Raypak 1005, 2005 User Manual
INSTALLATION & OPERATING
L
W
ULTRA HIGH EFFICIENCY
INSTRUCTIONS
Models 1005–2005
Types H, WH & WHP
WARNING: Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury, exposure to hazardous materials* or loss of
life. Review the information in this manual carefully. *This unit contains materials that
have been identified as carcinogenic, or possibly carcinogenic, to humans.
FOR YOUR SAFETY: 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.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3400.55B Effective: 09-22-09 Replaces: 02-24-09 P/N 241344 Rev. 3
Rev. 3 reflects the following:
Changes to: Fig. 3 on page 6, Fig. 10 on page 11, Pool Heater instructions and Fig. 17 on page 17, Fig. 19 on page 21,
Table M on page 25, Mode 1 and Mode 4 instructions on page 33, Fig. 35 and Fig. 36 on page 33, Modes 6-8 instructions
on page 34, Tables P-R on pages 34-35, “Auto Limit - Auto Reset” instructions on page 39, wiring diagrams on pages 42-43.
Additions: PVC Venting Option on pages 30-31, which includes new Figs. 30-33, new Fig. 39 on page 34.
Deletions: Vent Table on page 28 (identical to Table M on page 25)
2
CONTENTS
WARNINGS 4
Pay Attention to These Terms 4
BEFORE INSTALLATION 5
Product Receipt 5
Model Identification 5
Ratings and Certifications 5
Installations at Elevation 5
Component Locations 6
General Information 6
Time/Temperature Relationships
in Scalds 7
GENERAL SAFETY 7
INSTALLATION 8
Installation Codes 8
Equipment Base 8
Clearances 8
Combustion and Ventilation Air 9
Conventional Combustion Air Supply 13
Water Piping 14
Hydronic Heating 15
Domestic Hot Water 16
Combined Potable Water and Space
Heating 17
Pool Heating 17
Gas Supply 19
Electrical Power Connections 20
Field Wiring Connection 22
Venting 22
Venting Installation Tips 24
Venting Configurations 24
Outdoor Installation 29
PVC Venting Option 30
Controls 32
Heater Sequence of Operation 38
WIRING DIAGRAMS 42
Models 1005 & 1505 42
Model 2005 43
START-UP 44
Pre Start-up 44
Pre Start-up Check 44
Initial Start-up 45
Preparation 45
Start-Up 45
OPERATION 49
Lighting Instructions 49
To Turn Off Gas To Appliance 49
TROUBLESHOOTING 50
UDB Fault History 51
MAINTENANCE 51
Suggested Minimum
Maintenance Schedule 51
Preventive Maintenance
Schedule 52
APPENDIX 53
Inside Air Contamination 53
Important Instructions for the
Commonwealth of
Massachusetts 54
WARRANTIES 55
3
WARNINGS
Pay Attention to These Terms
ndicates the presence of immediate hazards which will cause severe
DANGER:
I
personal injury, death or substantial property damage if ignored.
WARNING:
CAUTION:
NOTE:
DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
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 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.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
CAUTION: If this heater is to be installed above
radiation level, it must be provided with a low water
cut-off device at the time of heater installation.
CAUTION: This heater requires forced water
circulation when the burner is operating. Severe
damage will occur if the heater is operated without
proper water flow circulation.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
CAUTION: If this heater is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.
4
BEFORE INSTALLATION
Raypak strongly recommends that this manual be reviewed thoroughly before installing your XTherm
heater. Please review the General Safety information
before installing the heater. Factory warranty does not
apply to heaters that have been improperly installed or
operated. (Refer to the warranty at the back of this
manual.) Installation and service must be performed
by a qualified installer, service agency or gas supplier.
If, after reviewing this manual, you still have questions
which this manual does not answer, please contact
your local Raypak representative or visit our website at
www.raypak.com.
he upper rear jacket panel of the heater. The model
t
number will have the form H7-2005 or similar depending on the heater size and configuration. The letter(s)
in the first group of characters identifies the application
H = Hydronic Heating, WH = Domestic Hot Water
(
(DHW), WHP = Water Heater for Pool Heating). The
umber which follows identifies the firing mode (7 =
n
electronic modulation, 1 = On/Off). The second group
of characters identifies the size of the heater (four
numbers representing the approximate MBTUH input),
and, where applicable, a letter, indicating the manufacturing series.
Ratings and Certifications
Thank you for purchasing a Raypak product. We hope
you will be satisfied with the high quality and durability
of our equipment.
Product Receipt
On receipt of your heater it is suggested that you visually check for external damage to the shipping crate. If
the crate is damaged, make a note to that effect on the
Bill of Lading when signing for the shipment. Next,
remove the heater from the shipping packaging.
