Raypak H7-1005A Installation Manual
INSTALLATION & OPERATING
ULTRA HIGH EFFICIENCY
INSTRUCTIONS
Models 1005A–2005A
Types H, WH & P
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. 3400.552 Effective: 08-02-13 Replaces: NEW P/N 241513 Rev. 1
2
CONTENTS
WARNINGS 4
BEFORE INSTALLATION 5
Product Receipt 5
Model Identification 5
Ratings and Certifications 5
Installations at Elevation 5
Component Locations 6
General Information 6
GENERAL SAFETY 7
Time/Temperature Relationships in
Scalds 7
INSTALLATION 8
Installation Codes 8
Equipment Base 8
Clearances 8
Combustion and Ventilation Air 9
Conventional Combustion Air Supply 11
Water Piping 13
Hydronic Heating 15
Applications & Modes 16
Domestic Hot Water 17
Pool Heating 19
Gas Supply 21
Electrical Power Connections 22
Field Wiring Connection 24
Venting 27
Venting Installation Tips 30
Venting Configurations 30
Outdoor Installation 35
Controls 36
User Interface 38
WIRING DIAGRAM 44
START-UP 45
Pre Start-up 45
Start-Up 46
OPERATION 50
Lighting Instructions 50
To Turn Off Gas To Appliance 50
TROUBLESHOOTING 50
MAINTENANCE 53
Suggested Minimum
Maintenance Schedule 53
Preventative Maintenance Schedule 54
Filter Maintenance 55
Filter Replacement 55
APPENDIX 56
Inside Air Contamination 56
IMPORTANT INSTRUCTIONS FOR
THE COMMONWEALTH OF
MASSACHUSETTS 57
START-UP CHECKLIST 59
WARRANTY 60
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.
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.
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: Both natural gas and propane have an
odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.
WARNING: UL recognized fuel gas detectors are
recommended in all enclosed propane and natural
gas applications wherein there is a potential for an
explosive mixture of fuel gas to accumulate and their
installation should be in accordance with the
detector manufacturer's recommendations and/or
local laws, rules, regulations, or customs.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
• 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 above
radiation level, it must be provided with a low water
cut-off device at the time of heater installation.
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.
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.
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.
he upper rear jacket panel of the heater. The model
t
number will have the form H7 or similar depending on
the heater size and configuration. The letter(s) in the
first group of characters identifies the application (H =
ydronic Heating, WH = Domestic Hot Water (DHW),
H
and P = Pool heating). The number which follows iden-
ifies the firing mode (7 = electronic modulation). The
t
second group of characters identifies the size of the
heater (the four numbers representing the approximate MBTUH input), and, where applicable, a letter,
indicating the manufacturing series.
Ratings and Certifications
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
• ANSI Z21.56 · CSA 4.7 - latest edition, Gas-Fired
Pool Heaters
• SCAQMD Rule 1146.2
• Low-lead content (<.25%) CSA-certified
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
heater is constructed in accordance with Section IV of
the American Society of Mechanical Engineers
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.
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
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. Altering the ASME or CSA ratings of the
vessel also violates national, state, and local
approval codes.
(ASME) Heater Pressure Vessel Code and bears the
ASME stamp. This heater also complies with the latest
edition of the ASHRAE 90.1 Standard.
Installations at Elevation
Rated inputs are suitable for up to 2,000 ft elevation
without de-rating. Consult your local representative or
the factory for installations at altitudes over 2,000 ft
above sea level. No hardware changes are required to
the heaters for installations up to 10,000 ft (adjustments may be required).
5
INJECTOR
PUMP(S)
H
EATER
PUMP
Component Locations
Model
Max
Input Min Input
Water
Conn
(NPT)
Vent
Size
Comb
Air
Xtherm MBTUH MBTUH In Nat LP In In
1005A 999 140 2 1/2 1-1/4 1 6 6
1505A 1500 210 2 1/2 1-1/4 1 8 8
2005A 1999 280 2 1/2 2 1 8 8
Gas Conn
(NPT)
Fig. 3: Component Locations – Rear
Panels omitted for clarity
Fig. 1: Component Locations – Side
Top panel, blower and gas train omitted for clarity
Fig. 4: Component Locations – Top
General Information
Panels omitted for clarity
Fig. 2: Component Locations – Front
Table A: Basic Data
6
GENERAL SAFETY
Water temperature over 125°F can
cau s e i nsta n t s e v er e b u r ns or d eath
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.
