Raypak Xtherm 1005A User manual

P/N 241513 Rev. 5
AAWARNING: 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

to humans.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other com-
bustible 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. 3400.552D Effective: 09-20-18 Replaces: 08-23-18
INSTALLATION AND
OPERATION MANUAL
Models 1005A - 2005A
Type H, WH, and P
ULTRA HIGH EFFICIENC
Y

2
CONTENTS
1. WARNINGS ................................................................... 3
1.1. Pay Attention to These Terms..............................3
2. BEFORE INSTALLATION ............................................ 4
2.1. Product Receipt........................................................4
2.2. ModelIdentication................................................4
2.3. RatingsandCertications.....................................4
2.4. Installations at Elevation........................................4
2.5. Component Locations............................................5
2.6. General Safety...........................................................6
3. INSTALLATION............................................................. 7
3.1. Installation Codes....................................................7
3.2. Equipment Base.......................................................7
3.3. Clearances.................................................................7
3.4. Outdoor Installation ................................................8
3.5. Combustion and Ventilation Air ..........................8
3.6. Air Supply ................................................................ 11
3.7. Water Piping ........................................................... 12
3.8. Raypak Integral Cold Water Protection.......... 13
3.9. Hydronic Heating.................................................. 14
3.10. Pool/Spa Water Chemistry ................................ 21
3.11. Gas Supply .............................................................. 21
3.12. Electrical Power Connections.......................... 23
3.13. Field Wiring Connections................................... 24
3.14. Venting - General .................................................. 28
3.15. Vent Terminal Location ....................................... 30
3.16. Venting Installation Tips..................................... 31
3.17. VerticalVentingCongurations ....................... 31
3.18. Horizontal Through-the-Wall and Direct
Vent(CategoryIV)................................................. 32
3.19. Direct Vent - Vertical ............................................ 34
3.20. Common Venting .................................................. 35
3.21. Outdoor Installation ............................................. 35
3.22. Condensate Treatment ....................................... 36
3.23. PVCVentingOption(D-32) ................................ 37
3.24. Centrotherm™ Polypropylene Venting
Option(D-33).......................................................... 38
4. CONTROLS..................................................................39
4.1. Ignition Control Functions ................................. 39
4.2. High Limit - Manual Reset ................................. 39
4.3. HighLimit-AutoReset(Optional)................... 39
4.4. Variable-Speed Injector Pump ......................... 39
4.5. Condensate Float Switch ................................... 40
4.6. Flow Switch ............................................................ 40
4.7. LowWaterCut-O(Optional)............................ 40
4.8. HighandLowGasPressureSwitches
(Optional)................................................................. 40
4.9. Blocked Vent Switch ............................................ 41
4.10. User Interface ........................................................ 41
5. WIRING DIAGRAM FOR MODELS
 ...........................................................47
 .....................................................................48
6.1. Pre Start-up............................................................. 48
6.2. Pre Start-up Check............................................... 48
6.3. Initial Start-up......................................................... 48
6.4. Preparation ............................................................. 48
6.5. Start-Up.................................................................... 49
  ................................................................52
7.1. Lighting Instructions............................................ 52
7.2. ToTurnOGasToAppliance ........................... 52
8. TROUBLESHOOTING................................................52
8.1. XTherm Error Codes............................................ 52
8.2. Heater Errors.......................................................... 52
8.3. Heater Faults.......................................................... 52
8.4. XTherm Fault Text................................................. 53
9. MAINTENANCE .........................................................55
9.1. Suggested Minimum
Maintenance Schedule....................................... 55
9.2. Preventive Maintenance Schedule................. 56
9.3. Filter Maintenance ............................................... 57
 ...................................................................57
10.1. Inside Air Contamination.................................... 57

COMMONWEALTH OF MASSACHUSETTS .........58

Section 2.5.1, updated Table A "Basic Product Data" on page 5.

