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Raypak Xtherm 1005A User Manual

Raypak Xtherm 1005A
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P/N 241513 Rev. 5
AA
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

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

Table of Contents

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Raypak Xtherm 1005A Specifications

General IconGeneral
ModelXtherm 1005A
CategoryHeater
Fuel TypeNatural Gas or Propane
EfficiencyUp to 95%
Ignition TypeDirect Spark Ignition
Voltage120V
Warranty5 years

Summary

warnings

pay-attention-to-these-terms

Explains the meaning of DANGER, WARNING, CAUTION, and NOTE terms used in the manual.

before-installation

product-receipt

Instructions for checking the heater upon delivery and reporting any shipping damage.

model-identification

How to identify the model and serial number of the heater.

ratings-and-certifications

Lists the standards and certifications the heater complies with.

installations-at-elevation

Information on how elevation affects heater performance and required adjustments.

component-locations

component-locations-side-view

Illustrates the location of components on the side of the heater.

component-locations-front-view

Illustrates the location of components on the front of the heater.

component-locations-rear-view

Illustrates the location of components on the rear of the heater.

component-locations-top-view

Illustrates the location of components on the top of the heater.

general-information-and-safety

general-information

Provides basic product data like input, water/gas connections, vent size, and comb air.

general-safety

Discusses safety precautions for hot water use, scald risks, and temperature settings.

installation-procedures

installation-codes

Lists required installation codes and regulations for safe setup.

equipment-base-preparation

Guidelines for selecting and preparing the mounting base for the heater.

clearances-for-installation

Specifies minimum clearances from combustible surfaces and for servicing.

combustion-and-ventilation-air-requirements

outdoor-installation-guidelines

Provides guidelines for installing the heater in outdoor locations.

combustion-and-ventilation-air-indoor

Details requirements for combustion and ventilation air for indoor installations.

combustion-air-filter-and-ducting

combustion-air-filter-maintenance

Information about the integral combustion air filter and its maintenance.

ducted-combustion-air-installation

Instructions for installing ducting for combustion air supply.

air-intake-component-installation

Step-by-step instructions for installing the air intake components.

air-supply-requirements

truseal-combustion-air-system

Details on sealing the combustion air system for direct vent.

us-installations-air-supply

Requirements for air supply for indoor and outdoor installations in the US.

water-piping-and-protection

canadian-installations-air-supply

Air supply requirements for installations in Canada.

water-piping-general-installation

General guidelines for water piping installation to prevent damage.

piping-sensor-and-protection-systems

relief-valve-piping-safety

Safety instructions for installing relief valve discharge piping.

temperature-pressure-gauge-location

Information about the location of the temperature and pressure gauge.

hydrostatic-test-procedure

Guidance on performing a hydrostatic test on the system piping.

system-sensor-installation-guide

Instructions for installing the system sensor, including placement and wiring.

raypak-integral-cold-water-protection

Explanation of the CWP system and its operation.

hydronic-heating-system-components

pump-selection-for-hydronic-heating

Guidance on selecting the correct pump for the hydronic heating system.

feedwater-regulator-installation

Recommendations for installing and setting a feedwater regulator.

piping-considerations-for-hydronic-systems

General piping considerations for hydronic heating systems.

air-separation-and-expansion-tank-installation

Requirement for installing an expansion tank and air separator.

three-way-valves-usage-warning

Warning against using three-way valves for regulating system water temperature.

applications-and-control-modes

modes-primary-secondary-piping-configuration

Overview of application modes for the VERSA IC control system.

hydronic-heating-modes-details

mode-2-for-type-h-units

Details on Mode 2 for hydronic heating with indirect DHW.

mode-3-hydronic-heating

Details on Mode 3 for hydronic heating with indirect DHW.

hot-water-and-pool-heating-applications

domestic-hot-water-dhw-configuration

Specifics for Domestic Hot Water (DHW) configuration.

potable-water-and-space-heating-precautions

Precautions for using the heater for both potable water and space heating.

chemical-feeders-pool-heating-and-winterizing

automatic-chemical-feeders-precautions

Precautions for using automatic chemical feeders with the heater.

pool-heating-installation-requirements

Installation requirements and safety precautions for pool heating applications.

winterizing-your-heater-procedure

Steps for safely winterizing the heater.