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.
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.
CAUTION: Hotter water increases the risk of
scalding! There is a hot water scald potential if the
thermostat is set too high.
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
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)
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
s recommended that a suitable catch pan,
i
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.).
If the heater needs to be secured to the ground, use
the hole pattern shown in Fig. 5, following local codes.
Additional clearance may be required when using the
factory anchor bracket.
Clearances
Fig. 5: Anchor Hole Locations
Heater
Side
Floor* 0” 0”
Rear 12” 36”
Right Side 1” 24”
Left Side 1” 1”
Top 0” 10”
Front Open 24”
Vent 1” 1”
*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.
Minimum Clearance
from Combustible
Surfaces
Minimum
Service
Clearance
Equipment Base
The heater should be mounted on a level, structurally
sound surface. The heater is approved for installation
on a combustible surface but must NEVER be
installed on carpeting. Gas-fueled equipment installed
in enclosed parking garages must be located at least
18 in. above the floor.
Indoor Installations
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.
8
he combustion air intake elbow MUST be used for
T
outdoor installations. It is shipped loose to be installed
on the air filter intake at the rear of the heater at the job
site. The elbow MUST be oriented with the opening
acing downward (shipped loose).
f
in. Clearance
Heater
Side
Rear 12” 36”
Right Side 1” 24”
Left Side 1” 1”
Top Unobstructed 10”
Vent
Termination
Table D: Clearances – Outdoor Installations
M
from Combustible
Surfaces
12” 12”
inimum
M
Service
Clearance
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.
Fig. 6: Minimum Clearances from Combustible
Surfaces – Indoor and Outdoor Installations
Outdoor Installations
These heaters are design-certified for outdoor installation. Heaters must not be installed under an overhang
unless clearances 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. Roof water drainage must be diverted away
from heaters installed under overhangs.
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 cause non-warrantied damage to the heater.
(See the Appendix.)
NOTE: It is recommended that the intake vent be
insulated to minimize sweating when inistalled in
cold climates.
9
U.S. Installations
1
Canadian Installations
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 extended above meter/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/CSA-B149 Installation Codes
t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that se rves
both dwellings
TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of term inal and
underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)
* Clearances in accordance with local installation codes and the requirements of the gas supplier
3 ft (91 cm) within a
height 15 ft above the
meter/regulator assembly
Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table E: Vent/Air Inlet Termination Clearances
10
Combustion Air Filter
Debris Screen
In take A ir Co llar
his heater is supplied with an integral combustion air
T
filter. This filter will reduce the amount of particulates
assed through the combustion system and heat
p
exchanger but will not protect against chemical air
contamination (See Appendix). The filter must be
checked periodically to verify that adequate combus-
ion air is being supplied to the heater. See the
t
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. Install combustion air direct vent in accordance
with Fig. 35 (horizontal) or Fig. 36 (vertical) of this
manual (pages 33 and 34, respectively).
2. Ventilation of the space occupied by the heater(s)
is recommended and can be provided by an opening(s) for ventilation air at the highest practical
point communicating with the outdoors. The total
cross-sectional areas should be at least 1 in.² of
free area per 20,000 BTUH (111 mm² per kW) of
total input rating of all equipment in the room,
when the opening is communicating directly with
the outdoors or through vertical duct(s). The total
cross-sectional area should be at least 1in.² of free
area per 10,000 BTUH (222 mm² per kW) of total
input rating of all equipment in the room, when the
opening is communicating with the outdoors
through horizontal duct(s). Damage to the equipment due to inadequate ventilation of the space is
not a warrantable failure.
Fig. 11: Remove the Debris Screen
5. Install the intake air collar using the six screws
removed in step 8 above.
3. 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.
4. Remove the debris screen (or cover panel for
model 1005) by removing the six screws holding it
in place.
Fig. 12: Install the Intake Air Collar
6. Replace all the access panels.
7. Install combustion air direct vent in accordance
with Fig. 27 (horizontal) or Fig. 28 (vertical) of this
manual (pages 27 and 28, respectively).
