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Raypak 500 Boiler User Manual

Contents

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2. TECHNICAL DATA XPak 85 XPak 120 nput Output Input 0 2000 ft 0 610 m Btu hr 25 600 87 000 27 300 119 500 KW 7 5 25 5 8 0 35 0 Input 2000 4500 ft 7 610 1375 m Btu hr 25 600 82 900 27 300 114 300 KW 7 5 24 3 8 0 33 5 Output 176 F 86 F 7 80 C 30 C Btu hr 25 200 76 600 26 600 108 300 KW 7 4 22 5 7 8 31 7 Energy Guide AFUE Yo 91 8 92 6 Gas Gas supply pressure Natural Gas A n vv C 6 82 KPa 1 70 Min gas supply pressure Natural Gas A n w C 3 5 kPa 0 87 Max gas supply pressure Natural Gas A n w C 10 5 kPa 2 62 Gas supply pressure LPG E n vv C 11 kPa 2 75 Min gas supply pressure LPG E n w C 8 kPa 1 99 Max gas supply pressure LPG E n vv C 13 kPa 3 24 Gas Rate max natural gas A ft37hr 87 77 121 01 sm3 hr 2 49 3 43 Gas Rate min natural gas A ft3 hr 26 14 28 01 sm3 hr 0 74 0 79 Gas Rate max LPG E bs hr 4 02 5 55 kg hr 1 82 2 52 Gas Rate min LPG E bs hr 1 20 1 28 kg hr 0 54 0 58 System Data Minimum relief valve capacity Ibs hr 87 119 50 Maximum operating pressure p s i 45 bar 3 1 Minimum operating pressure p s i 6 52 bar 0 45 Recommended system pressure p s i 15 bar 1 Boiler max flow rate ltr hr G
3. Terminal Description Technical Indications strip specifications reference M3 Main supply 120 VAC 60 Hz The main supply cable must be anchored to the boiler frame Fig 39 and pass through the m strains relief field supplied Cable as specified in c the electrical supply M3a 3 way valve b Connections for DHVV Model Honeywell VC6011 actuator VCZMK6000 external 3 way valve 120 VAC 60 Hz Cartridge valve Q The 3 way valve cable must be anchored to the boiler frame Fig 39 and pass through the strains relief field 2 supplied Fig 39 Cable as specified in the electrical supply M4 Outdoor sensor 12 K Ohm B3760 M4 Remote control Open therm plus protocol Only Raypak Part No 013073 M4a Room thermostat 24 VDC Volt free Jumper when not used M4a Tank sensor 10 K Ohm B3435 Immersion type s for DHVV If the boiler is installed with a tank sensor the Jumper o on the PCB must be in position 2 Fig 61 D 2 Tank thermostat On off NO Volt free m for DHVV If the boiler is installed with a tank termostat the 5 Jumper on the PCB must be in position 3 Fig 61 9 gt 3 M3b Under floor heating limit On off NC Volt free g thermostat and condensate This is a generic input to lock out the boiler Jumper when generic available alarm not used If the contact will be open the alarm number 21 will appear on the display and the boiler is lock out REMOTE CONTROL EXTERN
4. 13 ELECTRICAL CHECKS Any electrical checks must be carried out by a ServiceTechnician Qualified GROUND CONTINUITY TEST Isolate the boiler from the electrical supply and using a suitable multi meter carry out a resistance test Connect test leads between an appliance ground point and the ground wire of the appliance supply cable The resistance should be less than 1 OHM If the resistance is greater than 1 OHM check all ground wires and connectors for continuity and integrity SHORT CIRCUIT CHECK Isolate the boiler from the electrical supply and using a suitable multi meter carry out a short circuit test between the Live amp Neutral connections at the appliance terminal strip Fig 35 Repeat above test on the Live amp Ground connections at the appliance terminal strip NOTICE Should it be found that the fuse has failed but no fault is indicated a detailed continuity check will be required to trace the fault A visual inspection of components may also assist in locating the fault POLARITY CHECK With the boiler connected to the electrical supply and using a suitable multimeter carry out the following voltage tests Connect test leads between the Live amp Neutral connections at the boiler terminal strip Fig 35 The meter should read approximately 120VAC If so proceed to next stage Connect test leads between the Live amp Ground connections at the boiler terminal strip Fig 35 The meter should rea
5. 52 Fig 70 Nr WATER PRESSURE SWITCH Fig 69 Locate and remove the screw 1 from the water pressure switch Remove the wiring Carefully remove the switch Replace in the reverse order FLOW SENSOR PRIMARY THERMISTOR Fig 1 Unclip and remove the air chamber front cover Unclip the primary thermistor from the flow outlet pipe Disconnect thermistor electrical plug Replace in the reverse order RETURN SENSOR RETURN THERMISTOR Fig 1 Unclip and remove the air chamber front cover Unclip the return sensor from the return inlet pipe Disconnect sensor electrical plug Replace in the reverse order PRINTED CIRCUIT BOARD Fig 71 Pull the control slightly forward and lower it Push the clips A and remove cover after carefully taking note of all wiring connections and jumper tag configurations unhook and remove connection block B Disconnect all wiring from the PCB locate and remove the PCB securing screws remove the required PCB Replace in the reverse order ensuring that the position of the 3 control knobs are correctly aligned with the respective potentiometers on the PCB Ensure that the correct jumper configuration has been made It will be necessary to check the functioning of the PCB is set for the correct boiler type application GAS VALVE Fig 72 The gas valve must be changed as complete unit Disconnect the electrical plug and leads from th
6. The wall must be vertically plumb and capable of carrying the weight of the XPak and its related components The building frame studs must be 16 on center If not you must use 1 2 minimum plywood 24 x 48 fastened with at least 14 12 x 3 3 16 x 3 round head tapping screws to the frame of the building to provide proper support for the boiler Alternate methods of mounting must not be used ex toggle bolts hollow wall anchors or any other fastener other than 12 x 3 3 16 x 3 round head tapping screws CAUTION If the XPak is not vertically plumb improper and unsatisfactory operation may occur This will cause excessive condensation build up causing unnecessary maintenance and nuisance fault codes 4 INSTALLATION STEPS Prior to lifting the XPak Boiler onto the wall use the enclosed template to level and locate the wall bracket Mount the wall bracket using lag screws Ensure the bracket is level when mounted Extreme care is needed to ensure the bolts are secured in the studs Hang the boiler on the bracket and secure the bottom of the boiler with two 2 additional lag screws This will provide additional strength and support to the XPak boiler XPAK PIPING 1 RELIEF VALVE The XPak has a pressure relief valve factory fitted Connect discharge piping to safe disposal location following guidelines in the WARNING below 3 SEPARATE LOW WATER CUTOFF A low water cutoff may be required by state local