Report any damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that
you receive the correct number of packages as indicated on the Bill of Lading.
Claims for shortages and damages must be filed with
the carrier by consignee. Permission to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.
When ordering parts, you must specify the model and
serial number of the heater. When ordering under warranty conditions, you must also specify the date of
installation.
Standards:
• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired
Hot Water Boilers
• CAN 3.1 - latest edition, Industrial and
Commercial Gas-Fired Package Boilers
• ANSI Z21.10.3 · CSA 4.3 - latest edition, Gas Water Heaters
• SCAQMD Rule 1146.2
All Raypak heaters are National Board Approved, and
design-certified and tested by the Canadian Standards
Association (CSA) for the U.S. and Canada. Each primary heat exchanger is constructed in accordance
with Section IV, and each secondary heat exchanger
in accordance with Section VIII, of the American
Society of Mechanical Engineers (ASME) Heater
Pressure Vessel Code and bears the applicable ASME
stamp. This heater also complies with the latest edition
of the ASHRAE 90.1 Standard.
WARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube
bundle headers, or any ASME parts not
manufactured and/or approved by Raypak will
instantly void the ASME and CSA ratings of the
vessel and any Raypak warranty on the vessel.
Altering the ASME or CSA ratings of the vessel also
violates national, state, and local approval codes.
Purchased parts are subject to replacement only
under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted. Parts will
be replaced in kind only per Raypak’s standard warranties.
Model Identification
The model identification number and heater serial
number are found on the heater rating plate located on
Installations at Elevation
Rated inputs are suitable for up to 4,500 ft elevation
without de-rating. Consult your local representative or
the factory for installations at altitudes over 4,500 ft
above sea level. No hardware changes are required to
the heaters for installations up to 10,000 ft (adjustments may be required).
5
AIR FILTER
ACCESS PANEL
Component Locations
Fig. 1: Component Locations – Right Side
Fig. 2: Component Locations – Top
Fig. 3: Component Locations – Rear
General Information
Gas
Conn.
(NPT)
Vent Size
(in.)
Model
No.
MBTUH
Input
Water
Conn.
(NPT)
Max. Min. N P Flue Intake
1005 999 250 2-1/2 1-1/4 1 6 6
1505 1500 375 2-1/2 1-1/4 1 8 8
2005 1999 500 2-1/2 2 1 8 8
Table A: Basic Data
6
GENERAL SAFETY
Water temperature over 125°F can
cause instant severe burns or death
from scalds.
Children, disabled, and elderly are
at highest risk of being scalded.
See instruction manual before setting temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are
available, see manual.
Water
Temp.
Time to Produce Serious
Burn
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About 1 second
Table courtesy of The Shriners Burn Institute
To meet commercial hot water use needs, the high
limit safety control on this water heater will shut off the
main gas valve before the outlet temperature reaches
210°F. However, water temperatures over 125°F can
cause instant severe burns or death from scalds.
When supplying general purpose hot water, the recommended initial setting for the temperature control is
125°F.
Safety and energy conservation are factors to be considered when setting the water temperature on the
thermostat. The most energy-efficient operation will
result when the temperature setting is the lowest that
satisfies the needs of the application.
Water temperature over 125°F can cause instant
severe burns or death from scalds. Children, disabled
and elderly are at highest risk of being scalded.
• Feel water before bathing or showering.
• Temperature limiting valves are available.
NOTE: When this water heater is supplying general
purpose hot water for use by individuals, a
thermostatically controlled mixing valve for reducing
point of use water temperature is recommended to
reduce the risk of scald injury. Contact a licensed
plumber or the local plumbing authority for further
information.
Maximum water temperatures occur just after the
heater’s burner has shut off. To determine the water
temperature being delivered, turn on a hot water
faucet and place a thermometer in the hot water
stream and read the thermometer.
This section applies to Hot Water Supply Boilers and
Hot Water Heaters ONLY. For sanitary rinse applications where outlet temperatures of 180°F to 195°F are
required, a boiler is recommended since the 210°F
limit on water heaters will NOT allow the heater to
maintain these desired sanitary rinse temperatures.
Time/Temperature Relationships in Scalds
The following chart details the relationship of water
temperature and time with regard to scald injury and
may be used as a guide in determining the safest
water temperature for your applications.
