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INSTALLATION & OPERATING
INSTRUCTIONS
ULTRA HIGH EFFICIENCY
Models 1005–2005
L
Types H, WH & WHP
W
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 vapo
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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. Deletion
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CONTENTS WARNINGS 4 Outdoor Installation 29 Pay Attention to These Terms 4 PVC Venting Option 30 BEFORE INSTALLATION 5 Controls 32 Product Receipt 5 Heater Sequence of Operation 38 Model Identification 5 WIRING DIAGRAMS 42 Ratings and Certifications 5 Models 1005 & 1505 42 Installations at Elevation 5 Model 2005 43 Component Locations 6 START-UP 44 General Information 6 Pre Start-up 44 Time/Temperature Relationships Pre Start-up Check 44 in Scalds 7 Initial Start-up 45 GENERAL SAFETY 7 Preparati
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WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. Indicates special ins
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the upper rear jacket panel of the heater. The model BEFORE INSTALLATION number will have the form H7-2005 or similar depend- ing on the heater size and configuration. The letter(s) Raypak strongly recommends that this manual be re- in the first group of characters identifies the application viewed thoroughly before installing your XTherm (H = Hydronic Heating, WH = Domestic Hot Water heater. Please review the General Safety information (DHW), WHP = Water Heater for Pool Heating). The before ins
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Component Locations AIR FILTER ACCESS PANEL Fig. 1: Component Locations – Right Side Fig. 3: Component Locations – Rear General Information Gas MBTUH Vent Size Water Conn. Model Input (in.) Conn. (NPT) No. (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 Fig. 2: Component Locations – Top 6
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GENERAL SAFETY 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 rec- ommended initial setting for the temperature control is 125°F. Safety and energy conservation are factors to be con- sidered when setting the water temperature on the thermo
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The temperature of the water in the heater can be reg- Equipment Base ulated by using the Raypak Modulating Temperature Control. To comply with safety regulations, the control The heater should be mounted on a level, structurally is set at 120°F when shipped from the factory (Mode 3 sound surface. The heater is approved for installation default setting for Tank Target). on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed To adjust the water temperatu
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Roof water drainage must be diverted away from heaters installed under overhangs. Min. Clearance Minimum Heater from Combustible Service Side Surfaces Clearance Rear 12” 36” Right Side 1” 24” Left Side 1” 1” Top Unobstructed 10” Vent 12” 12” Termination 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 tha
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Fig. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 2 U.S. Installations Canadian Installations Clearance above grade, veranda, porch, A 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening; 1 foot (30 cm) B 3 ft (91 cm) opened above opening C Clearance to permanently closed window ** Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- D 5
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Combustion Air Filter Inside Air Intake This heater is supplied with an integral combustion air Cover Panel 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 combus- tion air is being supplied to the heater. See the Maintenance section of this manual for information on checking the filter a
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8. Remove the debris screen (or cover panel for 12. Provide adequate ventilation of the space occu- model 1005) by removing the six screws holding it pied by the heater(s) by an opening(s) for in place. ventilation air at the highest practical point com- municating with the outdoors. The total 2 cross-sectional area shall be at least 1 in. of free 2 area per 20,000 BTUH (111 mm per kW) of total input rating of all equipment in the room when the opening is communicating directly with the out- doo
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2. One permanent opening, commencing within 12 Conventional Combustion Air in. (305 mm) of the top of the enclosure, shall be Supply permitted where the equipment has clearances of at least 1 in. (25 mm) from the sides and back and U.S. Installations 6 in. (152 mm) from the front of the appliance. The opening shall directly communicate with the out- doors or shall communicate through a vertical or All Air from Inside the Building horizontal duct to the outdoors or spaces that freely communicate
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Relief Valve Installation and Piping WARNING: Care must be taken to ensure that the equipment room is not under negative pressure WARNING: Pressure relief valve discharge piping conditions. must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe 3. For heaters not using a barometric damper in the to any area where freezing could occur. Refer to vent system, and when air supply is provided by local codes. natural air flow from outdoors for a power
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Leaks must be repaired at once to prevent damage to Feedwater Regulator the heater. NEVER use petroleum-based stop-leak compounds. Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the To perform hydrostatic test: highest point of the system. Install a check valve or back flow device upstream of the regulator, with a 1. Connect fill water supply. With bleed valve open, manual shut-off valve as required by local codes. fill heater with water. When w
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System Model 1005 Model 1505 Model 2005 1 2 1 2 1 2 Return Temp Supply Temp Minimum Pipe Size Supply Temp Minimum Pipe Size Supply Temp Minimum Pipe Size (°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 80 138 2"NPT 2 1/2"NPT 147 2"NPT 2 1/2"NPT 154 2 1/2"NPT 3"NPT 100 138 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"N
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NOTE: If local codes require a vacuum relief valve, CAUTION: Power to the heater should be acquire one locally and install per valve interlocked with the main system pump to make sure manufacturer’s instructions. the heater does not fire without the main system pump in operation. Improper flow control can damage the heater. Uncontrolled flow (too high) or Combined Potable Water and restricted flow (too low) can seriously damage the Space Heating heater. Follow these instructions to make sure the
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Tank Model 1005 Model 1505 Model 2005 2 2 2 Return Temp Soft/Med Sup. Hard Sup. Minimum Tubing Size Soft Sup. Med Sup. Hard Sup. Minimum Tubing Size Soft/Med Minimum Tubing Size 1 1 1 1 1 1 Temp (°F) Temp (°F) Temp (°F) Temp (°F) Temp (°F) Sup. Temp (°F) (°F) <80' equiv. 80-200' equiv. <80' equiv. 80-200' equiv. <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" 100 138 135 2 1/2" 3" 150 145 143 2 1/2" 3" 1
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Automatic chemical dosing devices are usually more of the heater gas controls. Refer to Table J on page 20 efficient in heater water, unless controlled, they can for maximum pipe lengths. lead to excessive chlorine level which can damage your heater. Gas Supply Connection CAUTION: The XTherm is not for use with salt CAUTION: The heater must be disconnected from water chlorinators—damage to heater may occur. the gas supply during any pressure testing of the gas supply system at test pressures in
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1-1/4” NPT 1-1/2” NPT 2” NPT 2-1/2” NPT Model No. N P N P N P N P 1005 35 55 35 90 125 300 300 1505 10 15 15 25 60 150 150 275 2005 35 90 85 210 3 Natural Gas – 1,000 BTU/ft , 0.60 specific gravity at 0.5 in. WC pressure drop 3 Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. WC pressure drop Table J: Maximum Equivalent Pipe Length • Safety wiring must be NEC Class 1. Gas Supply Pressure • Heater must be electrically grounded as required by the NEC. A minimum of 4.0 in. WC and a max