7. The boiler must only be installed on a wall Do not restrict or seal any air intake or outlet openings f you find any defects you must inform the owner of the system of the defect and the associated hazard in writing DANGER if flammable gas explodes Beware if you smell gas there may be an explosion hazard Warning If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other boiler What to do if you smell gas Do not try to light any boiler 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 1f 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 Observe these instructions as general warnings Chemicals used to clean the system and or inhibit corrosion must be pH neutral i e they should ensure that the level of the pH in the system water remains neutral Premature failure of certain components can occur if the pH level in the system water is out of normal levels Raypak recommends that an inhibitor suitable for use with aluminum heat exchangers is used to
8. aucun interrupteur Ne pas vous servir des t l phones dansle b timent o vous vous trouvez Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur Si vous ne pouvez rejoindre le fournisseur de gaz appelez le sservice des incendies L installation et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz Cette notice doit tre conserv e de mani re tre lisible et proximit de la chaudi re ou dans un endroit s r pour une utilisation future Catalog No 2100 52 Effective 6 1 09 A Bheem Company Replaces New Subject to technical changes Slight changes may be made to the illustrations process steps and technical data as a result of our policy of continuous improvement About these instructions These Installation Instructions contain important information for the safe and professional installation start up and maintenance of the boiler with boiler capacities 87 000 and 120 000 btu hr These Installation Instructions are intended for qualified installers who have the necessary training and experience for working on heating and gas systems About the XPak The boiler was designed for heating water for a space heating system and generating hot water e g for domestic purposes The boiler can be fitted with a remote control or an On Off room thermostat 24 V external sensor and with
9. 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code 2 In accordance with the current CAN CGA B149 Installation Codes t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves both dwellings TT Permitted 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 ft 30cm Clearances in accordance with local installation codes and the requirements of the gas supplier 26 NOTICE The following illustrations are simplified conceptual illustrations only Legend for illustrations 23 24 25 26 27 28 29 30 31 32 Two pipes vent adaptors included with the boiler Mounting Clip set of 4 3 94 100 mm for coaxial 90 Elbow 3 80 mm single wall Adaptor 80 mm gt 3 included with the boiler 1 pcs 45 Elbow 3 80 mm single wall Vertical vent termination 3 28 ft 1 m 3 94 100 mm coaxial Straight Pipe 1 64 ft 0 5 m 3 80 mm single wall Roof Flashing flat universal Straight Pipe 3 28 ft 1 m 3 80 mm single wall Straight Pipe 6 56 ft 2 m 3 80 mm single wall Roof Flashing sloping universal 45 Elbow 3 94 100 mm coaxial Horizontal inlet air vent 2 82 ft 0 86 m 3 80 mm single wall Straight Pipe 1 64 ft 0 5 m 3 94 100 mm coaxial Ada
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11. OCI 0 O H ILL DU Fig 48 Fig 49 Fig 53 Fig 54 B green indicator LED boiler status E3 EN Closed TT i osition NN Fig 55 p NG N ULI vg nr Fig 50 Fig 51 Fig 56 Fig 57 Code Description of alarm Status AL10 Ignition attempts finished no flame condensate present Block AL20 Limit thermostat fault blocked flue switch flue thermostat Block AL21 Low temperature thermostat condensate pump safety Block device fault AL29 Flue sensor over temperature lock out Block AL60 Water tank probe fault Block AL71 Delivery probe fault open short circuit Stop AL73 Return probe fault open short circuit Stop AL28 Returmn delivery probe differential fault Block AL26 Return over temperature Block AL79 Delivery over temperature return delivery probe Block differential fault AL41 Sistem water pressure low Stop AL40 System water pressure low after 10 minutes Block AL34 Fan tacho fault Block AL52 Generic electronic fault Block AL55 No boiler mode configuration fault corresponding jumper Block absent AL91 The main heat exchanger need to be cleaned Advice call the Raypak technical service For AL41 faults If the pressure on the water gauge located on the control panel is less than 7 psi 0 5 bar proceed as follows Turn the function selector to Fig 54 Fill the system until the pressure indicated on the water gauge lies between 14 21 psi 1 1 5 bar Fig 45 pos A Move the function selector to th
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13. 2 BOILER SUPPLY XPak boilers are supplied with the following vent components and they are certified together with the XPak boiler as a constructional unit 60 100 mm vent exit Fig 16 pos 1 Leftside intake air factory sealed with two screws for two pipes solutions Fig 16 pos 2 Right side intake air factory sealed with two screws for two pipes solutions Fig 16 pos 3 Vent adaptor for two pipes vent system 80 mm dia exit Fig 16 pos 5 Fig 19 Intake air adaptor fortwo pipes vent system 80 mm dia exit Fig 16 pos 6 Fig 18 3 adaptor inside diameter 3 Fig 16 pos 4 Fig 17 Paper template to fix the boiler and the flues Fig 15 3 INSTALLATIONS OF SUPPLIED VENT COMPONENTS In the case of installations using two pipes or room dependent air the following instructions must be observed 1 Install the vent adapter Fig 19 to the boiler vent connection Fig 16 pos 1 2 Use the two supplied screws to ensure the closing between the adapter and boiler Fig 16 pos 5 3 Insert the 3 adapter Fig 17 into the vent adapter Fig 19 in the case using 3 vents 4 Install the air adapter Fig 18 to the boiler air connection choose right or left installation Fig 16 pos 2 3 using the two supplied screws Fig 16 pos 6 in the case of two pipes room sealed vent installation 2 80mm Fig 18 GASKET FITTED 80 mm 101 mm Fig 19 25
14. Fig 79 Disconnect the 2 upper rubber condensate pipes A Remove the pin B that secures the trap to the air box plate Disconnect the lower rubber condensate pipe C from the condensate trap Carefully remove the condensate trap Replace in the reverse order FLUE COLLECTOR AND FLUE THERMOSTAT REMOVAL Fig 80 Unclip and remove the air chamber front and left side covers Locate and remove the screw A that secures the flue gas analysis test point cover B Disconnect the silicon pipe right hand of the blocked flue switch Remove the clip C and the flue thermostat D Gently pull down and to the left and ease the flue collector from its location Replace in the reverse order 55 13 LPG INSTRUCTIONS This instruction mustbe retained adjacent to the boiler as they contain important details about the conversion made WARNING This conversion kit shall be installed by a qualified service agency in accordance with the manufacturers instructions and all applicable codes and requirements of the authority having jurisdiction If the information in this instructions is not followed exactly a fire an explosion or production of carbon monoxide may result causing property damage personal injury or loss of life The qualified service The XPak boiler is factory supplied to use natural gas The boiler can use
15. Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468
16. condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Place in operation the appliance being inspected Follow the lighting instructions Adjustthermostat so appliance will operate continuously Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI 7223 1 latest edition Correct by resizing to approach the minimum size as determined using the appropriate tables in Table 13 of ANSI 2223 1 2006 of that code Canadian installations must comply with B149 Installation Code PREPARE XPAK CAUTION Cold weather handling If boiler has been stored in a very cold location below O F 18 C before installation handle with care until the plastic components come to room temperature 1 1 REMOVE XPAK BOILER FROM BOX XPak is heavy and awkward to lift Care must be taken to place it in a safe location prior to installation on the wall to prevent damage to the bottom mechanical connections 2 PLACING THE WA
17. reconnect the external thermostat circuit wires to boiler low voltage terminal strip Allow the boiler to cycle 8 TESTING FOR GAS LEAKS Prior to start up of the boiler you must check the external tightness of the gas supply valve and confirm this in the start up report Inspect the entire installation including the gas meter WARNING Before starting the XPak and during initial operation smell near the floor and around the heater for gas odorant or any unusual odor Remove heater front door and smell interior of heater enclosure Do not proceed with startup if there is any indication of a gas leak Repair any leak at once WARNING LPG boiler only Your propane supplier mixes an odorant with the LPG to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the LPG supplier verify the correct odorant level in the gas WARNING Cover endangered positions before leak testing Do not spray the leak testing agent onto cables plugs or electrical connection lines Do not allow it to drip onto them either DANGER Leaks may be caused to pipes and screw connections during commissioning and maintenance activities Carry out a proper leak test Only use approved leak detection agents for leak detection Disconnect the heating system from the power supply Check the exterior tightness of
18. 1 2 6 5 2 0 6 1 60 1 1 4 3 5 6 9 0 8 2 15 1 1 2 4 0 8 0 0 9 2 50 NOTICE The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi 3 5 kPa 22 BOILER TEMPLATE Fig 15 Na 1 D Wall Mounting Information bx g XPak comes with a template 4 53 Hole for 60 100mm coaxial vent GZ R 3 vent adaptor supplied which allows you to easily mark 0 BP the location of the screvvs for the Inlet air either right or left F m 3 inlet air adapter ot supplied mounting bracket and the location FE 1 of the flue gas pipe on the wall Raypak coaxial PP vent system 7 only 7 2 pics The connection to the gas circuits nan Na must be made on site 3 4 gas for 5 16 lag D D D cock is supplied with the boiler Q inside 3 15 IT een 2x fitted Exhaust vent adapter supplied Screw 2x supplied Screw 2x supplied l 4
19. 4 MINIMUM CLEARANCES FROM VENT AIRINLET TERMINATION Fig 20 V vent terminal X air supply inlet area where terminal is not permitted Tab 6 U S Installations Canadian Installations2 A Clearance above grade veranda porch deck or balcony 1 ft 30 cm 1 ft 30 cm B Clearance to window or door that may 4 ft 1 2m below or to side of be opened opening 1 foot 30 cm above 3 ft 91 cm opening C Clearance to permanently closed window ki D Vertical clearance to ventilated soffit located above 5 ft 1 5m the terminal within a horizontal distance of 2 ft 61cm from the centerline of the terminal E Clearance to unventilated soffit i Clearance to outside corner i a G Clearance to inside corner 6 ft 1 83m H Clearance to each side of center line 3 ft 91 cm within a height extended above meter regulator assembly 15 ft above the meter regulator assembly Clearance to service regulator vent outlet 6 ft 1 83m J Clearance to non mechanical air supply inlet to 4 ft 1 2m below or to 3 ft 91 cm building or the combustion air inlet to any other side of opening 1 ft appliance 30 cm above opening K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 6 ft 1 83m 10 ft 3m horizontally L Clearance above paved sidewalk or paved driveway 7 ft 2 13m 7 ft 2 13m t located on public property M Clearance under veranda porch deck or balcony
20. 7 BOILER FAN SPEEDS The boiler fan speeds require to be checked and or adjusted prior to making any adjustments to the gas valve or if the main PCB has been replaced ATTENTION Gas type and appliance fan speed output must be set according to the specific appliance specification Raypak accepts no responsibility if the gas type and or fan speed is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge CHECKING ADJUSTING THE BOILER FAN SPEEDS Move the selector switch to the OFF position and remove the 3 selector knobs ABSOLUTE MAX FAN SPEED Locate the MAX trim pot Fig 59 and gently adjust clockwise or counterclockwise to achieve the correct fan speed see Table 10 below NOTICE The display shows the fan RPM in multiples of 1000 i e 2 5 2500RPM ABSOLUTE MIN FAN SPEED Locate the MIN trim pot Fig 59 and gently adjust clockwise or counterclockwise to achieve the correct fan speed see Table 10 below NOTICE The display shows the fan RPM in multiples of 1000 i e 2 5 2500RPM IGNITION FAN SPEED NOTICE Do this operation only after the adjusting of absolute max and min fan speed Locate the IGN trim pot Fig 59 and gently adjust clockwise or counter clockwise to achieve the correct fan speed see Table 10 below NOTICE The display shows the fan RPM in multiples of 1000 i e 2 5 2500RPM HEATING FAN SPEED Locate the HTG trim
21. Electrode 19 Spark Electrode 20 Top automatic air vent drain pipe 21 Condensate level sensor 22 Cylindric Burner 23 Fan assembly 24 Mixer 25 Gas modulator coil 26 Gas valve 27 Pressure relief valve R Boiler IN connection F Boiler OUT connection Gas connection P Pressure relief valve drain C 8 O O OB ON Condensate drain pipe 11 10 Fig 1 XPAK 85 DE C XPAK 120 2 8 rr KET Lie R 16 m 22 7 74 m P 2 Cp xx 0 Te ee y R K x F aK 20 21 22 28 24 25 26 27 20 21 22 23 24 25 26 27 Fig 1A Pressure gauge Green led 2 digit LED display Red led Temperature selector space heating Mode selector switch Temperature selector Domestic Hot Water Off reset Select this position when the boiler needs to be reset or switched off G Summer mode The domestic hot water function provided by the water tank