Table B: Time to Produce Serious Burn
7
Heater
Side
Minimum Clea rance
from Combustible
Surfaces
Minimum
Service
Clearance
Floor* 0” 0”
Rear 12” 36”
Right
Side
1” 24”
Left Side 1” 1”
Top 0” 10”
Front Open 24”
Vent 1” 1”
The temperature of the water in the heater can be regulated by using the Raypak Modulating Temperature
Control. To comply with safety regulations, the control
is set at 120°F when shipped from the factory (Mode 3
default setting for Tank Target).
To adjust the water temperature, follow the instruction
for the operation of the control starting on page 33 of
this manual. The control is shown below for identification purposes only. (See Fig. 4.)
Equipment Base
The heater should be mounted on a level, structurally
ound surface. The heater is approved for installation
s
on a combustible surface but must NEVER be
nstalled on carpeting. Gas-fueled equipment installed
i
in enclosed parking garages must be located at least
18 in. above the floor.
CAUTION: This heater should be located in an
area where water leakage will not result in damage
to the area adjacent to the appliances or to the
structure. When such locations cannot be avoided, it
is recommended that a suitable catch pan,
adequately drained, be installed under the
appliance. The pan must not restrict air flow.
In addition, the heater shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation or service (circulator replacement, control
replacement, etc.).
Fig. 4: Modulating Temperature Control
CAUTION: Hotter water increases the risk of
scalding! There is a hot water scald potential if the
thermostat is set too high.
INSTALLATION
INSTALLATION
Installation Codes
Installations must follow these codes:
• Local, state, provincial, and national codes, laws,
regulations and ordinances
• National Fuel Gas Code, ANSI Z223.1/NFPA 54 –
latest edition (NFGC)
• National Electrical Code, ANSI/NFPA 70 - latest
edition (NEC)
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1,
(CSD-1) when required
• For Canada only: CAN/CSA B149 Natural Gas
and Propane Installation Code and CSA C22.1
C.E.C. Part 1 (C22.1)
If the heater needs to be secured to the ground, use
the brackets that were used to bolt the heater to the
shipping pallet.
Clearances
Indoor Installations
*DO NOT install on carpeting.
Table C: Clearances – Indoor Installations
For ease of servicing, provide a minimum clearance of
at least 24 in. on the right side, 24 in. in front, at least
36 in. on the rear and 10 in. above the top of the
heater. This will allow the heater to be serviced in its
installed location without movement or removal of the
heater.
8
oof water drainage must be diverted away from
Heater
Side
Min. Clearance
from Combustible
Surfaces
Minimum
Service
Clearance
Rear 12” 36”
Right Side 1” 24”
Left Side 1” 1”
Top Unobstructed 10”
Vent
Termination
12” 12”
R
heaters installed under overhangs.
Table D: Clearances – Outdoor Installations
Combustion and Ventilation Air
NOTE: Use of this heater in construction areas
where fine particulate matter, such as concrete or
dry-wall dust, is present may result in damage to the
heater that is not covered by the warranty. If
operated in a construction environment, a clean
source of combustion air must be provided directly to
the heater.
Venting not shown for clarity. Heater must be vented per instruc-
Fig. 5: Minimum Clearances from Combustible
Surfaces – Indoor and Outdoor Installations
tions in this manual
Service clearances less than the minimum may
require removal of the heater to service either the heat
exchanger or the burner components. In either case,
the heater must be installed in a manner that will
enable the heater to be serviced without removing any
structure around the heater.
Outdoor Installations
These heaters are design-certified for outdoor installation. Heaters must not be installed under an overhang
unless they are in accordance with local installation
codes and the requirements of the gas supplier. Three
sides must be open in the area under the overhang.
Indoor Units
This heater must be supplied with sufficient quantities
of non-contaminated air to support proper combustion
and equipment ventilation. Combustion air can be supplied via conventional means where combustion air is
drawn from the area immediately surrounding the
heater, or via direct vent, where combustion air is
drawn directly from outside. All installations must comply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty. (See
the Appendix.)
NOTE: It is recommended that the intake vent be
insulated to minimize sweating.
