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Raypak XTherm Series, Инструкция по установке и эксплуатации

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WARNINGS 4

BEFORE INSTALLATION 

5

Product Receipt 

5

Model Identification 

5

Ratings and Certifications 

5

Installations at Elevation 

5

Component Locations 

6

General Information 

7

GENERAL SAFETY 7

Time/Temperature Relationships in 

Scalds 8

INSTALLATION 8

Installation Codes 

8

Equipment Base 

9

Clearances 9

Combustion and Ventilation Air 

10

Conventional Combustion Air Supply  12

Water Piping 

14

Hydronic Heating 

16

Applications & Modes 

17

Domestic Hot Water 

19

Pool Heating 

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

MAINTENANCE 

55

Suggested Minimum 

Maintenance Schedule 

55

Preventative Maintenance Schedule  56

Filter Maintenance 

57

APPENDIX 58

Inside Air Contamination 

58

  IMPORTANT INSTRUCTIONS FOR THE 

COMMONWEALTH OF MASSACHUSETTS 

59

START-UP CHECKLIST 

60

WARRANTY 61

CONTENTS

3

Содержание XTherm Series

Страница 1: ...iquids 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 to...

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

Страница 3: ...ting 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 Contr...

Страница 4: ...onnect 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 informat...

Страница 5: ...rd 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 w...

Страница 6: ...VC 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 L...

Страница 7: ...R 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...

Страница 8: ...o 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 foll...

Страница 9: ...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...

Страница 10: ...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 mi...

Страница 11: ...elow 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 o...

Страница 12: ...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...

Страница 13: ...th 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...

Страница 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 f...

Страница 15: ...w 50 F Continuous operation below 50 F 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 propo...

Страница 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 o...

Страница 17: ...ibrary 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...

Страница 18: ...oosted 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...

Страница 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 Su...

Страница 20: ...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 co...

Страница 21: ...ecommend 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 heat...

Страница 22: ...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 sho...

Страница 23: ...nd 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 Connect...

Страница 24: ...ration 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...

Страница 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 c...

Страница 26: ...anagement 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 s...

Страница 27: ...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 communic...

Страница 28: ...e 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 CAUTI...

Страница 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 manuf...

Страница 30: ...ck 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...

Страница 31: ...er 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 bui...

Страница 32: ...braced 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 V...

Страница 33: ...e 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...

Страница 34: ...llations 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...

Страница 35: ...t 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...

Страница 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...

Страница 37: ...lier 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...

Страница 38: ...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 fixe...

Страница 39: ...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...

Страница 40: ...supplied to the indirect system Boil OUTLET All Current boiler outlet temperature Boil INLET All Current boiler inlet temperature Boil T All Current temperature difference between boiler outlet and b...

Страница 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 indire...

Страница 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 Lim...

Страница 43: ...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 cl...

Страница 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 Bo...

Страница 45: ...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...

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

Страница 47: ...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...

Страница 48: ...e 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 l...

Страница 49: ...C 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...

Страница 50: ...dle 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 t...

Страница 51: ...ow 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...

Страница 52: ...perature 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 W...

Страница 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...

Страница 54: ...ary 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...

Страница 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...

Страница 56: ...l 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...

Страница 57: ...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 pressur...

Страница 58: ...ontaminated ar eas this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners ch...

Страница 59: ...l 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 an...

Страница 60: ...utes Vent Size _____________ Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material ____...

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Страница 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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