or 12 whichever is less Fig 17 Single Pool Heater Application Set the control in Mode 2 for all single heater pool installations For multiple heater installations using an external modulating sequencer use Mode 8 Automatic Chlorinators and Chemical Feeders CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty All chemicals must be introduced and completely di luted into the pool or spa water before being circulated through the heater Do not place chlorine tablets or bromine sticks in the skimmer High chemical concen trations will result when the pump is not running e g overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical back up into the heater when the pump is shut off NOTE High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid corrosion of the heat exchanger in the heater Such damage is not covered under the
56. e provincial and national codes laws regulations and ordinances e National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition NFGC e National Electrical Code ANSI NFPA 70 latest edition NEC e Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 CSD 1 when required e For Canada only CAN CSA B149 Natural Gas and Propane Installation Code and CSA C22 1 C E C Part 1 C22 1 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 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 brackets that were used to bolt the heater to the shipping pallet Clearances Indoor Insta
57. e adjustment In the absence of other information the values pro vided in Tables R and S should be used as default settings Heater Sequence of 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 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 The igniter will be powered and once proven will heat up for 20 seconds The gas valve is then energized for a 4 second trial for ignition period Trial for ignition is fixed at 50 input The heater is allowed to modulate once flame is proven and the firing rate will adjust to match the load based on the configuration and settings of the temperature control or external input As the water approaches 120 F entering the pri mary heat exchanger the injector pumps will begin feeding water from the system into the heater operating to maintain 120 F minimum into the pri mary heat exchanger Once the heat demand is satisfied the gas valve will close and the blower will run a 30 second post purge The heater pump will continue to circulate water for 0 to 10 minutes depending on the pump delay setting on the Raypak modulating tempera ture control 38 Ignition Module When additional heat is needed the c
58. e 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 Menu Field Item Field Displays the current menu Displays an 7 ie abbreviated f name of th OUTDR DSGN DIFF H selected item BOILSUPINOUT yy C i Number Field STARTMINMAX Displays the TARGETMASSA Tim M current value of j Boil lem pLymopEPoo DHW 1212 the selected OPENCLSSTG G BB g WwsD tem paw L External Input Status Field Modulation Offset Signal Displays the current status Vaina P of the control s para Modulating inputs outputs Control and operation Buttons A Vv Selects ltem Menus Items and adjusts settings Fig 40 Modulating Temperature Control Display To make an adjustment to a setting in the control begin by selecting the ADJUST menu To change from the view menu to the adjust menu simultaneous ly press and hold all three buttons for 1 second The menu name ADJUST will be displayed in the menu field The menu will automatically revert back to the view menu after 20 seconds of keyboard inactivity Then scroll to the desired item using the scroll button Fi nally use the A or W button to make th
59. eatly Equivalent Length ft 2 1 2 NPT 3 NPT Table G Equivalent Lengths of Pipe for Typical Fittings TH YQ IF s Maximum 4 times the pipe diameter or 12 whichever is less Fig 15 Dual Heaters Reverse Return with Primary Secondary Piping Domestic Hot Water Maximum 4 times the pipe diameter or 12 whichever is less Fig 14 Single Heater with Primary Secondary Piping When designing the hot water piping system for domestic hot water applications water hardness should be considered See Table H on page 18 for the required tubing sizes and expected supply tempera tures for different operating conditions Water hardness is expressed in grains per gallon Fig 16 Single Domestic Hot Water Heater and Storage Tank NOTE If local codes require a vacuum relief valve acquire one locally and install valve manufacturer s instructions Combined Potable Water and Space Heating per CAUTION When this heater is used for both potable water and space heating observe the following to ensure proper operation All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water used for space heating
60. egulate system water temperatures by reducing flow in the boiler should not be used 15 XTherm heaters have an integral cold water protection system to maintain required temperatures and flow rates System Model 1005 Model 1505 Model 2005 Return Temp Supply Temp Minimum Pipe Size Supply Temp Minimum Pipe Size Supply Temp Minimum Pipe Size F F lt 80 equiv 80 200 equiv F lt 80 equiv 80 200 equiv F lt 80 equiv 80 200 equiv 60 138 2 NPT 2 1 2 NPT 147 2 NPT 2 1 2 NPT 154 2 NPT 2 1 2 NPT 80 138 2 NPT 2 1 2 NPT 147 2 NPT 2 1 2 NPT 154 2 1 2 NPT 3 NPT 100 138 2 1 2 NPT 3 NPT 147 2 1 2 NPT 3 NPT 154 2 1 2 NPT 3 NPT 120 145 2 1 2 NPT 3 NPT 158 2 1 2 NPT 3 NPT 170 2 1 2 NPT 3 NPT 140 165 2 1 2 NPT 3 NPT 178 2 1 2 NPT 3 NPT 190 2 1 2 NPT 3 NPT 160 185 2 1 2 NPT 3 NPT 198 2 1 2 NPT 3 NPT 210 2 1 2 NPT 3 NPT Approximate high fire heater outlet temperature based on the standard heater pump and the recommended connecting pipe size Minimum pipe size based on total equivalent feet of supply and return piping between the system loop and heater Table F Boiler Temperatures and Minimum Pipe Size at Varying Return Temperatures Fitting Type 90 Elbow Std 90 Elbow Long rad Note Equivalent lengths are calculated based on typical operating conditions with typical Schedule 40 pipe fittings and valves Equivalent lengths are approximate and may vary gr