9
U.S. Installations
1
Canadian Insta llations
2
A
Clearance above grade, veranda, porch,
deck, or balcony
1 ft (30 cm) 1 ft (30 cm)
B
Clearance to window or door that may be
opened
4 ft (1.2m) below or to side
of opening; 1 foot (30 cm)
above opening
3 ft (91 cm)
C Clearance to permanently closed window **
D
Vertical clearance to ventilated soffit located
above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the
terminal
5 ft (1.5m) *
E Clearance to unventilated soffit **
F Clearance to outside corner **
G Clearance to inside corner 6 ft (1.83m) *
H
Clearance to each side of center line ex-
tended above meter/regulator assembly
*
3 ft (91 cm) within a height
15 ft above the me-
ter/regulator assembly
I Clearance to service regulator vent outlet * 6 ft (1.83m)
J
Clearance to non-mechanical air supply inlet
to building or the combustion air inlet to any
other appliance
4 ft (1.2m) below or to side
of opening; 1 ft (30 cm)
above opening
3 ft (91 cm)
K Clearance to mechanical air supply inlet
3 ft (91 cm) above if within
10 ft (3m) horizontally
6 ft (1.83m)
L
Clearance above paved sidewalk or paved
driveway located on public property
7 ft (2.13m)
7 ft (2.13m) t
M
Clearance under veranda, porch, deck or
balcony
* 12 in. (30 cm) TT
1
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
2
In accordance with the current CAN/CGA-B149 Installation Codes
t Vent terminal shall not terminat e directly above sidewalk or paved driveway located between 2 single family dwellings that serves
both dwellings
TT Per mitted only if veranda, porc h, deck, or balcony is fully open on a minimu m of two sides beneath the floor and top of terminal and
underside of ver anda, porch, deck or balcony is greater than 1 ft (30c m)
* Clearances in accordance with local installation codes and the requirements of the gas supplier
Fig. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table E: Vent/Air Inlet Termination Clearances
10
Combustion Air Filter
Inside Air Intake
Opening
I
nside Air Intake
Cover Panel
Condensate
Drip Pan
Air Intake
Cover Panel
Air Filter
Access
Panel
This heater is supplied with an integral combustion air
filter. This filter will reduce the amount of particulates
passed through the combustion system and heat
exchanger but will not protect against chemical inside
air contamination (See Appendix). The filter must be
checked periodically to verify that adequate combustion air is being supplied to the heater. See the
Maintenance section of this manual for information on
checking the filter and establishing service intervals.
Direct Vent
If outside air is drawn through the intake pipe directly
to the unit for combustion:
1. Convert the unit to draw air through an air intake
duct at the rear of the cabinet. As shipped,
XTherm heaters draw combustion air from inside
the cabinet.
2. Turn off all power to the heater.
3. Ensure that the heater is cool to the touch before
proceeding with the installation.
4. Remove both the left and right rear side access
panels.
Fig. 8: Install the Inside Air Intake Cover Panel
6. Optional—For applications where condensation
may form on cold intake air ducting, install the condensate drip pan to the bottom of the air filter box
using the four screws provided (make sure the pan
is angled slightly downward toward the rear of the
heater as shown in Fig. 9).
Fig. 9: Install the Condensate Drip Pan
Fig. 7: Remove the Rear-side Access Panels
5. From the right-rear side access area, install the
inside air intake cover panel using the nine hexhead screws provided (see Fig. 8).
7. Remove the air intake cover panel by removing
the 5 phillips head screws holding it in place.
Fig. 10: Remove the Air Intake Cover
11
8. Remove the debris screen (or cover panel for
Debris Screen
Intake Air Collar
model 1005) by removing the six screws holding it
in place.
Fig. 11: Remove the Debris Screen
12. Provide adequate ventilation of the space occupied by the heater(s) by an opening(s) for
ventilation air at the highest practical point communicating with the outdoors. The total
ross-sectional area shall be at least 1 in.
c
area per 20,000 BTUH (111 mm
2
per kW) of total
2
f free
o
input rating of all equipment in the room when the
pening is communicating directly with the out-
o
doors or through vertical duct(s). The total
2
cross-sectional area shall be at least 1 in.
of free
area per 10,000 BTUH (222 mm2per kW) of total
input rating of all equipment in the room when the
opening is communicating with the outdoors
through horizontal duct(s).
13. In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of
a motorized sealed damper to prevent the circulation of cold air through the heater during the
non-operating hours.
9. Install the intake air collar using the six screws
removed in step 8 above.
Fig. 12: Install the Intake Air Collar
10. Replace all the access panels.
TruSeal™ Combustion Air
In addition to the 13 previous steps, combustion air
may be ducted directly to the heater by using PVC,
CPVC or sealed single-wall galvanized ducting. The
duct will attach directly to the field installed air collar
located on the rear of the heater, using three or four
sheet metal screws (not supplied) equally positioned
around the circumference of the duct. The screws and
duct connection point should be sealed with RTV (not
supplied). TruSeal is generally used when damaging
contaminants are present in the mechanical room. All
ducting must be self-supported.
CAUTION: Use TruSeal combustion air if
damaging airborne contaminants are or may be
present in the heater area. See the Appendix of this
manual regarding air contamination.
NOTE: Make sure that the air intake piping is
installed in a manner that allows full access to the air
filter without damage to the filter.
