Raypak XVers 856-3006 Guide

USER’S INFORMATION MANUAL
CATALOG NO. 3400.581A Effective: 05-15-18 Replaces: 10-18-17 P/N 241716 Rev. 2
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.
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.
Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
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.
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.
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.
L’installation et l’entretien doivent être assurés
par un installateur ou un service d’entretien
qualifié ou par le fournisseur de gaz.
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.
Models 0856 - 3006
Type H

WARNINGS
Pay Attention to These Terms
AADANGER Indicates the presence of immediate hazards which will cause severe personal injury, death or
substantial property damage if ignored.
AAWARNING Indicates the presence of hazards or unsafe practices which could cause severe personal injury,
death or substantial property damage if ignored.
AACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury
or product or property damage if ignored.
CAUTION 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.
NOTE Indicates special instructions on installation, operation, or maintenance which are important but
not related to personal injury hazards.
AADANGER: Make sure the gas on which the boiler will
operate is the same type as that specied on the heater
rating plate.
AAWARNING: Boiler using propane gas are dierent from
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.
AAWARNING: Do not use this heater if any part has
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.
AAWARNING: To minimize the possibility of improper
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.
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.
AAWARNING: Risk of electrical shock. More than one
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.
AAWARNING: Should overheating occur or the gas
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.
AACAUTION: If this boiler is to be installed in a negative
or positive pressure equipment room, there are special
installation requirements. Consult factory for details.
AAWARNING: Both natural gas and propane have an
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.
Revision 2 reects the following changes:
Removed California Proposition 65 warning.

A. Cet appareil ne comporte pas de veilleuse. Il est
muni d’un dispositif d’allumage qui allume automa-
tique-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.
- 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’ap-
pareil par un technicien qualifié et remplacez toute
partie du sys-tème de contrôle et toute commande
qui ont été plongés dans l’eau.
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.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE
INSTRUCTIONS DE MISE EN MARCHE
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 automa-
tique-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
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’admis-
sion de gaz de l’appareil” et appelez un technicien
qualifie ou le fournisseur de gaz.
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.
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.

F10446
WATER INLET
3" FLANGE
FLUE
OUTLET
CONDENSATE
DRAIN 1" NPT
GAS SUPPLY
CONNECTION WATER OUTLET
3" FLANGE
UNIT HIGH
VOLTAGE WIRING
HEAT
EXCHANGER
DRAIN
CONDENSATE
SWITCH
(BEHIND COVER)
RATING PLATE
PRESSURE RELIEF VALVE
TEMP INLET
SENSOR
(NOT SHOWN)
Component Locations
Fig. 1: Component Locations — Sides
Figure 2. Component Locations — Front View Figure 3. Component Locations — Rear View
F10444
CONTROL BOX
FRONT OF HEATER
GAS VALVE
GAS TRAIN
HEAT EXCHANGER
T & P GAUGE
FLOW SWITCH
GAS SUPPLY
CONNECTION
WATER OUTLET
(3" FLANGE)
FLOW SENSOR
WATER INLET
(3" FLANGE)
OPTIONAL LOW GAS
PRESSURE SWITCH
VENT TEMP SENSOR
LOW WATER PROBE
HIGH GAS
PRESSURE SWITCH
(OPTIONAL ON
MODELS 0856-2506)
GAS SHUTTER
PIM
HIGH VOLTAGE
SWITCH
VERSA BOARD
3-POSITION
LOW VOLTAGE
SWITCH
TOUCHSCREEN
DISPLAY
LOW
VOLTAGE
FIELD
CONNECTION
AIR FILTER
BEHIND COVER
RESET BUTTON
ASME DATA PLATE
* AUTO RESET
HIGH LIMIT
(BEHIND CORNER
POST)
* MANUAL RESET
HIGH LIMIT
(BEHIND
CORNER POST)
F10445
* Optional equipment
TRANSFORMER
BOX
BLOCKED VENT
PRESSURE SWITCH

drain is inspected and ensure that condensate is
being directed to appropriate condensate treat-
ment system or drain, as required by local codes.
3. Check that area is free from combustible mate-
rials, 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.
6. Check flame strength signal as noted on display.
Remove and visually inspect hot surface igniter
and sensor for damage, cracking or debris build-
up.
7. Check operation of safety devices. Refer to manu-
facturers’ instructions.
8. Follow oil-lubricating instructions on pump (if
re-quired). Over-oiling will damage pump. Water-
lubricated 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 instruc-
tions on valve.
2. Test low water cut-off (if equipped). Refer to man-
ufacturer’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.)
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.
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 func-
tion, deterioration or leakage.
3. Visually inspect for proper operation of the con-
densate 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.
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

Weekly
For low-pressure boilers, test low-water cut-off device.
(With boiler in pre-purge, depress the low water cut-
off 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.
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 record-
ed 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 mani-
fold pressure. (See “Manifold Check” in the I&O
Manual.)
4. Check piping and wiring of all interlocks and shut-
off valves.
5. Check air filter and replace as necessary.
Annually
1. Test flame failure detection system and pilot turn-
down.
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 pro-
pane 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
solution (while boiler is operating). Test other oper-
ating 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 test-
ed.
6. Perform leakage test on gas valves (See I&O
Manual).
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 pres-
sure. (See “Manifold Check” on I&O Manual).
7. Test safety/safety relief valves in accordance with
ASME Heater and Pressure Vessel Code Section
IV.
8. Inspect filter and replace as necessary.

www.raypak.com
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] Fax [phone]
Litho in U.S.A.