COMMERCIAL MODELS: XTHERM 1005 THROUGH 2005
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1 COMMERCIAL MODELS: XTHERM 1005 THROUGH 2005 CATALOG NO Effective: Replaces: RAYPAK ILLUSTRATED PARTS LIST MODEL SIZES: 1005, 1505 & 2005 MODEL TYPES: MODULATING VERTICAL BOILER H, WH, & WHP CAT IV DATES OF MANUFACTURE: THROUGH CURRENT THE PARTS LISTED ARE FOR STANDARD EQUIPMENT FOR THIS MODEL TYPE. RAYPAK RESERVES THE RIGHT TO SUBSTITUTE, DELETE OR CHANGE ANY PART WITHOUT NOTIFICATION. THE ADDITION OF OPTIONS MAY ALSO CHANGE SOME OF THE PARTS. ORDER REPLACEMENT PARTS FROM ACTUAL HEATER COMPONENTS. FOR DETAILED INSTRUCTIONS, SEE "HOW TO USE YOUR RAYPAK ILLUSTRATED PARTS LIST", CATALOG NO Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA (805) FAX (805) Litho In U.S.A. P/N
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3 HEAT EXCHANGER DETAIL SURFACES REQUIRE HIGH-TEMPERATURE RTV SEALANT (ITEM 5-M). FOLLOW MANUFACTURER S INSTRUCTIONS.
4 J-BOX DETAIL GAS TRAIN DETAIL
5 BLOWER DETAIL MODELS 1005 & 1505 MODEL 2005 SURFACES REQUIRE HIGH-TEMPERATURE RTV SEALANT (ITEM 5-M). FOLLOW MANUFACTURER S INSTRUCTIONS.
6 BYPASS DETAIL
7 SECONDARY HEAT EXCHANGER DETAIL CAUTION 39-S PVC VENT ADAPTER AVAILABLE FOR REPAIR ONLY. NOT AVAILABLE FOR FIELD CONVERSION. SURFACES REQUIRE HIGH-TEMPERATURE RTV SEALANT (ITEM 5-M). FOLLOW MANUFACTURER S INSTRUCTIONS.
8 CALL OUT DESCRIPTION B BURNER ASSEMBLY 1-B Adapter Assembly F F F 2-B Adapter Gaskets and Heat Sheild F F F 3-B Flame Sensor Probe F F F 4-B Igniter F F F 5-B Burner F F F C CONTROLS 1-C Auto Reset Adjustible High Limit 240F Max F F F Auto Reset Adjustible High Limit 180F Max F F F Auto Reset Adjustible High Limit 200F Max F F F 2-C Manual Reset Adjustible High Limit 240F F F F Manual Reset Adjustible High Limit 200F F F F 3-C Manual Reset Fixed High Limit 240F F F F Manual Reset Fixed High Limit 200F F F F 4-C Remote Aquastat (Tankstat) 2-Stage B-3 (Not Shown) F F F 5-C Controller Modulating (Tekmar) H7 & WH F F F Controller On/Off (Tekmar) WHP F F F 6-C Controller 4-Stage B-21 / B-23 Digital Optional (Not Shown) F F F Controller 2-Stage B-26 / B-27 Digital Optional (Not Shown) F F F 7-C Sensor Outdoor Air B-23 / B F F F 8-C Sensor Water B-21 thru B F F F 9-C Sensor Water screw-in (Tekmar) F F F 11-C Flow Switch F F F 12-C Printed Circuit Board UDB (Diagnostic) F F F 13-C Printed Circuit Board UGB (Blower) N/A N/A F 14-C Printed Circuit Board CWR F F F 20-C Relay DPDT 24VDC F F F 15-C CWR Control (Inverter) F F F 19-C Chip - Inverter Prog F F F 16-C Diagnostic Display F F F 17-C Air Vent Pressure Switch F F F 18-C Air Intake Pressure Switch F F F J CONTROL BOX 1-J Control Box Complete N/A N/A N/A 2-J Transformer 120/ VA F F N/A Transformer 120/ VA N/A N/A F 3-J Terminal Block w / Ground Lug F F F 4-J Terminal Block 2 Space F F F 5-J Blower Relay 120 VAC F F N/A 6-J Pump Relay 24 VAC F F F 7-J Pump