Raypak X-THERM 1005–2005 Installation & Operating Instructions Manual

Raypak X-THERM 1005–2005 Installation & Operating Instructions Manual

1005–2005 types h, wh & whp
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INSTALLATION & OPERATING
ULTRA HIGH EFFICIENCY
Models 1005–2005
Types H, WH & WHP
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. 3400.55A
California Hot Water Supply, Inc.
INSTRUCTIONS
Effective: 02-24-09
L
W
Replaces: 09-24-08
(800) 249-7244
P/N 241344 Rev. 2
1

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  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS ULTRA HIGH EFFICIENCY Models 1005–2005 Types H, WH & WHP 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: Fig. 1, 2 and 3 on page 6; the Relief Valve Installation and Piping section on page 14; Fig. 14–16 on page 16; Fig. 17 on page 17; Table I on page 18; step 6 of the Heater Sequence of Operation sec- tion on page 36;...
  • Page 3: Table Of Contents

    CONTENTS WARNINGS Controls Pay Attention to These Terms Heater Sequence of Operation BEFORE INSTALLATION WIRING DIAGRAMS Product Receipt Models 1005 & 1505 Model Identification Model 2005 START-UP Ratings and Certifications Installations at Elevation Pre Start-up Component Locations Pre Start-up Check General Information Initial Start-up Time/Temperature Relationships...
  • 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

    If, after reviewing this manual, you still have questions turing series. which this manual does not answer, please contact your local Raypak representative or visit our website at Ratings and Certifications www.raypak.com. Standards: Thank you for purchasing a Raypak product.
  • Page 6: Component Locations

    Component Locations Fig. 1: Component Locations – Right Side Fig. 3: Component Locations – Rear General Information MBTUH Vent Size Water Conn. Model Input (in.) Conn. (NPT) (NPT) Max. Min. Flue Intake 1005 2-1/2 1-1/4 1505 1500 2-1/2 1-1/4 2005 1999 2-1/2 Table A: Basic Data...
  • Page 7: Time/Temperature Relationships In Scalds

    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 temperature control is 125°F.
  • Page 8: Installation

    Equipment Base 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 The heater should be mounted on a level, structurally is set at 120°F when shipped from the factory (Mode 3 sound surface.
  • Page 9: Combustion And Ventilation Air

    Roof water drainage must be diverted away from heaters installed under overhangs. Min. Clearance Minimum Heater from Combustible Service Side Surfaces Clearance Rear 12” 36” Right Side 1” 24” Left Side 1” 1” Unobstructed 10” 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...
  • Page 10 Fig. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening;...
  • Page 11 Combustion Air Filter Inside Air Intake This heater is supplied with an integral combustion air Cover Panel 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).
  • Page 12 Debris Screen 13. 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.
  • Page 13: Conventional Combustion Air Supply

    2. One permanent opening, commencing within 12 Conventional Combustion Air in. (305 mm) of the top of the enclosure, shall be Supply permitted where the equipment has clearances of at least 1 in. (25 mm) from the sides and back and U.S.
  • Page 14: Water Piping

    160 psi operating pressure. piping between the load loop and the heater loop, However, Raypak does recommend hydrostatic test- the operating conditions and the size of the heater. ing of the piping connections to the heater and the rest See Table G on page 16.
  • Page 15: Hydronic Heating

    Feedwater Regulator the heater. NEVER use petroleum-based stop-leak compounds. Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the To perform hydrostatic test: highest point of the system. Install a check valve or back flow device upstream of the regulator, with a 1.
  • Page 16: Domestic Hot Water

    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) <80' equiv. 80-200' equiv. (°F) <80' equiv. 80-200' equiv. (°F) <80' equiv. 80-200' equiv. 2"NPT 2 1/2"NPT 2"NPT...
  • Page 17 NOTE: If local codes require a vacuum relief valve, CAUTION: Power to the heater should be acquire locally install valve interlocked with the main system pump to make sure manufacturer’s instructions. the heater does not fire without the main system pump in operation.
  • Page 18 Tank Model 1005 / t f Minimum Tubing Size Med Sup. Hard Sup Minimum Tubing Size / t f Minimum Tubing Size Temp (°F) Temp (°F) 80-200' equiv. Temp (°F) Temp (°F) Temp (°F) <80' equiv. 80-200' equiv. Sup. Temp (°F) <80' equiv.
  • Page 19: Gas Supply

