Raypak 1005 Finishing, Safety Inspection, Follow-Up, Leak Test Procedure Dual-Seat Gas Valve

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Model No.

Manifold Gas Pressure

(High Fire Values)

 

Natural Gas

Propane Gas

1005

-1.1

-0.6

1505

-1.6

0.3

2005

-1.8

-2.0

Table W: XTherm Manifold Pressure Settings

CAUTION: Special manifold and air settings may be required.

Finishing

1.Record all data on the “Start-up Checklist” located at the back of this manual.

2.Disconnect the manometers and reconnect the cap on the fan pressure switch tee and reinsert the sealing screws into the bleedle valves.

3.Start-up is complete and the heater should be operating properly.

Safety Inspection

1.Check all thermostats and high limit settings.

2.During the following safety checks leave manome- ters hooked up, check and record.

3.If other gas-fired appliances in the room are on the same gas main, check all pressures on the XTherm with all other equipment running.

4.Check thermostats for ON-OFF operation.

5.Check high limits for ON-OFF operation.

6.While in operation, check flow switch operation.

7.Check the low gas pressure switch (if provided). (For proper adjustment, use the attached manometers, if available, to set pressure. The scales on the switch are approximate only.) Low gas pressure switch (if provided) must be set at 3.0 in. WC for natural gas and propane gas.

8.Make sure that the high gas pressure switch (op- tional) is set to 3.0 in. WC for both natural gas and propane gas.

Follow-Up

Safety checks must be recorded as performed. Turn heater on. After main burner ignition:

1.Check manometer for proper readings.

2.Cycle heater several times and re-check readings.

3.Remove all manometers and replace caps and screws.

4.Check for gas leaks one more time.

Leak Test Procedure: Dual-Seat Gas Valve

Proper leak testing requires three pressure test points in the gas train.

Remove the access panel on the rear of the heater to access the gas valve for this test. Test point A is a blee- dle valve located upstream of the combination gas valve on the supply manifold.

NOTE: May have to remove HGPS (if applicable) to conduct this test.

Test point B is a bleedle valve located between the two automatic gas valve seats.

Test point C is a bleedle valve located downstream of both automatic gas valve seats and upstream of the manual valve. Refer to Fig. 54.

These tests are to be conducted with the electrical power to the heater turned OFF.

1.Manually close the downstream leak test valve.

2.Open the bleedle valve at test point A and connect a manometer to it. Verify that there is gas pressure and that it is within the proper range (NOTE: must not exceed 14.0 in. WC).

3.Open test point B and connect a rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up of pressure. Increasing pressure indicates a leaking gas valve which must be replaced.

4.Next, close the upstream manual gas valve (field supplied) and remove the manometers from the bleedle valves in test point A and test point B. Connect a rubber tube from the test point A blee-