11. Install combustion air direct vent in accordance
with Fig. 27 (horizontal) or Fig. 28 (vertical) of this
manual (pages 27 and 28, respectively).
12
Conventional Combustion Air
Supply
U.S. Installations
All Air from Inside the Building
The confined space shall be provided with TWO permanent openings communicating directly with an
additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for a
room large in comparison (NFGC). The total input of all
gas utilization equipment installed in the combined
space shall be considered in making this determination. Each opening shall have a minimum free area of
2
per 1,000 BTUH (2,225 mm2per kW) of the total
1 in.
input rating of all gas utilization equipment in the confined space, but not less than 100 in.2(645 cm2). One
opening shall commence within 12 in. (305 mm) of the
top, and one opening shall commence within 12 in.
(305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than
3 in. (76 mm) in any direction.
2. One permanent opening, commencing within 12
in. (305 mm) of the top of the enclosure, shall be
permitted where the equipment has clearances of
at least 1 in. (25 mm) from the sides and back and
6 in. (152 mm) from the front of the appliance. The
opening shall directly communicate with the outdoors or shall communicate through a vertical or
horizontal duct to the outdoors or spaces that
freely communicate with the outdoors, and shall
have a minimum free area of:
a. 1 in.2per 3,000 BTUH (740 mm2per kW) of
the total input rating of all equipment located in
the enclosure, and
b. Not less than the sum of the areas of all vent
connectors in the confined space.
WARNING: Do not use the “one permanent
opening” method if the equipment room is under
negative pressure conditions.
Canadian Installations
All Air from Outdoors
The confined space shall communicate with the outdoors in accordance with one of the methods below.
The minimum dimension of air openings shall not be
less than 3 in. (76 mm) in any direction. Where ducts
are used, they shall be of the same cross-sectional
area as the net free area of the openings to which they
connect.
1. Two permanent openings, one commencing
within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of
the enclosure, shall be provided. The openings
shall communicate directly, or by ducts, with the
outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
a. Where directly communicating with the out-
doors or where communicating to the
outdoors through vertical ducts, each open-
ing shall have a minimum free area of 1 in.
per 4,000 BTUH (550 mm2per kW) of total
input rating of all equipment in the enclosure.
b. Where communicating with the outdoors
through horizontal ducts, each opening shall
2
have a minimum free area of 1 in.
2
BTUH (1,100 mm
per kW) of total input rat-
per 2,000
ing of all equipment in the enclosure.
CAUTION: All combustion air must be drawn from
the air outside of the building; the mechanical equipment room must communicate directly with the
outdoors.
1. Ventilation of the space occupied by the heater
shall be provided by an opening(s) for ventilation
air at the highest practical point communicating
with the outdoors. The total cross-sectional area of
such an opening(s) shall be at least 10% of the
area required in 2. and 3. (below), but in no case
shall the cross-sectional area be less than 10 in.
(65 cm2).
2. For heaters using a barometric damper in the vent
system there shall be a permanent air supply
opening(s) having a cross section area of not less
than 1 in.2per 7,000 BTUH (320 mm2per kW) up
to and including 1 million BTUH, plus 1 in.2per
14,000 BTUH (160 mm2per kW) in excess of 1
2
million BTUH. This opening(s) shall be either
located at or ducted to a point not more than 18 in.
(450 mm) nor less than 6 in. (152 mm) above the
floor level. The duct can also “goose neck” through
the roof. The duct is preferred to be straight down
and terminated 18 in. (450 mm) from the floor, but
not near piping. This air supply opening requirement shall be in addition to the air opening for
ventilation air required in 1. (above).
2
13
WARNING: Care must be taken to ensure that the
equipment room is not under negative pressure
conditions.
3. For heaters not using a barometric damper in the
vent system, and when air supply is provided by
natural air flow from outdoors for a power burner
and there is no draft regulator, drafthood or similar
flue gas dilution device installed in the same
space, in addition to the opening for ventilation air
required in 1., there shall be a permanent air supply opening(s) having a total cross-sectional area
of not less than 1 in.2for each 30,000 BTUH (74
mm2per kW) of total rated input of the burner(s),
and the location of the opening(s) shall not interfere with the intended purpose of the opening(s)
for ventilation air referred to in 1. This opening(s)
can be ducted to a point not more than 18 in. (450
mm) nor less than 6 in. (152 mm) above the floor
level. The duct can also “goose neck” through the
roof. The duct is preferred to be straight down 18
in. (450 mm) from the floor, but not near piping.
4. Refer to the B149 Installation Code for additional
information.
