Table of Contents
Advertisement
INSTALLATION & OPERATING
ULTRA HIGH EFFICIENCY
Models 2505–4005
Types H, WH & 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. *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.
CATALOG NO. 3400.57A
INSTRUCTIONS
Effective: 08-01-17
Replaces: 08-18-14
P/N 241549 Rev. 2
Advertisement
Table of Contents
Related Manuals for Raypak XTherm Series
Summary of Contents for Raypak XTherm Series
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS ULTRA HIGH EFFICIENCY Models 2505–4005 Types H, WH & 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. *This unit contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans.
- Page 2 Rev. 2 reflects the following: Changes to: Additions: Deletions:...
-
Page 3: Table Of Contents
CONTENTS WARNINGS Condensate Managment BEFORE INSTALLATION Outdoor Installation Product Receipt Controls Model Identification User Interface Ratings and Certifications INTERNAL FLOW DIAGRAM Installations at Elevation WIRING DIAGRAMS Component Locations START-UP General Information Pre Start-up GENERAL SAFETY Start-Up Time/Temperature Relationships in OPERATION Scalds Lighting Instructions INSTALLATION... -
Page 4: Warnings
WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. -
Page 5: Before Installation
Standards: at www.raypak.com. • ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Thank you for purchasing a Raypak product. We hope Hot Water Boilers you will be satisfied with the high quality and durability • CAN 3.1 - latest edition, Industrial and Commercial of our equipment. -
Page 6: Component Locations
Component Locations NOTE: External injection pump not shown. Pump is shipped loose for field installation by others. GAS TRAIN BLOWER GAS VALVE CONTROL BOX CONDENSING HEAT EXCHANGER ASSY 2-WAY VALVE (CWP) FLUE GAS ANALYZER PRIMARY TEST PORT HEAT EXCHANGER PRIMARY PUMP FRONT OF HEATER PRESSURE RELIEF VALVE... -
Page 7: General Information
Hot Water Heaters ONLY. For sanitary rinse appli- ca-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. Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat. -
Page 8: Time/Temperature Relationships In Scalds
INSTALLATION NOTE: When this water heater is supplying general purpose hot water for use by individuals, a thermostatically-controlled mixing valve for reducing Installation Codes point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed Installations must follow these codes: plumber or the local plumbing authority for further information. -
Page 9: Equipment Base
Equipment Base Top View The heater should be mounted on a level, structurally sound surface. The heater is approved for installa- tion 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. -
Page 10: Combustion And Ventilation Air
Minimum Clearance Minimum When installed according to the listed minimum from Combustible Service Heater Side Surfaces Clearance clear-ances from combustible construction, these heaters can still be serviced without removing per- Rear 12" 36" manent structural construction around the heater. However, for ease of servicing, a clearance of at least Front Open 30"... - Page 11 Clearance above grade, veranda, porch, deck, or balcony Fig. 8: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations 1 ft (30 cm) 1 ft (30 cm) Clearance to window or door that may be 4 ft (1.2m) below or to side 3 ft (91 cm) of opening...
-
Page 12: Conventional Combustion Air Supply
RTV (not supplied). All ducting shall be self-supporting. 3. In cold climates, and to mitigate potential freeze- up, Raypak highly recommends the installation of a motorized sealed damper to prevent the circulation of cold air through the heater during non-operating hours. - Page 13 an additional room(s) of sufficient volume so that the a. 1 in. per 3,000 BTUH (740 mm per kW) of com-bined volume of all spaces meets the criteria for the total input rating of all equipment located a room large in comparison (NFGC). The total input of in the enclosure, and all gas utilization equipment installed in the combined space shall be considered in making this determina-...
