Raypak XTherm 2505 Installation & Operating Instructions Manual Download Page 6

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PRIMARY

HEAT EXCHANGER

CONDENSING

HEAT EXCHANGER ASSY

GAS TRAIN

BLOWER

GAS VALVE

CONTROL BOX

FRONT OF HEATER

PRESSURE

RELIEF VALVE

T & P GAUGE

2-WAY VALVE (CWP)

FLUE GAS ANALYZER

TEST PORT

PRIMARY PUMP

WATER

INLET

4” GROOVED

CONDENSATE

DRAIN

1-1/4 NPT PVC

FLUE OUTLET

RATING

PLATE

AIR INLET

FILTER

GAS SUPPLY

CONNECTION

2-1/2 NPT

HIGH VOLTAGE

ELECTRICAL

CONNECTIONS

WATER OUTLET

4” GROOVED

Component Locations

Panels omitted for clarity

Fig. 1: Component Locations – Side

Fig. 3: Component Locations – Rear

VERSA IC

LOW VOLTAGE

SWITCH

HIGH VOLTAGE

SWITCH

PIM

Panels omitted for clarity

Fig. 2: Component Locations – Front

NOTE:

External injection pump not shown. Pump is

shipped loose for field installation by others.

Summary of Contents for XTherm 2505

Page 1: ...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...

Page 2: ...2 Rev 2 reflects the following Changes to Additions Deletions ...

Page 3: ...ating 20 Gas Supply 21 Electrical Power Connections 22 Field Wiring Connection 23 Venting 28 Venting Installation Tips 31 Venting Configurations 31 Condensate Managment 36 Outdoor Installation 37 Controls 37 User Interface 40 INTERNAL FLOW DIAGRAM 45 WIRING DIAGRAMS 46 START UP 47 Pre Start up 47 Start Up 47 OPERATION 52 Lighting Instructions 52 To Turn Off Gas To Appliance 52 TROUBLESHOOTING 52 M...

Page 4: ...connect switch may be required to de energize the equipment before servicing CAUTION This heater requires forced water circulation when the burner is operating See tables F and G for flow rate information Severe damage will occur if the heater is operated without proper water flow circulation CAUTION If this heater is to be installed above radiation level it must be provided with a low water cut o...

Page 5: ...ard warranties 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 2505 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 ...

Page 6: ...PVC FLUE OUTLET RATING PLATE AIR INLET FILTER GAS SUPPLY CONNECTION 2 1 2 NPT HIGH VOLTAGE ELECTRICAL CONNECTIONS WATER OUTLET 4 GROOVED Component Locations Panels omitted for clarity Fig 1 Component Locations Side Fig 3 Component Locations Rear VERSA IC LOW VOLTAGE SWITCH HIGH VOLTAGE SWITCH PIM Panels omitted for clarity Fig 2 Component Locations Front NOTE External injection pump not shown Pump...

Page 7: ...ER FRONT OF HEATER OUTDOOR AIR COVER SHOWN Top panel blower and gas train omitted for clarity Fig 4 Component Locations Top Max Min Flue Intake 2505 2501 200 10 10 3005 3000 240 10 10 3505 3500 280 10 12 4005 4000 560 12 12 Model No MBTUH Input Vent Size in 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 sinc...

Page 8: ...To determine the water temperature being delivered turn on a hot water fau cet and place a thermometer in the hot water stream and read the thermometer 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 Temp ...

Page 9: ...e ground use the hole pattern shown in Fig 5 following local codes Clearances Indoor Installations 9 Heater Side Minimum Clearance from Combustible Surfaces Minimum Service Clearance Floor 0 0 Rear 12 36 Right Side 1 24 Left Side 1 1 Top 0 10 Front Open 30 Vent 1 1 DO NOT install on carpeting Table C Clearances Indoor Installations Fig 6 Minimum Clearances from Combustible Surfaces Indoor and Outd...