22. Inc The boiler can also be operated with separate air intake and exhaust piping The termination shall be at least 4 ft 1220 mm for the U S and 6ft 1830 mm for Canada away from a gas utility meter service regulator or the like for room air applications only The termination shall terminate at least 4 ft 1220 mm below 4 ft 1220 mm horizontally from or 1 ft 305 mm above any door window or gravity air inlet into any building Vent must be atleast 12 inches 305 mm above grade anticipated snow line or roof surface Canada 18 457 mm minimum Vent termination must be at least 7 ft 2135 mm above a public walkway see Fig 20 Vent must be 3 ft 915 mm above any forced air intake within 10 ft 3050 mm see Fig 20 Do not extend exposed vent pipe outside the building beyond recommended distance Condensate could freeze and block vent pipe Vent should terminate at least 3 ft 915 mm away from adjacent walls inside corners and below roof overhang It is not recommended to terminate vent above any door or window condensate can freeze causing ice formations Do not use chimney as a raceway if another boiler or fireplace is vented into or through chimney All vent pipes must be glued except for the flue gas adapter which is fix into place and the first connection to the flue gas adapter Installed you can slide the pipe onto the adapter properly supported and the exhaust pipe must be pitched a minimum of a 1 4 in
23. LED Fig 52 Off boiler on stand by no flame On burner on the boiler works regularly Red indicator LED Fig 53 Stop just the fault code flashes on the digital display Block the red indicator LED lights up and the fault code flashes on the digital display The fault code is not displayed in the OFF RESET mode To display it move the function selector to Xf or During combustion analysis and the freeze protection mode instead it is displayed To reset the boiler turn the function selector to OFF RESET and then move it to be required position Fig 47 If the boiler still doesn t work call in the local Service Technician Pressure gauge Green led 2 digit LED display Red led Temperature selector space heating Mode selector switch Temperature selector Domestic Hot Water The parts of the manual refering to the DHW circuit should be only considered if a indirect water tank with sensor is installed case B Fig 61 QGumuocup Fig 45 44 Open m position H JO MET D red indicator LED fault Fig 46 DHW mode
24. The appliance comes with a factory installed jumper for room thermostat connection to allow basic operation of the boiler via the mode selector switch f it is anticipated that external controls will be required please refer to the wiring diagrams remove room thermostat jumper if there is the remote control installed on the low voltage terminal strip M4 Fig 35 External connection board connections Make all electrical connections inside the external connection box Open the cover of the external connection box Fig 34 Connecting incoming power The boiler must be electrically grounded in accordance with local codes or in absence of local codes with the National Electrical Code ANSI INFPA 70 and or the CSA C22 1 Electrical Code Boiler terminal strip Fig 35 The XPak terminal strip is divided in two separated area low voltage and high voltage area The high voltage area is dedicated to connections incoming power ground neutral line a fuse 4A is factory fit directly on the terminal strip 3 pins M3 connection for 3 way DHW valve field supplied 3 pins M3a The low voltage area is dedicated to external sensor 2 pins M4 remote control 2 pins M4 DHW tank sensor 2 pins M4a DHW tank thermostat 2 pins M2 Room thermostat 2 pins M4a factory jumper External alarm 3 pins M3b factory jumper 6 CONNECTING THE ELECTRICAL SUPPLY 120V Unhook and remove the termi
25. also LPG gas by installing a kit supplied with every unit The conversion to LPG is possible by 1 2 Install the new gas injector Modify the fan speed according the data in the table The kit is composed by 1 2 3 4 Injector black coating to be recognized from the natural gas that is not black coated Relative gas sticker red color to be attached under the boiler instead of the natural gas sticker yellow color factory installed Instruction of the kit LPG label to be affixed on the boiler casing and completed in by the organization making this conversion Operations for conversion DABONS Switch off the boiler Change the gas injector Apply the red sticker Switch on the boiler Set the new fan speed Fill the final part of this instruction GAS SUPPLY The gas supply must be connected to the boiler by a competent LPG installer and must be of sufficient size to supply the boiler at its maximum output An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and agency is responsible for the proper installation of this kit The installation is not proper and complete until the operation ofthe converted appliance is checked as specified in the manufacturer s instructions supplied with the kit LPG INSTRUCTIONS PROPANE GAS CAUTION The gas supply shall be shut off prior to disconnecting the electrical power before proc
26. b total flue length EXHAUST TWO PIPES SINGLE WALL ROOM AIRDEPENDENT OPERATION 29 Stainless Steel 3 Vent System US CANADA Vent System Room Air independent Operation Sealed Combustion Operation Fig 12 14 15 17 Tab 7 Vent System diameter 3 Vent system material Stainless steel Two pipes vent adaptors included with the boiler adaptor 80 mm gt 3 included with the boiler 1 pcs for flue adaptor 80 mm gt 3 for intake air Field supplied Order No Combustion air intake vent material 3 Field supplied Order No ULCVUL listed1 Stainless steel Vent material 45 elbow EqL 2 ft 0 6m Field supplied Order No 90 elbovv EqL 3 ft 0 9m Bird Screen c w Termination Field supplied Order No Venting support dia 3 Field supplied Order No stainless steel vent material must be ULC UL listed stainless steel AL29 4C for category IV boilers Sources FasNseal Protech System Inc 2 Order Mounting Clip for each straight length of vent pipe installed boiler can not support weight of vent system 3 allowable material for combustion air ABS CPVC PVC or stainless steel Do not exceed maximum equivalent vent length Always follow XPak Venting System Installation Instructions Stainless Steel Vent System US CANADA Vent System Room Air Dependent Operation Fig 13 16 18 Tab 8 Vent System diame
27. be made for this expansion in the system design CAUTION It is highly recommended that you carefully follow the glycol manufacturers recommended concentrations expansion requirements and maintenance recommendations pH additive breakdown inhibitor reduction etc You must carefully calculate the additional friction loss in the system as well as the reduction in heat transfer co efficients pH must be maintained between 6 8 XPak 85 16 15 14 12 DA o u Soy 10 D Ke 7 g 24 m KA 3 E 5 y 3 m 0 6 0 0 20 41 61 81 102 122 142 163 183 203 224 244 264 285 305 Flovv rate gph Fig 6 XPak 120 Residual head ftvvc 0 20 41 61 81 102 122 142 163 183 203 224 244 264 285 305 Flovv rate gph 18 XPAK INSTALLATION DIAGRAMS NOTICE The following illustrations are simplified conceptual illustrations only Key for installation sample diagrams XPak boiler Gas shut off valve Expansion vessel Radiators Under floor heating Pressure relief valve discharge pipe Indirect DHW tank 3 way valve Room thermostat 24V Remote control Raypak Condensate drain pipe Valve ball Hydraulic manifold box package High limit thermostat flo