61. emicals e calcium chloride used for thawing e sodium chloride used for water softening e refrigerant leaks e paint or varnish removers e hydrochloric acid muriatic acid e cements and glues e antistatic fabric softeners used in clothes dryers e chloride type bleaches detergents and cleaning solvents found in household laundry rooms e adhesives used to fasten building products e similar products Areas where contaminated combustion air commonly exists e dry cleaning laundry areas e metal fabrication plants e beauty shops e refrigeration repair shops e photo processing plants e auto body shops e plastic manufacturing plants e furniture refinishing areas and establishments e new building construction e remodeling areas e open pit skimmers Check for areas and products listed above before in stalling heater If found e 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 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 fin
62. ent is required Manifold Check 1 Check manifold gas pressure at the gas valve out let pressure tap connection D in Fig 51 This pressure should read per the values in Table W for natural and propane gas If the pressure reading differs by more than 0 2 in WC STOP Call the factory for directions on what to do next Net Blower Suction Model No in WC Setting Tolerance Table U XTherm Air Pressure Settings Model No Amp Draw Sering Tolerance 46 Table V XTherm Blower Amp Draw Reference Information Manifold Gas Pressure Model No High Fire Values art Gas_ Propane Gas 005 a Table W XTherm Manifold Pressure Settings CAUTION Special manifold and air settings may be required 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 thermostats and high limit settings 2 During the following safety checks leave manome ters 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 XTherm with all other equipment running 4 Check thermostats for ON OFF operation 5 Check high limits for ON OFF operation 6 While in
63. external input signal and converts this to a boiler target temperature The Offset setting is then added to the boiler target temperature OUTDR Outdoor air temperature OUTDR DESIGN Design outdoor air temperature used in the heat loss calculation OUTDR START Starting outdoor air temperature PUMP DLY Sets the operating time of the pump once the CFH is satisfied TANK Current DHW tank temperature Mode 3 TANK DIFF Storage tank differential Mode 3 TANK TARGET Target temperature in the DHW storage tank Mode 3 ta SI ss om e Sa sons o eo erneer et E KAZA MAE UA E ai o a e or 8 onto 0 rr ncor sensor on COO KA ow o ee me Table S Error Codes UNITS Selects the temperature units to be displayed F or C WWSD Selects the outdoor temperature that shuts the heater off no matter what the demand NOTE The WWSD segment is displayed on the LCD Operation The Raypak modulating temperature control uses a Liquid Crystal Display LCD as a method of supply ing information The LCD is used to setup and monitor system operation by means of three push buttons Item amp and W shown at the bottom of Fig 40 All items displayed by the control are organized into two menus the view menu and the adjust menu The active menu is displayed in the upper right hand side of the display in the menu field The default menu is the view menu When the temperature control is powered up th
64. fy the model and serial number of the heater When ordering under war ranty conditions you must also specify the date of installation Purchased parts are subject to replacement only under the manufacturer s warranty Debits for defec tive replacement parts will not be accepted Parts will be replaced in kind only per Raypak s standard war ranties Model Identification 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 Pool Heating The number which follows identifies the firing mode 7 electronic modulation 1 On Off The second group of characters identifies the size of the heater four numbers representing the approximate MBTUH input and where applicable a letter indicating the manufac turing series Ratings and Certifications Standards e ANSI Z21 13 CSA 4 9 latest edition Gas Fired Hot Water Boilers e CAN 3 1 latest edition Industrial Commercial Gas Fired Package Boilers e ANSI Z21 10 3 CSA 4 3 latest edition Gas Wa ter Heaters e SCAQMD Rule 1146 2 and All Raypak heaters are National Board Approved and design certified and tested by
65. g where no action occurs All temperature controllers have a deadband and the purpose is to prevent short cycling of the heater The on board temperature controller has a deadband of 2 F around the differen tial Differential A heat source must be operated with a temperature differential in order to prevent short cycling The temperature differential is divided around the target temperature or set point The Call For Heat CFH contact will close in the controller when 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 Target temperature 160 F 71 C 165 F 74 C S e ol 155 F 68 C J Joane Time 160 F 71 C gt Water Temperature 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 See Fig 35 HEATER RAYPAK MODULATING BOILER OUTLET yy TEMP CONTROL SENSOR IN nacera el a HEADER BOILER INLET F SENSO
