Raypak XVers 856-3006 User's Information Manual

USER’S INFORMATION MANUAL

Models 0856 - 3006

Type H

WARNING: If the information in this manual
is not followed exactly, a fire or explosion
may result causing property damage, personal
injury or loss of life.

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 in an explosion
or fire.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do
not use any phone in your building.

• Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.

• If you cannot reach your gas supplier,
call the fire department.

Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.

AVERTISSEMENT: Assurez-vous de bien suivres
les instructions données dans cette notice
pour réduire au minimum le risque d’incendie
ou d’explosion ou pour éviter tout dommage
matériel, toute blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ni
d’autres vapeurs ou liquides inflammables dans
le voisinage de cet appareil ou de tout autre
appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAZ:

• Ne pas tenter d’allumer d’appareils.

• Ne touchez à aucun interrupteur. Ne pas
vous servir des téléphones dansle bâtiment
où vous vous trouvez.

• Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivez les instructions
du fournisseur.

• Si vous ne pouvez rejoindre le fournisseur
de gaz, appelez le sservice des incendies.

L’installation et l’entretien doivent être assurés
par un installateur ou un service d’entretien
qualifié ou par le fournisseur de gaz.

CATALOG NO. 3400.581A Effective: 05-15-18 Replaces: 10-18-17 P/N 241716 Rev. 2

WARNINGS

Pay Attention to These Terms

DANGER

AA

WARNING

AA

CAUTION

AA

CAUTION

NOTE

DANGER: Make sure the gas on which the boiler will

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operate is the same type as that specied on the heater

rating plate.

WARNING: Boiler using propane gas are dierent from

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natural gas models. A natural gas heater will not function
safely on propane and vice versa. Conversions of boiler
gas type should only be made by qualied installers using
factory supplied components. The heater should only
use the fuel type in accordance with listing on rating
plate. Any other fuel usage will result in death or serious
personal injury from re and/or explosion.

WARNING: Should overheating occur or the gas

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supply valve fail to shut, do not turn o or disconnect the
electrical supply to the heater. Instead, shut o the gas
supply at a location external to the heater.

WARNING: Do not use this heater if any part has

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been under water. Immediately call a qualied service
technician to inspect the heater and to replace any part
of the control system and any gas control which has been
under water.

Indicates the presence of immediate hazards which will cause severe personal injury, death or
substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause severe personal injury,
death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause minor personal injury
or product or property damage if ignored.

CAUTION used without the warning alert symbol indicates a potentially hazardous condition
which could cause minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which are important but
not related to personal injury hazards.

CAUTION: This boiler requires forced water circulation

when the burner is operating. See I&O Manual for ow

rate information. Severe damage will occur if the heater

is operated without proper water ow circulation.

WARNING: Risk of electrical shock. More than one

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disconnect switch may be required to de-energize the
equipment before servicing.

NOTE: Minimum pipe size for the heater inlet/outlet
connections is dependent on the equivalent length of
piping between the load loop and the heater loop, the
operating conditions and the size of the heater.

WARNING: Both natural gas and propane have an

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odorant added to aid in detecting a gas leak. Some people
may not physically be able to smell or recognize this
odorant. If you are unsure or unfamiliar with the smell
of natural gas or propane, ask your local gas supplier.
Other conditions, such as “odorant fade,” which causes
the odorant to diminish in intensity, can also hide,
camouage, or otherwise make detecting a gas leak by
smell more dicult.

WARNING: To minimize the possibility of improper

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operation, serious personal injury, re, or damage to the

heater:

• Always keep the area around the heater free of

combustible materials, gasoline, and other ammable
liquids and vapors.

• Heater should never be covered or have any blockage
to the ow of fresh air to the heater.

Revision 2 reects the following changes:

Removed California Proposition 65 warning.

CAUTION: If this boiler is to be installed in a negative

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or positive pressure equipment room, there are special
installation requirements. Consult factory for details.

POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE

AVERTISSEMENT: Quiconque ne respecte pas
à la lettre les instructions dans la présente notice
risque de déclencher un incendie ou une explosion
entraî-nant des dommages, des blessures ou la
mort.

A. Cet appareil ne comporte pas de veilleuse. Il est

muni d’un dispositif d’allumage qui allume automa­tique-ment le brûleur. Ne tentez pas d’allumer le
brûleur manuellement.

B. AVANT DE FAIRE FONCTIONNER, reniflez tout

autour de l’appareil pour déceler une odeur de
gaz. Reniflez près du plancher, car certains gaz
sont plus lourds que l’air et peuvent s’accumuler
au niveau du sol.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAZ:

- Ne pas tenter d’allumer d’appareil.

INSTRUCTIONS DE MISE EN MARCHE

- Ne touchez à aucun interrupteur; ne pas
vous servir des téléphones se trouvant dans
le bâtiment.