water-chemistry-gas-supply-and-connections

pool-spa-water-chemistry-guidelines

Guidelines for maintaining proper pool/spa water chemistry.

automatic-chlorinators-and-chemical-feeders

Precautions for using automatic chlorinators and chemical feeders.

gas-supply-overview-and-warnings

General information and warnings regarding gas supply.

gas-supply-connection-and-pressure-requirements

gas-supply-connection-instructions

Detailed instructions for connecting the gas supply.

gas-supply-pressure-considerations

Requirements and considerations for gas supply pressure.

electrical-power-connections-and-controls

field-connected-devices-recommendations

Recommendations for connecting field-supplied devices and controls.

electrical-and-field-wiring-procedures

making-electrical-connections-steps

Step-by-step instructions for making electrical connections.

field-wiring-connections-overview-and-cautions

General cautions and warnings for field wiring.

wiring-the-enable-disable-function

Instructions for wiring the enable/disable function.

wiring-the-outdoor-sensor

Instructions for connecting the outdoor sensor.

advanced-wiring-configurations

wiring-the-indirect-sensor

Instructions for wiring the indirect sensor.

wiring-optional-0-10-volt-building-control-signal

How to wire an optional 0-10 volt building control signal.

wiring-cascade-system-communication-bus

Instructions for wiring the cascade system communication bus.

communication-and-venting-systems

modbus-bms-communication-details

Information on connecting to building automation via Modbus.

alarm-connection-instructions

How to connect an alarm annunciator or light.

venting-general-guidelines-and-precautions

General guidelines and precautions for installing the vent system.

appliance-categories-explanation

Explanation of heater categories based on vent pressure and condensate.

vent-terminal-location-and-requirements

vent-terminal-location-guidelines

Guidelines for locating the vent terminal to ensure safety and prevent issues.

us-installations-vent-termination-requirements

Specific vent termination requirements for US installations.

venting-configurations-and-installation-tips

canadian-installations-venting-requirements

Vent termination requirements for Canadian installations.

venting-installation-tips

Tips for supporting and installing vent piping.

vertical-venting-configurations

Guidance on vertical venting configurations.

venting-installation-and-termination-details

vertical-venting-installation-details

Details on maximum and minimum venting lengths and pipe diameter.

vertical-venting-termination-requirements

Requirements for vent terminal placement and clearance.

horizontal-venting-installation-and-termination

horizontal-through-the-wall-and-direct-vent-installation

Instructions for horizontal through-the-wall and direct vent installations.

horizontal-venting-installation-steps

Installation steps for horizontal venting configurations.

horizontal-venting-termination-guidelines

Guidelines for terminating horizontal vents.

direct-vent-vertical-installation-and-termination

direct-vent-vertical-installation-guidelines

Installation guidelines for vertical direct vent systems.

direct-vent-vertical-termination-requirements

Requirements for terminating vertical direct vent systems.

common-venting-and-outdoor-installation

common-venting-procedures-and-requirements

Information on common venting configurations and requirements.

outdoor-installation-guidelines-and-precautions

Guidelines and precautions for installing heaters outdoors.

freeze-protection-for-outdoor-units

How to enable and operate freeze protection features.

condensate-treatment-procedures

condensate-treatment-instructions

Instructions for treating condensate to prevent damage and meet codes.

pvc-venting-option-d-32-details

pvc-venting-cleaning-and-termination-guide

Details on using the PVC venting option, including cleaning and termination.

polypropylene-venting-option-d-33-information

polypropylene-venting-installation-guide

Information on using Centrotherm polypropylene vent material.

controls-and-safety-features

ignition-control-functions-explanation

Explains how the ignition system works and lockout conditions.

high-limit-manual-reset-device

Information on the manual reset high limit safety device.

high-limit-auto-reset-optional-feature

Details on the optional auto-reset high limit feature.

variable-speed-injector-pump-system

Information about the variable-speed injector pump system.

control-features-and-safety-switches

condensate-float-switch-function

Explanation of the condensate float switch and its function.

flow-switch-safety-function

Details on the dual-purpose flow switch and its safety function.

low-water-cut-off-optional-device

Information on the optional low water cut-off device.

high-and-low-gas-pressure-switches

Explains the function of high and low gas pressure safety switches.

user-interface-and-settings-management

blocked-vent-switch-operation-details

Details on the blocked vent pressure switch.

user-interface-overview-and-menus

Overview of the touchscreen user interface and its menus.