66. g with any electrical connections or components Observe proper wire colors while making electri cal connections Many electronic controls are polarity sensitive Components damaged by im proper electrical installation are not covered by warranty Provide overload protection and a disconnect means for equipment serviceability as required by local and state code Install heater controls thermostats or building management systems in accordance with the applicable manufacturers instructions 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 Field Wiring Connection CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause im proper and dangerous operation Verify proper operation after servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is discon nected to avoid potential serious injury or damage to components amp SS SS SS LA 5 SS SSS Sss The ir SIS 3 SS SS NS By Ss f Ca SSNs n SSS SS Q ds SSs SS e amp gt amp SS SSs ii Ww i Fig 22 Rear Wiring Location Venting CAUTION Proper installation of flue venting is critical for the safe and efficient operation of the heater General Appl
67. he wiring diagram shipped with the heater Use appropriately sized wire as defined by NEC CSA and or local codes All primary wiring should be rated for 125 of the minimum required service Before starting the heater verify that the correct 120VAC volt age is being supplied to the heater and pump If any of the original wire supplied with the heater must be replaced it must be replaced with 105 C or its equivalent Power is connected to the heater via the rear wiring box as shown at the top of Fig 19 Main heater power is connected to terminals 1 2 and 3 and pump power is connected to terminals 4 5 and 6 Field wiring connections such as sensors interlocks enable disable and alarm contacts are made at the low voltage terminal strip at the front of the heater as shown at the bottom of Fig 19 Field Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source MAIN POWER IN HoT Ju ga FIELD WIRING USE COPPER CONDUCTORS ONLY Ole ene FACTORY TRE REAR WIRING BOX LINE VOLTAGE ELECTRICAL CONNECTIONS O QUQUEUG a o oo S1918 Bae JT JUMPERED OPTIONAL WHEN NOT USED z TEED WIRING OPTIONAL OPTIONAL FRONT WIRING PANEL LOW VOLTAGE
68. iance 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 A heater which operates with a non pos itive vent static pressure and with a vent gas temperature that avoids excessive condensate pro duction in the vent Category Il A heater which operates with a non pos itive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent Category Ill A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent 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 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 CAUTION Condensate drains for the vent piping are required for installations of the XTherm Follow vent manufacturer instructions for installation and location of condensate drains in the vent Condensate drain trap must be primed with water to prevent gas flue leak and must be routed to an appropriate container for neutralization before dis posal as required by local codes
69. ible products i e gasoline etc Pre Start up Check 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 5 Prime the heater condensate trap mounted in the bottom of the secondary heat exchanger WARNING Condensate trap must be primed prior to heater start up to prevent flue gas leakage through the condensate management system Verify that traps maintain a prime under operating conditions Extended operation with non condensing conditions may require an engineered condensate management system 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 NOTE Digital manometers are not recommended Preparation WARNING Do not turn on gas at this time Check Power Supply With multi meter at incoming power check voltage between Hot Common 2120 VAC Hot Ground 120 VAC Common Ground lt 1 VAC WARNING If Common Ground is gt 1 VAC STOP Contact electrician to correct ground failure Failure to do this may burn out 120V 24V transformer or may cause other safety
70. ing Season Schedule annual service call 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 func tion deterioration or leakage Ensure that condensate drain is inspected and ensure that condensate is being directed to appropriate con densate management system or drain as required by local codes 3 Check that area is free from combustible materi als gasoline and other flammable vapors and liquids 4 Check for and remove any obstruction to the flow of combustion or ventilation air to heater 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 7 Check operation of safety devices Refer to manu facturers instructions 8 Follow oil lubricating instructions on pump if re quired Over oiling will damage pump Water lubricated circulators do not need oiling 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 10 Check blower and blower motor 11 Check for piping leaks around pumps relief valves and other fittings Repair if found DO NOT use petroleum based stop leak 12 Check the fault history and reset as necessary Pe
71. ions 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 Periodically check venting system The heater s 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 Do not locate adjacent to any window door walk way or gravity air intake The vent must be located a minimum of 4 ft horizontally from such areas Install above grade level and above normal snow levels Vent terminal must be at least 3 ft above any forced air inlet located within 10 ft Adjacent brick or masonry surfaces must be pro tected with a rust resistant sheet metal plate 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 NOTE Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition 29 FLUE EXHAUST VENT CAP HEATER UNIT TEST PORT y LI INSULATED EKHAUST VENTING i H 12 MIN IILL EEE Vj CONDENSATION TRAP Fig 29 Outdoor Venting Freeze Protection The Raypak electronic temperature control includes a freeze