Relief Valve Installation and Piping
WARNING: Pressure relief valve discharge piping
must be piped near the floor and close to a drain to
eliminate the potential of severe burns. Do not pipe
to any area where freezing could occur. Refer to
local codes.
The heater is supplied with a Section IV “HV” stamped
relief valve sized for the full input of the unit and a “UV”
stamped relief valve to protect the section VIII secondary heat exchanger. The relief valve assembly is
shipped loose and must be mounted directly to the
heater outlet. No valve shall be installed between the
heater and the relief valves. The relief valves shall be
mounted with their spindles vertical (see Fig. 1, 2 and
3 on page 6). Relief valve discharge piping shall provide no less than the cross sectional area of the relief
valve outlet and must be routed to a safe point of discharge. Installation must comply with all national, state
and local codes.
WARNING: The pressure relief valve must be
installed at the outlet of the heater. No valve is
permitted to be installed between the heater and the
relief valve.
Water Piping
General
The heater should be located so that any water leaks
will not cause damage to the adjacent area or struc-
tures.
CAUTION: This heater must be installed with a
Primary-Secondary piping arrangement for the
integral pumping system to function properly.
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.
See Table G on page 16.
Temperature & Pressure Gauge
The temperature and pressure gauge is shipped loose
for field installation and must be installed within 12
inches of the boiler outlet (if possible) in an easily
readable location. Installation must comply with ASME
Section IV as well as all applicable national, state and
local codes.
Hydrostatic Test
Unlike many types of heaters, this heater does not require hydrostatic testing prior to being placed in
operation. The heat exchanger has already been factory-tested and is rated for 160 psi operating pressure.
However, Raypak does recommend hydrostatic testing of the piping connections to the heater and the rest
of the system prior to operation. This is particularly
true for hydronic systems using expensive glycolbased anti-freeze. Raypak recommends conducting
the hydrostatic test before connecting gas piping or
electrical supply.
14
Leaks must be repaired at once to prevent damage to
the heater. NEVER use petroleum-based stop-leak
compounds.
To perform hydrostatic test:
. Connect fill water supply. With bleed valve open,
1
fill heater with water. When water flows from bleed
valve, shut off water. Close bleed valve. Carefully
fill the rest of the system, making sure to eliminate
any entrapped air by using high-point vents. Close
feed valve. Test at standard operating pressure for
at least 24 hours.
2. Make sure constant gauge pressure has been
maintained throughout test.
3. Check for leaks. Repair if found.
Feedwater Regulator
Raypak recommends that a feedwater regulator be installed and set at 12 psi minimum pressure at the
highest point of the system. Install a check valve or
ack flow device upstream of the regulator, with a
b
manual shut-off valve as required by local codes.
Piping
All high points should be vented. A heater installed
above radiation level must be provided with a low water cut-off device (sales order option F-10). This
heater, when used in connection with a refrigeration
system, must be installed so that the chilled medium is
piped in parallel with the heater with appropriate
valves to prevent the chilled medium from entering the
heater.
Raypak Integral Cold Water
Protection
CAUTION: Damage due to internal condensation
may occur if the heater inlet water temperature does
not exceed 50°F (22°C) within 7 minutes of start-up.
XTherm heaters are equipped with an integral cold
water protection system. Units equipped with the dual
injector pump system are designed to operate with
heater inlet water temperatures down to 50°F continuous. Under start up conditions the dual injector system
can operate with fluid temperatures down to 32°F.
Operation at lower temperatures will create unwarrantable damage to the injector pumps. XTherm WH
and WHP models equipped with single injector pumps
are designed for typical domestic hot water and commercial pool heating operating conditions respectively.
Contact your local representative or the factory for
applications assistance.
Hydronic Heating
The piping system of a hot water heater connected to
heating coils located in air handling units where they
may be exposed to circulating refrigerated air, must be
equipped with flow control valves or other automatic
means to prevent gravity circulation of the heater
water during the cooling cycle. It is highly recommended that the piping be insulated.
Air-Separation/Expansion Tank
All heaters should be equipped with a properly sized
expansion tank and air separator fitting as shown in
Fig. 13.
Pump Selection
The heater is equipped with an integral cold water protection system that includes dual modulating injector
pumps to pull the required flow from the system loop
and a heater pump, sized by the factory, for the optimal T across the primary heat exchanger. The
system is designed for continuous return temperatures
from 50°F to 180°F.
Fig. 13: Air-Separation/Expansion Tank
Three-Way Valves
WARNING: Three-way valves intended to regulate
system water temperatures by reducing flow in the
boiler should not be used.
XTherm heaters have an integral cold water protection
system to maintain required temperatures and flow
rates.
