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START-UP

Pre Start-up

Filling System (Heating Boilers)

Fill system with water. Purge all air from the system.

Lower system pressure. Open valves for normal sys-

tem operation, and fill system through feed pressure.

Manually open air vent on the compression tank until

water appears, then close vent.

Air Purge (Domestic Hot Water/Pool

Heaters)

Purge all air from system before heater operation. This

can be normally accomplished by opening a down-

stream valve.

Venting System Inspection

1. Check all vent pipe connections and flue pipe ma-

terial.

2. Make sure vent terminations are installed per code

and are clear of all debris or blockage.

For Your Safety

This appliance has a hot surface igniter. It is equipped

with an ignition device which automatically lights the

burners. Do not try to light the burners by hand.

WARNING:

If you do not follow these instructions

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

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.

WHAT TO DO IF YOU SMELL GAS:

•

Do not try to light any appliance.

•

Do not touch any electrical switch; do not use any

telephone in your building.

•

Immediately call your gas supplier from 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 serv-

ice technician. Forced or attempted repair may

result in a fire or explosion.

•

Do not use this appliance if any part has been

under water, immediately call a qualified service

technician to inspect the appliance and to replace

any part of the control system and any gas control

which has been under water.

•

Check around unit for debris and remove com-

bustible products, i.e. gasoline, etc.

Pre Start-up Check

1. Verify the heater is filled with water.

2. Check system piping for leaks. If found, repair

immediately.

3. Vent air from system. Air in system can interfere

with water circulation.

4. Purge air from gas line to heater.

Initial Start-up

Required tools

•

(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

(Metric Allen wrenches will be required for servicing

the gas valve, but not during start-up)

NOTE:

Digital manometers are not recommended.

CAUTION:

An air vent valve should be installed at

the highest point in the system for proper operation.

If water piping is located higher than the header, an

air vent valve should be located at the highest point

in the installed system.

NOTE:

The following steps must be performed by a

factory-trained technician.

Содержание Xtherm 1005A

Страница 1: ...ids 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 cal...

Страница 2: ...2 ...

Страница 3: ...er 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 Interface 38 WIRING DIAGRAM 44 START UP 45 Pre Start up 45 Start Up 46 OPERATION 50 Lighting Instructions 50 To Turn Off Gas To Appliance 50 TROUBLESHOOTING 50 MAINTENANCE 53 Suggested Minimum Maint...

Страница 4: ...lammable 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 State of California to cause cancer birth defects or other reproductive harm WARNING Risk of electrical shock More than one disconnect switch may be required to de energize the equipment before servicin...

Страница 5: ...s 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 number will have the form H7 or similar depending on the heater size and configuration The letter s in the first group of characters identifies the application H Hydronic Heating WH Domestic Hot Wate...

Страница 6: ...ower 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 Vent Size Comb Air Xtherm MBTUH MBTUH In Nat LP In In 1005A 999 140 2 1 2 1 1 4 1 6 6 1505A 1500 210 2 1 2 1 1 4 1 8 8 2005A 1999 280 2 1 2 2 1 8 8 Gas Conn NPT ...

Страница 7: ...f 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 purpose hot water for use by individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed p...

Страница 8: ...allations 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 NFPA 70 latest edition NEC Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 CSD 1 when required For Canada only CAN CSA B149 Natural Gas and Propane Installati...

Страница 9: ...port 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 where combustion air is drawn directly from outside All installations must com ply with the requirements of the NFGC U S and B149 Canada and all local codes NOTE Use of this heater in construction a...

Страница 10: ...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 Gas Code 2 In accordance with the current CAN CSA B149 I...

Страница 11: ...d 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 the equip ment due to inadequate ventilation of the space is not a warrantable failure 3 In cold climates and to mitigate potential freeze up Raypak highly recommends the installation of a motorized s...

Страница 12: ...ini 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 below The minimum dimension of air openings shall not be less than 3 in 76 mm in any direction Where ducts are used they shall be of the same cross sectional area as the net free area of the openings...

