Raypak P-2505 User Manual

- GENERAL

1.1 SUMMARY

A. Section includes condensing, gas-fired copper finned-tube, gas domestic pool heaters

Specifier Note: Use as needed

B. Related Sections

1. Building Services Piping – Division 22 10 00

2. Breeching, Chimneys, and Stacks (Venting) – Division 23 51 00

3. Electrical – Division 23 09 33

1.2 REFERENCES

A. ANSI Z21.56/CSA 4.7

B. ASME, Sections IV and VIII

C. 2006 UMC, Section 1107.6

D. ANSI/ASHRAE 15-1994, Section 8.13.6

E. National Fuel Gas Code, ANSI Z223.1/NFPA 54

F. National Electrical Code, ANSI/NFPA 70

G. ASME CSD-1, 2012 (when required)

XTHERM®, TYPE P - MODELS 2505-4005

SUGGESTED SPECIFICATIONS

WATER-TUBE POOL HEATERS

Catalog No.: 6000.70
Effective: 09-15-16
Replaces: NEW

1.3 SUBMITTALS

A. Product data sheet (including dimensions, rated capacities, shipping weights, accessories)

B. Wiring diagram

C. Warranty information

D. Installation and operating instructions

1.4 QUALITY ASSURANCE

A. Regulatory Requirements

1. ANSI Z21.56/CSA 4.3

2. Local and national air quality regulations for low NOx (0-30 PPM NOx emissions) pool heaters

B. Certifications

1. CSA

2. ASME HLW Stamp and National Board Listed – Primary

3. ASME U Stamp and National Board Listed – Secondary

4. ISO 9001

1.5 WARRANTY

A. Limited one-year warranty from date of installation

B. Limited twenty-five-year thermal shock warranty

C. Limited five-year primary heat exchanger warranty

D. Limited ten-year secondary heat exchanger warranty

- PRODUCTS

2.1 MANUFACTURER

A. Raypak, Inc.

1. Contact: 2151 Eastman Ave., Oxnard, CA 93030; Telephone: [phone];
Fax: [phone]; Web site: www.raypak.com

2. Product: XTherm® condensing cupro-nickel finned-tube pool heater(s)

Project Name / Date

2.2 POOL HEATERS

A. General

1. The pool heater(s) shall be fired with gas at a rated input of BTU/hr.

2. The pool heater(s) shall be CSA tested and certified with a minimum thermal efficiency of 97
percent at full fire.

3. The pool heater(s) shall be ASME inspected and stamped and National Board registered for
160 PSIG maximum allowable working pressure and 170ºF maximum allowable temperature,
complete with a Manufacturer's Data Report.

4. The pool heater(s) shall have a floor loading of 146 lbs. /square foot or less.

B. Primary Heat Exchanger

1. The primary heat exchanger shall be of a single-bank, vertical multi-pass design and shall
completely enclose the combustion chamber for maximum efficiency. The tubes shall be set
vertically and shall be rolled into a powder-coated, ASME pool heater quality, carbon steel
tube sheet.

2. The primary heat exchanger shall be sealed to 160 PSIG rated bronze headers with silicone
"O" rings, having a temperature rating over 500°F.

3. The low water volume primary heat exchanger shall be explosion-proof on the water side and
shall carry a twenty-five-year warranty against thermal shock.

4. The headers shall be secured to the tube sheet by stud bolts with flange nuts to permit
inspection and maintenance without removal of external piping connections. A heavy gauge
stainless steel slotted primary heat exchanger wrap shall ensure proper combustion gas flow
across the copper-finned tubes.

5. The pool heater(s) flue connection, combustion air opening, gas connection, water
connections, condensate drain and electrical connections shall be located on the rear.

6. The primary heat exchanger shall have accessible pool heater drain valves with hose bibs to
drain the water section of the primary heat exchanger.

C. Secondary Heat Exchanger

1. The secondary heat exchanger shall be a single-bank, multi-pass design constructed of
stainless steel and bear the ASME U stamp.

2. The pool heater(s) shall be capable of operating at inlet water temperatures as low as 50°F.

D. Condensate Drain

1. The heater(s) will feature a condensate drain switch which will shut down the heater(s) if the
condensate drain is blocked.

E. Burners

1. The combustion chamber shall be of the sealed combustion type employing the Raypak high
temperature FeCrAloy woven mesh burner, mounted in a vertical orientation.

2. The burner must be capable of firing at both a complete blue flame with maximum gas and air
input as well as firing infrared when gas and air are reduced. The burner must be capable of
firing at 100% of rated input when supplied with 4.0” WC of inlet gas pressure, so as to
maintain service under heavy demand conditions; no exceptions.

3. The burner shall use a combustion air blower to precisely control the fuel/air mixture for
maximum efficiency. The combustion air blower shall operate for a pre-purge period before
burner ignition and a post-purge period after burner operation to clear the combustion
chamber.

F. Ignition System

1. The pool heater(s) shall be equipped with a 100 percent safety shutdown.

2. The ignition shall be Hot Surface Ignition type with full flame rectification by remote sensing
separate from the ignition source, with a three-try-for-ignition sequence, to ensure consistent
operation.

3. The igniter will be located to the side of the heat exchanger to protect the device from
condensation during start-up.

4. The ignition control module shall include an LED that indicates 15 individual diagnostic flash
codes.

Project Name / Date

5. An external viewing port shall be provided, permitting visual observation of burner operation.

G. Gas Train

1. The pool heater(s) shall have a firing/leak test valve and pressure test valve as required.

2. The pool heater(s) shall have dual-seated main gas valve.

3. Gas control trains shall have a redundant safety shut-off feature, main gas regulation, shut-off

cock and plugged pressure tapping to meet the requirements of ANSI Z21.56/CSA 4.7.