Contactor 120 VAC F F F 14-J Relay DPDT 24VAC F F F 8-J Relay SPDT 24 VAC (Alarm) F F F Relay SPDT 24 VAC (Enable/Disable) F F F Relay SPDT 24 VAC (Remote Status) F F F 9-J Ignition Control HSI Single Try F F F Ignition Control HSI Three Try F F F 10-J Rocker Switch (Burner / Pump) F F F 11-J On / Off Shut Down Switch F F F 12-J Reset Switch (CWR) F F F 13-J Indicator Lamp F F F F FAN 1-F Blower Combustion Air F F F 2-F Adapter Gasket F F F 3-F Adapter Gasket F F N/A 4-F Adapter Plate F F N/A 5-F Plenum Assembly F F F 6-F Air Shutter F F F 7-F Hose Duct 6" F F N/A Hose Duct 8" N/A N/A F
9 CALL OUT DESCRIPTION G GAS TRAIN 1-G Valve Gas Modulating (Dungs) Natural Gas F F F Valve Gas Modulating (Dungs) Propane Gas F F F 2-G Valve Coil Nat F F F Valve Coil Pro F F F 3-G Inlet Gas Filter F F F 4-G Swirler F F F 5-G O Rings (Includes Gas Valve and Adapter O Rings) F F F 6-G Adapter Gas Valve 1" Inlet (Includes O Rings) F F F Adapter Gas Valve 1-1/4" Inlet (Includes O Rings) F F N/A Adapter Gas Valve 2" Inlet (Includes O Rings) N/A N/A F 7-G Adapter Gas Valve Outlet (Includes Venturi & O Ring) F F F 8-G Adapter Swirl Plate F F F 9-G Nozzle Natural Gas F F F Nozzle Propane Gas F F F 10-G Valve Gas Ball (WOG) F F F 11-G Motorized Safety Shut Off Valve (Optional Not Shown) F F F 12-G Solenoid Safety Shut Off Valve Nat (Optional) F F F Solenoid Safety Shut Off Valve Pro (Optional) F F F 13-G Vent Valve Gas Nat (Optional) F F F Vent Valve Gas Pro (Optional) F F F 14-G Switch Low Gas Pressure (Optional) F F F 15-G Switch High Gas Pressure (Optional) F F F H HEAT EXCHANGER (Primary) 1-H Heat Transfer Cupro-Nickle Bronze (Includes 18-S) F F F Heat Transfer Cupro-Nickel Cast Iron (Includes 18-S) F F F Heat Transfer Copper Bronze (Includes 18-S) F F F Heat Transfer Copper Cast Iron (Includes 18-S) F F F 2-H Inlet/Outlet Header Bronze F F F Inlet/Outlet Header Cast Iron F F F 3-H Return Header Bronze F F F Return Header Cast Iron F F F 4-H Studbolt F F F 5-H Header Gasket (20 PCS) F F F 6-H Drain Valve F F F 7-H Air Vent Valve F F F 8-H Air Vent Waste Connector Adapter F F F HS HEAT EXCHANGER (Condensing) 1-HC Heat Exch Stainless Steel (Includes 21-S) F F F 2-HC Condensate Float Switch F F F 3-HC O Ring Seal F F F M MISCELLANEOUS COMPONENTS 1-M Flow Switch Paddle (Taco) F F F 2-M Window Combustion Chamber F F F 3-M T & P Gauge 0-90 PSI F F F T & P Gauge PSI F F F 4-M PRV 30 PSI F F F PRV 45 PSI F F F PRV 60 PSI F F F PRV 75 PSI F F F PRV 125 PSI F F F PRV 150 PSI F F F 21-M UV PRV 150 PSI F F F 5-M RTV Sealant 2.8 oz (Not Shown) F F F RTV Sealant 10 oz (Not Shown) F F F 6-M Flue Collector Vertical Seal Gasket F F F 7-M Insulation Blanket Return Header F F F 8-M Flue Exhaust Adapter Gasket Round F F F 9-M Flue Exhaust Adapter Gasket Rectangle F F F 10-M Plenum Gasket Upper and Lower F F F 11-M Access Panel Gasket Condensing Heat Exch F F F 12-M Flange Gasket 2" or 2-1/2" NPT F F F 13-M Condensate Hose F F F 14-M Condensate Neutralizer (Not Shown) M Membrane Switch F F F 16-M Touch up Paint (Green) Not Shown Touch up Paint (Dark Gray) Not Shown M Inlet/Outlet Water Grommet 2-1/2" NPT F F F PRV Discharge Grommet 1" Thru 1-1/4" NPT F F F 18-M Wire Harness F F F 20-M Plastic Handle F F F
