CATALOG NO. 9300.742
COMMERCIAL
MODELS: XTHERM 1005 THROUGH 2005
Effective:
Replaces:
09-01-08
NEW
RAYPAK ILLUSTRATED PARTS LIST
MODEL SIZES: 1005, 1505 & 2005
MODEL TYPES: MODULATING VERTICAL BOILER H, WH, & WHP CAT IV
DATES OF MANUFACTURE: 09-01-08 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. 9001.10
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030
(805) 278-5300 FAX (805) 278-5489
Litho In U.S.A.
P/N 241345
HEAT EXCHANGER DETAIL
J-BOX DETAIL
BLOWER DETAIL
MODELS 1005 & 1505
MODEL 2005
GAS TRAIN DETAIL
BYPASS DETAIL
SECONDARY HEAT EXCHANGER DETAIL
CALL
OUT
B
1005
1505
2005
DESCRIPTION
BURNER ASSEMBLY
Adapter Assembly
1-B
011749F
011751F
011752F
007400F
011754F
011749F
011751F
011752F
007400F
011755F
011750F
011751F
011752F
007400F
011756F
2-B
Adapter Gaskets and Heat Sheild
Flame Sensor Probe
3-B
4-B
5-B
Igniter
Burner
C
CONTROLS
1-C
Auto Reset Adjustible High Limit 240F Max
Auto Reset Adjustible High Limit 180F Max
Auto Reset Adjustible High Limit 200F Max
Manual Reset Adjustible High Limit 240F
Manual Reset Adjustible High Limit 200F
Manual Reset Fixed High Limit 240F
Manual Reset Fixed High Limit 200F
Remote Aquastat (Tankstat) 2-Stage B-3 (Not Shown)
Controller Modulating (Tekmar) H7 & WH7
Controller On/Off (Tekmar) WHP
Controller 4-Stage B-21 / B-23 Digital Optional (Not Shown)
Controller 2-Stage B-26 / B-27 Digital Optional (Not Shown)
Sensor Outdoor Air B-23 / B-27
Sensor Water B-21 thru B-27
Sensor Water screw-In (Tekmar)
Sensor Water (Temp Tracker) B-36 thru B-38
Flow Switch
011860F
006445F
012546F
007144F
008081F
008520F
008093F
007392F
012407F
012253F
009862F
009861F
010786F
010787F
011861F
012187F
007142F
012571F
N/A
011860F
006445F
012546F
007144F
008081F
008520F
008093F
007392F
012407F
012253F
009862F
009861F
010786F
010787F
011861F
012187F
007142F
012571F
N/A
011860F
006445F
012546F
007144F
008081F
008520F
008093F
007392F
012407F
012253F
009862F
009861F
010786F
010787F
011861F
012187F
007142F
012571F
011759F
011717F
012661F
012662F
011760F
011761F
2-C
3-C
4-C
5-C
6-C
7-C
8-C
9-C
10-C
11-C
12-C
13-C
14-C
15-C
16-C
17-C
18-C
Printed Circuit Board UDB (Diagnostic)
Printed Circuit Board UGB (Blower)
Printed Circuit Board CWR
CWR Control (Inverter)
Diagnostic Display
Air Vent Pressure Switch
011717F
012661F
012662F
011760F
011761F
011717F
012661F
012662F
011760F
011761F
Air Intake Pressure Switch
J
CONTROL BOX
Control Box Complete
Transformer 120/24 100 VA
Transformer 120/24 150 VA
Terminal Block w / Ground Lug
Terminal Block 2 Space
Blower Relay 120 VAC
Pump Relay 24 VAC
Pump Contactor 120 VAC
Relay SPDT 24 VAC (Alarm)
Relay SPDT 24 VAC (Enable/Disable)
Relay SPDT 24 VAC (Remote Status)
Ignition Control HSI Single Try
Ignition Control HSI Three Try
Rocker Switch (Burner / Pump)
On / Off Shut Down Switch
Reset Switch (CWR)
1-J
2-J
N/A
007373F
N/A
N/A
007373F
N/A
N/A
N/A
011762F
008523F
011763F
N/A
007925F
007906F
009039F
009039F
009039F
009057F
007374F
006872F
007380F
005641F
011848F
3-J
4-J
5-J
6-J
7-J
8-J
008523F
011763F
008977F
007925F
007906F
009039F
009039F
009039F
009057F
007374F
006872F
007380F
005641F
011848F
008523F
011763F
008977F
007925F
007906F
009039F
009039F
009039F
009057F
007374F
006872F
007380F
005641F
011848F
9-J
10-J
11-J
12-J
13-J
Indicator Lamp
F
FAN
1-F
2-F
3-F
4-F
5-F
Blower Combustion Air
Adapter Gasket
Adapter Gasket
Adapter Plate
Plenum Assembly
Air Shutter
Hose Duct 6"
Hose Duct 8"
012444F
011885F
011886F
011887F
011863F
011875F
007420F
N/A
012446F
011885F
011886F
011887F
011863F
011875F
007420F
N/A
011765F
011885F
N/A
N/A
011864F
011876F
N/A
6-F
7-F
012680F
G
GAS TRAIN
1-G
Valve Gas Modulating (Dungs) Natural Gas