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Contents Installation & Operating Instructions Page Contents Pay Attention to These Terms Model Identification Before InstallationInstallations at Elevation Product ReceiptMax Min Component LocationsGeneral Information Gas Vent Size Conn InputWater Time to Produce Serious Temp Burn General SafetyTime/Temperature Relationships in Scalds Equipment Base InstallationInstallation Codes Indoor InstallationsHeater Min. Clearance Minimum From Combustible Outdoor InstallationsCombustion and Ventilation Air Indoor UnitsTable E Vent/Air Inlet Termination Clearances Direct Vent Combustion Air FilterRemove the Debris Screen TruSeal Combustion AirAll Air from Inside the Building InstallationsCanadian Installations Conventional Combustion Air SupplyGeneral Relief Valve Installation and PipingTemperature & Pressure Gauge Water PipingHydronic Heating Fitting Type Equivalent Length ft 2 NPT Domestic Hot WaterAutomatic Chlorinators and Chemical Feeders Combined Potable Water and Space HeatingPool Heating Winterizing Your Heater Pool/Spa Water ChemistryWater Hardness Gas SupplyGas Supply Connection Gas Supply Pressure Electrical Power ConnectionsMaking the Electrical Connections Check the Power SourceAppliance Categories Field Wiring ConnectionSupport of Vent Stack Vent Terminal Location InstallationsInstallation Venting Installation TipsVenting Configurations Canadian InstallationsMax. Length* ft CertifiedTotal Effective Combustion Air Air Inlet LengthCommon Venting Model Vent Size Volume Flue ProductsHorizontal Through-the-Wall Venting Horizontal Through-the-Wall and Direct Venting CategoryDirect Vent Vertical Direct Vent-VerticalOutdoor Venting Outdoor InstallationPVC Venting Option CleaningPVC vent assembly instructions Freeze ProtectionPVC Vent Adapter Controls Termination using Adapter ThimbleDifferential Graph Operating ModesBoil Target 78F Boil Max 86F Boil Min 70F ‘Burner’ Delay 10 VDC 20 mA Boiler Target Modes Default Setting Range10 VDC 20 mA Definitions Rank Number Field Type Fault DescriptionOperation Ignition Module Heater Sequence of OperationCode Condition High Limit-Manual ResetHigh Limit-Auto Reset Optional Flow SwitchLow Water Cut-Off Optional Modulating Temperature ControlHigh & Low Gas Pressure Switches Optional Condensate Float Switch Air Pressure SwitchUDB Diagnostic Board Blocked Vent SwitchWiring Diagrams Models 1005 Model Pre Start-up Check START-UPPre Start-up Required tools Initial Start-upPreparation Start-UpManifold Check Model No Net Blower Suction Setting In. WCModel No Amp Draw Setting Blower CheckFollow-Up Safety InspectionLeak Test Procedure Dual-Seat Gas Valve FinishingGAS Post Start-Up CheckTo Turn Off Gas To Appliance OperationLighting Instructions Step TroubleshootingSuggested Minimum Maintenance Schedule MaintenanceUDB Fault History Semi-Annually Preventive Maintenance SchedulePeriodically WeeklyAs Required AppendixInside Air Contamination Important Instructions for the Commonwealth of Massachusetts Models Limited Parts Warranty Xtherm Types H and WHLimited Parts Warranty Xtherm Types WHP START-UP Checklist for FAN-ASSISTED Raypak Products Page
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1005 specifications

Raypak is a prominent name in the heating industry, known for its innovative and efficient heating solutions for residential and commercial applications. The models 2005, 1005, and 1505 are notable offerings from Raypak, each designed to provide reliable performance, energy efficiency, and user-friendly operation.

The Raypak 2005 model stands out for its robust construction and high efficiency. It utilizes advanced technology to ensure consistent heating and reliability. With a high-capacity output, the 2005 is ideal for larger pools and spa applications, efficiently maintaining desired temperatures even during colder months. Its digital control system allows for precise temperature settings, enabling users to customize their heating needs effectively.

The 1005 model is an excellent choice for medium-sized pools and spas, offering a perfect balance of power and energy efficiency. One of its key features is the ability to operate quietly, making it suitable for residential areas where noise can be a concern. The 1005 employs a reliable gas burning system that maximizes fuel efficiency and provides fast heating. Its compact design also makes it easy to install, saving space while delivering exceptional performance.

The Raypak 1505 model is designed for versatility, catering to a wide range of heating requirements. One of its standout characteristics is its corrosion-resistant heat exchanger, which ensures long-lasting performance even in harsh environments. The 1505 also incorporates a user-friendly digital interface, allowing for easy operation and monitoring of temperature settings. It supports both natural gas and propane, providing flexibility to users based on their energy source preferences.

All three models—the 2005, 1005, and 1505—benefit from Raypak's commitment to energy efficiency. They are designed to meet stringent environmental standards while minimizing operational costs for the user. Additionally, their reliable safety features, such as pressure switches and safety valves, ensure safe operation across various conditions.

In summary, Raypak's 2005, 1005, and 1505 models exhibit a combination of efficiency, durability, and user-friendliness. With their advanced technologies and adaptable designs, these heaters are suitable for a wide array of heating applications, providing users with reliable solutions for their heating needs. Whether for residential or commercial use, Raypak's commitment to quality and innovation makes these models excellent choices for anyone seeking dependable heating solutions.
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