Page 10: ...r 12 36 Front Open 30 Access Side 1 24 Opposite Side 1 1 Top Unobstructed 10 Vent Termination 12 12 AIR FILTER ACCESS PANEL BOTH SIDES Fig 7 Outdoor Air Intake When installed according to the listed minimum clear ances from combustible construction these heaters can still be serviced without removing per manent structural construction around the heater However for ease of servicing a clearance of ...

Page 11: ...below or to side of opening 1 ft 30 cm above opening 3 ft 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t M Clearance under veranda porch deck or balcony 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel G...

Page 12: ...d by an opening s for ventilation air within 12 of the highest practical point communicating with the outdoors The total cross sectional area of these openings shall be at least 1 square inch free air space per 20 000 BTUH 111 mm2 per kW of total input rating of all equipment in the room when the opening is communicating directly with the outdoors or through vertical duct s The total cross section...

Page 13: ...ith 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 13 a 1 in 2 per 3 000 BTUH 740 mm2 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 Canadian Installation...

Page 14: ... in such a way that ensures the sensor bulb is in the flow path Raypak Integral Cold Water Protection mm2 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 ...

Page 15: ...ow 50ºF Continuous operation below 50ºF return water temperature may cause operational issues for the unit as well as temperature control insta bility XTherm WH models are equipped with pumps and proportional valves which are constructed with materials appropriate for domestic hot water operating conditions Contact your local representative or the factory for applications assistance Hydronic Heati...

Page 16: ...tems have unique levels of operating diversity that must be accounted for in the system design The system should always include adequate system flow in excess of the connected boiler flow for proper operation Where the system flow may drop below the connected boiler flow a buffer decoupler may be needed Failure to design for adequate flow i e bypasses 3 way control valves flow limiting balance dev...

Page 17: ...library at www raypak com Min System Flow 120 of Max Boiler Flow Mode 1 Type H Units Only Sys Ret Temp F Model 2505 30F Sys Delta T Model 3005 30F Sys Delta T Model 3505 32F Sys Delta T Model 4005 33F Sys Delta T Supply Temp F Sys Flow GPM Pipe max eq ft Supply Temp F Sys Flow GPM Pipe max eq ft Supply Temp F Sys Flow GPM Pipe max eq ft Supply Temp F Sys Flow GPM Pipe Max eq ft 3 4 3 4 3 4 3 4 60 ...

Page 18: ...boosted to Target Max when using the Indirect DHW sensor S5 during an indirect call for heat Priority mode toggles off the System Pump P2 when an indirect call for heat is present The Boiler Injection Pump P1 runs during any call for heat The Indirect DHW Pump P3 runs during an indirect call for heat with no off delay The Boiler Injection Pump P1 is delayed off as user defined in the BOILER menu a...

Page 19: ... hd Soft 2 4 Med 5 15 Hard 16 25 Pipe max eq ft 190gpm 2 1ft hd Supply Temp F Sys Flow GPM Supply Temp F Sys Flow GPM Supply Temp F Sys Flow GPM Supply Temp F Sys Flow GPM Supply Temp F Sys Flow GPM Supply Temp F Sys Flow GPM 3 4 3 4 80 144 74 139 81 137 83 100 350 148 84 139 97 139 97 110 100 144 108 139 122 137 128 100 350 148 119 139 146 139 146 110 120 149 164 149 164 149 164 100 350 150 190 1...

Page 20: ...n is mandatory for all Pool Applications 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 poolstat Install sensor in supply to pool as shown in Fig 22 For data on acceptable pool chemistry see Table I NOTE The allowable concentrations of salt and of ...

Page 21: ...recommend ed that a union be installed in the gas supply piping DANGER Make sure the gas on which the heater will operate is the same type as specified on the heater s rating plate 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 to inches regulator must be installed to reduce the gas supply...

