COMMERCIAL MODELS: XTHERM 1005A THROUGH 2005A
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1 COMMERCIAL MODELS: XTHERM 1005A THROUGH 2005A CATALOG NO Effective: Replaces: NEW RAYPAK ILLUSTRATED PARTS LIST MODEL SIZES: 1005A, 1505A & 2005A MODEL TYPES: MODULATING VERTICAL BOILER H, WH & P CAT IV DATES OF MANUFACTURE: THROUGH CURRENT - H MODELS 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
2 6-O 10-C 28-S 8-J 11-C 27-S 3-O 7-O 10-J 8-C 9-C 6-J 4-O 18-S 7-J 26-S 17-C 1-S 35-S 31-S 14-C 16-C 14-S 9-J 19-M 15-C 6-S 4-S 13-S 15-S 7-S 13-S 1-J 5-S 1-C 2-C 17-S 10-S 16-S 19-M 12-S 11-S 5-V 8-S 12-S 30-S 20-M 22-S 20-S 6-V 4-V 1-B 19-S 12-C 13-C 5-B 4-B 1-O 2-V 2-B 3-V 1-H 3-B 1-V 7-V
3 HEAT EXCHANGER DETAIL 8-H 2-S 7-C 7-H 6-C 2-H 4-H 5-H 6-M 3-S 9-M 6-M 5-H 4-H 6-H 1-M 3-H 9-S 7-M SURFACES REQUIRE HIGH-TEMPERATURE RTV SEALANT (ITEM 5-M). FOLLOW MANUFACTURER S INSTRUCTIONS.
4 J-BOX DETAIL 25-S 3-C 2-J 3-J 4-C 2-O 5-C 4-J 5-J GAS TRAIN DETAIL 17-G 12-G 15-G 14-G 16-G 2-G 18-G 5-G 7-G 6-G 5-G 13-G 1-G 11-G 3-G 10-G 11-G
5 BLOWER DETAIL 1-F 5-F MODELS 1005A & 1505A 3-F 7-F 4-F 2-F 4-G 6-F 9-G 8-G MODEL 2005A 1-F 5-F 6-F 29-S 4-G 2-F 9-G 8-G 7-F SURFACES REQUIRE HIGH-TEMPERATURE RTV SEALANT (ITEM 5-M). FOLLOW MANUFACTURER S INSTRUCTIONS.
6 BYPASS DETAIL 4-M 3-M 2-M 1-P 4-P 12-M 3-P 12-M 12-M 2-P 7-P 6-P
7 SECONDARY HEAT EXCHANGER DETAIL CAUTION 24-S PVC VENT ADAPTER IS FACTORY INSTALLED ONLY. NOT AVAILABLE SEPARATELY. 33-S 8-V 10-M 23-S 24-S 8-O 8-M 32-S 11-M 2-HC 3-HC 10-M 34-S 1-HC 13-M 21-S 36-S SURFACES REQUIRE HIGH-TEMPERATURE RTV SEALANT (ITEM 5-M). FOLLOW MANUFACTURER S INSTRUCTIONS.
8 CALL 1005A 1505A 2005A OUT DESCRIPTION B BURNER ASSEMBLY 1-B Adapter Assembly F F F 2-B Adapter Gaskets and Heat Shield 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 Adjustable High Limit 240F Max F F F Auto Reset Adjustable High Limit 200F Max F F F Auto Reset Adjustable High Limit 180F Max F F F 2-C Manual Reset Adjustable High Limit 240F F F F Manual Reset Adjustable High Limit 200F F F F 3-C PIM (Platform Ignition Module) Multi Try F F F PIM (Platform Ignition Module) Single Try CSD F F F 4-C Fuse 5 Amp (Fast Acting) F F F 5-C PC Board VERSA IC F F F 6-C Inlet Sensor (2 Wire) F F F 7-C Outlet/Limit Sensor (4 Wire) F F F 8-C System Water Sensor 10K F F F 9-C Indirect DHW Sensor 10K F F F 10-C Sensor Outdoor Air B F F F 11-C Indirect Tank Aquastat Control B F F F 12-C Flow Switch F F F 13-C Flow Switch Paddle (Taco) F F F 14-C CWR Control (Inverter) N/A N/A N/A 15-C Chip - Inverter Prog N/A N/A N/A 16-C Vent Pressure Switch F F F 17-C Fuse 5 Amp (Pump) (Slow Blow) F F F J CONTROL BOX 1-J Control Box Complete N/A N/A N/A 2-J Transformer 120/ VA F F F 3-J Terminal Block w / Ground Lug F F F 4-J LCD Display PC Board F F F 5-J Switch/Decal Membrane F F F 6-J Pump Contactor 120 VAC (Wiring Box) F F F 7-J Rocker Switch F F F 8-J On / Off Shut Down Switch 30 Amp F F F 9-J Indicator Lamp LED F F F 10-J PC Board Adapter Status Lights Wiring 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 1005A 1505A 2005A OUT DESCRIPTION G GAS TRAIN 1-G Valve Gas Modulating 120V (Dungs) Natural Gas F F F Valve Gas Modulating 120V (Dungs) Propane Gas F F F 2-G Valve Coil 120V Nat F F F Valve Coil 120V Pro F F F 3-G Inlet Gas Filter Natural Gas F F F Inlet Gas Filter Propane Gas 