Raypak XTherm 1005A Installation And Operation Manual
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Raypak XTherm 1005A Installation And Operation Manual

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INSTALLATION AND
OPERATION MANUAL
Models 1005A - 2005A
Type H, WH, and P
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property
A
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 com-
bustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or
fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3400.552D
ULTRA HIGH EFFICIENCY
Effective: 09-20-18
Replaces: 08-23-18
P/N 241513 Rev. 5

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Summary of Contents for Raypak XTherm 1005A

  • Page 1 INSTALLATION AND OPERATION MANUAL ULTRA HIGH EFFICIENCY Models 1005A - 2005A Type H, WH, and P 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.

  • Page 2: Table Of Contents

    3.6. Air Supply ..............11 6.2. Pre Start-up Check ..........48 3.7. Water Piping ............12 6.3. Initial Start-up ............48 3.8. Raypak Integral Cold Water Protection ..13 6.4. Preparation ............. 48 3.9. Hydronic Heating ..........14 6.5. Start-Up ..............49 3.10.

  • Page 3: Warnings

    1. WARNINGS 1.1. Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe personal injury, death or DANGER substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, WARNING death or substantial property damage if ignored.

  • Page 4: Before Installation

    Heaters • ANSI Z21.56 · CSA 4.7 - latest edition, Gas-Fired Pool Thank you for purchasing a Raypak product. We hope you Heaters will be satisfied with the high quality and durability of our • SCAQMD Rule 1146.2 equipment.

  • Page 5: Component Locations

    2.5. Component Locations HIGH VOLTAGE BLOWER GAS TRAIN ELECTRICAL CONNECTIONS (ALTERNATE CONSTRUCTION) GAS SUPPLY OPERATING CONNECTION CENTER COMBUSTION AIR INLET (OPTIONAL) WATER OUTLET 2-1/2 NPT PRIMARY HEAT EXCHANGER WATER INLET FRONT OF 2-1/2 NPT HEATER FLUE OUTLET CONDENSING HEAT EXCHANGER CONDENSATE DRAIN 3/4 NPT, PVC F10241...

  • Page 6: General Safety

    2.5.1. General Information Input Gas Conn Vent Size Comb Air Model Water Conn MBTUH (kW) (NPT) (NPT) In. (mm) In. (mm) 1005A 999 (293) 140 (41.0) 2-1/2" 1-1/4" 1" 6 (152) 6 (152) 1505A 1500 (440) 210 (61.6) 2-1/2" 1-1/4" 1" 8 (203) 8 (203) 2005A 1999 (586) 280 (82.1) 2-1/2"...

  • Page 7: Installation

    (29 mm) Service clearances less than the minimum may require Figure 5. XTherm 1005A-2005A Anchor Hole Locations removal of the heater to service either the heat exchanger or the burner components. In either case, the heater must 3.2. Equipment Base...

  • Page 8: Outdoor Installation

    3.4. Outdoor Installation TOP VIEW Heaters must not be installed under an overhang unless clearances are in accordance with local installation codes and the requirements of the gas supplier. 36" (914 mm) Three sides must be completely open in the area under SERVICE CLEARANCE the overhang.
  • Page 9 Figure 7. Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, deck, or 1' (30 cm) 1' (30 cm) balcony 4' (1.2 m) below or to side of Clearance to window or door that may be opened 3' (91 cm) opening Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2' (61 cm) from 5' (1.5 m)
  • Page 10 3. In cold climates, and to mitigate potential freeze- 6. Remove the air intake cover panel by removing the up, Raypak highly recommends the installation of a five Phillips head screws holding it in place. motorized sealed damper to prevent the circulation of cold air through the heater during the non- operating hours.

  • Page 11: Air Supply

    7. Remove the debris screen (or cover panel for model ® 3.5.5. TruSeal Combustion Air 1005A) by removing the screws holding it in place. In addition to the previous steps, the combustion air system can be sealed to meet Direct Vent requirements by sealing the mounting screws and duct connection point with RTV (not supplied). All ducting MUST be self- supported. CAUTION: Use TruSeal combustion air if damaging airborne contaminants are or may be present in the heater area.