Page 22: ...5 30 45 80 200 400 600 4005 25 35 65 160 300 400 CAUTION For proper operation no more than a 30 drop in gas supply pressure from no load to full load conditions is acceptable Under no circumstances should the pressure be outside the listed operational range Model No Manifold Gas Pressure High Fire Values in WC Natural Gas Propane Gas 2505 4 0 6 7 3005 6 5 8 5 3505 6 1 9 1 4005 4 5 8 2 Gas Supply P...

Page 23: ...und is proven See Fig 26 Fig 26 Multi meter Check the power source AC 108 VAC Minimum 132 VAC Maximum BC 108 VAC Minimum 132 VAC Maximum AB 216 VAC Minimum 264 VAC Maximum Making the Electrical Connections Refer to Fig 24 27 1 Verify that circuit breaker is properly sized by referring to heater rating plate A dedicated circuit breaker should be provided 2 NOTE Current draw noted on rating plate do...

Page 24: ...eration after servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is dis con nected to avoid potential serious injury or damage to components 2 If using an Outdoor Sensor option B 32 con nect the sensor wires to the terminals marked OUTDOOR SENSOR see Fig 29 Caution should be used to ensure neither of these termi nals becomes connected to ground 3 Use a minimum 18 AWG wire for r...

Page 25: ... DHW pump whenever the Indirect DHW call is active The Boiler pump will also be activated based on the Indirect DHW piping configuration setting Consult the VERSA IC manual Cat 5000 72 for additional configurations 3 Connect the indirect tank sensor to the terminals marked INDIRECT DHW SENSOR see wiring diagram Caution should be used to ensure neither of these terminals becomes connected to ground...

Page 26: ...Management system or other auxiliary control signal to the terminals marked 0 10V on the field wiring terminals see Fig 29 Caution should be used to ensure that the 0 10V connection does not create a short to ground Wiring the Cascade System Communication Bus 1 Designate the primary boiler as the master boiler boiler1 by leaving DIP switch 2 on the VERSA in the ON position All other VERSA controls...

Page 27: ...n 5 Connect the Enable Disable wiring to terminals 11 and 12 on the field wiring strip located on the Master boiler See Fig 29 This connection must be provided through dry contacts closure run communication cables parallel with or close to or against high voltage 120 volt or greater wir ing Raypak recommends that the total maximum length of each set of communication bus cables not exceed 200 feet ...

Page 28: ...he appliance categorization and suitability of a vent material for application on a Category IV vent system Using improper venting materials can result in personal injury death or property damage CAUTION Condensate drains for the vent piping are required for installations of the XTherm Follow vent manufacturer instructions for installation and loca tion of condensate drains in the vent Condensate ...

Page 29: ... use a specific vent starter adapter supplied by the vent manufacturer WARNING Use only the materials vent systems and terminations listed in Table P DO NOT mix vent systems of different types or manufacturers unless listed in this manual Failure to comply could result in severe personal injury death or substantial property damage NOTE The XTherm heater is supplied with a vent connector that MAY r...

Page 30: ...ock 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 4 ft hori zontally from or 1 ft above 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 ...

Page 31: ...der or near elbows 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 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 fl...

Page 32: ...raced to withstand snow and wind loads 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 P provides boiler discharge vent pressures at vent pressure switch and volumes of flue products at full fire for the calculation of appropriate vent and extractor sizing for common v...

Page 33: ...ne gas and flue temperature of 350 F at 100 firing rate mea sured at a test port 12 above the flue collar NOTE Data for 100 firing rate Table P Typical Vent Pressure and Volume of Flue Products Fig 36 Typical Common Venting Model No Vent Size in Vent Pressure in WC Volume of Flue Products CFM 2505 10 0 2 800 3005 0 3 960 3505 0 3 1120 4005 12 0 3 1280 VENT CAPS STACKED VERTICALLY FLUE GASES MOVING...

Page 34: ...allations utilize the heater mounted blow er 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 accordance with the NFGC U S or B149 Canada The total length of the horizontal through the wall flue system...