- Appelez immédiatement votre fournisseur de gaz

depuis un voisin. Suivez les instructions du four-

nisseur.

- Si vous ne pouvez rejoindre le fournisseur, appelez
le service des incendies.

C. Ne poussez ou tournez la manette d’admission

du gaz qu’à la main; ne jamais utiliser d’outil. Si la
manette reste coincée, ne pas tente de la réparer;
appelez un technicien qualifié. Le fait de forcer
la manette ou de la réparer peut déclencher une
explosion ou un in-cendie.

D. N’utilisez pas cet appareil s’il a été plongé dans

l’eau, même partiellement. Faites inspecter l’ap­pareil par un technicien qualifié et remplacez toute
partie du sys-tème de contrôle et toute commande
qui ont été plongés dans l’eau.

1. ARRÊTEZ! Lisez les instructions de sécurité sur la
portion supérieure de cette étiquette.

2. Réglez le thermostat à la température la plus
basse.

3. Coupez l’alimentation électrique de l’appareil.

4. Cet appareil ne comporte pas de veilleuse. Il est
muni d’un dispositif d’allumage qui allume automa­tique-ment le brûleur. Ne tentez pas d’allumer le
brûleur manuellement

5. Enlever le panneau de porte du réchauffeur.

6. Enfoncer légèrement le bouton de commande de
gaz et le tourner dans le sens horaire a la position
(Off).

7. Attendre cinq (5) minutes pour laisser échapper
tout le gaz. Reniflez tout autour de l’appareil,
y compris près du plancher, pour déceler une

COMMENT COUPER L’ADMISSION DE GAZ DE L’APPAREIL

1. Réglez le thermostat à la température la plus
basse.

2. Coupez l’alimentation électrique de l’appareil s’il
faut procéder à l’entretien.

3. Enlever le panneau de porte du chauffe-eau.

odeur de gaz. Si vous sentez une odeur de gaz,
ARRÊTEZ! Pas-sez à l’étape B des instructions
de sécurité sur la portion supérieure de cette
étiquette. S’il n’y a pas d’odeur de gaz, passer à
l’étape suivante.

8. Tourner le bouton de commande de gaz dans le
sens antihoraire à la position (ON).

9. Reposer le panneau de porte du réchauffeur.

10. Rétablir toutes les alimentations électriques de
l’appa-reil.

11. Réglez le thermostat à la température désirée.

12. Si l’appareil ne se met pas en marche, suivre les
ins-tructions intitulées “Comment couper l’admis­sion de gaz de l’appareil” et appelez un technicien
qualifie ou le fournisseur de gaz.

4. Tourner le bouton de commande de gaz dans le
sens horaire à la position (OFF). S’assurer que le
bouton reste contre l’arrêt.

5. Replacer le panneau de porte du chauffe-eau.

OUTLET

Component Locations

F10444

GAS SUPPLY

PRESSURE SWITCH

HIGH GAS

(OPTIONAL ON

MODELS 0856-2506)

GAS SHUTTER

CONTROL BOX

FRONT OF HEATER

GAS TRAIN

GAS VALVE

OPTIONAL LOW GAS
PRESSURE SWITCH

CONNECTION

FLOW SWITCH

WATER OUTLET
(3" FLANGE)

T & P GAUGE

LOW WATER PROBE

HEAT EXCHANGER

FLOW SENSOR

WATER INLET
(3" FLANGE)

RESET BUTTON

AIR FILTER

BEHIND COVER

LOW

VOLTAGE

FIELD

CONNECTION

VERSA BOARD

PIM

TRANSFORMER

* Optional equipment

BOX

F10445

Fig. 1: Component Locations — Sides

* AUTO RESET
HIGH LIMIT
(BEHIND CORNER
POST)

TOUCHSCREEN
DISPLAY

3-POSITION
LOW VOLTAGE
SWITCH

* MANUAL RESET
HIGH LIMIT
(BEHIND
CORNER POST)

BLOCKED VENT
PRESSURE SWITCH

ASME DATA PLATE

HIGH VOLTAGE
SWITCH

GAS SUPPLY

CONNECTION

UNIT HIGH

VOLTAGE WIRING

RATING PLATE

TEMP INLET

SENSOR

(NOT SHOWN)

WATER INLET

3" FLANGE

HEAT

EXCHANGER

DRAIN

CONDENSATE

DRAIN 1" NPT

CONDENSATE

SWITCH

(BEHIND COVER)

VENT TEMP SENSOR

PRESSURE RELIEF VALVE

WATER OUTLET
3" FLANGE

FLUE

Figure 2. Component Locations — Front View

Figure 3. Component Locations — Rear View

MAINTENANCE

Suggested Minimum
Maintenance Schedule

Regular service by a qualified service agency and
maintenance must be performed to ensure maximum
operating efficiency.