3
AADANGER Indicates the presence of immediate hazards which will cause severe personal injury, death or
substantial property damage if ignored.
AAWARNING Indicates the presence of hazards or unsafe practices which could cause severe personal injury,
death or substantial property damage if ignored.
AACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury
or product or property damage if ignored.
CAUTION CAUTION used without the warning alert symbol indicates a potentially hazardous condition
which could cause minor personal injury or product or property damage if ignored.
NOTE Indicates special instructions on installation, operation, or maintenance which are important but
not related to personal injury hazards.
1. WARNINGS
1.1. 
AADANGER: Make sure the gas on which the heater will

rating plate.
AAWARNING: Do not use this heater if any part has
       
technician to inspect the heater and to replace any part
of the control system and any gas control which has been
under water.
AAWARNING: To minimize the possibility of improper

heater:
• Always keep the area around the heater free of

liquids and vapors.
• Heater should never be covered or have any blockage

AAWARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize the
equipment before servicing.
AAWARNING: Should overheating occur or the gas

         
supply at a location external to the heater.
AACAUTION: If this heater is to be installed above
radiation level, it must be provided with a low water cut-

AACAUTION: If this heater is to be installed in a negative
or positive pressure equipment room, there are special
installation requirements. Consult factory for details.
AAWARNING: 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,
        

AAWARNING: 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.

4
2. BEFORE INSTALLATION
Raypak strongly recommends that this manual be re-
viewed 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qualied
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.
NOTE: Raypak recommends laying out and installing the
vent system before installing water piping. This will ensure
that the venting system and associated components will

Thank you for purchasing a Raypak product. We hope you
willbesatisedwiththehighqualityanddurabilityofour
equipment.
2.1. 
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eect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.
Claimsforshortagesanddamagesmustbeled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.
2.2. 
Themodelidenticationnumberandheaterserialnumber
are found on the rating plate located on the rear jacket
panel of the heater.
The model number will have the form H7 or similar
dependingontheheatersizeandconguration.
• Theletter(s)intherstgroupofcharactersidenties
the application (H=Hydronic Heating, WH=Water
Heating,P=PoolHeating).
• Thenumberwhichfollowsidentiestheringmode
(7=electronicmodulation).
• The second group of characters identies the size
of the heater (the four numbers representing the
approximateMBTUHinput),and,whereapplicable,a
letter, indicating the manufacturing series.
2.3. 
2.3.1. Standards
• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Hot
Water Heaters
• CAN 3.1 - latest edition, Industrial and Commercial
Gas-Fired Package Heaters
• 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-certied
All Raypak heaters are National Board registered, and
design-certied 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(ASME)HeaterPressure
Vessel Code and bears the applicable ASME stamp. H
models bear the "H" stamp. WH and P models bear the
"HLW" stamp. This heater also complies with the latest
edition of the ASHRAE 90.1 Standard.
AAWARNING: Altering any Raypak pressure vessel by
installing replacement heat exchangers, or any ASME
parts not manufactured and/or approved by Raypak will
instantly void the ASME and CSA ratings of the vessel and
any Raypak warranty on the vessel. Altering the ASME or
CSA ratings of the vessel also violates national, state, and
local approval codes.
2.4. Installations at Elevation
Ratedinputsaresuitableforupto2000ft(610m)elevation
without de-rating. Consult your local representative or
thefactoryforinstallationsataltitudes over2000ft (610
m) above sea level. No hardware changes are required
to the heaters for installations up to 10,000 ft (3,050 m)
(adjustmentsmayberequired).Aderateofupto4%per
1000ft(305m)mayapply.

5
2.5. Component Locations
Figure 1. Component Locations – Side View
Figure 2. Component Locations - Front View
Figure 3. Component Locations - Rear View
Figure 4. Component Locations - Top View
GAS TRAINBLOWER
CONDENSING
HEAT
EXCHANGER
OPERATING
CENTER
PRIMARY HEAT
EXCHANGER
FRONT OF
HEATER
VFD
(ALTERNATE CONSTRUCTION)
BURNER FLAME
VIEWING PORT
F10241
HIGH VOLTAGE
ELECTRICAL CONNECTIONS
GAS SUPPLY
CONNECTION
FLUE OUTLET
WATER INLET
2-1/2 NPT
CONDENSATE DRAIN
3/4 NPT, PVC
WATER OUTLET
2-1/2 NPT
COMBUSTION AIR
INLET (OPTIONAL)
F10243
HIGH VOLTAGE
SWITCH
LOW VOLTAGE
SWITCH
F10242
LOW VOLTAGE
ELECTRICAL
CONNECTIONS
LOW VOLTAGE
CONDUIT
CONNECTION
TOUCHSCREEN
DISPLAY
IGNITER
FLAME SENSOR
FRONT OF HEATER
BURNER
F10244