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 w/shutter (Includes O Ring) Natural F F F Adapter Gas Valve Outlet w/shutter (Includes O Ring) Propane 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 Bleedle Valve 1/8 MPT F F F 12-G Motorized Safety Shut Off Valve M-1(Optional) F F F 13-G Gas Valve Body M1 Nat (Optional) F F F Gas Valve Body M1 Pro (Optional) F F F 14-G Solenoid Safety Shut Off Valve M-10 Nat (Optional) F F F Solenoid Safety Shut Off Valve M-10 Pro (Optional) F F F 15-G Vent Valve Gas M-15 Nat (Optional) F F F Vent Valve Gas M-15 Pro (Optional) F F F 16-G Switch Low Gas Pressure (Optional) F F F 17-G Switch Low Gas Pressure w/m-1 or M-10 (Optional) F F F 18-G Switch High Gas Pressure (Optional) F F F H HEAT EXCHANGER (Primary) 1-H Heat Transfer Cupro-Nickel 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 Stud Bolt 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 Window Combustion Chamber F F F 2-M T & P Gauge 0-75 PSI F F F T & P Gauge PSI F F F T & P Gauge PSI F F F 3-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 4-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 Touch-up Paint Green Cool Dark Gray M Wire Harness F F F 17-M LCD Display Wire Harness F F F 18-M LED Status Lights Wire Harness F F F 19-M Plastic Handle F F F 20-M Metal Handle F F F
10 CALL 1005A 1505A 2005A 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 6-O Alarm Bell 4" 24V F F F 7-O Relay 3PDT 24 VAC (Alarm) F F F 8-O Vent Limit Switch Manual Reset PVC Venting F F F Polypropylene Venting 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 F High Temperature Potable Process Bypass Pump Bronze (Medium Water) F F F Bypass Pump Bronze (Hard Water) F F 2-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 Cartridge F F F 6-P Injector Pump Bronze (WH) N/A N/A N/A Injector Pump Bronze (P) N/A N/A N/A 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 Support 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 with Stiffeners F F F 9-S Return Header Cover F F F 10-S Jacket Upper Front Panel w/lcd Display F F F 11-S Jacket Lower Front Panel F F F 12-S Jacket Side/Front Panel F F F 13-S Jacket Side/Rear Panel F F F 14-S Jacket Upper Rear Panel F F F 15-S Access Panel Intake Air F F F 16-S Jacket Lower Rear Panel F F F 17-S Access Panel Lower Rear F F F 18-S Upper Front Panel w/led Lights F F F 19-S Base Assembly F F F 20-S Leg Bracket Primary Heat Exch ( 4 pcs per boiler) F F F 21-S Leg Bracket Condensing Heat Exch ( 2 pcs per boiler) F F F 22-S Base Reflector Panel F F F 23-S Flue Exhaust Adapter Assembly F F F 24-S Flue Exhaust Adapter Assembly PVC N/A N/A N/A 25-S Control Box Assy F F F 26-S Control Box Cover Panel with Digital Display F F F 27-S Control Box Cover Panel with Power Switch F F F 28-S 24V Wiring Panel F F F 29-S Intake Air Adapter (plenum to Duct) N/A N/A F 30-S Intake Air Collar F F F 31-S Access Panel Wiring Box F F F 32-S Access Panel Condensing Heat Exch F F F 33-S Plenum Upper Condensing Heat Exch F F F 34-S Plenum Lower Condensing Heat Exch F F F 35-S Filter Access Cover F F F 36-S Condensate Hose Bracket F F F V VENTING 1-V Outdoor Stack F F F 2-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 Flue Exhaust Adapter for PVC Venting F F F 8-V Flue Exhaust Adapter for Polypropylene Venting
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