Raypak 2005, 1505 User Manual

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Xtreme Performance

Xtreme Performance

97%thermal efficiency!

97%thermal efficiency!

We use commercial grade Cupro­Nickel finned tubing in the primary
heat exchanger. Standard copper­based heat exchangers can not
stand up to the harsh environment
of commercial pool heating. Your
customers expect the best and
Raypak delivers with professional
grade commercial pool heaters.

Raypak’s Next Generation Condensing
Heater

Time-honored technologies unite with cutting-edge advancements in
Raypak’s new XTherm vertical heater. Never before has a vertical
heater provided both the installer and pool builder such installation
flexibility, ease-of-commissioning, reliability and long-term
performance. Small space, not a problem. The XTherm has one of the
smallest installed footprints of any vertical condensing heater. Our
compact design makes it the perfect choice for those hard to reach
retrofit projects. Raypak’s XTherm is built with commercial-grade
components and materials. From our steel channel base to our
stainless steel flue wrapper, and secondary heat exchanger, you can tell
the XTherm is built to last. It’s easy to handle and install, but still user
friendly to service. Now is the perfect time to take a closer look at
Raypak.

Flexibility

Industry-leading vent length allowances afford greater vent location
options, thus reducing wasted space. Vent versatility is further
enhanced by the self-tuning combustion system which compensates
for unusual chimney and vent configurations.

Category IV - CSA-certified 97%
efficiency at full fire for water heaters in
pool applications. When the job requires
high efficiency, XTherm meets your needs.
The XTherm can use either AL29-4C
stainless steel, PVC or CPVC for venting.
Just specify the D-32 vent option when
using PVC vent.

Optional PVC Vent

Simplicity

The Raypak XTherm will precisely heat your pool. Utilizing the latest
European technology for the combustion-components, the optimum
fuel-air ratio is maintained throughout the entire range of the load­tracking operation. The XTherm automatically self-tunes to
accommodate the widest range of gas supply pressures. The high
quality integrated blower-gas valve is self-correcting and allows
smooth operation with fluctuating gas supply pressures. The Raypak
XTherm is cutting edge technology with atmospheric simplicity

.

Key Features

• PVC vent capable - optional at time of order

• 3 models from 1,000,000 to 2,000,000 BTUH

• 97% thermal efficiency at full fire in pool applications

• Minimum continuous inlet water temperature (50°F)

• Small footprint, less than 11 square feet

• AB 1953 low lead compliant

• On-board diagnostic center, real English, no codes

• All models indoor/outdoor certified

• Complete cabinet protects all controls and wiring

• Meets all current Low NOx regulations, including the new

2010 SCAQMD revisions

• Suitable for altitudes up to 10,000 ft.

(derate above 5,000 ft.)

• Equipped with all cupro-nickel, bronze and stainless steel

waterways

Think Green

At the heart of every Raypak XTherm is a unique integral evaporator
system - the first defense against condensation in the primary heat
exchanger. Raypak’s evaporator system collects and re-evaporates
condensate which may form during initial start-up.

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Think Raypak

1. Low Voltage Wiring Terminal

Up front and easy to get to. Makes sensor wiring and
BMS wiring simple and clean.

2. On Board Diagnostic Center

Factory-mounted standard equipment. Gives
relevant service feedback as well as possible
solutions to clear the fault. All in plain english, no
cryptic codes to decipher. The control also stores up
to 16 fault codes in its history file for the service
technician to review.

3. TempTracker Mod Controller

Standard equipment on the XTherm. This factory­mounted multi-function control delivers precise
temperature control with selectable mode displays
that are easy to access and read.

10. Heater Pump

Sometimes referred to as the primary pump. This
fixed speed pump keeps flow constant through the
primary heat exchanger.

11. Water Inlet

The XTherm can accept 50°F continuous inlet water
temperature.

4. Combustion Air Fan

Cast aluminum, non-sparking construction. The state
of the art variable-speed fan is controlled by the
TempTracker Mod and works in smooth harmony
with the main gas valve.

5. Dungs Gas Valve

The XTherm uses a state-of-the-art main gas valve
manufactured in Germany. This precision gas valve
works in perfect unison with the combustion air fan.
The result is silky smooth light-offs.

6. Flow Switch

Monitors water flow and provides safe shut down if
water flow drops below the minimum required.