-
Page 14: Water Piping
See Table F and Table G. rantable failure. When required, Raypak recommends the boiler be isolated from the system piping prior to Relief Valve Piping flushing or cleaning, using any cleaning agent. -
Page 15: Hydronic Heating
XTherm heaters are equipped with an integral cold Drywell water protection system, which uses a proportional Fitting two-way valve and injection pump to modulate the System return water flow, forcing the boiler pump to pull water Thermal Sensor from the boiler outlet to the inlet during operation. Paste This feature allows the system to achieve and main- tain a specific inlet temperature target. - Page 16 50°F to 200°F. Feedwater Regulator Raypak recommends that a feedwater regulator be Fig. 15: Hydrolic Piping above radiation level must be provided with a low wa-ter cut-off device (sales order option F-10). This...
-
Page 17: Applications & Modes
Three-Way Valves Three-way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used. Raypak heaters are high-recovery, low-mass Fig. 17: MODE 1 - Single Boiler with heaters which are not subject to thermal shock. - Page 18 Mode 2 (Type H Units Only) This mode selection is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4) with indirect DHW on the system loop (with or without priority). The system temperature is controlled by the System sensor (S3).
-
Page 19: Domestic Hot Water
the Indirect Supply sensor (S6) and the Target Max setting when using the Indirect DHW sensor (S5). The Boiler/Injection Pump (P1) runs during all heat calls regardless of priority. The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The Boiler/Injection Pump (P1) is delayed “off”... -
Page 20: Pool Heating
To complete installation of the heater, the system sen- NOTE: WH units will operate to a maximum tank sor must be installed in the return water line, upstream temperature of 150°F. For setpoints above 150ºF, of the heater. The supplied electronic operating con- an “H”... -
Page 21: Gas Supply
Potable Water and Space Heating adjacent 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- CAUTION: When this heater is used for both potable to-inches regulator must be installed to reduce the gas water and space heating, observe the following to supply pressure if it is higher than noted above. -
Page 22: Electrical Power Connections
Gas Supply Pressure CAUTION: For proper operation, no more than a 30% drop in gas supply pressure from no-load A minimum of 4.0 in. WC and a maximum of 10.5 in. to full-load conditions is acceptable. Under no WC upstream gas pressure is required under load and circumstances should the pressure be outside the no-load conditions for natural gas. -
Page 23: Field Wiring Connection
System Pump and Indirect DHW Pump as required for Check the power source: the system depending on the mode selected within the VERSA IC control system. AC = 108 VAC Minimum, 132 VAC Maximum BC = 108 VAC Minimum, 132 VAC Maximum AB = 216 VAC Minimum, 264 VAC Maximum Fig. - Page 24 Field Wiring Connection 2. Where using a System Sensor (S3), connect the sensor wires to the terminals marked SYSTEM SENSOR (See Fig. 29). CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause 3. Use a minimum of 18 AWG wire for runs up to 150 im-proper and dangerous operation.
- Page 25 FIELD WIRING BLOCKS FACTORY WIRING Fig. 29: Low Voltage Field Wiring Wiring the Indirect Sensor NOTE: Alternately, a thermostat contact closure can be used in lieu of the sensor for indirect operation. 1. An indirect sensor connection is not required if an Connect the thermostat to the terminals marked indirect water heater is not used in the installation.
- Page 26 Direct Drive (UP) input and a Target Temperature For systems requiring more than 4 connected (DOWN) setpoint. boilers, an external sequencer such as the Raypak Temp-Tracker Mod+ Hybrid can be used. 3. For a 4-20mA application, refer to the VERSA IC manual (Cat.
- Page 27 (120 volt or greater) wir- 11 and 12 on the field wiring strip located on the ing. Raypak recommends that the total maximum Master boiler (See Fig. 29). This connection must be provided through dry contacts closure.
-
Page 28: Venting
Alarm Connection Category III – A heater which operates with a positive vent pressure and with a vent gas temperature that An alarm annunciator or light may be connected to avoids excessive condensate production in the vent. the alarm contacts on the field wiring terminal strip. The Alarm Contacts are 3A rated dry contacts on a Category IV –... - Page 29 10” Z Vent 2SVEE1090 2SVSRTX10 2SVDSA10 3005 6” to 36” Lengths 3505 12” Z Vent 4005 2SVEE1290 2SVSRTX12 2SVDSA12 6” to 36” Lengths *D-15 Vent Terminal MUST be ordered from Raypak Table N: Certified Stainless Steel Terminations and Adaptors - Category IV...