72. ir switch hose The burner should go off almost immediately d Reattach cap on tee Burner should re ignite after pre purge time delay NOTE Ignition control may have to be reset after this por tion of the test To restart system follow lighting instructions in the Operation section 11 12 13 14 15 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 Check that the heater is cycled with the thermo stat 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 Observe several operating cycles for proper oper ation Set the heater thermostat to desired temperature Review all instructions shipped with this heater with owner or maintenance person return to enve lope and give to owner or place the instructions inside front panel on heater OPERATION Lighting Instructions 1 Before lighting make sure you have read all of the safety information in this manual Remove upper front panel Set the thermostat to the lowest setting Turn off all electrical power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn on main manu
73. ished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 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 vent ed 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 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 de
74. ithin 12 in 305 mm of the top and one opening shall commence within 12 in 305 mm of the bottom of the enclosure The mini mum dimension of air openings shall be not less than 3 in 76 mm in any direction All Air from Outdoors The confined space shall communicate with the out doors 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 com mencing 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 com municate with the outdoors Where directly communicating with the out doors or where communicating to the outdoors through vertical ducts each open ing 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 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 mm 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 whe
75. lane 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 54 of this manual Canadian Installations Refer to latest edition of the B149 Installation Code A vent shall not terminate 1 Directly above a paved sidewalk or driveway which is located between two single family dwell ings and serves both dwellings 2 Less than 7 ft 2 13 m above a paved sidewalk or paved driveway located on public property 3 Within 6 ft 1 8 m of a mechanical air supply inlet to any building 4 Above a meter regulator assembly within 3 ft 915 mm horizontally of the vertical centre line of the regulator 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 mechani cal air supply inlet to any building or the combustion air inlet of any other appliance Underneath a verandah porch or deck unless the verandah porch or deck is fully open on a mini mum 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 Venting Installation Tips Support piping e horizontal runs at least every 5 ft
76. le Preventive Maintenance Schedule APPENDIX Inside Air Contamination Important Instructions for the Commonwealth of Massachusetts WARRANTIES WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe personal injury death or substantial property damage if ignored Indicates the presence of hazards or unsafe practices which could cause severe personal injury death or substantial property damage if ignored Indicates special instructions on installation operation or maintenance which Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored 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 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 To minimize the possibility of improper operation serious personal injury fire or damage to the heater Always keep the area around the
77. lion BTUH plus 1 in 2 per 14 000 BTUH 160 mm 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 require ment shall be in addition to the air opening for ventilation air required in 1 above WARNING Care must be taken to ensure that the equipment room is not under negative pressure conditions For heaters not using a barometric damper in the 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 sup ply opening s having a total cross sectional area of not less than 1 in 2 for each 30 000 BTUH 74 mm per kW of total rated input of the burner s and the location of the opening s shall not inter fere 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 mm nor less than 6 in 152 mm above the floor level The duct can also goose neck through the roof The duct is preferre
78. llations Heater Minimum Clearance h from Combustible Side Surfaces ror o Rear 12 Rear 12 Minimum Service Clearance DO NOT install on carpeting Table C Clearances Indoor Installations For ease of servicing provide a minimum clearance of at least 24 in on the right side 24 in in front at least 36 in on the rear and 10 in above the top of the heater This will allow the heater to be serviced in its installed location without movement or removal of the heater TOP VIEW 36 SERVICE CLEARANCE 24 1 X THERM L 1 24 REAR EXHAUST INSTALLATION FRONT VIEW A 1 SERVICE CLEARANCE f VERTICAL CLEARANCE ALL INSTALLATIONS Venting not shown for clarity Heater must be vented per instruc tions in this manual Fig 5 Minimum Clearances from Combustible Surfaces Indoor and Outdoor Installations 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 Outdoor Installations These heaters are design certified for outdoor installa tion Heaters must not be installed under an overhang unless they are in accordance with local installation codes a