Страница 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 The heater should be located so that any water leaks will not cause damage to the adjacent area or struc tures Relief Valve Piping Temperature Pressure Gauge The temperature and pressure gauge is sh...

Страница 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 provided with a low wa ter cut off device sales order option F 10 This heater when used in connection with a refrigeration system must be installed so that the chilled medium is piped in parallel with t...

Страница 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 temperature based on the standard heater pump and the recommended connecting pipe size Model 1005 Minimum Pipe Size2 Model 1505 Minimum Pipe Size2 Model 2005 Minimum Pipe Size2 2 Minimum pipe size base...

Страница 16: ...Piping 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 Raypak heaters are high recovery low mass heaters which are not subject to thermal shock Applications Modes The VERSA IC Control system is designed for a wide range of applications The installer design en...

Страница 17: ...re 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 boiler firing rate is determined by the water temperature at the Indirect Supply sensor S6 and the Target Max setting when using the Indirect DHW sensor S5 The Indirect DHW Pump P3 runs during an indirect...

Страница 18: ...ration 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 process heating applica tions NOTE If local codes require a vacuum relief valve acquire one locally and install per valve manufacturer s instructions Fig 17 WH Units Single Water Heater with Tank H Un...

Страница 19: ...vice 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 120 F at the inlet to the pri mary heat exchanger on all XTherm models To complete installation of the heater the system sen sor must be installed in the return water line upstream of the heater The ...

Страница 20: ...age 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 Corrosive water can cause unwar rantable damage to the heater tors are usually more efficient in heater water unless controlled they can lead to excessive chlorine level which can damage your heater Furthe...

Страница 21: ...t 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 load condi tions for natural gas A minimum of 4 0 in WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 13 0 in WC is required for propane gas The gas pressure regula...

Страница 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 enable disable and alarm contacts are made at the low voltage terminal strip at the front of the heater as shown at the bottom of Fig 19 Electrical Power Connections Installations must follow these cod...

Страница 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 be installed when field connected controllers are mounted more than 50 equivalent feet 18 AWG from heater See wiring diagrams WARNING Using a multi meter check the following voltages at the circuit ...

Страница 24: ...o 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 weather conditions NOTE A grounding electrode conductor shall be used to connect the equipment grounding conductors the equipment enclosures and the grounded service conductor to the grounding electrode...

Страница 25: ...for 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 pump and Boiler pumps as needed If an optional Indirect DHW sensor is connected the PIM will pass this signal to the VERSA This allows the VERSA to optimize the Indirect DHW demand to maintain the Indi...

Страница 26: ...are 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 sensor if used to terminals 8 and 9 on the field wiring strip located on the Master boiler See Fig 25 4 Connect the Enable Disable wiring to terminals 11 and 12 on the field wiring strip located on the Ma...

Страница 27: ...d 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 IV gas burning heaters such as the AL29 4C stainless steel vents offered by Heat Fab Inc 800 772 0739 Protech System Inc 800 766 3473 Z Flex 800 654 5600 or American Metal Products 800 423 4270 Pipe...

Страница 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 window or gravity air intake Condensate can freeze causing ice formations 11 Locate or guard vent to prevent condensate from damaging exterior finishes Use a rust resistant sheet metal backing plate agai...

Страница 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 of a mechanical air supply inlet to any building 4 Above a meter regulator assembly within 3 ft 915 mm horizontally of the vertical centre line of the regulator 5 Within 6 ft 1 8 m of any gas servic...

Страница 30: ...ear 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 cal damage or separation of joints Termination The vent terminal should be vertical and should termi nate outside the building at least 2 ft above the highest point of the roof that is within 8 ft T...

Страница 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 replaced If PVC vent is to be used refer ence the instructions starting on page 30 Fig 24 Typical Common Venting Note Units rotated 90 for clarity Typical multi unit installations have the heaters in...

