Raypak XTHERM 1505 User Manual

Models
1005, 1505, 2005

Up to 99% thermal efficiency!

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Xtreme Performance

Up to

99% thermal efficiency!

Think Green

Think Raypak

Raypak’s Next Generation Condensing
Modulating Heater

Time-honored technologies unite with cutting-edge advancements in
Raypak’s new XTherm modulating vertical heater. Never before has
a vertical heater provided both the installer and building owner 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 96% efficiency at full fire for hydronic boil­ers and 97% for domestic hot water heaters

When the job requires high efficiency, XTherm meets your

load!)

needs.

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.

(Up to 99% at part

tion. Our smooth 4:1 turndown ensures efficiency is maintained
throughout the firing rate and actually increases during part load,
right when you want it! 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

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

• California bill AB-1953 low lead compliant

• 96% thermal efficiency hydronic and 97% domestic hot water

• Minimum continuos inlet water temperature (50°F)

• Modulating gas valve and burner, up to 4:1turndown

• Small footprint, less than 11 square feet

• 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.)

• Water heater models are equipped with all copper and bronze

waterways.

• Boiler models are equipped with cast iron headers and pumps

with the option to upgrade to bronze. All other waterway
plumbing is copper.

• 0-10 VDC Remote set point BMS Interface

• 0-10 VDC Direct Drive

True Modulation

Modulation is nothing new to Raypak, we have honed our gas modu­lation experience for over 50 years. The Raypak XTherm will precisely
track the heating load with it’s built-in TempTracker Mod control,
eliminating costly overshooting. Utilizing the latest European technol­ogy for the combustion-components, the optimum fuel-air ratio is
maintained throughout the entire range of the load-tracking opera-

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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 load­tracking with selectable mode displays that are easy
to access and read.

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 and a 4:1 turn
down.

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.

10. Water Outlet

11. Water Inlet

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

12. Cold Water Run Pumps

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 delta-T in the heat
exchanger.

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.

15. Vertical 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.

8. Gas Inlet

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

9. Boiler Pump

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

13. Flue Outlet

Stainless steel Category IV compatible.

14. Stainless Steel Secondary Heat Exchanger

Recovers waste heat to boost efficiency into 96%+
range. The XTherm utilizes a separate high-grade
stainless steel heat exchanger. This allows the corro­sive combustion condensate to be collected safely

17. Viewing Port

Allows for easy burner inspection.

18. Weather-Proof Jacket

Heavy gauge galvanized steel with a UV-resistant
Polytuf powder coat finish is impervious to weather
and corrosion.

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