6
2.5.1. General Information
Model
No.
Input
MBTUH (kW) Water Conn

Gas Conn
 Vent Size Comb Air
Max Min Nat  In. (mm) In. (mm)
1005A 999(293) 140(41.0) 2-1/2" 1-1/4" 1" 6(152) 6(152)
1505A 1500(440) 210(61.6) 2-1/2" 1-1/4" 1" 8(203) 8(203)
2005A 1999(586) 280(82.1) 2-1/2" 2" 1" 8(203) 8(203)
Table A. 
2.6. General Safety
This section applies to Hot Water Supply Boilers and Hot
Water Heaters ONLY.
To meet commercial hot water use needs, the high limit
safetycontrolonthiswaterheaterwill shuto themain
gas valve before the outlet temperature reaches 210°F
(99°C).However,watertemperaturesover125°F(52°C)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(52°C).
For sanitary rinse applications where outlet temperatures
of 180°F (82°C) to 195°F (91°C) are required, a boiler is
requiredbecausethe210°F(99°C)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-ecientoperationwillresult
whenthetemperaturesettingisthelowestthatsatises
the needs of the application.
Water temperature over 125°F (52°C) can cause instant
severe burns or death from scalds. Children, disabled and
elderly are at highest risk of being scalded. See Table B.
• Feel water before bathing or showering.
• Temperature limiting valves are available.
NOTE: When this water heater is supplying general-
purposehotwaterforusebyindividuals,athermostatically-
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o.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.
AACAUTION: Hotter water increases the risk of scalding!
There is a hot water scald potential if the thermostat is
set too high.
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.
See instruction manual before set-
ting temperature at water heater.
Feel water before bathing or show-
ering.
Temperature limiting valves are
available, see manual.
Water Temp. 
120°F(49°C) More than 5 minutes
125°F(52°C) 1-1/2 to 2 minutes
130°F(54°C) About 30 seconds
135°F(57°C) About 10 seconds
140°F(60°C) Less than 5 seconds
145°F(63°C) Less than 3 seconds
150°F(66°C) About 1-1/2 seconds
155°F(68°C) About 1 seconds
Table B. 

7
Figure 5. 
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 is recommended that a
suitable catch pan, adequately drained, be installed under

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 Figure 5, following local codes.
Additional clearance may be required when using the
factory anchor bracket.
3.3. Clearances
3.3.1. Indoor Installations
Heater Side
Minimum
Clearances from
Combustible
Surfaces
in. (mm)
Minimum Service
Clearance
in. (mm)
Floor * 0 0
Rear 12(305) 36(914)
Right Side 1(25) 24(610)
Left Side 1(25) 1(25)
Top 010(254)
Front Open 24(610)
Vent 1(25) 1(25)
See also National Fuel Gas Code, Table 10.2.3, Clearance Reduction
* DO NOT install on carpeting
Table C. Clearances - Indoor Installations
Foreaseofservicing,aclearanceofatleast24"(610mm)
ontherightside,atleast24"(610mm)infrontand36"
(914mm)abovethetopoftheheaterisrequired.Thiswill
allow the heater to be serviced in its installed location
without movement or removal of the heater.
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.
0.75"
(19 mm)
32.88"
(835 mm)
REAR OF UNIT
0.56"
(14 mm)
0.56"
(14 mm)
DIA. TYP.
1.125"
(29 mm)
48.50"
(1232 mm)
FRONT OF UNIT
F10245
3. INSTALLATION
3.1. 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 Heaters, 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)
3.2. Equipment Base
The heater should be mounted on a level, structurally
sound housekeeping pad. 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"
(457mm)abovetheoor.

8
3.4. 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 completely open in the area under
the overhang. Roof water drainage must be diverted away
from heaters installed under overhangs.
AACAUTION: Do not install where the condensate can
freeze. Take appropriate measures.
Heater Side
Minimum
Clearances from
Combustible
Surfaces
in. (mm)
Minimum Service
Clearance
in. (mm)
Rear 12(305) 36(914)
Right Side 1(25) 24(610)
Left Side 1(25) 1(25)
Top Unobstructed Unobstructed
Vent
Termination 12(305) 12(305)
Table D. 
3.5. Combustion and Ventilation Air
NOTE: Use of this heater in construction areas where

