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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5432
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6 7
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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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Xtreme Versatility
Can be installed indoor or outdoors!
1. High Voltage Wiring Box
120VAC connections.
2. Removable Air Filter
Easy access and easily removable for inspection and
replacement. 12”x20”high capacity filter is rated
MERV 8.
3. Direct Vent Capability
Every XTherm is direct vent capable. By installing an
optional vent pipe adapter and air plenum plug, your
XTherm is ready for direct vent.
3a. Outdoor Cover
If your job requires outdoor installation, an optional
air 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
7. Access Panel to Cold Run Pumps
Easily removable access panel even when unit is
plumbed in place. Provides full access to inspect and
service the Cold Run Pump system and condensate
drain switch.
8. Flue Outlet
Stainless steel Category IV compatible.
9. Condensate Drain
3/4”-NPT PVC connection for condensate removal.
Raypak offers condensate neutralizer kits that can be
plumbed between the heater and the drain.
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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
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LOW VOLTAGE
CONDUIT
CONNECTION
(BY OTHERS)
FLUE CONNECTION
Xtremely Small Footprint
H-Models Hydronic
Weight
(lbs.)
Boiler
Amps
Pump
Amps
†
Model
B
Ht.
D E F
Dimensions (inches)
*
K
G
NPT
Flue Ø
L M
N
C/A Ø
P R Y
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.
†
Separate wiring connection required for pumps.
Model
1005 999 959 96% 999 969 97% 250
MBTUH
1505 1500 1440 96% 1500 1455 97% 375
MBTUH
Input
2005 1999 1919 96% 1999 1939 97% 500
Heater
Side
Floor* 0 N/A
Rear 12 36
From Combustible
Boiler
Output Efficiency
Surfaces (min.)
For Service
(recommended)
MBTUH
Input
Right Side 1 24
Left Side 11
Front 24 24
CLEARANCES
Top Indoor 0 10
Vent Stack Indoor 1 N/A
Vent Cap Outdoor 12 12
*Do not install on carpeting
Note: Local codes may require increased clearances
Outdoor Unobstructed Unobstructed
Water Heaters
Output Efficiency
XTherm
Model
1005 12 10 12 10 12 14
1505 12 10 12 14 12 17
2005 18 17 18 17 N/A N/A
Water hardness grains per gallon
Soft = 0-4 • Medium = 5-15 • Hard = 16-25
Minimum
Input
Water Heater Power Requirements
Soft
Heater Pumps Heater PumpsHeater Pumps
HardMedium
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XTherm
ULTRA HIGH EFFICIENCY
®
Model
Xtreme Pumping
Cold Water Run System
The XTherm comes standard with a state-of-the-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 one or two variable speed pumps, depending on model size and type, to inject just the right amount of
water from the main system loop into the boiler to maintain the optimum inlet temperature. This allows the full capacity of the boiler 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. For models using the twin pump design, each pump
acts independently giving the boiler up to a 10:1 flow
turndown. All of this keeps the condensate were it
belongs, in the stainless steel secondary heat exchanger.
Recovery Rates
Temperature Rise (°F)
140 150120 130100 11080 9060 7040 503020
1005 5,817 3,878 2,908 2,327 1,939 1,662 1,454 1,293 1,163 1,058 969 895 831 776
TYPE WH
1505 8,733 5,822 4,367 3,493 2,911 2,495 2,183 1,941 1,747 1,588 1,456 1,344 1,248 1,164
2005 11,639 7,759 5,813 4,656 3,880 3,325 2,910 2,586 2,328 2,116 1,940 1,791 1,663 1,552
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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. This control can be used for
space heating and hot water supply with 8 application-specific modes to meet various
applications, including outdoor reset for heating systems. The control monitors and displays inlet and outlet temperatures on all applications as well as monitor outdoor temperature when an outdoor reset mode is selected. Only Raypak’s TempTracker Mod
allows for a user definable outdoor reset ratio. 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.
• P or PID logic
• 0-10VDC Setpoint Input
• 0-10VDC Direct Drive Input
• 4-20ma output
• Building management direct control
• 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. Raypaks diagnostic center monitors the fault outputs of the Fenwal ignition control. Converting the
Fenwal’s flashing lights into real English fault codes 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 BMS safety interface.
Example Diagnostic Fault Report
Water Flow Sw Fault
Check Boiler Pump, Purge Air, Replace Flow Switch
Diagnostic Information
Safety Faults Ignition Control Faults
• Condensate Drain • Low Air
• Manual High Limit • Flame- No CFH
• Auto High Limit • Ignition Lockout
• Low Water Cut-off • Low HSI Current
• Vent Pressure • Low 24VAC
• High Gas Pressure • Internal Control Fault
• Low Gas Pressure
• Controller Alarm
• Flow Switch
• Blower Switch
• Factory Option
• External Interlock
• Cold Water Run
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Water Heaters
ULTRA HIGH EFFICIENCY
®
(Type WH)
ASME, National Board Registered, 160 PSI • HLW Stamp N/A
• H Stamp N/A
Heat Exchanger Tubes • Copper
• Cupro Nickel
Bronze Headers
Cast Iron Headers N/A
Stainless Steel Condensing Heat Exchanger • U Stamp
Pressure Relief Valve • 60 PSI
(mounted on outlet) • 125 PSI
HEAT EXCHANGERJACKETOTHER
Temperature & Pressure Gauge
Pump • 120V, Single-Phase
• 30, 45, 75, 150 PSI
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 dry contacts
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 (up to 4:1 Turndown)
OPERATING CONTROLS
Multiple Boiler Controller • TempTracker Mod+, up to 16 boilers
• Outdoor Reset Sensor N/A
Boilers
(Type H)
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
Low Water Cut-Off, 24V • With Manual Reset and Test Buttons
Flow Switch
Modulating Combination Gas Valve
Combustion Air Blower
Additional Safety Valve • Motorized (externally mounted)
GAS TRAIN
• Solenoid (externally mounted)
CSA-Certified Efficiency • 96% at Full Fire N/A
• 97% at Full Fire N/A
Air Filter
TruSeal Direct-Vent Ready
Alarm System
CSD-1 / GE GAP Control System
Low NOx • Meets all current requirements
Cold Water Run • Prevents condensation in primary heat exchanger
= Standard = Optional
Raypak, Inc. • 2151 Eastman Avenue, Oxnard, CA 93030 • phone: (805) 278-5300 • fax: (800) 872-8725 • www.raypak.com
Cat. No. 1000.21C Effective 01-15-11 Replaces 10-01-10
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