10 CALL OUT DESCRIPTION O OPTIONS 1-O Remote Sensor (LWCO) F F F 2-O Control PC Board (LWCO) F F F 3-O Test / Reset Switch (LWCO) F F F 4-O Silencer/Reset Switch (Alarm) F F F 5-O Alarm Bell 3" F F F Alarm Bell 4" F F F 6-O Relay DPDT 24 VAC (Alarm) F F F 7-O Flue Exhaust Temp Limit 162 F F F F P PUMPS 1-P Bypass Pump Bronze (Soft Water) F F F Bypass Pump Bronze (Medium Water) F F F Bypass Pump Bronze (Hard Water) F F Bypass Pump CI F F P Pump Flange Gasket F F F 3-P Dual Injector Pump Bronze F F F Dual Injector Pump CI F F F 4-P Pump Flange Gasket F F F 5-P Pump Cartrige F F F 6-P Injector Pump Bronze (WH) F F Injector Pump Bronze (WHP) F F F 7-P Pump Flange Gasket F F F S SHEETMETAL 1-S Jacket Top F F F 2-S Flue Collector Front (No Opening) (Includes 6-M) F F F 3-S Flue Collector Rear (Opening) (Includes 6-M and 9-M) F F F 4-S Heat Transfer Supports F F F 5-S Upper Cabinet Supports Front F F F 6-S Upper Cabinet Supports Rear F F F 7-S Upper Cabinet Supports Side F F F 8-S Vertical Cabinet Supports F F F 9-S Return Header Cover F F F 10-S Jacket Upper Front Panel F F F 11-S Jacket Lower Front Panel F F F 12-S Jacket Side Panel F F F 13-S Jacket Upper Rear Panel F F F 14-S Access Panel Intake Air F F F 15-S Jacket Lower Rear Panel F F F 16-S Access Panel Lower Rear F F F 17-S Base Assembly F F F 18-S Leg Bracket Primary Heat Exch ( 4 pcs per boiler) F F F 19-S Leg Bracket Condensing Heat Exch ( 2 pcs per boiler) F F F 20-S Base Reflector Panel F F F 21-S Flue Exhaust Adapter Assembly F F F 39-S Flue Exhaust Adapter Assembly PVC F F F 22-S Control Box Assy F F F 23-S Control Box Cover Panel w/display F F F 24-S Control Box Cover Panel F F F 25-S Power Switch Mounting Panel F F F 26-S Blower/Pump Switch Mounting Panel F F F 27-S Controller Mounting Panel F F F 28-S CWR Control Mounting Panel F F F 29-S Control Box Blank Cover Long F F F 30-S Control Box Blank Cover Short F F F 31-S 24V Wiring Panel F F F 32-S Intake Air Adapter (plenum to Duct) N/A N/A F 33-S Intake Air Collar F F F 34-S Access Panel Wiring Box F F F 35-S Access Panel Condensing Heat Exch F F F 36-S Plenum Upper Condensing Heat Exch F F F 37-S Plenum Lower Condensing Heat Exch F F F 38-S Filter Access Cover F F F 40-S Condensate Hose Bracket F F F V VENTING 1-V Outdoor Stack V Vent Cap Vertical for Indoor Units V Vent Cap Horizontal Thru-the-Wall for Indoor Units V Intake Air filter Box F F F 5-V Air Filter Media F F F 6-V Condensate Drip Pan F F F 7-V Vent Termination Adapter PVC F F F
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