7. Vent Pressure Switch

Monitors vent pressure and provides safe shut down
if back pressure is excessive.

8. Gas Inlet

The XTherm will operate at 100% full rate with gas
pressures as low as 4.0”w.c.

9. Water Outlet

12. Cold Water Run Pump

The XTherm comes factory equipped with a built in
Cold Water Run system. This advanced water control
system keeps the inlet water temperature to the
primary heat exchanger above 120°F, regardless of
the incoming water temperature. It constantly self
adjusts and regulates the incoming water flow while
still maintaining a constant
exchanger.

13. Flue Outlet

The stainless steel flue outlet is compatible with
AL29-4C. PVC or CPVC vent material may be used in
conjunction with the D-32 vent option on the
XTherm. Dramatically cut your installation costs by
using these non-metallic vent materials.

14. Stainless Steel Secondary Heat Exchanger

Recovers waste heat to boost efficiency up to 97%.
The XTherm utilizes a separate high-grade stainless
steel heat exchanger. This allows the corrosive
combustion condensate to be collected safely
without damaging the heater. There is a condensate
disposal connection on the rear of the heater. The
XTherm is also equipped with a condensate switch
that will sense a blocked condensate drain, which
protects the heater.

ΔT in the heat

15. Vertical Primary Heat Exchanger

Cylindrical, multi-pass heat exchanger captures all
radiant energy, eliminating the need for heavy
refractory.

16. Drain Valve

One of two drain valves located at the bottom of the
heat exchanger. A third drain valve is located on the
secondary heat exchanger. This allows for complete
winterizing and drainage of the heater.

17. Viewing Port

Allows for easy burner inspection.

18. Weather-Proof Jacket

Heavy gauge galvanized steel with a UV-resistant
Polytuf powder coat is impervious to weather and
corrosion. The Polytuf coating passes the 1000 hour
salt spray test (ASTM B117).

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Xtreme Versatility

Xtreme Versatility

Can be installed indoor or outdoors!

Can be installed indoor or outdoors!

1. High Voltage Wiring Box

120VAC connections.

2. Removable Air Filter

Provides easy access and is easily removable for
inspection and replacement. 12”x20”high capacity
filter is rated MERV 8 (95% - 98% arrestance.)

3. Direct Vent Capability

Every XTherm is direct vent capable. By installing the
optional vent pipe adapter (D-18) and air plenum plug,
your XTherm is ready for direct vent. This makes it ideal
for storage of pool chemicals in the same room as the
XTherm. Damaging chemicals are not in contact with
the heat exchanger or combustion chamber.

vent plug easily screws on to cover the direct vent air
intake. The combustion air will then be drawn from
inside the heater through screened plenum openings.

See photo above right.

4. Gas Inlet

The XTherm will operate at 100% full rate with gas
pressures as low as 4.0”w.c.

5. Water Outlet

6. Water Inlet

The XTherm can accept as low as 50°F continuous inlet
water temperature without damage to the primary heat
exchanger.

Internal Air Intake

plumbed in place. Provides full access to inspect and
service the Cold Run Pump system and condensate
drain switch.

8. Flue Outlet

The stainless steel flue outlet is compatible with AL29­4C. For a dramatic cost reduction over Category IV
stainless steel, PVC or CPVC vent material may be used
in conjunction with the D-32 vent option.

9. Condensate Drain

3/4”NPT PVC connection for condensate removal.
Raypak offers optional condensate neutralizer kits (Z-

12) that can be plumbed between the heater and the
drain.

3a. Outdoor Cover

If your job requires outdoor installation, an optional air

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7. Access Panel to Cold Run Pump

Easily removable access panel even when unit is

TOP VIEW

FRONT VIEW REAR VIEW

PROUDLY MADE IN AMERICA

ULTRA HIGH EFFICIENCY

50

B

31-1/8

12-7/16

Y

2-7/8

E

L

F

M

14-7/16

D

P

ØK - FLUE CONNECTION

2-1/2” NPT WATER INLET

2-1/2” NPT WATER OUTLET

ØN - COMBUSTION AIR
OPTIONAL

R

G- GAS CONNECTION

POWER CONNECTIONS

CONDENSATE DRAIN
CONNECTION

25

LOW VOLTAG E
CONDUIT
CONNECTION
(BY OTHERS)

FLUE CONNECTION

Xtremely Small Footprint

Xtremely Small Footprint

Total footprint: Less than 11 ft2!