Valve Gas Modulating (Dungs) Propane Gas
Valve Coil Nat
Valve Coil Pro
Inlet Gas Filter
011766F
011766F
012310F
012310F
012294F
011888F
012440F
011915F
011916F
N/A
012545F
012298F
012301F
012308F
011769F
011908F
011910F
011909F
011914F
011913F
011770F
011771F
011766F
011766F
012310F
012310F
012294F
011888F
012440F
011915F
011916F
N/A
012545F
012298F
012303F
012308F
011769F
011908F
011910F
011909F
011914F
011913F
011770F
011771F
011768F
011766F
012311F
012310F
012295F
011889F
012441F
011915F
N/A
011917F
012297F
012298F
012305F
012301F
011769F
011908F
011911F
011909F
011914F
011913F
011770F
011771F
2-G
3-G
4-G
5-G
6-G
Swirler
O Rings (Includes Gas Valve and Adapter O Rings)
Adapter Gas Valve 1" Inlet (Includes O Rings)
Adapter Gas Valve 1-1/4" Inlet (Includes O Rings)
Adapter Gas Valve 2" Inlet (Includes O Rings)
Adapter Gas Valve Outlet (Includes Venturi & O Ring)
Adapter Swirl Plate
Nozzle Natural Gas
Nozzle Propane Gas
Valve Gas Ball (WOG)
Motorized Safety Shut Off Valve (Optional Not Shown)
Solenoid Safety Shut Off Valve Nat (Optional)
Solenoid Safety Shut Off Valve Pro (Optional)
Vent Valve Gas Nat (Optional)
Vent Valve Gas Pro (Optional)
Switch Low Gas Pressure (Optional)
Switch High Gas Pressure (Optional)
7-G
8-G
9-G
10-G
11-G
12-G
13-G
14-G
15-G
CALL
OUT
H
1005
1505
2005
DESCRIPTION
HEAT EXCHANGER (Primary)
Heat Transfer Cupro-Nickle Bronze (Includes 18-S)
Heat Transfer Cupro-Nickel Cast Iron (Includes 18-S)
Heat Transfer Copper Bronze (Includes 18-S)
Heat Transfer Copper Cast Iron (Includes 18-S)
Inlet/Outlet Header Bronze
Inlet/Outlet Header Cast Iron
Return Header Bronze
Return Header Cast Iron
1-H
012574F
012577F
012580F
012583F
009103F
012332F
007204F
012330F
009104F
007343F
006536F
011866F
012575F
012578F
012581F
012584F
009103F
012332F
007204F
012330F
009104F
007343F
006536F
011866F
012576F
012579F
012582F
012585F
009103F
012332F
007204F
012330F
009104F
007343F
006536F
011866F
2-H
3-H
4-H
5-H
6-H
Studbolt
Header Gasket (20 PCS)
Drain Valve
Air Vent Valve
7-H
HS
HEAT EXCHANGER (Condensing)
Heat Exch Stainless Steel (Includes 21-S)
Condensate Float Switch
1-HC
2-HC
012586F
012589F
012590F
012587F
012589F
012590F
012588F
012589F
012590F
3-HC
O Ring Seal
M
MISCELLANEOUS COMPONENTS
Flow Switch Paddle (Taco)
Window Combustion Chamber
T & P Guage 0-75 PSI
T & P Guage 0-200 PSI
PRV 30 PSI
PRV 45 PSI
PRV 60 PSI
PRV 75 PSI
PRV 125 PSI
1-M
2-M
3-M
010026F
006947F
007205F
007399F
007748F
007221F
007222F
007223F
007224F
007225F
008924F
005755F
011772F
007241F
009735F
012591F
012593F
012595F
012596F
012597F
012664
010026F
006947F
007205F
007399F
007748F
007751F
007753F
007756F
007224F
007225F
008924F
005755F
011772F
007241F
009736F
012592F
012593F
012595F
012596F
012597F
012665
010026F
006947F
007205F
007399F
007748F
007752F
007754F
007756F
007758F
007225F
008924F
005755F
011772F
007241F
009736F
012592F
012594F
012595F
012596F
012597F
012665
4-M
PRV 150 PSI
5-M
RTV Sealant 2.8 oz (Not Shown)
RTV Sealant 10 oz (Not Shown)
Flue Collector Vertical Seal Gasket
Insulation Blanket Return Header
Flue Exhaust Adapter Gasket Round
Flue Exhaust Adapter Gasket Rectangle
Plenum Gasket Upper and Lower
Access Panel Gasket Condensing Heat Exch
Flange Gasket 2" or 2-1/2" NPT
Condensate Hose
6-M
7-M
8-M
9-M
10-M
11-M
12-M
13-M
14-M
15-M
16-M
Condensate Neutralizer (Not Shown)
Membrane Switch
012598F
750125
750126
012663F
010779F
012652F
008924F
012681F
012598F
750125
750126
012663F
010779F
012652F
008924F
012681F
012598F
750125
750126
012663F
010779F
012652F
008924F
012681F
Touch up Paint (Green) Not Shown
Touch up Paint (Dark Gray) Not Shown
Inlet/Outlet Water Grommet 2-1/2" NPT