8. Ventilation of the space occupied by the heater(s)
is recommended and can be provided by an opening(s) for ventilation air at the highest practical
point communicating with the outdoors. The total
cross-sectional areas should be at least 1 in.² of
free area per 20,000 BTUH (111 mm² per kW) of
total input rating of all equipment in the room,
when the opening is communicating directly with
the outdoors or through vertical duct(s). The total
11
cross-sectional area should be at least 1in.² of free
area per 10,000 BTUH (222 mm² per kW) of total
input rating of all equipment in the room, when the
opening is communicating with the outdoors
through horizontal duct(s). Damage to the equipment due to inadequate ventilation of the space is
ot a warrantable failure.
n
9. 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.
(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.
ll Air from Outdoors
A
he confined space shall communicate with the out-
T
doors 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.
TruSeal™ Combustion Air
In addition to the nine 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.
Conventional Combustion Air
Supply
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.
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.
opening shall commence within 12 in. (305 mm) of the
top, and one opening shall commence within 12 in.
2
(645 cm2). One
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
have a minimum free area of 1 in.2per 2,000
BTUH (1,100 mm2per kW) of total input rating of all equipment in the enclosure.
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.
2
12
Canadian Installations
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
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).
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.
2
per kW) of total rated input of the burner(s),
mm
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.
2
for each 30,000 BTUH (74
4. Refer to the B149 Installation Code for additional
information
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.
2
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 F on page 15.
Relief Valve Piping
Temperature & Pressure Gauge
The temperature and pressure gauge is shipped
mounted on the boiler outlet.
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.
Leaks must be repaired at once to prevent damage to
the heater. NEVER use petroleum-based stop-leak
compounds.
To perform hydrostatic test:
1. Connect fill water supply. Fill heater with water.
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.
13
3. Check for leaks. Repair any that are found.
Piping
Raypak Integral Cold Water
Protection
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
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.
Feedwater Regulator
All high points should be vented. A heater installed
bove radiation level must be provided with a low wa-
a
ter 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 pre-vent the chilled medium from entering
the heater.
NOTE: Hot water heating systems all have unique
levels of operating diversity that must be accounted
for in the system design. The system should always
include adequate system flow in excess of the
connected boiler flow for proper operation. Where
the system flow may drop below the connected
boiler flow a buffer/decoupler may be needed.
Failure to design for adequate flow (i.e. bypasses, 3
way control valves, flow limiting balance devices,
buffer tanks, etc.) will result in boiler short cycling
and may reduce boiler life. Always contact your local
Raypak representative for system design assistance
to avoid these issues.
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.
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
back flow device upstream of the regulator, with a
manual shut-off valve as required by local codes.
14
System
R
eturn Temp Su
pply
Tem p
1
S
u
p
p
l
y
Tem
p
1
Suppl
y
Tem
p
1
(
°F) (°F) <80' equiv. 80-200' equiv. (°F) <80' equiv. 80-200' equiv. (°F) <80' equiv. 80-200' equiv.
60 138 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
160 185 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
-Minimumpipe size based on total equivalent feet of supply and return
pip
in
g
between the s
y
s
tem loo
p
and heater.
able F: Boiler Temperatures and Minimum Pipe Size at Varying Return Temperatures
T
Air-Separation/Expansion Tank
All heaters should be equipped with a properly sized
expansion tank and air separator fitting as shown in
Fig. 12 .
Fig. 12: Air-Separation/Expansion Tank
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
15
Three-Way Valves
Three-way valves intended to regulate system water
temperatures by reducing flow in the boiler should not
be used. Raypak heaters are high-recovery, low-mass
heaters which are not subject to thermal shock.
Applications & Modes
The VERSA IC Control system is designed for a wide
range of applications. The installer/design engineer
should refer to the following Modes to determine which
best fits the intended application and functionality for
the unit being installed.
Type H models of XTherm have three modes available
to them to address the various applications the units
can be applied to. Type WH units will only have the
WH configuration available to them for use with
potable water applications when directly connected to
a hot water storage tank.