28. clean and free from any debris or obstruction Check and clean if necessary the condense trap to ensure correct operation Compare the performance of the appliance with its design specification The cause of any noticeable deterioration should be identified and fixed without delay The combustion blower motor does not require lubrication for proper operation DO NOT attempt to oil the motor or damage may occur 3 REPLACEMENT OF COMPONENTS Although it is anticipated that this appliance will give years of reliable trouble free service the life span of components will be determined by factors such as operating conditions and usage Should the appliance develop a fault the troubleshooting section will assist in determining which component is malfunctioning 4 COMPONENT REMOVAL PROCEDURE To remove a component access to the interior of the boiler is essential Isolate the appliance from the electrical supply And when necessary close all service valves on the boiler remove the casing and drain the water content from the boiler via the drain valve Ensure some water absorbent cloths are available to catch any residual water that may drip from the boiler or removed component Undertake a complete commissioning check after replacing any component ALWAYS TEST FOR GAS TIGHTNESS IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED OR DISTURBED AIR BOX FRONT COVER REMOVAL Fig 68 Locate the two clips and remove air box front cov
29. code or some insurance companies Check code requirements before installation of the XPak boiler If required Use a low water cutoff designed for hydronic installations Follow low water cutoff manufacturer s instructions NOTICE A hot water boiler installed above radiation level or as required by the Authority having jurisdiction must be provided with al low water cut off device either as apart of the boiler or at the time of the boiler installation 4 BACKFLOW PREVENTER Use a backflow preventer specifically designed for hydronic boiler installations This valve should be installed on the cold water fill supply line per local codes 5 FITTING THE HEATING CIRCUIT SUPPLY AND RETURN PIPES NOTICE To protect the entire heating system Raypak recommends installing a filter in the return circuit When connecting the boiler to an existing heating system this filter must definitely be installed Install shut off valves immediately before and after the dirt particle filter to enable the filter to be cleaned Install a filling and drain cock in the heating system supply pipe if required Also install a safety valve in the system WARNING To avoid water damage or scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line in a manner that will prevent possibility of severe burns or property damag
30. differential inverted Final Reset check pump ensure there is sufficient return sensor temperature higher than circulation around heating circuit s thermistors flowsensor temperature AL29 Flue sensor over temperature lock out Final Reset check appliance operation AL34 Fan blower signal fault Final Reset check appliance operation check fan AL40 Insufficient system water pressure Final Check refill system pressure reset check appliance operation AL41 Insufficient system water pressure Temporary Check refill system pressure check appliance operation AL52 Internal fault Final Reset check boiler operation AL55 Jumper tag fault Final Check jumper tag configuration AL60 Jumper tag fault Temporary Check jumper tag configuration AL71 Primary flow sensor fault Temporary Check primary thermistor check wiring AL73 Return sensor fault Temporary Check return thermistor check wiring AL74 Variation on temperature of primary Final Reset check boiler operation check and or return too high pump ensure there is sufficient circulation around heating circuit s AL79 Flow temperature too high or Final Reset check appliance operation check temperature differential between thermistors primary and return too high AL91 The main heat exchanger need to be Advice Call the Raypak technical service cleaned 51 12 SERVICING INSTRUCTIONS 1 GENERAL To ensure the continued safe and efficient operation of the boiler it is recomm
31. external design Temp Tshift 86 F 30 C standard systems radiators 77 F 25 C underfloor systems If the calculation generates an intermediate value between two curves choose the nearest offset heating curve to that value E g if the value obtained by the calculation is 1 3 it lies between curve 1 and curve 1 5 In this case select the nearest curve i e 1 5 Select KT by turning the trimmer located under the domestic hot water temperature knob A The settable values of KT are standard system 1 0 1 5 2 0 2 5 3 0 floor system 0 2 0 4 0 6 0 8 TYPE OF HEAT REQUEST STANDARD If a room thermostat is connected to the boiler room thermostat The room thermostat makes a heat request when its contact closes while it stops it when its contact opens Though delivery temperature is automatically calculated by the boiler the user may manually override it By modifying HEATING on the user interface C the HEATING SET POINT will no longer be available but just a value that can be set from 5 to 5 as required Please note that the number displayed is a comfort level 5 means feel hotter 5 means feel colder Modifications to this value do not directly change flow temperature but affect the calculation made to automatically determine its value by modifying the reference temperature of the system 0 68 F 20 C PROGRAMMABLE TIMER DAY NIGHT If a programmable timer day night selector is connected to the boi
32. failure of the condensate pump alarm 21 Only corrosion resistant materials may be used for condensate drainage purposes e g braided hose Do not use galvanized materials or materials containing copper for piping couplings etc Please note that other requirements may apply depending on local regulations and or project specific details It is advisable to contact your local waterworks office authority responsible for waste water regulations well before commencing with the installation of the neutralization unit in order to establish details of local regulations that apply NOTICE Pipe ventilation must take place between the siphon trap and the neutralization unit if applicable 7 ELECTRICAL CONNECTIONS Devices such as outdoor sensor 3 way valve tank sensor tank thermostat remote controls are all connected to the external connection board The electrical connections to the boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installations should also conform with CSA C22 1 Canadian Electrical Code Part 1 if installed in Canada 1 EXTERNAL CONNECTION BOARD CONNECTIONS A qualified electrician should connect the electrical supply to the appliance If controls external to the appliance are required a competent person must undertake the design of any external electrical circuits ANY EXTERNAL CONTROL OR WIRING MUST BE SERV