  • Page 12: Water Piping

    b. Where communicating with the outdoors “goose neck” through the roof. The duct is preferred through horizontal ducts, each opening shall to be straight down and terminated 18" (450 mm) have a minimum free area of 1 square inch per from the floor, but not near piping.

  • Page 13: Raypak Integral Cold Water Protection

    12 IN. (305 mm) heat exchanger has already been factory-tested and is rated for 160 psi (1100 kPa) operating pressure. However, SYSTEM Raypak does recommend hydrostatic testing of the piping PIPING connections to the heater and the rest of the system F10501 prior to operation. This is particularly true for hydronic 5 FT.

  • Page 14: Hydronic Heating

    (i.e. bypasses, 3-way control valves, flow-limiting balance devices, buffer tanks, etc.) will result in heater short-cycling and may reduce heater life. Always contact your local Raypak representative for Figure 15. Air-Separation/Expansion Tank system design assistance to avoid these issues.
  • Page 15 Indirect available. For detailed information on the VERSA IC control H mode 3 system, see the VERSA IC manual (5000.72). This manual Indirect can be found in the document library at www.raypak.com. H mode 3 Supply Mode 1 (Type H Units Only) Poolstat This mode selection is for hydronic heating systems with Table J.
  • Page 16 The system temperature is controlled by the System sensor NOTE: MODE 1 can also be used for process heating (S3). The integral boiler pump (P1) runs during any call for applications in conjunction with a buffer/storage tank heat. The System Pump (P2) runs whenever the system when operating temperatures above 150°F (66°C) are is enabled for heating and the outdoor air temperature is required.
  • Page 17 Priority mode toggles off the System Pump (P2) when an Mode 2 (Type H Units Only) indirect call for heat is present. The Indirect DHW Pump This mode selection is for hydronic heating systems with (P3) runs during an indirect call for heat with no “off” delay. single or multiple boilers (Maximum 4 boilers) in primary/ The System Pump (P2) delay “off” as user-defined in the secondary piping configuration with or without Outdoor ADJUST menu, and the integral Boiler / Injector pump (P1) Air Reset (S4) with indirect DHW on the system loop (with is delayed “off” as user-defined in the BOILER menu. The or without priority). The system temperature is controlled System Pump (P2) runs whenever the system is enabled by the System sensor (S3). See Figure 18.
  • Page 18 3.9.7. Domestic Hot Water 3.9.8. Potable Water and Space Heating CAUTION: When this heater is used for both potable NOTE: Soft = 3–4 grains per gallon; Medium = 5–15 grains water and space heating, observe the following to ensure per gallon; Hard = 16–25 grains per gallon. proper operation.
  • Page 19 MODBUS VERSA ENABLE 0-10 VDC / 4-20mA CITY HW SUPPLY WATER TANK FACTORY INSTALLED SENSOR FIELD INSTALLED SENSOR HW RETURN Figure 20. WH Units - Single Water Heater with Tank H Units - Single Boiler with Process Tank (MASTER) MODBUS VERSA VERSA VERSA...
  • Page 20 3.9.9. Automatic Chemical Feeders CAUTION: Power to the heater should be interlocked with the main system pump to make sure the heater All chemicals must be introduced and completely diluted does not fire without the main system pump in operation. into the water before being circulated through the heater.

  • Page 21: Pool/Spa Water Chemistry

    Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool and Spa Types Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C) 7.3-7.4 7.3-7.4 7.6-7.8 Total Alkalinity (ppm) 120-150 120-150 80-120 Calcium Hardness (ppm) 200-300 150-200 200-400 Salt (ppm) 4500 Maximum 4500 Maximum 4500 Maximum Free Chlorine (ppm)* Total Dissolved Solids (ppm) 3000 Maximum** 3000 Maximum** 3000 Maximum** *Free Chlorine MUST NOT EXCEED 5 ppm! **In saltwater chlorinated pools, the total TDS can be as high as 6000 ppm.
  • Page 22 When connecting additional gas utilization equipment 3.11.1. Gas Supply Connection to the gas piping system, the existing piping must be checked to determine if it has adequate capacity for the CAUTION: The heater must be disconnected from the combined load. gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa).