    Raypak water heaters can operate lime/scale-free 1/2 psi (3.45 kPa). Relieve test pressure in the gas using potable water with a hardness not exceeding 25...
  • Page 20: Electrical Power Connections

    1-1/4” NPT 1-1/2” NPT 2” NPT 2-1/2” NPT Model 1005 1505 2005 Natural Gas – 1,000 BTU/ft , 0.60 specific gravity at 0.5 in. WC pressure drop Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. WC pressure drop Table J: Maximum Equivalent Pipe Length Gas Supply Pressure •...
  • Page 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 = <1 VAC Maximum Fig.
  • Page 22: Field Wiring Connection

    temperature that avoids excessive condensate pro- NOTE: A grounding electrode conductor shall be duction in the vent. used connect equipment grounding conductors, the equipment enclosures, and the Category II – A heater which operates with a non-pos- grounded service conductor to the grounding itive vent static pressure and with a vent gas electrode.
  • Page 23 Combustion Exhaust Heater Venting Certified Combustion Air Air Supply Configuration Category Materials Inlet Material Vertical Venting From Inside Building (Non-Direct Venting) Horizontal Through- CAT IV the-Wall Venting AL29-4C Vertical Galvanized Steel Venting From Outside Building (Direct Venting) Horizontal Through- CPVC the-Wall Venting Table L: Venting Category Requirements from combustible materials.
  • Page 24: Venting Installation Tips

    5. Terminate vent at least 6 ft away from adjacent 8. Underneath a verandah, porch or deck, unless the walls. verandah, porch or deck is fully open on a mini- mum of two sides beneath the floor, and the 6. DO NOT terminate vent closer than 5 ft below roof distance between the top of the vent termination overhang.
  • Page 25 Vertical Vent Air Inlet Certified Combustion Air Model Vent Size Height (ft) Max. Length* (ft) Vent Intake Pipe (in.) Material Material Min. Max. 6” Ø 8” Ø 10” Ø Galvanized 1005 100** Steel, Category IV PVC, (AL29-4C) 1505 ABS, 85** CPVC 2005 Vent lengths are based on a lateral length of 2 ft.
  • Page 26 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 27 Horizontal Through-the-Wall and Direct Venting (Category IV) Fig. 27: Horizontal Through-the-Wall Direct Venting Fig. 25: 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 28 The direct vent cap Fig. 28: Direct Vent - Vertical must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved CAUTION: This venting system requires the stainless steel flue direct vent cap must be used (sales installation of a condensate drain in the vent piping order option D-15).
  • Page 29: Outdoor Installation

    tion in any arrangement that does not exceed the Outdoor Installation lengths shown in Tables M and O. The vent cap is not considered in the overall length of the venting system. XTherm heaters are certified for outdoor operation in non-freezing conditions only.
  • Page 30: Controls

    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.
  • Page 31 Operating Modes Mode 4 – Not recommended. Mode 5 – Outdoor reset using primary/secondary pip- Mode 1 – Not recommended. ing. The heater is operated as in Mode 2. However, the target temperature is based on outdoor reset. See Fig. Mode 2 –...
  • Page 32 2-10 VDC 4-20 mA* Boiler Target --- (OFF) --- (OFF) 50°F MODULATING 71.3°F 92.5°F 113.8°F 135°F 156.3°F 177.5°F 198.8°F 220°F *Requires a 500Ω resistor. Table Q: 2-10 VDC or 4-20 mA External Input Signal *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig.
  • Page 33 Item Modes Default Setting Range 1, 2 160°F OFF, 70 to 220°F Boil Target 160°F OFF, 70 to 190°F 4, 5, 6, 7 180°F OFF, 70 to 220°F 1, 2, 4, 5, 6, 7, 8 200°F OFF, 120 to 225°F Boil Max 180°F OFF, 120 to 190°F...
  • Page 34 Definitions 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 NOTE: The defined terms are not active in all 50°F (10°C). An input voltage of 10 VDC corresponds modes of control operation.
  • Page 35 Modulation Offset Signal Displays the current status of the control’s The Raypak modulating temperature control uses a Modulating inputs, outputs Liquid Crystal Display (LCD) as a method of supply- Control and operation ing information. The LCD is used to setup and monitor...
  • Page 36: Heater Sequence Of Operation