Maintenance as outlined below may be performed by
the owner.

drain is inspected and ensure that condensate is
being directed to appropriate condensate treat­ment system or drain, as required by local codes.

3. Check that area is free from combustible mate­rials, gasoline, and other flammable vapors and
liquids.

4. Check for and remove any obstruction to the flow
of combustion or ventilation air to boiler.

5. Follow pre-start-up check in the Start-up section.

Daily

1. Check that the area where the boiler is installed
is free from combustible materials, gasoline, and
other flammable vapors and liquids.

2. Check for and remove any obstruction to the flow
of combustion or ventilation air to boiler.

Monthly

1. Check for piping leaks around pumps, mixing
valves, relief valves, and other fittings. If found,
repair at once. DO NOT use petroleum-based
stop-leak compounds.

2. Visually inspect venting system for proper func­tion, deterioration or leakage.

3. Visually inspect for proper operation of the con­densate drains in the venting, and the internal
condensate trap. Clean trap as necessary. If leaks
are observed, repair at once.

4. Check air vents for leakage.

6. Check flame strength signal as noted on display.
Remove and visually inspect hot surface igniter
and sensor for damage, cracking or debris build­up.

7. Check operation of safety devices. Refer to manu­facturers’ instructions.

8. Follow oil-lubricating instructions on pump (if
re-quired). Over-oiling will damage pump. Water­lubricated circulators do not need oiling.

9. To avoid potential of severe burn, DO NOT REST
HANDS ON OR GRASP PIPES. Use a light touch;
return piping will heat up quickly.

10. Check blower and blower motor

11. Check for piping leaks around pumps, relief valves
and other fittings. Repair, if found. DO NOT use
petroleum-based stop-leak.

Periodically

1. Check relief valve. Refer to manufacturer’s instruc­tions on valve.

Yearly (Beginning Of Each Heating
Season)

Schedule annual service call by qualified service
agency.

1. Visually check top of vent for soot. Call service
person to clean. Some sediment at bottom of vent
is normal.

2. Visually inspect venting system for proper function,
deterioration or leakage. Ensure that condensate

2. Test low water cut-off (if equipped). Refer to man­ufacturer’s instructions.

Preventive Maintenance
Schedule

The following procedures are recommended and are
good practice for all XVers installations.

Daily

1. Check gauges, monitors and indicators.

2. Check instrument and equipment settings.
(See “Post Start-Up Check” in the I&O Manual.)

Weekly

For low-pressure boilers, test low-water cut-off device.
(With boiler in pre-purge, depress the low water cut­off test button. Boiler should shut-off and ignition fault
light should come on. Depress reset button on front of
boiler control panel to reset).

Monthly

1. Check flue, vent, stack, or outlet dampers.

5. Check valve coil for 60 cycle hum or buzz. Check
for leaks at all valve fittings using a soapy water
solution (while boiler is operating). Test other oper­ating parts of all safety shut-off and control valves
and increase or decrease settings (depending on
the type of control) until the safety circuit opens.
Reset to original setting after each device is test­ed.

6. Perform leakage test on gas valves (See I&O
Manual).

2. Test blower air pressure. (See the I&O Manual.)
Replace the filter when the intake air pressure
increases by –0.5 in. WC from the reading record­ed on the start-up checklist.

3. Test high and low gas pressure interlocks (if
equipped). (See “Safety Inspection” in the I&O
Manual.)

Semi-Annually

1. Recalibrate all indicating and recording gauges.

2. Check flame failure detection system components.

3. Check firing rate control by checking the mani­fold pressure. (See “Manifold Check” in the I&O
Manual.)

4. Check piping and wiring of all interlocks and shut­off valves.

5. Check air filter and replace as necessary.

Annually

7. Inspect and clean burner using shop air (See I&O
Manual).

As Required

1. Recondition or replace low water cut-off device.

2. Check drip leg and gas strainers.

3. Check flame failure detection system. (See “Post
Start-Up Check” in the I&O Manual.) Verify high
and low fire flame signal, compare to start-up data,

4. Check flame signal strength as noted on display.

5. Check igniter (Resistance reading should be
40-75 ohms at 77°F (25°C).

6. Check firing control by checking manifold pres­sure. (See “Manifold Check” on I&O Manual).

7. Test safety/safety relief valves in accordance with
ASME Heater and Pressure Vessel Code Section
IV.

1. Test flame failure detection system and pilot turn­down.

2. Test high limit and operating temperature. (See
“Post Start-Up Check” in the I&O Manual.)

3. Check flame sensor.

4. Conduct a combustion test at high and low fire.
Carbon dioxide should be 8.6 to 9.4% at full fire
for natural gas, and between 9.9 to 10.7% for pro­pane gas. Carbon monoxide should be <100 ppm.

8. Inspect filter and replace as necessary.

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