79. located at the bottom of the front panel to check igniter operation Gas valve should open in 45 60 seconds The heater ignites at 50 of full rate as indicated on the LCD display of the temperature control located in the upper right of the front panel If the burner fails to light on the first trial it will go into lockout with the optional single try ignition module If the heater is equipped with the standard three try ignition module it will try for ignition up to three times before going into lockout Wait until the controller indicates 100 on the fir ing rate display screen approximately 30 seconds Blower Check NOTE Most commercially available amp probes are not accurate enough and or are not shielded well 1 Check the net blower suction using a 6 0 6 U tube enough to read accurately in the heater manometer by connecting one end to the blower suction pressure tee attached to the negative side environment Blower amp draw readings are for reference only of the air pressure switch point A in Fig 53 and the other end to the tracking pressure tee attached to the positive side of the air pressure switch point B in Fig 53 Read the differential pressure with the heater firing at 100 input and compare to Table U Check the tracking pressure by removing the end of the U tube manometer from the blower suction pressure tee point A in Fig 53 Replace the cap on the blower suction tee and
80. management system The condensate float switch is located inside the vent outlet plenum at the left rear of the heater Fig 51 Condensate Float Switch 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 WIRING DIAGRAMS Models 1005 amp 1505 MaLVGH F
81. nd 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 Heater Min Clearance Minimum eas from Combustible Service Side Surfaces Clearance Vent 12 12 Termination Table D Clearances Outdoor Installations Combustion and Ventilation Air 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 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 outside All installations must com ply with the requirements of the NFGC U S and B149 Canada and all local codes CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty See the Appendix NOTE It is recommended that the intake vent be insulated to minimize sweating INSIDE CORNER DE TAIL VLLLLLLLLL
82. not be recovered Diagnostic information is provided any time a fault is recorded This information is intended to assist in locating the problem with the heater but is not exhaus tive If multiple fault conditions occur at the same time only the fault that caused the heater to shut down will be recorded in the history 51 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 flammable vapors and liquids 2 Check for and remove any obstruction to the flow of combustion or ventilation air to heater Monthly 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 2 Visually inspect burner flame 3 Visually inspect venting system for proper func tion deterioration or leakage 4 Visually inspect for proper operation of the con densate drain in the venting and on the heater If leaks are observed repair at once 5 Check air vents for leakage 6 Visually inspect air intake and filter for obstruc tions 7 Check the fault history for potential issues and reset as necessary Yearly Beginning Of Each Heat
83. nting ii n Z s ot NOTE 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 inline collec tor for condensing stacks or an inline vertical or horizontal collector available from several of the listed vent manufacturers ALTERNATE COMBUSTION 7 N AIR INTAKE LOCATION INSULATED EXHAUST VENTING FLUE EXHAUST VENT CAP l l l l HEATER UNIT I TEST PORT N wi 12 MIN S558 77 AA CONDENSATION TRAP Fig 27 Horizontal Through the Wall Direct Venting CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s instructions Failure to install a condensate drain in the venting system will void all warranties on this heater 27 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 out doors Adequate combustion and ventilation air must be supplied to the equipment room in
84. ny door window or gravity air 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 the latest edition of the National Fuel Gas Code Vent termination requirements are as follows 1 Vent must terminate at least 4 ft below or 4 ft hori zontally from any door window or gravity air inlet to the building 2 The vent must not be less than 7 ft above grade when located adjacent to public walkways 3 Terminate vent at least 3 ft above any forced air inlet located within 10 ft 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 23 5 Terminate 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 clearance from the wall 8 Terminate vent at least 1 ft above grade including normal snow line 9 Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal p
85. of 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 Zip Code Installation Site Daytime Telephone Number Contractor Installer RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 9786 805 278 5300 Fax 800 872 9725 www raypak com 56 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 CLEARANCES Regulator Model amp Size CFH Front Clearance In Gas Line Size in room In NPT Right Side Clearance In Length of Gas Line Eq Ft Left Side Clearance In Low Gas Pressure Setting In WC Rear Clearance In High Gas Pressure Setting In WC Overhead Clearance In Gas Shut Off Valve Type Ball Lube cock ELECTRICAL Sediment Trap Y N Voltage Supply VAC No Load Load Port Std Full Voltage 24 VAC VAC Voltage Com to Ground VAC VISUAL INSPECTION OF COMPONENTS Hot Surfa
86. om scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before set ting temperature at water heater Feel water before bathing or show ering Temperature limiting valves are available see manual Time Temperature Relationships in Scalds 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 Water Time to Produce Serious Temp Burn 120 F More than 5 minutes 125 F 1 1 2 to 2 minutes 130 F About 30 seconds Table courtesy of The Shriners Burn Institute Table B Time to Produce Serious Burn The temperature of the water in the heater can be reg ulated by using the Raypak Modulating Temperature Control To comply with safety regulations the control is set at 120 F when shipped from the factory Mode 3 default setting for Tank Target To adjust the water temperature follow the instruction for the operation of the control starting on page 33 of this manual The control is shown below for identifica tion purposes only See Fig 4 oe g eee Fig 4 Modulating Temperature Control CAUTION Hotter water increases the risk of scalding There is a hot water scald potential if the thermostat is set too high INSTALLATION Installation Codes Installations must follow these codes e Local stat