PRV Discharge Grommet 1" Thru 1-1/4" NPT
Wire Harness
17-M
18-M
19-M
20-M
RTV Sealant 2.8 oz (Not Shown)
Plastic Handle
O
OPTIONS
1-O
2-O
3-O
4-O
5-O
Remote Sensor (LWCO)
Control PC Board (LWCO)
Test / Reset Switch (LWCO)
Silencer/Reset Switch (Alarm)
Alarm Bell 3"
Alarm Bell 4"
Relay DPDT 24 VAC (Alarm)
PUMPS
Bypass Pump Bronze (Soft Water)
Bypass Pump Bronze (Medium Water)
Bypass Pump Bronze (Hard Water)
Bypass Pump CI
Pump Flange Gasket
Dual Injector Pump Bronze
Dual Injector Pump CI
007228F
007157F
005641F
005641F
005642F
005643F
011720F
007228F
007157F
005641F
005641F
005642F
005643F
011720F
007228F
007157F
005641F
005641F
005642F
005643F
011720F
6-O
1-P
P
011845F
011845F
007348F
011846F
012666F
012600F
012601F
012667F
951153F
011845F
007348F
007351F
011846F
012666F
012600F
012601F
012667F
951153F
012668F
012669F
012666F
007351F
007351F
950648
2-P
3-P
012666F
012600F
012601F
012667F
951153F
012668F
012669F
012666F
4-P
5-P
6-P
Pump Flange Gasket
Pump Cartrige
Injector Pump Bronze (WH)
Injector Pump Bronze (WHP)
Pump Flange Gasket
012669F
012666F
7-P
CALL
OUT
S
1005
1505
2005
DESCRIPTION
SHEETMETAL
Jacket Top
1-S
2-S
3-S
4-S
5-S
6-S
7-S
8-S
9-S
012602F
011789F
012603F
012606F
012607F
012608F
012609F
012610F
007257F
012613F
012615F
012618F
012621F
012671F
012624F
012672F
012627F
007306F
012628F
007307F
012631F
012633F
012634F
012682F
011872F
011873F
011874F
011978F
012635F
011870F
012636F
N/A
012602F
011791F
012604F
012606F
012607F
012608F
012609F
012611F
007257F
012613F
012616F
012619F
012622F
012671F
012625F
012674F
012627F
007306F
012629F
007307F
012632F
012633F
012634F
012682F
011872F
011873F
011874F
011978F
012635F
011870F
012636F
N/A
012602F
011793F
012605F
012606F
012607F
012608F
012609F
012612F
007257F
012614F
012617F
012620F
012623F
012671F
012626F
012674F
012627F
007306F
012630F
007307F
012632F
012633F
012634F
012682F
011872F
011873F
011874F
011978F
012635F
011870F
012636F
011881F
012676F
012651F
012638F
012641F
012644F
012683F
Flue Collector Front (No Opening) (Includes 6-M)
Flue Collector Rear (Opening) (Includes 6-M and 9-M)
Heat Transfer Supports
Upper Cabinet Supports Front
Upper Cabinet Supports Rear
Upper Cabinet Supports Side
Vertical Cabinet Supports
Return Header Cover
Jacket Upper Front Panel
Jacket Lower Front Panel
Jacket Side Panel
Jacket Upper Rear Panel
Access Panel Intake Air
Jacket Lower Rear Panel
10-S
11-S
12-S
13-S
14-S
15-S
16-S
Access Panel Lower Rear
17-S
18-S
19-S
20-S
21-S
22-S
23-S
24-S
25-S
26-S
27-S
28-S
29-S
30-S
31-S
32-S
33-S
34-S
35-S
36-S
37-S
38-S
Base Assembly
Leg Bracket Primary Heat Exch ( 4 pcs per boiler)
Leg Bracket Condensing Heat Exch ( 2 pcs per boiler)
Base Reflector Panel
Flue Exhaust Adapter Assembly
Control Box Assy
Control Box Cover Panel w/Display
Control Box Cover Panel
Power Switch Mounting Panel
Blower/Pump Switch Mounting Panel
Controller Mounting Panel
CWR Control Mounting Panel
Control Box Blank Cover Long
Control Box Blank Cover Short
24V Wiring Panel
Intake Air Adapter (plenum to Duct)
Intake Air Collar
012675F
012651F
012638F
012639F
012642F
012683F
012676F
012651F
012638F
012640F
012643F
012683F
Access Panel Wiring Box
Access Panel Condensing Heat Exch
Plenum Upper Condensing Heat Exch
Plenum Lower Condensing Heat Exch
Filter Access Cover
V
VENTING
1-V
2-V
3-V
4-V
5-V
6-V
Outdoor Stack
011894
010802
006644
012645F
012599F
012678F
011895
010803
006646
012646F
012599F
012678F
011895
010803
006646
012647F
012599F
012678F
Vent Cap Vertical for Indoor Units
Vent Cap Horizontal Thru-the-Wall for Indoor Units
Intake Air filter Box
Air Filter Media
Condensate Drip Pan
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