Fig. 13: MODE 1 - Single Boiler with
Primary/Secondary Piping
Mode 1 (Type H Units Only)
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4). The system temperature is
controlled by the System sensor (S3). The integral
boiler pumps (P1) run during any call for heat. The
System Pump (P2) runs whenever the system is
enabled for heating and the outdoor air temperature is
lower than the warm weather shut down (WWSD) temperature setting (if utilized). The System Pump is
delayed “off” as user defined in the ADJUST menu.
16
Fig. 14: MODE 1 - Boiler Cascade with
Primary/Secondary Piping
NOTE: MODE 1 can also be used for process heating applications in conjunction with a buffer/storage
tank when operating temperatures above 160°F are
required. Care must be given to ensure water hardness is no more than 15 grains per gallon for scale
free operation.
Fig. 15: MODE 2 - Single Boiler with Indirect
on System Loop
Mode 2 (Type H Units Only)
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4) with indirect DHW on the system loop (with or without priority). The system
temperature is controlled by the System sensor (S3).
The Indirect DHW sensor (S5) determines the indirect
call/tank setpoint. The system temperature is boosted
to Target Max when using the Indirect DHW sensor
(S5) during an indirect call for heat. Priority mode toggles off the System Pump (P2) when an indirect call for
heat is present. The Indirect DHW Pump (P3) runs
during an indirect call for heat with no “off” delay. The
System Pump (P2) delay “off” as user defined in the
ADJUST menu. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor
air temperature is lower than the WWSD temperature
setting (if utilized) unless an indirect call for heat is
present with priority.
Fig. 16: MODE 3 - Single Boiler with Indirect
on Boiler Loop
Mode 3 (Type H Units Only)
This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4) with indirect DHW on the boiler loop (with priority). The system temperature is
controlled by the Supply sensor (S3) whenever the
indirect call for heat is not active. The DHW Supply
sensor (S5) determines the indirect call/tank setpoint.
During an indirect call for heat the boiler firing rate is
determined by the water temperature at the Indirect
Supply sensor (S6) and the Target Max setting when
using the Indirect DHW sensor (S5). The Indirect DHW
Pump (P3) runs during an indirect call for heat with no
“off” delay. The System Pump (P2) delay “off” as user
defined in the ADJUST menu. The system pump (P2)
runs whenever the system is enabled for heating and
the outdoor air temperature is lower than the WWSD
temperature setting (if utilized) unless an indirect call
for heat is present.
NOTE: A Tank Aquastat can be used in lieu of the
Indirect DHW Sensor (S5). See the Versa IC manual for additional details.
Domestic Hot Water
When designing the water piping system for domestic
hot water applications, water hardness should be considered. Table G indicates the suggested flow rates for
soft, medium and hard water. Water hardness is expressed in grains per gallon.
17
T
ank
u
S
tf
o
S
.
p
uS draH
.
p
uS deM/tfo
S
p
meT nr
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 tubing size based on total equivalent feet of supply and return
pip
ing between the tank and heater.
Model 1005
Minimum Tubin
g
Size
2
Minimum Tubing Size
2
Minimum Tubin
g
Size
2
500
2
led
o
M
5
0
5
1
led
o
M
Table H: Hot Water Supply Temperatures and Minimum Pipe Size at Varying Return Temperatures
∆T = Temperature rise, °F
∆P = Pressure drop through heat exchanger, ft
SHL = System head loss, ft (based on heater and tank connections of no more than 100 eq. ft. of tubing)
gpm = Gallons per minute, flow rate
MTS = Minimum tubing size
*Must utilize optional cupro-nickel tubes. If over 25 grains per gallon, a water softener/treatment system must be utilized.
**Caution: For scale free operation with "Hard Water" (16-25 grains per gallon of total hardness), the operating control must NOT be set
higher than 130 F. For higher than 130 F operation, a water softener/treatment system must be utilized.
***Care should be given to prevent over-softening of the water as over-softened water can become aggressive. Cupro-nickel tubes are
recommended for water softened below 5 grains per gallon.
Table G: Domestic Water Heater Flow Rate Requirements
NOTE: Soft = 3–4 grains per gallon; Medium = 5–15
grains per gallon; Hard = 16–25 grains per gallon.