87. ombustion air blower starts to purge air from the combustion cham ber for 15 seconds On proof of air flow the air proving switch closes and the igniter is energized To ensure safe operation the gas valve cannot open until the igniter is verified The main burner is automat ically lit when the device is powered and pre purged The heater performs its own safety check and opens the main valve only after the igniter is proven to be capable of ignition The standard ignition module will attempt to light three times before locking out To reset it turn off power to the heater wait 30 seconds and re apply power AN Fig 41 Ignition Module The optional single try ignition module will lock out after failing to light one time To 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 Turning off the power to the heater WILL NOT reset the single try ignition module System OK No faults present Possible control fault Check power Flame in combustion chamber 2 Flashes No call for heat 3 Flashes Ignition lockout 4 Flashes Low HSI current 5 Flashes Low 24 VAC 6 Flashes Internal fault Replace control Table T Ignition Module Diagnostic LED Flash Codes High Limit Manual Reset This heater is equipped with a fixed setting manual re set high limit temperature device as standard or it may h
88. on 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 47 to reset a tripped pressure switch The LED will go out when the switch is reset Fig 47 High Low Gas Pressure Switch Air Pressure 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 Fig 48 Air 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 49 Blocked Vent Switch 41 UDB Diagnostic Board This heater is eguipped with a diagnostic board which will indicate faults as they occur Refer to the Trouble shooting section for instructions on accessing reviewing and clearing these faults g Q Fig 50 UDB Diagnostic Board with Display 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
89. on page 17 Fig 19 on page 21 Table 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 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 CONTENTS WARNINGS Pay Attention to These Terms BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information Time Temperature Relationships in Scalds GENERAL SAFETY INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Domestic Hot Water Combined Potable Water and Space Heating Pool Heating Gas Supply Electrical Power Connections Field Wiring Connection Venting Venting Installation Tips Venting Configurations DnA A Outdoor Installation PVC Venting Option Controls Heater Sequence of Operation WIRING DIAGRAMS Models 1005 amp 1505 Model 2005 START UP Pre Start up Pre Start up Check Initial Start up Preparation Start Up OPERATION Lighting Instructions To Turn Off Gas To Appliance TROUBLESHOOTING UDB Fault History MAINTENANCE Suggested Minimum Maintenance Schedu
90. ons would jeopardize the safety and health of inhabitants 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 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 Installation XTherm heaters are certified for outdoor operation in non freezing conditions only Freezing conditions may cause condensate to freeze in the condensate drain line and trap causing the unit to shut down from a blocked condensate drain Additionally components of the condensate management system may be dam aged by the ice formation Units installed in freezing climates for seasonal use must be winterized to avoid freeze damage to the heater Outdoor models must be vented with listed vent mate rial per the following instructions and installed with the optional factory supplied outdoor vent kit A special vent cap is provided in accordance with CSA require ments It must be installed directly on the vent pipe as illustrated in Fig 29 on page 30 Care must be taken when locating the heater out doors 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 precaut
91. ore proceeding with the installation 4 Remove both the left and right rear side access panels 7 x 5 Inside Air Intake Cover Panel b h sanf RS Fig 8 Install the Inside Air Intake Cover Panel Optional 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 Inside Air Intake Opening Fig 7 Remove the Rear side Access Panels 5 From the right rear side access area install the inside air intake cover panel using the nine hex head screws provided see Fig 8 7 Fig 9 Install the Condensate Drip Pan Remove the air intake cover panel by removing the 5 phillips head screws holding it in place Air Filter Access Panel Air Intake Cover Panel Fig 10 Remove the Air Intake Cover 8 Remove the debris screen or cover panel for model 1005 by removing the six screws holding it in place