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.
3.5.1. Indoor Units
NOTE: On Indoor installations, the clear panel in the outer
bezel may be removed to allow access to the touchscreen
without removing the outer panel.
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,(asshipped
from factory, combustion air is drawn through louvers in
jacket panels) or via direct vent, where combustion air
is drawn directly from outside. (See Section 3.6.1 for
instructions on how to connect ducting to the unit). All
installations must comply with the requirements of the
NFGC(U.S.)andB149(Canada),andalllocalcodes.
AACAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and cause a non-warrantable failure. See the
Appendix.
NOTE: It is recommended that the intake vent be insulated
to minimize sweating in freezing climates.
Figure 6. Minimum Clearances from Combustible
Surfaces – Indoor and Outdoor Installations
TOP VIEW
36" (914 mm)
SERVICE
CLEARANCE
24" (610 mm)
XTHERM
24"
(610 mm)
36" (914 mm)
SERVICE
CLEARANCE
1" (25 mm)
REAR EXHAUST INSTALLATION
FRONT VIEW
VERTICAL CLEARANCE
(ALL INSTALLATION)
10" (254 mm)
SERVICE
CLEARANCE
MIN 4" HOUSEKEEPING PAD (BY OTHERS)
REQUIRED FOR GRAVITY DRAIN OF CONDENSATE

9
Figure 7. Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
U.S. Installations1Canadian Installations 2
AClearance above grade, veranda, porch, deck, or
balcony 1'(30cm) 1'(30cm)
B Clearance to window or door that may be opened 4'(1.2m)belowortosideof
opening 3'(91cm)
C Clearance to permanently closed window * *
D
Verticalclearancetoventilatedsotlocatedabovethe
terminalwithinahorizontaldistanceof2'(61cm)from
the centerline of the terminal
5'(1.5m) *
EClearancetounventilatedsot * *
F Clearance to outside corner * *
G Clearance to inside corner 6'(1.83m) *
HClearance to each side of center line extended above
meter/regulator assembly *
3'(91cm)withinaheight15'
above the meter/regulator
assembly
I Clearance to service regulator vent outlet *6'(1.83m)
J
Clearance to non-mechanical air supply inlet to
building or the combustion air inlet to any other
appliance
4'(1.2m)belowortosideof
opening;1'(30cm)above
opening
3'(91cm)
K Clearance to mechanical air supply inlet 3'(91cm)aboveifwithin
10'(3m)horizontally 6'(1.83m)
LDo not terminate above paved sidewalk or paved
driveway
Slip hazard due to frozen
condensate
Slip hazard due to frozen
condensate
M Clearance under veranda, porch, deck or balcony *12"(30cm)t
1In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.
2In accordance with the current CAN/CSA-B149 Installation Codes.
tPermitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal, and underside
ofveranda,porch,deckorbalconyisgreaterthan1'(30cm).
*Clearances in accordance with local installation codes and the requirements of the gas supplier.
Table E. Vent/Air Inlet Termination Clearances

10
Inside Air Intake
Cover Panel
Figure 8. 
5. Optional—For applications where condensation
may form on cold intake air ducting, install the
condensate drip pan to the bottom of the air filter
boxusing thefourscrewsprovided (verifythat the
pan is angled slightly downward toward the rear of
the heater as shown in Figure 9).
Condensate
Drip Pan
Figure 9. 
6. Remove the air intake cover panel by removing the
five Phillips head screws holding it in place.
Air Intake
Cover Panel
Air Filter
Access
Panel
Figure 10. Remove the Air Intake Cover
3.5.2. Combustion Air Filter
Thisheaterissuppliedwithanintegralcombustionairlter.
Thislterwill reducethe amount ofparticulatespassed
through the combustion system and heat exchanger but
will not protect against chemical air contamination (See
Appendix). The lter must be checked periodically to
verify that adequate combustion air is being supplied to
the heater. See the Maintenance section of this manual for
informationoncheckingthelterandestablishingservice
intervals.
3.5.3. Ducted Combustion Air
Combustion air may be ducted directly to the heater using
PVC, CPVC or sealed single-wall galvanized ducting.
The resulting installation meets the requirements for a
direct-vent installation. See venting section for detailed
information.
1. Install combustion air duct in accordance with
Figure 38 and Figure 39.
2. Ventilation of the space occupied by the heater(s)
is required 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 must 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must
beatleast1in.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.
3. In cold climates, and to mitigate potential freeze-
up, 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. Such a damper must be electrically
interlockedtotheunit(s)suchthatacallforheatfrom
any connected unit will energize the damper, but no
connected unit is allowed to fire until the damper
proves fully open.
3.5.4. Installation Instructions
1. Turn off all power to the heater. All necessary parts
are provided with the appliance.
2. Ensure that the heater is cool to the touch before
proceeding with the installation.
3. Remove both the left and right rear side access
panels.
4. From the right-rear side access area, install the
inside air intake cover panel using the nine hex-head
screws provided. See Figure 8.