Raypak 1005 - Manual

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 p...

Equipment Base The heater should be mounted on a level, structurally sound surface. The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed in enclosed parking garages must be located at least 18 in. above the floor. I...

9 Fig. 5: Minimum Clearances from Combustible Surfaces – Indoor and Outdoor Installations Roof water drainage must be diverted away from heaters installed under overhangs. Heater Side Min. Clearance from Combustible Surfaces Minimum Service Clearance Rear 12” 36” Right Side 1” 24” Left Side 1” 1” To...

12. Provide adequate ventilation of the space occu- pied by the heater(s) by an opening(s) for ventilation air at the highest practical point com- municating with the outdoors. The total cross-sectional area shall be at least 1 in. 2 of free area per 20,000 BTUH (111 mm 2 per kW) of total input rati...

13 Conventional Combustion Air Supply U.S. Installations All Air from Inside the Building The confined space shall be provided with TWO per- manent openings communicating directly with an additional room(s) of sufficient volume so that the com- bined volume of all spaces meets the criteria for a roo...

Relief Valve Installation and Piping The heater is supplied with a Section IV “HV” stamped relief valve sized for the full input of the unit and a “UV” stamped relief valve to protect the section VIII second- ary heat exchanger. The relief valve assembly is shipped loose and must be mounted directly...

15 Leaks must be repaired at once to prevent damage to the heater. NEVER use petroleum-based stop-leak compounds. To perform hydrostatic test: 1. Connect fill water supply. With bleed valve open, fill heater with water. When water flows from bleed valve, shut off water. Close bleed valve. Carefully ...

Table F: Boiler Temperatures and Minimum Pipe Size at Varying Return Temperatures System Return Temp Supply Temp 1 Supply Temp 1 Supply Temp 1 (°F) (°F) <80' equiv. 80-200' equiv. (°F) <80' equiv. 80-200' equiv. (°F) <80' equiv. 80-200' equiv. 60 138 2"NPT 2 1/2"NPT 147 2"NPT 2 ...

NOTE: If local codes require a vacuum relief valve, acquire one locally and install per valve manufacturer’s instructions. Combined Potable Water and Space Heating 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with po...

18 Tank u S t f o S . p u S d r a H . p u S d e M / t f o S p m e T n r u t e R p. Med Sup. Hard Sup d e M / t f o S . (°F) Temp 1 (°F) Temp 1 (°F) <80' equiv. 80-200' equiv. Temp 1 (°F) Temp 1 (°F) Temp 1 (°F) <80' equiv. 80-200' equiv. Sup. Temp 1 (°F) <80' equiv. 80-200' equiv. 60 138 13...

Automatic chemical dosing devices are usually more efficient in heater water, unless controlled, they can lead to excessive chlorine level which can damage your heater. Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical suppli- er for the correct level...

20 • Safety wiring must be NEC Class 1. • Heater must be electrically grounded as required by the NEC. • In Canada, CSA C22. 1 C.E.C. Part 1. XTherm heaters are wired for 120VAC single phase power. Models 1005 and 1505, except WH 1505 mod- els equipped with a heater pump for hard water, require 15A ...

Field Wiring Connection Venting General Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Category I – A heater which operates with a non-pos- itive vent static pressure and with a vent...

Table L: Venting Category Requirements Vent Terminal Location 1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 2. Give special attention to the location of the vent termination to avoid possibility of property dam- age or personal in...

5. Terminate vent at least 6 ft away from adjacent walls. 6. DO NOT terminate vent closer than 5 ft below roof overhang. 7. The vent terminal requires a 12 in. vent terminal clearance from the wall. 8. Terminate vent at least 1 ft above grade, including normal snow line. 9. Multiple direct vent inst...

Table M: Category IV Venting 1 Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. 2 Consult factory for longer vent runs. * Subtract 10 ft per elbow. Max. 4 elbows. ** Adapters supplied by others. Termination The vent terminal should be v...

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 N provides the volume of flue products at full fire for the calculation of appropriate vent sizing and extractor for...