adjusting-the-xtherm-setpoint

How to adjust the heater's setpoint temperature using the interface.

view-menu-information

Describes the information available in the View Menu.

menu-initial-adjustment-guide

Guide to making initial adjustments via the interface menus.

boiler-menu-functions-and-details

boiler-menu-items-and-descriptions

Details the items and functions available in the Boiler Menu.

monitor-menu-data-and-explanation

monitor-menu-operational-data

Explains how to view operational data like run times and temperatures.

toolbox-menu-and-outdoor-reset

toolbox-menu-functions-and-diagnostics

Describes the functions available in the Toolbox Menu for diagnostics.

outdoor-reset-concept-explanation

Explains how outdoor temperature influences heating water temperature.

reset-ratio-settings-details

reset-ratio-settings-calculations

Details settings used to calculate the reset ratio for outdoor reset.

wiring-diagrams-for-models

wiring-diagram-models-1005a-to-2005a

Provides detailed wiring diagrams for the heater models.

start-up-procedures-and-checks

pre-start-up-steps-and-checks

Steps and checks before initiating heater start-up.

pre-start-up-check-list

A checklist of pre-start-up verification steps.

start-up-preparation-and-sequence

initial-start-up-procedures-and-tools

Procedures and tools needed for the first start-up.

preparation-tasks-before-start-up

Tasks to complete before the actual start-up sequence.

start-up-sequence-of-operations

The sequence of operations for starting the heater.

start-up-checks-tests-and-leak-procedures

blower-check-and-manifold-check

How to check the blower operation and manifold gas pressure settings.

user-test-and-safety-inspection

How to perform user tests and safety inspections during start-up.

leak-test-procedure-for-gas-valve

Procedure for leak testing the gas valve.

post-start-up-checks-and-verification

post-start-up-checklist-items

A final checklist of items to verify after start-up.

operation-and-troubleshooting-guide

lighting-instructions-for-operation

Step-by-step guide for lighting the heater.

turning-off-gas-to-appliance-procedure

Procedure for safely turning off gas to the appliance.

xtherm-error-codes-explanation

How the heater displays error codes and general troubleshooting.

heater-errors-faults-and-fault-text

heater-errors-description-and-location

Explains how error conditions are displayed and where to find details.

heater-faults-information-and-indicators

Information on fault conditions, indicators, and general troubleshooting steps.

xtherm-fault-text-and-error-display

Details on error items and their descriptions/troubleshooting.

led-error-code-listing-for-pim

pim-led-error-code-listing-and-troubleshooting

Explains LED flash codes on the PIM for error identification.

maintenance-schedule-and-sensor-values

sensor-resistance-values-table

Table of sensor resistance values at different temperatures.

suggested-minimum-maintenance-schedule

Overview of recommended maintenance intervals and tasks.

daily-maintenance-checks-section-9-1-1

Daily maintenance checks to be performed.

monthly-maintenance-checks-section-9-1-2

Monthly maintenance checks and inspections.

yearly-maintenance-beginning-of-season

Annual maintenance tasks to perform before the heating season.

preventive-maintenance-schedule-details

periodic-maintenance-checks-section-9-1-4

Periodic maintenance checks for components like relief valves.

preventive-maintenance-schedule-daily-9-2-1

Daily preventive maintenance tasks.

preventive-maintenance-schedule-weekly-9-2-2

Weekly preventive maintenance tasks.

preventive-maintenance-schedule-monthly-9-2-3

Monthly preventive maintenance tasks.

preventive-maintenance-schedule-semi-annually-9-2-4

Semi-annual preventive maintenance tasks.

filter-maintenance-and-appendix-information

filter-maintenance-instructions

Instructions for maintaining the air filter.

appendix-overview-and-resources

Supplementary information and resources.

inside-air-contamination-effects-on-heater

Information on indoor air contaminants and their effect on the heater.

massachusetts-installation-requirements

massachusetts-specific-installation-instructions

Specific installation requirements for Massachusetts.

start-up-checklist-for-raypak-products

fan-assisted-raypak-products-checklist

A checklist for service technicians to fill out during start-up.

limited-warranty-terms-and-conditions

warranty-parts-replacement-procedure

Information on how to obtain replacement parts under warranty.

how-to-make-a-warranty-claim-process

Instructions on how to initiate a warranty claim.

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