15
Table F: Boiler Temperatures and Minimum Pipe Size at Varying Return Temperatures
System
R
eturn Temp Su
pply
T
emp
1
S
u
p
p
l
y
T
em
p
1
Suppl
y
T
em
p
1
(
°F) (°F) <80' equiv. 80-200' equiv. (°F) <80' equiv. 80-200' equiv. (°F) <80' equiv. 80-200' equiv.
6
0 138 2"NPT 2 1/2"NPT 147 2"NPT 2 1/2"NPT 154 2"NPT 2 1/2"NPT
8
0 138 2"NPT 2 1/2"NPT 147 2"NPT 2 1/2"NPT 154 2 1/2"NPT 3"NPT
1
00 138 2 1/2"NPT 3"NPT 147 2 1/2"NPT 3"NPT 154 2 1/2"NPT 3"NPT
120 145 2 1/2"NPT 3"NPT 158 2 1/2"NPT 3"NPT 170 2 1/2"NPT 3"NPT
1
40 165 2 1/2"NPT 3"NPT 178 2 1/2"NPT 3"NPT 190 2 1/2"NPT 3"NPT
1
60 185 2 1/2"NPT 3"NPT 198 2 1/2"NPT 3"NPT 210 2 1/2"NPT 3"NPT
1
-Approximate high fire heater outlet temperature based on the standard heater pump and the recommended connecting pipe
s
ize.
M
odel 1005
M
inimum Pi
p
e Size
2
M
odel 1505
M
inimum Pi
p
e
Size
2
M
odel 2005
M
inimum Pi
p
e Size
2
2
-
Minimum
pip
e
size based on total e
q
u
ivalent feet of su
p
p
lya
nd return
pip
in
g
b
etween the s
y
s
tem loo
p
a
nd heater.
Fitting Type
Equivalent Length (ft)
2-1/2” NPT 3” NPT
90° Elbow (Std.) 8.5 9.4
90° Elbow (Long rad.) 3.5 3.6
45° Elbow 3.0 3.4
Gate Valve (Full open) 1.6 1.6
Swing Check Valve 22 25
Note: Equivalent lengths are calculated based on typical operating
conditions with typical Schedule 40 pipe fittings and valves.
Equivalent lengths are approximate and may vary greatly.
Table G: Equivalent Lengths of Pipe for Typical Fittings
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 15: Dual Heaters (Reverse/Return)
with Primary/Secondary Piping
Domestic Hot Water
When designing the hot water piping system for
domestic hot water applications, water hardness
should be considered. See Table H on page 18 for the
required tubing sizes and expected supply temperatures for different operating conditions. Water
hardness is expressed in grains per gallon.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 14: Single Heater with Primary/Secondary Piping
Fig. 16: Single Domestic Hot Water Heater and Storage
16
Tank
NOTE: If local codes require a vacuum relief valve,
A
UTO LIMIT
(SET AT 110ºF)
acquire one locally and install per valve
manufacturer’s instructions.
Combined Potable Water and
Space Heating
CAUTION: When this heater is used for both
potable water and space heating, observe the
following to ensure proper operation.
1. All piping materials and components connected to
the water heater for the space heating application
shall be suitable for use with potable water.
2. Toxic chemicals, such as used for boiler treatment,
shall not be introduced into the potable water used
for space heating.
3. If the heater will be used to supply potable water,
it shall not be connected to any heating system or
components previously used with a non-potable
water heating appliance.
CAUTION: Power to the heater should be
interlocked with the main system pump to make sure
the heater does not fire without the main system
pump in operation. Improper flow control can
damage the heater. Uncontrolled flow (too high) or
restricted flow (too low) can seriously damage the
heater. Follow these instructions to make sure the
heater is properly installed.
4. When the system requires water for space heating
at temperatures higher than 140°F (60°C), a
means such as a mixing valve shall be installed to
temper the water in order to reduce scald hazard
potential.
Pool Heating
When a boiler or water heater is used in a pool heating application, ensure that all the following installation
requirements are met.
The XTherm must be equipped with a direct coupled
Cold Water Run injector pump for pool applications.
The integral wet rotor injector pump system supplied
with all H and model 1005 WH XTherm heaters must
not be used for pool service. The direct coupled Cold
Water Run injector pump package is optional on all H
and 1005 WH models and standard on 1505 and 2005
WH and all WHP models. The Cold Water Run system
must be set to maintain 120°F at the inlet to the primary heat exchanger on all XTherm models.
To complete installation of the heater, the system sensor must be installed in the return water line, upstream
of the heater. The supplied electronic operating control is configured to operate as the thermostat. A
separate auto limit is shipped loose to be installed in
the system piping downstream of the heater outlet.