Страница 32: ...ighly 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 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 h...

Страница 33: ...vent 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 potential ac cumulation of condensate in the vent pipes It is required that 1 The vent must be installed with a condensate drain located in proximity to the heater as directed by the vent manufacture...

Страница 34: ...e 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 of combustion and ventilation air Keep area clear and free of combustible and flammable materials 3 Do not locate adjacent to any window door walk way or gravity air intake The vent must be located a...

Страница 35: ...f 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 or skin contact immediately flush with plenty of water for 15 minutes and seek medical attention if irritation persists All primers cleaners and cements must meet all local codes Before using primers ...

Страница 36: ...skets 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 ends to the outlet and male ends towards the appliance It is not recommended to install polypropylene when the material temperature is below 32ºF Joining Lubricate gaskets and male ends of pipes with...

Страница 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 to UV light Appliance Start Up Once polypropylene installation is complete the heat ing system and flue should be commissioned following Raypak s instructions There is no cure time or wait time requ...

Страница 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 switch is indicative of a blocked drain or problem with the condensate management system The condensate float switch is located inside the vent outlet plenum at the left rear of the heater Flow Switch Th...

Страница 39: ...orts 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 the gas pres sure switch as necessary If the gas pressure regula tor in the valve fails the high gas pressure switch automatically shuts down the burner Operation of either the High or Low Gas Pressu...

Страница 40: ...r 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 mation Some of the items displayed are mode specific and are only observable when its corresponding mode is active Menu Initial Adjustment To change settings use the MENU key to scroll to the SETUP ADJUS...

Страница 41: ...re 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 SUPPLY H MODE 2 3 OFF 50 F to PIM value Target boiler temperature for the DHW heat exchanger during indirect DHW operation 180 F DHW PRIORITY H MODE 2 OFF ON Selects whether or not Indirect DHW priori...

Страница 42: ...ffset 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 PREPr All Blower during prepurge BLOW POSTt All Duration of blower postpurge BLOW POSTr All Blower during postpurge MIN RATE All Minimum modulation rate during operation START RATE All Start modulation ...

Страница 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 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 to clear SYSTEM HI All Records the highest supply temp...

Страница 44: ...y 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 Boil START at 70 F outdoor air OUT START and 180 F water temperature Boil DESIGN at 10 F out door air OUT DESIGN Each building has different heat loss characteristics A very well insulated building wil...

Страница 45: ...nnual 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 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 co...

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

Страница 47: ...one 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 serv ice technician Forced or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water immed...

Страница 48: ...s 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 controller located behind the front panel 4 If the burner fails to light on the first trial it will try for ignition up to three times before going into lock out with the standard ignition module If th...

Страница 49: ...s 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 1Hz On the second press of the Up button the test step is incremented If boiler outlet temperature reaches the PIM Hi Limit the boiler will be ramped down to keep the temperature in a safe range Pres...

Страница 50: ...the 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 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 in...

Страница 51: ...l 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 mal 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 t...

Страница 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 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 t...

Страница 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...

Страница 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 Check for proper water flow Check hi limit and outlet sensor 8 flashes Sensor Fault See VERSA for fault identification Check sensor wiring 9 flashes N A N A 10 flashes N A N A 11 flashes N A N A 12 ...

Страница 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 ...

Страница 56: ...heck 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 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 ...

Страница 57: ...gniter 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 rate control by checking the manifold pressure See Manifold Check on page 47 7 Test safety safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV Filter Maintenance I...

Страница 58: ...stion 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 glues antistatic fabric softeners used in clothes dryers chloride type bleaches detergents an...

Страница 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 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 sh...

Страница 60: ...60 ...

Страница 61: ...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...

Страница 62: ...se 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 transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only the unex pired portion of the original warranty Raypak makes no warranty ...

Страница 63: ...must 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 transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only the unex pired portion of the original warranty Raypak makes no warranty w...

Страница 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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