  • Page 23: Electrical Power Connections

    3.12. Electrical Power Connections WARNING: Electrical power connection must be performed by qualified licensed electrician(s) for the voltage being applied. FACTORY WIRING Installations must follow these codes: • National Electrical Code and any other national, state, provincial or local codes or regulations having jurisdiction.

  • Page 24: Field Wiring Connections

    6. Install heater controls, thermostats, or building management systems in accordance with the BLACK CIRCUIT BREAKER applicable manufacturers’ instructions. WHITE 7. Conduit should not be used as the earth ground. GREEN NOTE: A grounding electrode conductor shall be used GROUND to connect the equipment grounding conductors, the equipment enclosures, and the grounded service conductor to the grounding electrode.
  • Page 25 LOCATOR DIMPLES FOR LOW VOLATGE HIGH VOLTAGE CONDUIT WIRING Figure 28. Locator Dimples for Low-Voltage Conduit Figure 27. Wiring Location - High Voltage FIELD WIRING NOTE: Use only stranded copper conductors. TERMINAL BLOCKS ENABLE/ 120V 0 - 10 VDC ALARM EXTERNAL FAN/DAMPER EXTERNAL...
  • Page 26 INDIRECT DHW OVERRIDE. connected to the VERSA on the master. For systems requiring more than 4 connected heaters, an external sequencer such as the Raypak Temp-Tracker Mod+ CAUTION: Sensor and control wiring must NOT be run Hybrid can be used.
  • Page 27 2. Connect the system supply sensor to terminals 6 and 7 on the field wiring strip located on the Master heater. See Figure 29. FACTORY WIRING FIELD WIRING Figure 30. FT_BUS Wire Connection TO PIM MASTER Figure 32. Cascade Master-Pumps 3.

  • Page 28: Venting - General

    NOTE: Raypak strongly recommends installing the vent 3.14.2. Support of Vent Stack system before water piping. This will ensure that the The weight of the vent stack or chimney must not rest on venting system and associated components will fit into the heater vent connection.
  • Page 29 6” Z vent 1005A 2SVEE0690 2SVSRTX06 2SVSA06 6” to 4’ Lengths 1505A 8” Z vent 2SVEE0890 2SVSRTX08 2SVSA08 6” to 4’ Lengths 2005A *D-15 Vent Terminal MUST be ordered from Raypak. Table O. Certified Stainless Steel Terminations and Adaptors - Category IV...

  • Page 30: Vent Terminal Location

    2. The vent must not terminate above public walkways 3.15. Vent Terminal Location due to slip hazard from frozen condensate. 1. Condensate can freeze on the vent cap. Frozen 3. Terminate vent at least 3' (915 mm) above any forced condensate on the vent cap can result in a blocked air inlet located within 10' (3 m).

  • Page 31: Venting Installation Tips

    Combustion Air Heater Venting Combustion Air Inlet Exhaust Configuration Certified Materials Supply Category Material Vertical Venting From Inside Building CAT IV (Non-Direct Venting) Horizontal Through- Stainless Steel the-Wall Venting Galvanized Steel CPVC Vertical Venting From Outside Building Polypropylene* (Direct Venting) Horizontal Through- CPVC the-Wall Venting * Only Centrotherm polypropylene material is approved for use with the XTherm.

  • Page 32: Horizontal Through-The-Wall And Direct

    8' (2.4 m) from and in no case above or below (unless a 4' [1.2 m] OR LESS horizontal distance is maintained) electric meters, gas 2' MIN meters, regulators and relief equipment. (610 mm) The distance of the vent terminal from adjacent buildings, 2' MIN open windows and building openings must comply with (610 mm) the NFGC (U.S.) or B149 (Canada). Gas vents supported only by flashing and extended above the roof more than 5'...
  • Page 33 Figure 38. Horizontal Direct Venting 12" MIN (305 mm) 3.18.2. Termination 8.5" MIN The Raypak sidewall vent termination (sales option D-15) (215 mm) MUST be used and MUST be mounted on the exterior F10022 of the building. The D-15 cannot be installed in a well or CONDENSATE TRAP HOUSEKEEPING PAD below grade. The D-15 must be installed at least 1' (305...