33. fire VENTING Number of Tanks and Size Qty Gallons Vent Size Stack Height Plumbing Size Category sketch vent on reverse side Pump Size boiler Pump HP Vent Material Impeller trim Pump Model Vent Termination Type Louvers Screens Combustion Air Openings Low in2 Ventilation air High in2 EMISSIONS SETTINGS AND TEST INFORMATION ATFULLFIRE Nominal Factory Recommended Settings Blower Pressure Setting In WC See manual or card tag Supply Gas Pressure In WC See manual or card tag Verify stable pressure static amp dynamic condition Manifold Gas Pressure In WC See manual or card tag Tracking Pressure clean filter In WC The following measurements must be obtained with a Combustion Analyzer NOX PPM Less than 20 PPM If required by Certifying Agency Free Oxygen See manual PPM Less than 170 PPM CO2 See manual Model Number Serial Number Note draw venting with details such as extractors Site Altitude Above Sea Level Ft barometric dampers blast dampers or draft inducers Job Name Address Physical Location of Boiler Indoors Outdoors Ground Level Below Grade Mechanical Contractor Installer Date and Time of Start up Print Name and Signature of Start up Technician Information must be faxed to 805 278 5471 in order to ensure warranty consideration Attn Service Manager 67 Your XPak serial number for future reference Registered Quality Management System www raypak com
34. has been achieved the electronic circuitry increases the gas rate to 75 of the MAX Heating set by the corresponding HTG trimmer for a period of 15 minutes The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow temperature sensor consequently a high temperature at the flow sensor results in a lower fan speed As the water temperature increases the temperature sensors located on the flow pipe of the boiler reduce the fan speed via the electronic circuitry Depending on the load either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required When the boiler has reached the set point hysteresis the burner will switch off The built in anti cycle device prevents the burner from re lighting for approximately 3 minutes When the temperature of the flow sensor falls below the set point hysteresis the burner will re light NOTICE If the spark sensing electrode does not sense ignition the appliance will re attempt ignition a further 4 times then go to lockout When the set point has been reached the position of the heating temperature selector as measured at the primary thermistor the appliance will begin the modulation phase whereby the fan and gas valve will continuously modulate to maintain the set point If the temperature continues to
35. in 3 4 NPT female Boiler in connection in 3 4 NPT male Boiler out connection in 3 4 NPT male Pressure relief valve in 3 4 NPT female Condensate connection diameter rubber flexible in 0 825 female mm 21 female Boiler drain valve open ended wrench dimension in 7 16 mm 11 Boiler Dimensions And Weight Height x Width x Dept in 30 7 x 15 75 x 14 1 30 7 x 17 7 x 14 1 mm 780 x 400 x 358 780 x 450 x 358 Weight net Ibs 73 80 Kg 33 36 Components Burner Stainless Steel Main heat exchanger ASME approved extruded aluminum Gas valve Pump Groundfos UPM 15 52 Groundfos UPM 15 62 Pressure relief valve Watts M350 ASME approved Fan MVL RG 128 3 way valve for DHW tank field supply Honeywell VC6011 VCZMK6000 Injector Natural Gas A 0 20 inch 5 1 mm 0 26 inch 6 7 mm Injector LPG E black coated 0 15 inch 3 9 mm 0 19 inch 5 0 mm notes See jumpers configurations for heating temperature range setting lf the gas supply pressure exceeds the maximum gas supply pressure value a separate gas pressure regulator must be installed upstream of the heating system 11 PRINCIPLE COMPONENTS A fully integrated electronic control board featuring electronic temperature control anti cycle control pump over run actuator anti block function self diagnostic fault indicator full air gas modulation Radial aluminum heat exchanger Electronic ignition vvith flame supervision
36. is activated The display indicates the storage tank temperature only with the external water tank connected with a sensor Winter mode The boiler produces hot water for heating and if connected to an external water tank it provides domestic hot water The display indicates the boiler flow tem perature Ft Winter mode tank temperature The boiler produces hot water for heating and if connected to an external water tank with a sensor it provides domestic hot water The display indicates the storage tank temperature oy Temperature selector DHW Move the temperature selector clockwise to increase the hot water temperature in the water tank or counter clockwise to reduce the temperature working only if a tank sensor is connected P Ull Temperature selector Heating Move the temperature selector clockwise to increase the heating temperature or counterclockwise to reduce the temperature 2 digit LED display Displays the temperature according the mode selector switch During a fault condition the appropriate code will be displayed refer to the installation instructions regarding fault codes O Green LED lit Boiler is working responding to a heating tank request flame ON O Red LED lit Boiler has identified a fault and has shut down Refer to installation instructions on hovv to reset Pressure gauge Ensure the system pressure is set correctly minimum 7 p s i 0 45 bar D j
37. mass flow rate at rated full load A Ibs hr 90 39 123 17 kg hr 41 55 87 Flue gas mass flow rate at rated full load E Ibs hr 88 89 121 18 kg hr 40 32 54 97 Flue gas mass flow rate at rated partial load A Ibs hr 26 58 28 48 kg hr 12 06 12 92 Flue gas mass flow rate at rated partial load E Ibs hr 25 08 27 99 kg hr 11 88 12 70 Condensate flow rate A at max 122 86 F 50 30 C USG hr 0 37 0 41 Ttr hr 1 41 1 56 Condensate flow rate A at min 122 86 F 50 30 C USG hr 0 13 0 16 Ttr hr 0 48 0 6 Flue temperature at boiler return temp 86 F 30 C F 186 0 170 0 at full load A C 86 0 77 0 Flue temperature at boiler return temp 86 F 30 C F 163 0 165 0 at partial load A C 73 0 74 0 Flue temperature at boiler return temp 140 F 60 C 194 0 186 0 at full load A C 90 0 86 0 Max flues length de rate less 2 Max length horizontal coaxial 60 100 mm ft 6 5 6 5 m 2 2 Max total length 2 pipe 3 80 mm air flues ft 40 40 16 16 m 12 12 5 5 Max flues length de rate less 5 Max length horizontal coaxial 60 100 mm ft 26 26 m 7 8 7 8 Max total length 2 pipe 3 80 mm air flues ft 1304130 115 115 m 40 40 35 35 Minimum Clearances To Combustibles Top front rear in 0 0 0 mm 0 0 0 Left right vent pipe in 0 0 0 mm 0 0 0 Recommended Minimum Service Clearances Top front rear in 12 24 0 mm 300 600 0 Left right in 1 1 mm 25 25 Pipe Connections Gas supply connection shut off valve
