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  5. Installation & Operating Instructions Manual

Raypak 1005-2005 Installation & Operating Instructions Manual

Other manuals for 1005-2005: Specification Sheet, Specifications
Manual is about: 1005–2005 Types H, WH & WHP

Summary of 1005-2005

  • Page 1

    Installation & operating instructions catalog no. 3400.55a effective: 02-24-09 replaces: 09-24-08 p/n 241344 rev. 2 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 i...

  • Page 2

    Rev. 2 reflects the following: changes to: fig. 1, 2 and 3 on page 6; the relief valve installation and piping section on page 14; fig. 14–16 on page 16; fig. 17 on page 17; table i on page 18; step 6 of the heater sequence of operation sec- tion on page 36; the wiring diagrams on pages 40 and 41. T...

  • Page 3

    Warnings 4 pay attention to these terms 4 before installation 5 product receipt 5 model identification 5 ratings and certifications 5 installations at elevation 5 component locations 6 general information 6 time/temperature relationships in scalds 7 general safety 7 installation 8 installation codes...

  • Page 4

    Danger: indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Warning: indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Caut...

  • Page 5

    Before installation raypak strongly recommends that this manual be re- viewed thoroughly before installing your xtherm heater. Please review the general safety information before installing the heater. Factory warranty does not apply to heaters that have been improperly installed or operated. (refer...

  • Page 6

    General information table a: basic data component locations fig. 1: component locations – right side fig. 2: component locations – top fig. 3: component locations – rear model no. Mbtuh input water conn. (npt) gas conn. (npt) vent size (in.) max. Min. N p flue intake 1005 999 250 2-1/2 1-1/4 1 6 6 1...

  • Page 7

    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...

  • Page 8

    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...

  • Page 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” top ...

  • Page 10

    U.S. Installations 1 canadian installations 2 a clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) b clearance to window or door that may be opened 4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) c clearance to permanently closed wind...

  • Page 11

    Combustion air filter this heater is supplied with an integral combustion air filter. This filter will reduce the amount of particulates passed through the combustion system and heat exchanger but will not protect against chemical inside air contamination (see appendix). The filter must be checked p...

  • Page 12

    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...

  • Page 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 room l...

  • Page 14

    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...

  • Page 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 fil...

  • Page 16

    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) (°f) (°f) 60 138 2"npt 2 1/2"npt 147 2"npt 2 1/2"npt 154 2"npt 2 1/2"npt 80 138 2"npt 2 1/2"npt 147 2"npt 2 1/2"npt 154 2 1/2"npt 3"npt 100 138 2 1...

  • Page 17

    Note: if local codes require a vacuum relief valve, acquire one locally and install per valve manufacturer’s instructions. 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 potable wat...

  • Page 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) 80-200' equiv. Temp 1 (°f) temp 1 (°f) temp 1 (°f) 1 (°f) 60 138 135 2" 2 1/2" 150 145 143 2" 2 1/2" 154 2" 2 1/2" 80 138 135 2" 2 1/2" 150 145 143 2" 2 1/...

  • Page 19

    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...

  • Page 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 ser...

  • Page 21

    Check the power source: ac = 108 vac minimum, 132 vac max ab = 108 vac minimum, 132 vac max bc = making the electrical connections refer to fig. 19-22. 1. Verify that circuit breaker is properly sized by referring to heater rating plate. A dedicated circuit breaker should be provided. 2. Note: curre...

  • Page 22

    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...

  • Page 23

    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...

  • Page 24

    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...

  • Page 25

    Table m: category iv vertical venting 1 vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the nfgc for further details. * subtract 10 ft per elbow. Max. 4 elbows. ** adapters supplied by others. Termination the vent terminal should be vertical and should termi- nate ...

  • Page 26: Raypak Products

    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. Additiona...