H. Pool Heater Control

1. The following safety controls shall be provided:

a. High limit control with manual reset fixed 180°F.
b. Flow switch, mounted and wired.
c. PSIG ASME pressure relief valve, piped by the installer to an approved drain.
d. Temperature and pressure gauge.

2. The pool heater(s) shall be equipped with a VERSA IC® temperature controller with color

touchscreen display that incorporates an adjustable energy-saving pump control relay and
freeze protection, and is factory mounted and wired to improve system efficiency; three water
sensors included (system sensor and supply-to-pool sensor are loose).

I. Firing Mode: Provide electronic modulating control of the gas input to the pool heater.

J. Pool Heater Diagnostics

1. Provide external LED panel displaying the following pool heater status/faults:

a. Power on – Green
b. Call for heat – Amber
c. Burner firing – Blue
d. Service – Red

2. Provide monitoring of all safeties, internal/external interlocks with fault display by a 7” in. Color

Touchscreen Display:
a. System status
b. Ignition failure
c. Condensate blockage
d. Blower speed error
e. Low 24 VAC
f. Manual reset high limit
g. Auto reset high limit
h. Blocked vent
i. High gas pressure switch (standard)
j. Controller alarm
k. Flow switch
l. Sensor failure
m. Factory option

1. Inlet sensor (open or short)

2. Outlet sensor (open or short)

3. System sensor (open or short)

4. Air sensor (open or short)

5. Indirect DHW sensor (open or short)

6. Indirect DHW tank sensor (open or short)

7. Cold water protection sensor (open or short)

8. Internal control fault

9. ID card fault

10. Cascade communications error

Specifier Note: The remaining items in this section are options. Delete those that are
not being specified.

11. Auto reset high limit (optional)

12. Low water cut-off (optional)

13. Low gas pressure switch (optional)

Project Name / Date

3. Provide ignition module indicating the following flash codes by LED signal and displayed on
LCD display:
a. 1 flash – low air pressure
b. 2 flashes – flame in the combustion chamber w/o CFH
c. 3 flashes – ignition lock-out (flame failure)
d. 4 flashes – low hot surface igniter current
e. 5 flashes – low 24VAC
f. 6 flashes – vent temperature
g. 7 flashes – hi-Limit
h. 8 flashes – sensor fault
i. 9 flashes – low gas pressure
j. 10 flashes – water pressure
k. 11 flashes – blower speed fault
l. 12 flashes – low water cut-off
m. 13 flashes – hi-temperature ∆T
n. 14 flashes – Ft-Bus communications
o. 15 flashes – general safety limit

K. Combustion Chamber: The combustion chamber wrapper shall be insulated to reduce standby

radiation losses, reduce jacket losses and increase unit efficiency.

L. Cabinet

1. The corrosion-resistant galvanized-steel jackets shall be finished with a baked-on powder
coat, which is suitable for outdoor installation, applied prior to assembly for complete
coverage, and shall incorporate louvers in the outer panels to divert air past heated surfaces.

2. The pool heater(s), if located on a combustible floor, shall not require a separate combustible
floor base.

3. The pool heater(s) shall connect both the combustion air and flue products through the back of
the unit.

4. The heater shall have as standard an internal, combustion air filter rated to MERV 8 (>95%
arrestance).

M. Pool Heater Pump – Heater equipped with factory-packaged pump system.

N. Cold Water Protection System

1. The heater(s) shall be configured with a cold water protection automatic proportional bypass
system that ensures the primary heat exchanger will experience inlet temperatures in excess
of 120°F in less than 7 minutes to avoid damaging condensation.

2. The cold water protection system shall be configured with an injection pump (shipped loose)
and a proportional two-way valve that is controlled by a system-matched PID control that
injects the correct amount of cold water directly into the heater loop to maintain the required
minimum inlet temperature. The PID controller temperature sensor shall be located in the inlet
header of the primary heat exchanger.

2.3 POOL HEATER OPERATING CONTROLS

A. The pool heater(s) shall feature a digital controller, mounted and wired.

B. System water sensor and supply-to-pool sensor shall be shipped loose for field-installation by

installing contractor. Inlet/Outlet sensors are factory-installed.

2.4 DIRECT VENT

A. The pool heater(s) shall meet safety standards for direct vent equipment as noted by the 2006

Uniform Mechanical Code, section 1107.6, and ASHRAE 15-1994, section 8.13.6.

2.5 SOURCE QUALITY CONTROL

A. The pool heater(s) shall be completely assembled, wired, and fire-tested prior to shipment from the

factory.

B. The pool heater(s) shall be furnished with the sales order, ASME Manufacturer’s Data Report(s),

inspection sheet, wiring diagram, rating plate and Installation and Operating Manual.

Project Name / Date

- EXECUTION

3.1 INSTALLATION

A. Must comply with:

1. Local, state, provincial, and national codes, laws, regulations and ordinances

2. National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition

3. National Electrical Code, ANSI/NFPA 70 – latest edition

4. Canada only: CAN/CGA B149 Installation Code and CSA C22.1 CEC Part I

5. Manufacturer’s installation instructions, including required service clearances and venting

guidelines

B. Manufacturer’s representative to verify proper and complete installation.

3.2 START-UP

A. Shall be performed by Raypak factory-trained personnel.

B. Test during operation and adjust if necessary:

1. Safeties

2. Operating Controls

3. Static and full load gas supply pressure

4. Gas manifold and blower air pressure

5. Combustion analysis

C. Submit copy of start-up report to Architect and Engineer.

3.3 TRAINING

A. Provide factory-authorized service representative to train maintenance personnel on procedures

and schedules related to start-up, shut-down, troubleshooting, servicing, and preventive
maintenance.

B. Schedule training at least seven days in advance.

END OF SECTION

Project Name / Date