Page 35: ... exceed the distances listed in Tables O and Q Each elbow used Subtract 10 ft per elbow Max 4 elbows 1 Requires D 33 Poly vent adaptor limit kit Table Q Category IV Horizontal Vent Horizontal Direct Vent is equal to 10 ft of straight pipe This will allow instal lation in any arrangement that does not exceed the lengths shown in Tables O and Q The vent cap is not considered in the overall length of...

Page 36: ... The condensate from the boiler is acidic Its pH is typically between 3 2 and 4 5 Raypak recommends treating the condensate with a Condensate Treatment kit Sales order option Z 12 The Treatment kit is connected to the drain system and contains treatment media to raise the pH level of the condensate The kit may be added to avoid long term damage to the drainage system and to meet local code require...

Page 37: ...plier 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 con nected to more than one supply...

Page 38: ...e device The optional manual reset high limit is located inside the cabinet on the upper left corner post Access the limit by hinging the control box open to view and make adjustments Standard The fixed setting manual reset high limit is built into the PIM and utilizes a dual element sensor located on the outlet H 235ºF WH 180ºF P 150ºF NOTE Ignition modules are common for all model sizes However ...

Page 39: ...s pressure is present for proper valve regulator performance The low gas pressure switch automatically shuts down the heater if gas supply drops below the factory setting of 3 0 in WC for natu ral gas or propane gas The high gas pressure switch is standard and is mounted downstream of the gas valve If the gas pressure regulator in the valve fails the high gas pres sure switch automatically shuts d...

Page 40: ...g supplied to the indirect system Boil OUTLET All Current boiler outlet temperature Boil INLET All Current boiler inlet temperature Boil ΔT All Current temperature difference between boiler outlet and boiler inlet DHW SUPPLY H MODE 2 3 Current indirect DHW supply temperature requires IND Sensor ON in ADJUST menu TANK WH Current tank temperature P BOILER STATUS All IDLE PREP IGN MOD RATE POST SOFT ...

Page 41: ... 10 F Differential for the target indirect DHW tank temperature requires IND SENSOR ON 6 F IND SUPPLY H MODE 2 3 OFF 50 F to PIM value Target boiler temperature for the DHW heat exchanger during indirect DHW operation requires IND SENSOR OFF 180 F DHW PRIORITY H MODE 2 OFF ON Selects whether or not Indirect DHW priority is active during indi rect DHW operation OFF PRI OVR H MODE 2 3 Au 0 10hr to 2...

Page 42: ...or manual high limit The CFH will resume after the soft lockout fault has been corrected and a 15 min waiting period has expired VENT WALL Not available Not Available LIMIT TEMP ALL Current Outlet Limit temperature EMS Vdc ALL Current EMS signal in Volts DC FIRE RATE ALL PIM firing rate SPEEDX 1000 ALL Blower speed in revolutions per minute rpm x 1000 OUTLET MAX H Mode 1 2 3 Defines Max Outlet tem...

Page 43: ...c to clear INLET LO All Records the lowest boiler outlet temperature Press UP DOWN for 1 sec to clear DELTA T All Captures the highest Delta T Temperature recorded Press UP DOWN buttons for 3 sec to clear this entry OUTDOOR HI H MODE 1 2 3 Records the highest outdoor temperature Press UP DOWN for 1 sec to clear OUTDOOR LO H MODE 1 2 3 Records the lowest outdoor temperature Press UP DOWN for 1 sec ...

Page 44: ... degree the outdoor temperature drops the tempera ture of the heating water will increase one degree With the VERSA both ends of the slope are adjust able It is factory set at 70 F water temperature Boil START at 70 F outdoor air OUT START and 180 F water temperature Boil DESIGN at 10 F outdoor air OUT DESIGN Each building has different heat loss characteristics A very well insulated building will...