- Page 30 Use only the special gas vent pipes listed for use 5. The bottom of the vent terminal and the air intake with Category IV gas burning heaters, such as the shall be located at least 12 in. above grade, includ- AL29-4C stainless steel vents offered by Heat Fab ing normal snow line.
-
Page 31: Venting Installation Tips
5. Terminate vent at least 6 ft away from adjacent the verandah, porch or deck is fully open on a walls. mini-mum of two sides beneath the floor, and the distance between the top of the vent termination 6. DO NOT terminate vent closer than 5 ft below roof and the underside of the verandah, porch or deck overhang. - Page 32 Fig. 34: Vertical Venting Raypak does not support common venting under positive-pressure conditions. Use a variable-speed CAUTION: A listed vent cap terminal suitable for connection to the Cat IV vent materials, adequately extractor to draw the stack to negative pressure.
- Page 33 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 1” MINIMUM (TYP) an existing heater, the vent system MUST be veri- fied to be of the correct size and of Category IV UL Listed stainless steel vent material construction.
- Page 34 Horizontal Through-the-Wall Direct Venting (Category IV) D-15 D-15 Fig. 39: Horizontal Through-the-Wall Direct Venting Fig. 37: Horizontal Through-the-Wall 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.
- Page 35 1 ft above ground level install a condensate drain in the venting system will and above normal snow levels. The Raypak-approved void all warranties on this heater. horizontal, stainless steel flue direct vent cap must be used (sales order option D-15).
-
Page 36: Condensate Managment
3. The vent must be insulated through the length of from the boiler is acidic. Its pH is typically between 3.2 the horizontal run. and 4.5. Raypak recommends treating the condensate with a Condensate Treatment kit (Sales order option Termination Z-12). -
Page 37: Outdoor Installation
Outdoor Installation NOTE: The vent cap and air intake hood must be furnished by the heater manufacturer in accordance Units must not be installed where the condensate can with its listing (sales order option D-11). freeze. Units installed outdoors must be vented with listed vent material per the following instructions and NOTE: Condensate can freeze on the vent cap. - Page 38 To reset a high limit lock-out, press and release the Ignition Control Functions RESET button located on the user interface. When there is a call for heat, and all safeties are High Limit—Auto Reset (Optional) closed, then the combustion air blower starts to purge air from the combustion chamber.
- Page 39 High & Low Gas Pressure Switches Proportional Two-Way Valve (Optional) H model The optional low gas pressure switch mounts upstream of the gas valve (on the inlet flange to the gas valve) MASTER and is accessible through the removable access pan- els on the side or front of the heater to reset the gas SLAVE NORMAL pressure switch, as necessary.
-
Page 40: User Interface
end of the actuator motor. This will allow the motor to rotate into alignment with the bracket. Align the motor with the valve mounting bracket. With the motor and bracket aligned, slide the lock bracket forward to secure the motor to the anti-ro- Fig. - Page 41 This adjustment is for various types and sizes of units as well as MIX TRIM H / WH / P MIX -5 to 5 various actuator motor speeds and types supplied by Raypak MIX SPEED H / WH / P MIX SLOW <> MED <> FAST This setting defines speed of response.
- Page 42 Flame current in micro-amps (µA) MASS Thermal mass recovery see VERSA IC manual, catalog 5000.72. IDENTITY Identifies the unit as boiler, water heater or pool heater ID CARD Identifies Raypak Identity Card ERROR CODE Current Error Code Table T: Boiler Menu...
- Page 43 Monitor Menu The Monitor Menu records and displays critical Boiler 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.
- Page 44 MAX HEAT be set to OFF again by the user. (See VERSA IC Manual 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 DEFAULTS factory defaults to all settings.
