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INSTALLATION & OPERATING 

INSTRUCTIONS

CATALOG NO. 3400.552 

Effective: 08-02-13             Replaces:  NEW

P/N 241513 Rev. 1

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.

Models 1005A–2005A 

Types H, WH & P

ULTRA HIGH EFFICIENCY

Summary of Contents for Xtherm 1505A

Page 1: ...ds 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...

Page 2: ...2...

Page 3: ...r 17 Pool Heating 19 Gas Supply 21 Electrical Power Connections 22 Field Wiring Connection 24 Venting 27 Venting Installation Tips 30 Venting Configurations 30 Outdoor Installation 35 Controls 36 User...

Page 4: ...ammable liquids and vapors Heater should never be covered or have any blockage to the flow of fresh air to the heater WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals known to the Sta...

Page 5: ...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...

Page 6: ...wer and gas train omitted for clarity Fig 4 Component Locations Top Fig 3 Component Locations Rear Panels omitted for clarity Fig 2 Component Locations Front Model Max Input Min Input Water Conn NPT V...

Page 7: ...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 NOTE When this water heater is supplying general...

Page 8: ...llations must follow these codes Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition NFGC National Electrical Code ANSI...

Page 9: ...ort 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...

Page 10: ...t 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...

Page 11: ...be at least 1in 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 Damage to t...

Page 12: ...ni 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...

Page 13: ...neck through the roof The duct is preferred to be straight down 18 in 450 mm from the floor but not near piping 13 4 Refer to the B149 Installation Code for additional information Water Piping General...

Page 14: ...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 pro...

Page 15: ...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 1 Approximate high fire heater outlet te...

Page 16: ...iping Fig 13 MODE 1 Single Boiler with Primary Secondary Piping Three Way Valves Three way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used Raypa...

Page 17: ...e is controlled by the Supply sensor S3 whenever the indirect call for heat is not active The DHW Supply sensor S5 determines the indirect call tank setpoint During an indirect call for heat the boile...

Page 18: ...ation must be used and great care must be given to ensure water hardness is no more than 15 grains per gallon for scale free operation MODE 1 should be used and configured for setpoint operation for p...

Page 19: ...ice 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 P models The Cold Water Run system must be set to maintain...

Page 20: ...ge the heater providing the water is balanced Automatic chemical dosing devices and salt chlorina NOTE Chemical imbalance can cause severe damage to your heater and associated equipment CAUTION Corros...

Page 21: ...pressures in excess of 1 2 psi 3 45 kPa Gas Supply Pressure A minimum of 4 0 in WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 10 5 in WC under load and no loa...

Page 22: ...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 en...

Page 23: ...Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source NOTE Field supplied isolation relays should...

Page 24: ...150 feet 4 Mount the outdoor sensor on an exterior surface of the building preferably on the north side in an area that will not be affected by direct sunlight and that will be exposed to varying wea...

Page 25: ...or heat is active the PIM communicates this to the VERSA The VERSA calculates the optimal operation and sends the firing rate and pump output requests to the PIM so it can activate the Indirect DHW pu...

Page 26: ...re dry contacts rated for pilot duty only 5A maxi mum 2 Connect the system supply sensor to terminals 6 and 7 on the field wiring strip located on the Master PIM See Fig 25 3 Connect the Outdoor senso...

Page 27: ...with a vent gas temperature that may cause excessive condensate production in the vent See Table L for appliance category requirements Use only the special gas vent pipes listed for use with Category...

Page 28: ...guard vent termination to prevent acci dental contact by people or pets 9 DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area 10 DO NOT terminate above any door wind...

Page 29: ...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...

Page 30: ...foot from the heater to the vent termi nal The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physi ca...

Page 31: ...heater is installed to replace an existing heater the vent system MUST be verified to be of the correct size and of one of the Category IV vent materials identified in Table M If it is NOT it MUST be...

Page 32: ...ghly corrosive 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...

Page 33: ...ent cap is not 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...

Page 34: ...manufacturer sales order option D 11 2 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...

Page 35: ...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 o...

Page 36: ...kets are free of grease oil debris or damage Installation Vent pipes are joined by push fit connections with EPDM gaskets located in the sockets Pipes and components must be installed with the socket...

Page 37: ...located on the user interface Storage Components should be stored in a clean dry environ ment in their original packaging Non UV stabilized plastic components must be protected from prolonged exposure...

Page 38: ...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 swit...

Page 39: ...rts 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 panels on the rear of the heater to reset...

Page 40: ...H models and 125 F for WH models View Menu The VIEW menu is the default menu It displays sen sor temperatures the modulation rate of the blower heater cascade status pump operation and CFH infor mati...

Page 41: ...e 10 F DHW SENSOR H MODE 1 2 3 OFF ON Selects whether a DHW sensor is used for indirect DHW tank OFF DHW DIFF H MODE 2 3 2 F to 10 F Differential for the target indirect DHW tank temperature 6 F IND S...

Page 42: ...fset OPERATOR All Operator Limit Potentiometer PIM setting AUTO DIFF H MODE 1 2 3 Current auto differential PUMP PREPt All Duration of pump prepurge BLOW PREPt All Duration of blower prepurge BLOW PRE...

Page 43: ...the highest boiler inlet temperature Press UP DOWN for 1 sec to clear INLET LO All Records the lowest boiler outlet temperature Press UP DOWN for 1 sec to clear OUTDOOR HI H MODE 1 2 3 Records the hig...

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 adjustable It is factory set at 70 F water temperature Bo...

Page 45: ...nual temperature where the building is located This temperature is used when completing heat loss calculations for the building Boiler Design Boil DESIGN The Boil DESIGN temperature is the water tempe...

Page 46: ...46 WIRING DIAGRAM Models 1005A 2005A...

Page 47: ...ne 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...

Page 48: ...valve near the front of the unit to check igniter operation Gas valve should open in 45 60 sec onds 3 The heater ignites at 30 to 50 of full rate as indicated on the LCD display of the temperature co...

Page 49: ...for burner operation are only run for enabled boilers Local Heat DHW EMS demands must be present for burner operation On the first press of the Up button the test step is held and HOLD is flashed at...

Page 50: ...he test point B bleedle 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...

Page 51: ...allow 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 nor...

Page 52: ...temperature 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 i...

Page 53: ...er 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 B...

Page 54: ...the gas supply See table for more information 4 flashes N A N A 5 flashes Low Voltage Fault Check the 24 VAC input voltage The voltage must be above 18 0 VAC 6 flashes N A N A 7 flashes Hi Limit Fault...

Page 55: ...c 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 E...

Page 56: ...eck 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 Applian...

Page 57: ...niter Resistance reading should be 40 75 ohms 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...

Page 58: ...tion 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 fo...

Page 59: ...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...

Page 60: ...60...

Page 61: ...utes Vent Size _____________ Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material ____...

Page 62: ...e of chemical additives to water 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 transpor...

Page 63: ...ust be no greater than 1500 PPM 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 transport...

Page 64: ...64 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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