  • Page 34: Direct Vent - Vertical

    Care must be taken during assembly that all joints are The Raypak approved horizontal, stainless steel flue sealed properly and are airtight. direct vent cap MUST be used. The vent terminal must be located NO CLOSER than 12" (305 mm) off the wall. The vent must be installed to prevent the potential ac- cumulation of condensate in the vent pipes.

  • Page 35: Common Venting

    1. Outdoor models must be installed outdoors and 3.20. Common Venting must use the outdoor vent cap available from the Raypak does not support common venting of any product manufacturer (sales order option D-11). under positive vent pressure. Use a variable-speed 2. Periodically check venting system. The heater’s...

  • Page 36: Condensate Treatment

    The condensate from position. the heater is acidic. Its pH is typically between 3.2 and 4.5. Raypak recommends treating the condensate with a If the water temperature drops below 45°F (7°C) on Condensate Treatment kit (Sales order option Z-12). The the Outlet or Inlet sensors, the Boiler pump is enabled.

  • Page 37: Pvc Venting Option (D-32)

    Termination should be accomplished using the adapter FLUE VENT thimble as shown. The adapter thimble is supplied by Raypak as part of the D-32 option. PVC vent assembly instructions 1. Cut pipe ends squarely, removing all burrs and dirt. 2. Dry fit pipe and fittings to be connected for proper fit.

  • Page 38: Centrotherm™ Polypropylene Venting

    Pipes and components system and flue should be commissioned following must be installed with the socket ends to the outlet and Raypak’s instructions. There is no cure time or wait time male ends towards the appliance. required.

  • Page 39: Controls

    4. CONTROLS OPTIONAL (Adjustable) WARNING: Installation, adjustment and service of STANDARD heater controls, including timing of various operating (Fixed) 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.

  • Page 40: Condensate Float Switch

    water level drops below the level of the sensing probe. A 1 - ON 5-second time delay prevents premature lockout due to 2 - OFF temporary conditions such as power fluctuations or air 3 - OFF pockets. Figure 50. Low Water Cut-Off Board BK/Y 4.8.

  • Page 41: Blocked Vent Switch

    After making the setpoint selection press SET button 4.9. Blocked Vent Switch to apply the changes (a confirmation bar will turn green This heater is equipped with a blocked vent pressure showing that value has been applied). Minimum setpoint switch to prevent the operation of the heater when too is 50°F (10°C); maximum is 220°F (104°C) for H models, much of the vent is blocked.
  • Page 42 This adjustment is for various types and sizes of units MIX TRIM H / WH / P MIX -5 to 5 as well as various actuator motor speeds and types supplied by Raypak MIX SPEED H / WH / P MIX FAST <> MED <> SLOW This setting defines speed of response...
  • Page 43 Sets the length of the boiler pump purge FLAME CUR Flame current in micro-amps (µA) MASS Thermal mass recovery see VERSA IC control manual (5000.72). IDENTITY Identifies the unit as boiler, water heater or pool heater IGN TYPE PIM Board type ID CARD Identifies Raypak Identity Card ERROR CODE Current Error Code ERROR HISTORY Up to 15 Error Codes can be logged Table U. Boiler Menu...
  • Page 44 4.10.5. Monitor Menu The Monitor Menu records and displays critical Heater information, such as Cycle times, Run times, and Maximum/ Minimum temperature readings depending on the setup. Item Application Description RUN TIME Burner 1 Burner run time (hours). Press UP/DOWN for 1 sec to clear. Cycles Burner Number of burner cycles. Press UP/DOWN for 1 sec to clear. RUN TIME Boiler pump Boiler pump run time (hours). Press UP/DOWN for 1 sec to clear.
  • Page 45 Select ON to start the function. The setting will time out to OFF after 24 hours or can be set to MAX HEAT OFF again by the user. See VERSA IC control manual (5000.72) for details. P/N 104901 Software number of the Raypak VERSA. Resets to factory settings. Press UP and DOWN for 1 second to show CLR and load factory defaults DEFAULTS to all settings. This will also clear all history.
  • Page 46 Reset Ratio Settings Boil DESIGN The controller uses the four following settings to determine the reset ratio: 1. Heater Start (Boil START) The Boil START temperature is the theoretical heater DESIGN supply water temperature that the heating system requires when the outdoor air temperature equals the Boil START OUT START temperature setting.