92. protection feature In the event the water tem perature drops below 40 F at any of the heater temperature sensors the pump is turned on and will remain on until the temperature at all heater sensors rises to 45 F WARNING Do not install the heater outdoors if freezing conditions are typical The condensate will freeze and back up the flue system PVC Venting Option Venting of the XTherm with PVC material requires the factory installed D 32 adapter kit CAUTION The inlet water temperature to the XTherm must not exceed 170 F at 100 fire to use the PVC venting option The venting system must conform to local codes and or the current National Fuel Gas Code ANSI Z223 1 NFPA 54 The PVC vent adapter should appear as in Fig 30 and Fig 31 Cleaning Prior to installing the PVC pipe and fittings ensure that all burrs and or ridges have been removed Failure to remove burrs or ridges will result in the cement in the fitting socket being scraped from the socket surface producing a dry joint with a high probability of joint fail ure Remove all burrs with a knife or with abrasive paper Surfaces to be joined must be cleaned and be free of dirt moisture oil and other foreign materials DANGER Primer cleaner and cements are extremely flammable They are harmful or fatal if swallowed The vapors are harmful They may irritate eyes and skin and can be absorbed through the skin Read and observe all safety inform
93. re 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 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 mm per kW of the total input rating of all equipment located in the enclosure and b Not less than the sum of the areas of all vent connectors in the confined space WARNING Do not use the one permanent opening method if the equipment room is under negative pressure conditions 13 Canadian Installations CAUTION All combustion air must be drawn from the air outside of the building the mechanical equip ment room must communicate directly with the outdoors 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 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 mm per kW up to and including 1 mil
94. riodically 1 Check relief valve s Refer to manufacturer 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 Check burner flame Should see light blue flame at full input rate 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 Monthly 1 Check flue vent stack or outlet dampers 2 Test blower air pressure See Blower Check on page 46 3 Test high and low gas pressure interlocks if equipped See Safety Inspection on page 47 4 Check tracking pressure see Blower Check step number 2 on page 46 5 Reset fault history after any testing Semi Annually 1 Recalibrate all indicating and recording gauges 2 Check flame failure detection system components 3 Check firing rate control by checking the manifold pressure See Manifold Check on page 46 4 Check piping and wiring of all interlocks and shu
95. s 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 signal by installing a 500 O resistor on the external input signal device s terminals 2 10VDC or 4 20 mA external input signal When the 2 10VDC signal is selected an input voltage of 2 VDC corresponds to a boiler target temperature of 50 F 10 C An input voltage of 10 VDC corresponds to a boiler target temperature of 220 F 104 C As the voltage varies between 2 VDC and 10 VDC the boiler target temperature varies linearly between 50 F 10 C and 220 F 104 C If a voltage below 1 5 VDC is received the boiler target temperature is displayed as indicating that there is no longer an internal heat demand A 4 20 mA signal can be converted to a 2 10 VDC signal by installing a 500 0 resistor on the external input signal device s terminals FP Flame proof warning Warns that the control did not see burner flame within 5 min of call for heat MODE Operating mode of the heater OFFSET The Offset setting allows the boiler target temperature to be fine tuned to the external input sig nal The control reads the
96. setting and use of this control oo De Fig 45 Modulating Temperature Control Low Water Cut Off Optional 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 pre vents premature lockout due to temporary conditions such as power fluctuations or air pockets Fig 46 Low Water Cut Off High amp Low Gas Pressure Switches Optional The optional low gas pressure switch connection mounts upstream of the gas valve on the inlet flange to the gas valve and is accessible through the remov able access panel on the right side of the heater to reset the gas pressure switch as necessary Itis 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 accessible from the front of the heater to reset the gas pressure switch or through the removable access panel on the right side of the heater to reset the gas pressure switch as necessary If the gas pressure regulator in the valve fails the high gas pressure switch automatically shuts down the burner Operati
97. stream 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 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 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 blee GAS dle valve to the test point B bleedle valve and open the upstream manual gas valve Make sure that test point A amp B bleedle valves have been opened so as to allow gas to flow This will bring gas pressure to the second valve seat 1ST SEAT FIRING VALVE 2ND SEAT MANUAL VALVE T To BURNER TO BURNER wae Fig 54 Leak Test Procedure 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 leak ing gas valve which must be replaced Remove rubber tube and manometers Close each test point bleedle valve as the tubes are removed NOTE Reinstall HGPS as applicable 7 After no leakage has been verified at all valve seats and tes
98. t off valves Annually 1 Test flame failure detection system and pilot turn down 2 Test high limit and operating temperature See Post Start Up Check page 48 3 Check flame sensor 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 lt 100 ppm 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 6 Perform leakage test on gas valves See Fig 54 7 Test air switch in accordance with manufacturer s instructions Turn panel switch to the On posi tion until blower is proven then turn the switch to Off 8 Inspect and clean burner using shop air 9 Reset fault history after any testing As Required 1 Recondition or replace low water cut off device if equipped 2 Check drip leg and gas strainers 3 Check flame failure detection system See Post Start Up Check page 48 4 Check igniter Resistance reading should be 42 70 ohms at ambient temperature 5 Check flame signal strength Flame signal should be greater than 1 microampere