Dimensions (inches)

Model

1005 55-1/8 45 47-1/8 36-1/2 1-1/4 6 40-1/16 11-1/2 6 47-1/8 8-1/16 6-1/16 1065 12 10
1505 67-1/8 57 59-1/16 38-1/2 1-1/4 8 52-1/16 12-5/8 8 59-1/8 8-3/16 6-1/16 1234 12 14

PHYSICAL DATA

2005 81-1/8 71 71-3/16 38-1/2 2864-1/16 12-5/8 8 73-1/8 8-3/16 6-1/4 1461 18 17

*For propane gas, all models are 1-1/4” NPT.

†

Amp load does not include primary heater pump; a separate 120 VAC electrical connection must be supplied for the primary pump.

Model

1005 999 969 97%

MBTUH

1505 1500 1455 97%

B

Ht.

MBTUH

Input

D E F

Pool Heater

Output Efficiency

G

NPT

*

K

Flue Ø

L M

N

C/A Ø

P R Y

H-Models Hydronic

Weight

(lbs.)

Boiler
Amps

Pump

Amps

†

2005 1999 1939 97%

Heater

Side

Floor* 0 N/A
Rear 12 36
Right Side 1 24
Left Side 11
Front 24 24

CLEARANCES

Top Indoor 0 10

Outdoor Unobstructed Unobstructed
Vent Stack Indoor 1 N/A
Vent Cap Outdoor 12 12

* Do not install on carpeting Note: Local codes may require increased clearances

From Combustible

Surfaces (min.)

For Service

(Minimum)

The XTherm can be used with pools that are sanitized via Salt Water Chlorination;
up to 3000 PPM.

As with all Raypak heaters, please feel free to contact your local Raypak representative
or our Applications Department for assistance with planning your next installation.

Salt Water Chlorination

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68% 78% 82% 97%

4,000,000 $80,653 $66,424 $62,047 $49,756

BTUH

Annual Fuel Usage

50 meters X 25 meters X 2 meters deep

Efficiencies

68% 78% 82% 97%

2,000,000 $26,243 $22,039 $20,712 $16,898

BTUH

Annual Fuel Usage

25 meters X 25 meters X 1-1/2 meters deep

Efficiencies

Using one 2,000,000 BTUH Heater

Using two 2,000,000 BTUH Heater

The annual fuel usage is based on maintaining an indoor
swimming pool at 80ºF for 6 months of the year and using a
fuel cost of $1.00 per therm.

How to use the table below:

1. Select the desired temperature of the pool water.

2. Determine the mean (average) temperature of the month in which the pool will be
used.

3. Subtract the mean temperature from the desired swimming temperature. The
difference is the temperature rise.

4. Calculate the surface area of the pool in square feet.

5. Under the column headed by the temperature rise, determined in Step 3, find the
number closest to, but not less than, the pool surface area from Step 4. The left-hand
column will give you the correct model heater.

Sizing Formula

BTUH INPUT REQUIRED = (Pool Surface Area square feet) X (Temperature Rise) X (15)
This formula is based upon a 1º to 1-1/4º F temperature rise per hour and an average
3-1/2 MPH wind velocity.
Where high-wind conditions exist, select one size larger than determined by the
formula.

Xtreme Pumping

Xtreme Pumping

Cold Water Run System

The XTherm comes standard with a state-of­the-art Cold Water Run system factory mounted
and plumbed. Raypak’s Cold Water Run system
provides constant protection against
condensation in the primary heat exchanger.
The system utilizes a variable speed pump to
inject just the right amount of water from the
main system loop into the heater to maintain
the optimum inlet temperature. This allows the
full capacity of the heater to be utilized to meet
the system load, while at the same time
continuously maintaining the optimum inlet
water temperature to prevent condensation in
the primary heat exchanger. All of this keeps the
condensate were it belongs, in the stainless
steel secondary heat exchanger.

Rapid Heating

For 1-1/2ºF rise per hour: Increase BTUH input by 50%.
For 2ºF rise per hour: Increase BTUH input by 100%.
Always select a heater equal to or larger than the requirement. Over-sizing generally
reduces fuel costs.

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Xtreme Control

Xtreme Control

Simple Serviceability

Raypak’s easy-to-understand user interface, including on-board
diagnostics and LED operating status lights, tells the technician
all he needs to know. All service/repair components are readily
accessible from the front or side for maximum installation
flexibility. To enhance serviceability, the control box is completely
removable allowing total access.