Page 45: ...n completing heat loss calculations for the building Boiler Design Boil DESIGN The Boil DESIGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the OUT DESIGN temperature Warm Weather Shut Down WWSD When the outdoor air temperature rises above the WWSD setting the control turns on the WWSD segment in the display When the control is in Warm W...

Page 46: ...WIRING DIAGRAM Models 2505 4005 46 For a full size drawing visit www raypak com commercial wiring_diagrams ...

Page 47: ...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 turn the gas control valve handle Never use tools If the handle will not turn by hand do not try to repair it call a qualified ser vice technician Forced or attempted repair may result in a fire or explosion Do not use this appliance if any part has be...

Page 48: ...ve upstream of the heater Start Up 1 Turn power on 2 Turn on the heater wait approximately 15 sec onds after the blower starts the igniter should start to glow observable through the observation port located at the front below the gas valve Look into the sight glass located just below the gas valve near the front of the unit to check igniter operation Gas valve should open in 45 60 sec onds 3 The ...

Page 49: ...WC 3505 4 1 4 1 2 in WC 4005 1 0 1 9 2 in WC Table W XTherm Air Pressure Settings Table X XTherm Manifold Pressure Settings User Test Set DIP switch 1 on the VERSA IC control to ON Set USER TEST ON in the ToolBox Menu to start the user test function USER TEST is displayed in the Title Field UP keystrokes are used to advance through the user test The Boil MIN MAX steps for burner operation are only...

Page 50: ...edle valve and open the upstream manual gas valve Make sure that test point A B bleedle valves have been opened so as to allow gas to flow This will bring gas pressure to the second valve seat 5 Open the bleedle valve at test point C and connect a second rubber tube to it Connect the other end of the tube to a manometer and look for a build up of pressure Increasing pressure indicates a leak ing g...

Page 51: ...low one time operation of the limit and then must be returned to normal operation by turning DIP switch 8 back to the OFF position Power to the unit must then be cycled off then on to return to normal operation 9 Test ignition system safety device a Close manual gas valve Turn power on b Close Enable Disable circuit to call for heat c The burner should attempt three trials for igni tion for the st...

Page 52: ...mperature or manual reset high limit is not tripped c Enable Disable circuit is closed 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 valve field installed near gas inlet connection on back of heater 2 Remove upper front panel 3 Adjust setpoint to l...

Page 53: ...wer replace control DELTA T Temperature difference between the inlet and outlet exceeded the set point Check water flow LOW 24VAC Low 24 VAC power Check power supply wiring and transformer BLOW SPEED Blower speed out of range Check blower wiring and blower WARNING Do not use this appliance if any part has been under water Improper or dangerous operation may result Contact a qualified service techn...

Page 54: ...sary N A Red LED 6 Flashes N A Hi Limit Fault Red LED 7 Flashes Check for proper water flow Check hi limit setting and outlet sensor Sensor Fault Red LED 8 Flashes Check the VERSA IC Control for fault identification Check sensor and wiring N A Red LED 9 Flashes Check wiring at J8 pins 1 3 for loose or missing jumper Water Pressure Fault Red LED 10 Flashes Check system piping for leaks Check water ...

Page 55: ...nc tion deterioration or leakage 4 Visually inspect for proper operation of the con densate drain in the venting If leaks are observed repair at once 5 Check air vents for leakage Yearly Beginning Of Each Heating Season Schedule annual service 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 ...

Page 56: ...ll 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 49 3 Test high and low gas...

Page 57: ...s at 77 F 5 Check flame signal strength Flame signal should be greater than 1 microampere as measured at the 2 pins on the bottom of the PIM 6 Check firing rate control by checking the manifold pressure See Manifold Check on page 49 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 recomm...

Page 58: ...contaminated ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners chlorine based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varnish removers hydrochloric acid muriatic acid cements and...

Page 59: ...ll horizontally vented gas fueled equip ment 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 finished grade in the area of the venting including but not limited to decks and porches the following requirements shal...

Page 60: ...nutes 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____________ Pu...

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Page 66: ...66 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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