99. t valves open downstream leak test valve and restore electrical power to the heater 48 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 Confirm that the automatic air vent if used was opened two full turns during the venting proce dure Verify that air has been purged from the system Verify that air has been purged from the gas pip ing and that the piping has been checked for leaks Confirm that the proper start up procedures were followed Inspect burner to verify flame 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 delay Test limit control While burner is operating move indicator on high limit control below actual water temperature Burner should go off while blower and circulator continue to operate Raise setting on limit control above water temperature and burner should re ignite after pre purge time delay NOTE Ignition control may have to be reset after this portion of the test Test ignition system safety device a Open manual gas valve Turn power on b Set thermostat to call for heat c When the heater is in operation pull cap off of tee in a
100. tector with an alarm shall be installed 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 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a min imum 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 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 inspec tor observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 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 To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 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 res idential purposes c MANUFACTURER REQUIREMENTS GAS EQUIP
101. tion 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 Raypak s behalf THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROV IDED 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 war ranty 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 pro
102. upplied by Rapak as part of the D 32 option PVC vent assembly instructions Cut pipe ends squarely removing all burrs and dirt Dry fit pipe and fittings to be connected for proper fit Clean pipe and fitting with a cleaner Apply a coat of primer to pipe and fitting Apply a thin coat of cement to fitting avoiding pud dling inside 6 Apply a liberal coat of cement to pipe leaving no voids 7 QUICKLY assemble parts while cement is fluid If you 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 excess with a cloth The glue bonds by melting the PVC 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 WARNING Remember that vent pipes must be adequately and securely supported the vent weight must not be supported by the heater this may cause unwarrantable damage Fig 30 PVC Vent Adapter Rear panel and vent limit switch removed for clarity INSIDE UNIT CABINET OUTSIDE UNIT CABNET VENT TEMPERATURE LIMIT Fig 31 PVC Vent Adapter 31 Fig 32 Adapter Thimble
103. ure control is 125 F Safety and energy conservation are factors to be con sidered 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 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 e Feel water before bathing or showering e Temperature limiting valves are available 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 Maximum water temperatures occur just after the heater s 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 This section applies to Hot Water Supply Boilers and Hot Water Heaters ONLY For sanitary rinse applica 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 fr
104. valve field installed near gas inlet connection on back of heater 2 Remove upper front panel 3 Set the thermostat to lowest setting 4 Turn off all electrical power to the appliance if serv ice is to be performed 5 Replace access panel TROUBLESHOOTING YES m Check filter Correct the shutter setting or blower amp draw Is blower pressure setting vacuum correct YES Replace air pressure switch o Step 5 Is 24VAC at PS on ignition module Is connecting plug secure YES NO YES YES Step 8 NO gt Correct the gas pressure Step 9 50 UDB Fault History To view the fault codes in the UDB history file 1 Press the UP or DOWN buttons on the membrane switch for 2 seconds to access the fault history Press either button to scroll through the recorded faults in history The most recent fault recorded will be the first fault displayed the last 16 faults are stored in the his tory on a rolling basis There is no time or date stamp associated with these faults When the history of faults has been exhausted pushing the UP or DOWN buttons again will roll the fault history over and it will start again To exit the fault history wait for 10 seconds and the board will automatically exit the history mode To clear the fault history press and hold both the UP and DOWN buttons for 5 seconds while the power is on NOTE Once the history has been cleared it can
105. xchanger The system is designed for continuous return temperatures from 50 F to 180 F Feedwater Regulator Raypak recommends that a feedwater regulator be in stalled 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 Piping All high points should be vented A heater installed above radiation level must be provided with a low wa ter 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 prevent the chilled medium from entering the heater 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 recommend ed that the piping be insulated Air Separation Expansion Tank All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig 13 EXPANSION TANK AIR SEPARATOR WITH BLEED VALVE Fig 13 Air Separation Expansion Tank Three Way Valves WARNING Three way valves intended to r

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