TempTracker Mod

Raypak’s XTherm comes standard with TempTracker Mod control. The control monitors
and displays inlet and outlet temperatures. Adjustable limits prevent over-cycling,
saving energy and extending the life of the heater. Your XTherm is never down with a
sensor failure thanks to Raypak’s exclusive TempTracker software. It can operate with
as little as one functioning sensor, keeping you up and running until service arrives.

• Factory set PID logic

• 4-20ma output

• LCD Display

• Freeze Protection

On-Board Diagnostic Center

Raypak’s XTherm comes equipped with a microprocessor-controlled diagnostic control center that displays its information on a 2x20 character
LCD display in plain English. This control monitors system safeties, ignition faults and system status, while storing up to 16 reported faults.
Raypak’s diagnostic center monitors the fault outputs of the Fenwal ignition control, converting the Fenwal’s fault codes into real English that
anyone can understand. The control is also equipped with a SPDT dry contact relay output that is switched anytime a safety fault occurs. This
can be used for a heater alarm or a safety interface.

Example Diagnostic Fault Report:

Water Flow Sw Fault

Check Boiler Pump, Purge Air, Replace Flow Switch

Note: Diagnostic information rotates

Diagnostic Information

Safety Faults Ignition Control Faults

• PVC Vent Limit • Low Air

• Condensate Drain • Flame- No CFH

• Manual High Limit • Ignition Lockout

• Auto High Limit • Low HSI Current

• Low Water Cut-off • Low 24VAC

• Vent Pressure • Internal Control Fault

• High Gas Pressure

• Low Gas Pressure

• Controller Alarm

• Flow Switch

• Blower Switch

• Factory Option

• External Interlock

• Cold Water Run

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ASME, National Board Registered, 160 PSI • HLW Stamp 
Heat Exchanger Tubes • Cupro Nickel 
Bronze Headers 
Stainless Steel Condensing Heat Exchanger • U Stamp 
Pressure Relief Valve • 125 PSI 

(Mounted on Outlet) (Currently Shipped Loose)
Temperature & Pressure Gauge 

HEAT EXCHANGERJACKETOTHER

Pump - Primary • 120V, Single-Phase 

Indoor/Outdoor Certified 
Vent Terminal • Outdoor 

• Through-the-Wall 
Fully-Enclosed Controls 
Combustible Floor Rated 

120V Power Supply with 120V/24V Transformer 
On/Off Switch 
Programmable Pump Time Delay, Single-Phase • Included in TempTracker Mod Controller 
Terminal Block Connections • Enable / Disable 

(Front mounted) • External Interlocks 

• 0-10 VDC Setpoint/Direct Drive Input 
LCD diagnostic display with 16-Event History (2x20 character display, reads in plain English) 
Status Display Lights (4) 
Temperature Controller with 3 Water Sensors • TempTracker Mod 

OPERATING CONTROLS

Multiple Heater Controller • TempTracker Mod+, up to 16 heaters 

WHP

Hot Surface Ignition System • 1-try 

• 3-try 
High/Low Gas Pressure Switches 
Blocked Vent and Air Pressure Switches 
High Limit Switch • Manual Reset, Fixed 

SAFETIES

• Manual Reset, Adjustable 

• Automatic Reset, Adjustable (Shipped Loose) 
Low Water Cut-Off, 24V • With Manual Reset and Test Buttons 
Flow Switch 

Combination Gas Valve 
Combustion Air Blower 
Additional Safety Valve • Motorized (externally mounted) 

GAS TRAIN

• Solenoid (externally mounted) 

CSA-Certified Efficiency • 97% at Full Fire 
Air Filter 
TruSeal Direct-Vent Ready 
PVC Vent Adapter Option D-32 (Factory installed only) 
Alarm System 
CSD-1 / GE GAP Control System 
Low NOx • Meets all current requirements 
Cold Water Run - Variable Speed Pump • Prevents condensation in primary heat exchanger 

 = Standard  = Optional

Raypak, Inc. • 2151 Eastman Avenue, Oxnard, CA 93030 • phone: [phone] • fax: [phone] • www.raypak.com

Cat. No. 6200.12-E Effective 4-1-11 Replaces 1-1-11