38. new pipe sections up to and including the direct sealing point on the gas burner fitting 9 INITIAL FLUSHING OF THE SYSTEM The whole of the heating system must be flushed both cold and hot as detailed in Fig 42a Open all radiator or heating valves and the boiler flow amp return service valve Drain the boiler and system from the lowest points Open the drain valve full bore to remove any installation debris from the boiler prior to lighting Refill the boiler and heating system 10 PRE OPERATION CHECKS Before attempting the initial lighting of the appliance the following checks must be carried out Ensure all gas service valves from the meter to the appliance are open and the supply pipe has been properly purged Ensure the proper electrical checks have been carried out particularly continuity polarity and resistance to ground Ensure the 4 AMP fuses are installed Ensure the system has been filled vented and the pressure set to 15 p s i 1 bar Ensure the flue system has been installed properly and in accordance with the instructions Ensure all appliance service valves are open 11 INITIAL LIGHTING AND IGNITION SAFETY SHUTOFF DEVICE TEST Ensure the electrical supply to the appliance is switched on Ensure any external controls are switched to an ON position and are calling for heat Move the selector switch to the ON position 3 Si the appliance will now operate NOTICE
39. pot Fig 59 and gently adjust clockwise or counter clockwise to achieve the correct fan speed see Table 10 below NOTICE The display shows the fan RPM in multiples of 1000 i e 2 5 2500RPM FAN SPEED TABLE Use the following table to set the corresponding fan speeds that are relative to the boiler you are working on FAN SPEED rpm TABLE Tab 10 MODEL MAX MIN HTG IGN 85 5 800 2 000 5 800 3 700 120 5 600 1 500 5 600 3 700 Ill IGNO Fig 59 Fig 59a 8 CHECKING THE CO2 AND ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYZER solate the boiler from the electrical supply and remove the casing as described in Fig 33 Set the flue gas analyzer to read CO2 and insert the probe into the flue analysis test point Pos B in Fig 59a Restore the electrical supply to the boiler and switch the boiler to the OFF mode To adiust the gas valve you must first ensure that the fan speed potentiometers trim pot have been set correctly Tab 10 Remove the 3 selector knobs locate and press the CO button Fig 59 The appliance vvill novv operate in CO mode for approximately 15 minutes 9 GAS VALVE MAXIMUM PRESSURE SETTING Fig 61 Locate and gently turn the HTG trim pot until the maximum value max fan speed is obtained and check that it corresponds with the appropriate CO2 value Maximum for the
40. protect the boiler and system from the effects of corrosion and or electrolytic action The inhibitor must be administered in strict accordance with the manufacturers instructions A properly sized expansion tank must be installed in the boiler system No valve is to be placed between the boiler and the expansion tank When the boiler has been filled for the first time or the system has been drained and refilled it will be necessary to purge any air that may have become trapped within the appliance heat exchanger NOTE Glycol in the system must not exced 40 Observe these instructions for space heating water Thoroughly flush the system prior to filling Only use untreated main water to fill and top off the system Do not use water softners in the system Do not use inhibitors or other additives The maximum permissible flow rate of the XPAK 85 this is 5 7 GPM 1 300 Itr hr for the XPAK 120 is 6 2 GPM 1 400 Itr hr When using oxygen permeable pipes e g for floor heating systems you must separate the system using heat exchangers Unsuitable heating system water promotes the formation of sludge and corrosion This may damage the heat exchanger or affect its operation A properly sized expansion tank must be installed in the boiler system Tools materials and additional equipment For the installation and maintenance of the boiler you will need the standard tools for space heating ga
41. replace any defective part of the Boiler in accordance with the terms of this Limited Warranty The Limited Warranty does not include labor or transportation costs which are borne by the warranty claimant The repair or replacement Boiler or part will be warranted for only the unexpired portion of the original Applicable Warranty Period This Limited Warranty applies only to a Boiler that has NOT been moved from its original installation site In the event that replacement or repair parts are no longer available or significant design changes have occurred Raypak reserves the right to replace at its option the Boiler or part with a current equivalent part Please read this entire Limited Warranty to fully understand all of its terms and conditions APPLICABLE WARRANTY PERIODS XPAK Residential Extruded Aluminum Heat Exchanger The Applicable Warranty Period for the aluminum heat exchanger of the Boiler in a residential installation as defined in Additional Warranty Exclusions and Terms below is twenty 20 years after the original installation date of the Boiler During the first ten 10 years Raypak will pay for 100 of the cost of the replacement part or repair excluding labor and transportation costs For years 11 20 of the Applicable Warranty Period for the residential Boilers aluminum heat exchanger Raypak will provide a replacement part for a defective part provided that the warranty claimant pays the following percentages of the co
42. trap in order to keep flue gases from being discharged via the condensate drain The condensate formed both in the condensing boiler and in the flue gas pipe must be discharged into the public sevvage system n accordance vvith all applicable local regulations The condensate produced by a gas fired heating system has a pH value betvveen 3 and 4 Some local codes may require the use of a separate neutralization unit to treat the aggressive and corrosive condensate Raypak offers a Condensate Neutralizer Kit Z 12 option for use when managing the condensate is desired or required Order part number 013141 VVith a neutralization unit installed all condensate from the boiler and the flue gas pipe enters into the neutralization unit vvhere it is treated and released into the public sewage system with a safe pH value of above 6 5 The use of neutralization granulate performing the neutralizing process is dependent on the operation of the heating system To determine the required refill amount check granulate level several times during the first year of operation In some cases one granulate fill may last an entire year The condensate discharge outlet to the drainage system connection must be clearly visible It must be installed with a suitable gradient and provided with a stench trap If the condensate outlet of the boiler is lower than the drain a condensate pump must be used see electrical wiring to loch out the boiler in the case of
