Models 1005, 1505, 2005

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Models 1005, 1505, 2005

Up to

99%

thermal efficiency!

Can be

ven PVC ted wi th Use p Opti ipe on D -32

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.

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 operation. 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

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 (Up to 99% at part load!) 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 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.

2

True Modulation

• • • • • • • • • • • • •

• •

3 models from 1,000,000 to 2,000,000 BTUH California bill AB-1953 low lead compliant brass 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

2

3

4

5

6

7

8 9

1

10

11 12 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. 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 18 14 17 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. 13. Flue Outlet Stainless steel Category IV compatible. Optional CSA certified PVC and CPVC vent choice, choose option D-32 at time of order. 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

16

15

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. 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.

3

Xtreme Versatility Can be installed indoor or outdoors! 1

3a

2 3 4 5 6 7

2

8 9

Optional PVC Vent Connection 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

Internal Air Intake 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. 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 Incorporating leading edge combustion and heat exchanger technology, Raypak’s new 97% XTherm™ Condensing Boiler has for the first time, extended your option to select Stainless Steel, CPVC, or PVC venting

to the 2000 MBTU level. The PVC adapter is factory installed inside the boiler jacket. Where local codes allow, everyone knows selection of PVC venting can offer tremendous installation cost reduction. CSA approval for PVC venting has been granted for all XTherm™ models, including the 8” vent 2005. For single and multiple boiler systems, this can reduce installation cost 30-50% while still affording the energy saving benefits of condensing. Specify option code D-32 when ordering. 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.

Xtremely Small Footprint FLUE CONNECTION

50

G- GAS CONNECTION 12-7/16

TOP VIEW

POWER CONNECTIONS

Y

31-1/8

ØN - COMBUSTION AIR OPTIONAL

R

2-7/8

2-1/2” NPT WATER OUTLET PROUDLY MADE IN AMERICA

ULTRA HIGH EFFICIENCY

2-1/2” NPT WATER INLET

P

D B

ØK - FLUE CONNECTION

E L LOW VOLTAGE CONDUIT CONNECTION (BY OTHERS)

F

CONDENSATE DRAIN CONNECTION M

25

14-7/16

PHYSICAL DATA

FRONT VIEW

REAR VIEW

Dimensions (inches) Model

B Ht.

D

1005 1505 2005

55-1/8 67-1/8 81-1/8

45 57 71

E

G*

K NPT Flue Ø

F

47-1/8 36-1/2 1-1/4 59-1/16 38-1/2 1-1/4 71-3/16 38-1/2 2

6 8 8

L

N C/A Ø

M

40-1/16 11-1/2 52-1/16 12-5/8 64-1/16 12-5/8

6 8 8

P

R

Y

Operating H WH Weight Amps † Amps‡ (lbs.)

47-1/8 8-1/16 6-1/16 59-1/8 8-3/16 6-1/16 73-1/8 8-3/16 6-1/4

1065 1234 1461

22 26 35

15 15 21

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

MBTUH

†Includes boiler pump. Separate wiring connection required for boiler pump ‡Does not include water heater pump. Separate wiring connection required for water heater pump

Model MBTUH Input 1005 1505 2005

999 1500 1999

CLEARANCES

Heater Side Floor* Rear Right Side Left Side Front Top Indoor Outdoor Vent Stack Indoor Vent Cap Outdoor

Boiler Output

MBTUH Efficiency Input

959 1440 1919

96% 96% 96%

999 1500 1999

From Combustible For Service Surfaces (min.) (recommended) 0 12 1 1 24 0 Unobstructed 1 12

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

N/A 36 24 1 24 10 Unobstructed N/A 12

Heater Amps

Water Heaters Output

Efficiency

Minimum Input

969 1455 1939

97% 97% 97%

250 375 500

XTherm Model 1005 1505 2005

Add heater amps to pump amps to find total amp draw.

+ Pump Amps

Water Heater Pump Sizes Soft Medium Hard HP Amps HP Amps HP Amps 1/2 1/2 1

7 7 14

1/2 3/4 1

7 11 14

3/4 1 N/A

11 14 N/A

Note: Current draw (Amps) is for pump only Water hardness grains per gallon Soft = 0-4 • Medium = 5-15 • Hard = 16-25

5

Xtreme Pumping Cold Water Run System

TYPE WH

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.

6

XTherm Model 1005 1505 2005

Recovery Rates Temperature Rise (°F) 20

30

5,817 3,878 8,733 5,822 11,639 7,759

40

50

2,908 2,327 4,367 3,493 5,813 4,656

60

70

80

90

100

110

120

130

140

150

1,939 2,911 3,880

1,662 2,495 3,325

1,454 2,183 2,910

1,293 1,941 2,586

1,163 1,747 2,328

1,058 1,588 2,116

969 1,456 1,940

895 1,344 1,791

831 1,248 1,663

776 1,164 1,552

ULTRA HIGH EFFICIENCY

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 • Condensate Drain • Manual High Limit • Auto High Limit • Low Water Cut-off • Vent Pressure • High Gas Pressure • Low Gas Pressure • Controller Alarm • Flow Switch • Blower Switch • Factory Option • External Interlock • Cold Water Run

Ignition Control Faults • Low Air • Flame- No CFH • Ignition Lockout • Low HSI Current • Low 24VAC • Internal Control Fault

7

Water Heaters (Type WH)

Boilers (Type H)

    

N/A           

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) • Outdoor Reset Sensor Multiple Boiler Controller • TempTracker Mod+, up to 16 boilers • Y-200, up to 40 boilers (LonWorks optional)

         N/A  

           

Hot Surface Ignition System

        

        

   

   

N/A       

 N/A      

ULTRA HIGH EFFICIENCY

HEAT EXCHANGER

ASME, National Board Registered, 160 PSI Heat Exchanger Tubes Bronze Headers Cast Iron Headers Stainless Steel Condensing Heat Exchanger Pressure Relief Valve (mounted on outlet)

SAFETIES

OPERATING CONTROLS

JACKET

Temperature & Pressure Gauge Pump

Indoor/Outdoor Certified Vent Terminal

High/Low Gas Pressure Switches Blocked Vent and Air Pressure Switches High Limit Switch

GAS TRAIN

Low Water Cut-Off, 24V Flow Switch Modulating Combination Gas Valve Combustion Air Blower Additional Safety Valve

OTHER

CSA-Certified Efficiency Air Filter TruSeal Direct-Vent Ready Alarm System CSD-1 / GE GAP Control System Low NOx Cold Water Run   = Standard

• • • •

HLW Stamp H Stamp Copper Cupro Nickel

 N/A    N/A

• • • •

U Stamp 60 PSI 125 PSI 30, 45, 75, 150 PSI



• 120V, Single-Phase

• Outdoor • Through-the-Wall

• 1-try • 3-try

• • • •

Manual Reset, Fixed Manual Reset, Adjustable Automatic Reset, Adjustable With Manual Reset and Test Buttons

• Motorized (externally mounted) • Solenoid (externally mounted) • 96% at Full Fire • 97% at Full Fire

• Meets all current requirements • Prevents condensation in primary heat exchanger

  = Optional

Raypak, Inc. • 2151 Eastman Avenue, Oxnard, CA 93030 • phone: (805) 278-5300 • fax: (800) 872-8725 • www.raypak.com Cat. No. 1000.21A

Effective 12-01-09

Replaces 10-01-08

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Models 1005, 1505, 2005

Models 1005, 1505, 2005 Up to 99% thermal efficiency! Can be ven PVC ted wi th Use p Opti ipe on D -32 Xtreme Performance Up to 99% thermal ef...

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