NOTE: WH units will operate to a maximum tank
temperature of 160°F. For temperatures required
above 160°F an “H” model boiler configured for high
temperature potable operation must be used and
great care must be given to ensure water hardness
is no more than 15 grains per gallon for scale free
operation. MODE 1 should be used and configured
for setpoint operation for process heating applications.
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.
Fig. 17: WH Units - Single Water Heater with Tank
H Units - Single Boiler with Process Tank
WH – Direct DHW Configuration
When the unit is ordered as a “WH” configuration the
only application available to it is direct DHW with single or multiple heaters (Maximum 4 heaters). The tank
temperature is controlled by the System sensor (S3).
The integral Boiler Pumps (P1) run during any call for
heat. The System Pump (P2) output is active whenever the system is enabled. The Boiler Pumps are
delayed “off” after the Tank Target temperature is
achieved and as user defined in the ADJUST menu.
NOTE: If local codes require a vacuum relief valve,
acquire one locally and install per valve
manufacturer’s instructions.
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.
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.
18
F
ROM
FILTER
TO
POOL
CPVC, COPPER OR BRASS
A
UTO LIMIT
(SET AT 110°F)
Automatic Chemical Feeders
All chemicals must be introduced and completely diluted into the water before being circulated through the
eater. High chemical concentrations will result when
h
the pump is not running (e.g. overnight).
NOTE: High chemical concentrates from feeders
that are out of adjustment will cause rapid corrosion
to the heat exchanger. Such damage is not covered
under the warranty.
NOTE: Failure of a heat exchanger due to lime
scale build-up on the heating surface, low pH or
other chemical imbalance is non-warrantable.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can cause unwarrantable damage to the heater.
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 P 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. 18 for the thermostat/sensor location.
WARNING: To ensure safe operation of the
XTherm pool heater, all plumbing from the heater to
the main loop must be CPVC, copper or brass.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 18: Single Pool Heater Application
CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can
damage the heater and can cause unwarrantable
damage to the heater.
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 your
heater is properly installed.
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 stainless steel condensing 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 condensing
heat exchanger drain. Drain any piping of all water
that may experience below-freezing temperatures.
Install limit in supply to pool as shown in Fig. 18.
19
Recommended Level(s) Fiberglass Pools Fiberglass Spas
Other Pool and Spa
ypes
T
ater Temperature
W
H
p
Total Alkalinity (ppm) 120-150 120-150 80-120
Calcium Hardness (ppm) 200-300 150-200 200-400
Salt (ppm) 3000 Maximum 3000 Maximum 3000 Maximum
Free Chlorine (ppm)* 2-3 2-3 2-3
Total Dissolved Solids
(ppm)
*Free Chlorine MUST NOT EXCEED 5 ppm!
**In saltwater chlorinated pools, the total TDS can be as high as 4500 ppm.
NOTE: The allowable concentrations of salt and of the Total Dissolved Solids are lower for the XTherm than
for a typical residential pool heater, due to the higher water temperatures at which an XTherm operates.
Pool/Spa Water Chemistry
CAUTION: Corrosive water can cause unwar-
rantable damage to the heater.
NOTE: Chemical imbalance can cause severe
damage to your heater and associated equipment.
8-88°F (20-31°C)
6
.3-7.4
7
1500 Maximum** 1500 Maximum** 1500 Maximum**
Table H: Pool Water Chemistry
9-104°F (31-40°C)
8
.3-7.4
7
tors are usually more efficient in heater water, unless
controlled, they can lead to excessive chlorine level
which can damage your heater.
Further advice should be obtained from your pool or
spa builder, accredited pool shop, or chemical supplier for the correct levels for your water.
8-104°F (20-40°C)
6
.6-7.8
7
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.
Automatic chemical dosing devices and salt chlorina-
Automatic Chlorinators and
Chemical Feeders
All chemicals must be introduced and completely diluted into the pool or spa water before being circulated
through the heater. Do not place sanitizing chemicals
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
rapid corrosion to the heat exchanger. Such damage
is not covered under the warranty.
NOTE: Failure of a heat exchanger due to lime
scale build-up on the heating surface, low pH or
other chemical imbalance is non-warrantable.
20
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