See Fig. 17 for the thermostat/sensor location.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 17: Single Pool Heater Application
Set the control in Mode 2 for all single-heater pool
installations. For multiple-heater installations using
an external modulating sequencer, use Mode 8.
Automatic Chlorinators and Chemical
Feeders
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty.
All chemicals must be introduced and completely diluted into the pool or spa water before being circulated
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (e.g.
overnight). Chlorinators must feed downstream of the
heater and have an anti-siphoning device to prevent
chemical back-up into the heater when the pump is
shut off.
NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will cause
very rapid corrosion of the heat exchanger in the
heater. Such damage is not covered under the
warranty.
17
T
ank
uStfo
S
.
p
uSdra
H
.
p
uSdeM/tfo
S
p
meTnr
u
t
eR
p
.
Med Su
p
. Hard Sup
de
M/tfoS.
(°F)
T
emp
1
(°F) Temp1(°F)
<80' equiv. 80-200' equiv.
Temp
1
(°F) Temp
1
(°F) Temp1(°F)
<80' equiv. 80-200' equiv.
Sup. Temp
1
(°F)
<80' equiv. 80-200' equiv.
60 138 135 2" 2 1/2" 150 145 143 2" 2 1/2" 154 2" 2 1/2"
80 138 135 2" 2 1/2" 150 145 143 2" 2 1/2" 154 2 1/2" 3"
1
00 138 135 2 1/2" 3" 150 145 143 2 1/2" 3" 154 2 1/2" 3"
120 146 146 2 1/2" 3" 150 146 146 2 1/2" 3" 155 2 1/2" 3"
1
30 156 156 2 1/2" 3" 156 156 156 2 1/2" 3" 165 2 1/2" 3"
140 166 166 2 1/2" 3" 166 166 166 2 1/2" 3" 175 2 1/2" 3"
1
-Approximate high fire heater outlet temperature based on the specified heater pump and the recommended minimum
tubing
size.
2
-Minimum tubingsize based on total equivalent feet of supplyand return
pip
ingbetween the tank and heater.
Model 1005
Minimum Tub in
g
Size
2
Minimum Tub ingSize
2
Minimum Tubin
g
Size
2
5002led
o
M
5
0
51led
o
M
Table H: Hot Water Supply Temperatures and Minimum Pipe Size at Varying Return Temperatures
Winterizing Your Heater
Heaters installed outdoors as pool heaters in freezing
climate areas should be shut down for the winter. To
shut down the heater, turn off manual main gas valve
and main gas shut-off. Close isolation valves. Drain
the heater using the hose bibs located on the bottom
of both heat exchangers. Disconnect the condensate
hose from the secondary heat exchanger and drain
the condensate trap.
NOTE: There are 3 separate drains on the XTherm
that must ALL be drained to protect the heat
exchangers. These are accessible by removing the
lower front door from the heater for the 2 primary
drains and the right-rear panel for the secondary
drain. Drain any piping of all water that may
experience below-freezing temperatures.
Pool/Spa Water Chemistry
CAUTION: Corrosive water voids all warranties.
NOTE: Chemical imbalance can cause severe
damage to your heater and associated equipment.
Chemical imbalance can cause severe damage to the
pool heater and associated equipment. Maintain the
water chemistry according to the chart below. If the
mineral content and dissolved solids in the water
become too high, scale forms inside the heat exchanger tubes, reducing heater efficiency and damaging the
heater. If the pH drops below 7.2, this will cause corrosion of the heat exchanger and severely damage the
heater. Heat exchanger damage resulting from chemical imbalance is not covered by the warranty.
For your health and the protection of your pool equipment, it is essential that your water be chemically
balanced. The following levels must be used as a
guide for balanced water.
Occasional chemical shock dosing of the pool or spa
should not damage the heater providing the water is
balanced.
Recommended Level(s) Fiberglass Pools Fiberglass Spas
Other Pool and Spa
Types
Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)
pH 7.3-7.4 7.3-7.4 7.6-7.8
Total Alkalinity (ppm) 120-150 120-150 80-120
Calcium Hardness (ppm) 200-300 150-200 200-400
Salt (ppm) 140 Maximum** 140 Maximum** 140 Maximum**
Free Chlorine (ppm)* 2-3 2-3 2-3
Total Dissolved Solids
(ppm)
*Free Chlorine MUST NOT EXCEED 5 ppm!
**Not for use with salt water pools.
3000 Maximum 3000 Maximum 3000 Maximum
Table I: Water Chemistry
18
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