    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. Fig. 36: Ignition Module The optional single-try ignition module will lock out after failing to light one time.
  • Page 37 High Limit—Auto Reset (Optional) Code Condition This heater may be equipped with an optional adjust- System OK; No faults present able auto reset high limit temperature device. Possible control fault; Check power The optional adjustable auto reset high limit is located 1 Flash Low air inside the heater junction box.
  • Page 38 Modulating Temperature Control High & Low Gas Pressure Switches (Optional) This heater is equipped with a Raypak modulating temperature control. Refer to information starting on The optional low gas pressure switch connection page 31 for information on the setting and use of this mounts upstream of the gas valve (on the inlet flange control.
  • Page 39 UDB Diagnostic Board Air Pressure Switch This heater is equipped with a diagnostic board which This heater is equipped with an air pressure switch to will indicate faults as they occur. Refer to the Trouble- prove the operation of the blower before allowing the shooting section for instructions on accessing, ignition control to begin a trial for ignition.
  • Page 40: Wiring Diagrams

    WIRING DIAGRAMS - Models 1005 & 1505 California Hot Water Supply, Inc. (800) 249-7244...
  • Page 41: Model 2005

    Model 2005 California Hot Water Supply, Inc. (800) 249-7244...
  • Page 42: Start-Up

    START-UP 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. Pre Start-up WHAT TO DO IF YOU SMELL GAS: Filling System (Heating Boilers) •...
  • Page 43: Initial Start-Up

    Initial Start-up Required tools TO BURNER • (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 Fig.
  • Page 44 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 read accurately heater manometer by connecting one end to the blower environment. Blower amp draw readings are for suction pressure tee (attached to the negative side reference only.
  • Page 45 CAUTION: A listed vent cap terminal suitable for NOTE: For extractor sizing, typical CO levels are connection to the Cat IV vent materials, adequately 8.5% for natural gas and 9.5% for propane gas and sized, must be used to evacuate the flue products flue temperature of 150°...
  • Page 46 dle valve to the test point B bleedle valve and Post Start-Up Check open the upstream manual gas valve. Make sure that test point A & B bleedle valves have been Check off steps as completed: opened so as to allow gas to flow. This will bring gas pressure to the second valve seat.
  • Page 47: Operation

    11. Check to see that the high limit control is set times (one time on optional single-try ignition mod- above the design temperature requirements of the ule). If flame is not sensed, lockout will system. For multiple zones: Check to make sure commence.
  • Page 48 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 49: Troubleshooting

    TROUBLESHOOTING Does the power switch provide Check the switch and/or power to the control panel? line voltage Step 1 Is there a Call For Unit is in standby mode. Heat? Reattach. Step 2 Is Disable connection intact? Check and correct power Is there 120VAC at the blower or connections at main terminal Does the combustion air...
  • Page 50: Maintenance

    2. Visually inspect venting system for proper func- Daily tion, deterioration or leakage. Ensure that condensate drain is inspected and ensure that 1. Check gauges, monitors and indicators. condensate is being directed to appropriate con- densate management system or drain, as required 2.
  • Page 51: Appendix

    4. Conduct a combustion test at full fire. Carbon diox- start-up. The condensate from flue gas is acidic. ide should be 8.5 to 9.0% at full fire for natural gas, Combustion air can be contaminated by certain vapors and between 9.5 to 10.0% for propane gas. in the air which raise the acidity of the condensate.
  • Page 52: 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 53: Warranties

    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.
  • Page 54 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.
  • Page 55 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 56 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A. California Hot Water Supply, Inc. (800) 249-7244...

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