  • Page 47: Wiring Diagram For Models 1005A - 2005A

    5. WIRING DIAGRAM FOR MODELS 1005A - 2005A...

  • Page 48: Start-Up

    6. START-UP handle. Never use tools. If the handle will not turn by hand, do not try to repair it; call a qualified service technician. Forced or attempted repair may result in NOTE: The following steps must be performed by a a fire or explosion.

  • Page 49: Start-Up

    CO is above 100 ppm in either minimum supply pressure for natural gas is 4" WC, case, stop running the unit and contact your Raypak recommended supply is 7" WC, minimum supply representative. Visit www.raypak.com for contact pressure for propane gas is 4"...
  • Page 50 6.5.4. Safety Inspection Manifold Gas Pressure Model (High Fire Values) in W.C. 1. Check all thermostats and high limit settings. Natural Gas Propane Gas 2. During the following safety checks leave manometers hooked up, check and record. 1005A -4.6 -6.6 1505A -7.1 -8.0...
  • Page 51 Test point B is a bleedle valve located between the two 5. Open the bleedle valve at test point C and connect automatic gas valve seats. a second rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up Test point C is a bleedle valve located downstream of both of pressure.

  • Page 52: Operation

    9. Replace upper front panel. 9. 1To restart system, follow lighting instructions in the Operation section. 10. 1If heater fails to start, verify the following: 10. 1Check to see that the high limit control is set above a. There are no loose connections or that the the design temperature requirements of the system.

  • Page 53: Heater Faults

    8.3. Heater Faults WARNING: Do not use this appliance if any part has been under water. Improper or dangerous operation may 1. When a fault condition occurs, the controller will result. Contact a qualified service technician to inspect flash a red light on the PIM and display the error code the heater and to repair or replace any part of the heater on the user interface.
  • Page 54 8.4.2. LED Error Code Listing Active errors detected are indicated by LED lights on the PIM. Error Mode LED Flash Code on PIM Recommended Troubleshooting Normal Operation Red LED OFF Red LED Steady ON, Green Check that the proper ID Card is securely connected. Perform a power and ID Card Fault Power LED OFF system reset...

  • Page 55: Maintenance

    9. MAINTENANCE 8.4.3. Sensor Resistance Values 9.1. Suggested Minimum Water Sensor / Outdoor Sensor Maintenance Schedule Water Temperature Resistance (ohms) Regular service by a qualified service agency and 32°F (0°C) 32550 maintenance must be performed to ensure maximum 41°F (5°C) 25340 operating efficiency. 50°F (10°C) 19870 Daily and monthly maintenance as outlined below may be...

  • Page 56: Preventive Maintenance Schedule

    2. Test low water cut-off. Refer to manufacturer’s 10.5% for propane gas. If CO and CO2 are not within instructions. these ranges, stop running the unit and contact your Raypak representative. 3. Check and clean strainer in y-strainer or suction diffuser for debris, if equipped. 6. Check valve coil for 60-cycle hum or buzz. Check for leaks at all valve fittings using a soapy water solution 9.2.

  • Page 57: Filter Maintenance

    Areas where contaminated combustion air commonly 9.3. Filter Maintenance exists: NOTE: Use Raypak replacement filters, for models 0856 • dry cleaning/laundry areas - 1506 kit number 016860F; for models 1756 - 3006 kit • metal fabrication plants number 012552F. •...

  • Page 58: Important Instructions For The Commonwealth Of Massachusetts

    11. IMPORTANT INSTRUCTIONS FOR THE COMMONWEALTH OF MASSACHUSETTS 2. Product Approved side wall horizontally vented gas fueled The Commonwealth of Massachusetts requires compliance equipment installed in a room or structure separate from the with regulation 248 CMR 4.00 and 5.00 for installation of through dwelling, building or structure used in whole or in part for –...
  • Page 59 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.
  • Page 64 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

This manual is also suitable for:

Xtherm 1505aXtherm 2005a

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