  • Page 27

    Fig. 25: horizontal through-the-wall venting fig. 26: alt. Horizontal through-the-wall venting note: while a drain connection is required in the vent of all xtherm installations, the drain can be ac- complished in several different ways. The figures in this manual show the drain in a vent tee, howev...

  • Page 28

    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...

  • Page 29

    Tion in any arrangement that does not exceed the lengths shown in tables m and o. The 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 a...

  • Page 30

    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. Contro...

  • Page 31

    Operating modes mode 1 – not recommended. Mode 2 – setpoint operation using primary/secondary piping. The control operates the heater to satisfy a remote system sensor. The heater is turned off based on boiler max and boiler differential (factory default). See fig. 31. Mode 3 – dedicated dhw operati...

  • Page 32

    Modulating * fig. 34: mode 7 primary/secondary piping with external target temp 0-10 vdc 0-20 ma* boiler target 0 0 --- (off) 1 2 50°f 2 4 68.9°f 3 6 87.8°f 4 8 106.7°f 5 10 125.6°f 6 12 144.1°f 7 14 163.3°f 8 16 182.2°f 9 18 201.1°f 10 20 220°f table p: 0-10 vdc or 0-20 ma external input signal *re...

  • Page 33

    Table r: temperature control default setpoints—h7 & wh7 models item modes default setting range boil target 1, 2 160°f off, 70 to 220°f 3 160°f off, 70 to 190°f 4, 5, 6, 7 180°f off, 70 to 220°f boil max 1, 2, 4, 5, 6, 7, 8 200°f off, 120 to 225°f 3 180°f off, 120 to 190°f boil min 1, 2, 3, 4, 5, 6,...

  • Page 34

    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- mal m...

  • Page 35

    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 sensor o...

  • Page 36

    Fig. 36: 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 the ...

  • Page 37

    Table u: 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 inter...

  • Page 38

    Modulating temperature control this heater is equipped with a raypak modulating temperature control. Refer to information starting on page 31 for information on the setting and use of this control. Low water cut-off (optional) the optional low water cut-off automatically shuts down the burner whenev...

  • Page 39

    Air pressure switch this heater is equipped with an air pressure switch to prove the operation of the blower before allowing the ignition control to begin a trial for ignition. It is located on the right side of the lower flange of the blower mounting assembly, directly behind the junction box. Bloc...

  • Page 40

    Wiring diagrams - models 1005 & 1505 40 california hot water supply, inc. (800) 249-7244 40

  • Page 41

    Model 2005 41 california hot water supply, inc. (800) 249-7244 41.

  • Page 42

    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. ...

  • Page 43

    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 in. ...

  • Page 44

    4. When firing at 100%, the desired heater combus- tion co2 is between 8.5 and 9.0% for natural gas and 9.5 and 10.0% for propane with co less than 100 ppm. If this combustion cannot be achieved with the net blower suction within the tolerances specified in table v, contact the factory. The refer- e...

  • Page 45

    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...

  • Page 46

    Dle valve to 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...

  • Page 47

    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 hig...

  • Page 48: Raypak Products

    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. Additiona...

  • Page 49

    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 p erature controlle r ? Is 24vac at the...

  • Page 50

    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 combustible m...

  • Page 51

    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 5. Check valve coil for 60 cycle hum or buzz. Check for leaks at all valve fittings using a soapy water solution (while ...

  • Page 52

    (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 gas fueled ...

  • Page 53

    53 limited parts warranty xtherm – types h and wh models 1005-2005 scope raypak, inc. (“raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by raypak will be free from failure under normal use and service for the specified warranty periods and subjec...

  • Page 54

    54 limited parts warranty xtherm – types whp models 1005-2005 scope raypak, inc. (“raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by raypak will be free from failure under normal use and service for the specified warranty periods and subject to ...

  • Page 55: Raypak Products

    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. Additiona...

  • Page 56: Www.Raypak.Com

    Www.Raypak.Com raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (805) 278-5468 litho in u.S.A. California hot water supply, inc. (800) 249-7244 56.