-
Page 45: Internal Flow Diagram
RESET RATIO (See Fig. 52) The control uses the four following settings to determine the reset ratio: Boiler Start (Boil START) The Boil START temperature is the theoretical boiler supply water temperature that the heating system requires when the outdoor air temperature equals the OUT START temperature setting. -
Page 46: Wiring Diagrams
WIRING DIAGRAM - Models 2505–4005 For a full-size drawing visit: www.raypak.com/commercial/wiring_diagrams... -
Page 47: Start-Up
START-UP • Do not try to light any appliance. • Do not touch any electrical switch; do not use any NOTE: The following steps must be performed by a telephone in your building. factory-trained technician. • Immediately call your gas supplier from a neigh- bor’s telephone. -
Page 48: Start-Up
Start-Up WARNING: Do not turn on gas at this time. NOTE: The values in Tables U and W represent the between: conditions when the heater is at full firing rate at sea level. L1 - Ground (≈120 VAC) L2 - Ground (≈120 VAC) NOTE: Pressure and combustion data are provided with the heater. - Page 49 Blower Check CAUTION: Special manifold and air settings may be required. 1. Check blower suction using the manometer attached to the air pressure tee as shown in User Test Fig. 55, with the heater firing at 100% input. The reading should be as noted in Table W for both Set DIP switch #1 on the VERSA IC control to “ON”.
- Page 50 Leak Test Procedure: Dual-Seat Gas Valve Safety Inspection Proper leak testing requires three pressure test points 1. Check all thermostats and high limit settings. in the gas train. Remove the upper front panel and swing the front J-box out of the way to access the gas 2.
-
Page 51: Operation
the PIM, first set DIP switch #8 on the PIM to the ON position. This will activate a Commission Test Mode which will turn on the amber Alarm/ Test LED on the PIM. The fixed high limit setting is temporarily overridden to match the setpoint potentiometer position on the PIM. -
Page 52: Lighting Instructions
e. Incoming dynamic gas pressure to the gas valve is NOT less than 4.0 in. WC for natural Lighting Instructions gas or propane gas. 1. Before operation, make sure you have read all of To Turn Off Gas To Appliance the safety information in this manual. - Page 53 2. Note the error code, either through the flash code WARNING: When servicing or replacing any on the PIM and/or from the Toolbox menu on the components of this unit be certain that: user interface, and reference the explanation of •...
- Page 54 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 sys- ID Card Fault Power LED OFF tem reset.
-
Page 55: Maintenance
MAINTENANCE Sensor Resistance Values Suggested Minimum Water Sensor / Outdoor Sensor Maintenance Schedule Water Temperature (°F) Resistance (ohms) 32550 Regular service by a qualified service agency and maintenance must be performed to ensure maximum 25340 operating efficiency. 19870 Daily and monthly maintenance as outlined below may 15700 be performed by onsite maintenance staff. -
Page 56: Preventative Maintenance Schedule
Weekly 3. Check that area is free from combustible mate- rials, gasoline, and other flammable vapors and liquids. For low-pressure heaters, test low-water cut-off device. (With heater in pre-purge, depress the low water cut- 4. Check air filter and replace as necessary. off test button. -
Page 57: Filter Maintenance
7. Test safety/safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV. Filter Maintenance • Inspect quarterly • Replace as needed. The recommended interval is NOTE: Use Raypak replacement filters, kit number 014492F. once per year. -
Page 58: Appendix
APPENDIX Areas where contaminated combustion air commonly exists: Inside Air Contamination • dry cleaning/laundry areas All heaters experience some condensation during • metal fabrication plants start-up. The condensate from flue gas is acid- • beauty shops ic. Combustion air can be contaminated by certain •... -
Page 59: Important Instructions For The Commonwealth Of Massachusetts
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance (b) EXEMPTIONS: The following equipment is exempt from with regulation 248 CMR 4.00 and 5.00 for installation of 248 CMR 5.08(2)(a)1 through 4: through – the – wall vented gas appliances as follows: 1. -
Page 60: Start-Up Checklist
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. - Page 66 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
Need help?
Do you have a question about the XTherm Series and is the answer not in the manual?
Questions and answers