The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight. The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that: 1. The vent must be instal...

Combustion air supplied from outdoors must be free of particulate and chemical contaminants. To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc. The stainless steel flue direct vent cap must be fur- nished by the heater manufacturer in accordance with its li...

Freeze Protection The Raypak electronic temperature control includes a freeze protection feature. In the event the water tem- perature drops below 40°F at any of the heater temperature sensors, the pump is turned on and will remain on until the temperature at all heater sensors rises to 45°F. PVC Ve...

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. The XTherm is designed for use with Primary/Secondary pumping only, utilizing integral injector ...

33 Fig. 34: Differential Graph Operating Modes Mode 1 – Primary piping is prohibited. Mode 2 – Setpoint operation using primary/secondary piping, used for either hydronics or pool systems. The control operates the heater to satisfy a remote system sensor. The heater is turned off based on boiler max...

36 Definitions % OUT - Current percent modulation rate of heater. BOIL DSGN - Design boiler water temperature used in heat loss calculations. BOIL MASS - This setting allows adjustment in the field for high or low thermal masses; High thermal mass (setting=3) provides slower reaction, lower ther- ma...

37 Rank Item Field Number Field Type Fault Description 0 E01 Err Error EEPROM error 1 FP Err Warning Flame proof warning 2 BOIL OUT SHr Error Boiler outlet sensor short 3 BOIL OUT OPn Error Boiler outlet sensor open 4 BOIL IN SHr Error Boiler inlet sensor short 5 BOIL IN OPn Error Boiler inlet senso...

38 Fig. 41: Ignition Module The optional single-try ignition module will lock out after failing to light one time. To reset it, press and release the small, recessed black push button located inside of the cut-out on the lower right-hand corner of the ignition module case. Turning off the power to t...

39 Table T: Ignition Module Diagnostic LED Flash Codes Code Condition On System OK; No faults present Off Possible control fault; Check power 1 Flash Low air 2 Flashes Flame in combustion chamber; No call for heat 3 Flashes Ignition lockout 4 Flashes Low HSI current 5 Flashes Low 24 VAC 6 Flashes In...

44 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 ven...

45 Check Gas Supply Pressure 1. Slowly turn on main gas shut-off valve. 2. Read the gas supply pressure from the manome- ter; minimum supply pressure for natural gas is 4.0 in. WC, recommended supply is 7.0 in. WC, mini- mum supply pressure for propane gas is 4.0 in. WC, recommended supply is 11.0 i...

49 11. Check to see that the high limit control is set above the design temperature requirements of the system. For multiple zones: Check to make sure the flow is adjusted as required in each zone. 12. Check that the heater is cycled with the thermo- stat. Raise the setting on the thermostat to the ...

50 TROUBLESHOOTING Ste p 8 Ste p 7 Ste p 6 Ste p 9 Step 1 Step 2 Step 3 Step 4 Step 5 Is there a Call For Heat? Is Disable connection intact? Does the combustion air blower come on? Is 4-20mA present at the quick disconnects on the black and blue wires of the tem perature controlle r? Is 24VAC at th...

51 UDB Fault History To view the fault codes in the UDB history file: 1. Press the UP or DOWN buttons on the membrane switch for 2 seconds to access the fault history. 2. Press either button to scroll through the recorded faults in history. 3. The most recent fault recorded will be the first fault d...

52 2. Visually inspect venting system for proper func- tion, deterioration or leakage. Ensure that condensate drain is inspected and ensure that condensate is being directed to appropriate con- densate management system or drain, as required by local codes. 3. Check that area is free from combustibl...

53 4. Conduct a combustion test at full fire. Carbon diox- ide should be 8.5 to 9.0% at full fire for natural gas, and between 9.5 to 10.0% for propane gas. Carbon monoxide should be < 100 ppm. 5. Check valve coil for 60 cycle hum or buzz. Check for leaks at all valve fittings using a soapy water...

54 (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented ...

57 START-UP CHECKLIST FOR FAN-ASSISTED 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. Additi...