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44. 104 UBI9IUU99 IA195S p llilenb e 1129 U aeda o Aa LUOD puey q uin jou IIM DUEU ay J SIO0 SN qouy JOUOD seb y UN o puey noA Ajuo aen JU WLIed p o ay 29 rddns seb noA yoga youueo o suoloniysul sa rddns seb eu Mol o4 euoud soquBbleu e wo Ja11ddns seb uno UE Aja gipaww Dumping unoA ut auoyd Aue aen you U HAS 91149919 Aue yono jou Oq eouel dde Aue 1461 o Am jou oq SV 113NS NOA 21 OG OL LVHM 4001 ay UO allge IIVM pue 1e UU Jalagay si seb WOS sne q 100 ay o Dau il uls 0 JNS og seb Jo Base oouel dde eu punore Ile JEWS 9NIIYH3IdO 340434 puey Aq Jauing ay ybi o Al jou oq Jeng eu SJYDI l eonewo ne ydiym 2I1 P uollubi Ue yum paddinboa si 1 1o ld e ABU jou saop aduei dde siy lil Jo sso Jo Ainlul yeuosued Auadoid Buisneo jnsa Aew uoisojdx 10 e Ah ex SUONONJISUI MO OJ JOU OP NOA U JNINHYM 3240439 Ov34 ALIAVS HNOA 404 Fig 41 39 9 COMMISSIONING 1 CHECK CONTROL WATER CHEMISTRY WARNING Do not use petroleum based cleaning or sealing compounds in heater system Damage to elastomer seals and gaskets in system could occur resulting in substantial property damage Water pH between 6 0 and 8 0 1 Maintain heater water pH between 6 0 and 8 0 Check with litmus paper or have chemically analyzed by water treatment com
45. 4 90 176 80 158 70 LL 2 140 60 E Ww 122 50 W EF 104 40 T 86 30 68 20 20 15 10 5 0 5 10 15 20 CC 68 59 50 41 32 23 14 5 4 F OUTDOOR TEMPERATURE Fig 65 CF CC OUTDOOR RESET CORRECTION 194 90 176 80 158 70 140 60 D 50 R 122 104 40 T 86 30 68 20 414 5 50 10 30 25 20 15 10 5 0 5 10 15 20 CO 86 77 68 59 50 41 32 23 14 5 4 F Fig 66 OUTDOOR TEMPERATURE CC NIGHT SETBACK 194 90 176 20 158 70 Outdoor reset DAY 140 60 u 122 50 Outdoor reset NIGHT 104 40 Ww m 86 30 z 68 20 50 10 1 20 15 10 5 0 5 10 15 20 C 68 59 50 41 32 23 14 5 A F OUTDOOR TEMPERATURE Fig 67 50 17 FAULT CODES When the boiler detects a temporary fault condition the appropriate code is shown flashing on the display If when the fault code is final the pump will perform a 60 second post circulation and the red LED will be illuminated CODE CAUSE ALARM TYPE ACTION AL10 Ignition failure not flame sensed Final Reset check appliance operation condense sensor activated AL20 Limit thermostat fault blocked flue switch flue thermostat Final Reset check appliance operation AL21 External device fault UHT CPA Final Reset check appliance AL26 Return temperature too high Final Reset check pump ensure there is sufficient flow sensor temperature Circulation around heating circuit s AL28 Temperature
46. AL SENSOR OT M4 TANK THERMOSTAT LOW VOLTAGE ROOM THERMOSTAT jumper when not used THERMOSTAT OR CONDENSATE PUMP ALARM jumper when not used TANK SENSOR RE Fig 35 UNDERFLOOR HEATING LIMIT NG HIGH VOLTAGE F fuse 4AF BLUE COMMON BROWN CLOSED BLACK OPEN LO N PCB fuse 4AT 1 1 M3a 36 12 OUTDOOR SENSOR CONNECTION The user can program the desired supply temperature based on the outdoor temperature Once the outdoor sensor is connected to the control board the water temperature of the boiler will adjust to run the boiler more efficiently and provide greater comfort to the living space Connection Specification Wire 22 AWG maximum to 100 ft 30 m Outdoor Sensor is connected in the junction box on the XPak Route wires from the terminal strip to your outdoor sensor which will allow the user to change the temperature going to the Central Heating loop automatically Place the outdoor sensor preferably to the north or northwest or to the side which will be affected by changing weather conditions outside NOTE Do not locate the sensor in the direct sunlight 13 3 WA
47. After installation the boiler must be turned ON and the thermostat set for CFH and operated with the manual gas shut off valve below the unit closed Allow the boiler to go through its 5 ignition tries and then lock out The display should indicates the alarm code 10 After the test reset the control open the gas valve set the thermostat to the proper setting and ensure that the boiler operates properly 12 CHECKING GAS PRESSURE AND COMBUSTION ANALYSIS The boiler is factory set and requires no additional adjustment once installed f the installation does not include a gas meter for example LPG and there are no means by vvhich to calculate the gas rate then a combustion analysis test must be carried out in accordance vvith local regulations to ensure the appliance is left vvorking safely and correctly Additionally if the gas valve has been adjusted replaced or the appliance has been converted for use vvith another gas type then it becomes necessary to carry out a combustion analysis check to ensure that correct combustion is occurring If there are no means to gas rate the appliance and or carry out a combustion analysis check then it vvill not be possible to comple te the commissioning procedure Details on hovv to carry out the combustion analysis can be found in Section 11 NOTICE It s imperative that a sufficient dynamic gas pressure is maintained at all times Should the dynamic gas pr
48. ED FROM THE SAME ISOLATOR AS THAT OF THE APPLIANCE Wiring to the appliance must be rated for operation in contact with surfaces up to 194 F 90 C WARNING ELECTRICAL SHOCK HAZARD For your safety turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard Failure to do so can cause severe personal injury or death AVERTISSEMENT RISQUE DE CHOC ELECTRIQUE Pour votre s curit coupez l alimentation lectrique au niveau du tableau de distribution avant d effectuer tout raccordement lectrique afin d eviter un risque ventuel de choc lectrique La non observation du dernier point peut provoquer de graves blessures ou la mort NOTICE Wiring must be N E C Class 1 If original wiring as supplied with heater must be replaced use only TEW 221 F 105 C wire or equivalent Heater must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 2 ELECTRICAL SUPPLY The boiler requires a 120V 60Hz power supply Ensure the electrical supply is properly polarized The boiler must be grounded There must only be one common isolator providing complete electrical isolation for the boiler and any extern
49. Engineers ASME Boiler Pressure Vessel Code and bears the ASME H stamp This boiler also complies with the latest edition of the ASHRAE 90 1 Standard WARNING Altering any Raypak pressure vessel by installing replacement heat exchangers tube bundle headers 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 Installations at Elevation Rated inputs are suitable for up to 4 500 ft elevation see technical data table Consult the factory for installations at altitudes over 4 500 ft above sea level No hardware changes are required to the boilers for installations up to 10 000 ft adjustments may be required 4 REGULATIONS AND GUIDELINES The installation must be conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the latest edition of the National Fuel Gas Code ANSI 2223 1 In Canada installation must be in accordance with the requirements of CAN CSA B149 1 Natural Gas and Propane Installation Code Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Install CO detectors per local regulations Boiler requires yearly maintenance
50. F 013059F 52 Outlet Heat Exchanger Seal Gasket 013060F 013060F 53 Inlet Heat Exchanger Seal Gasket 013061F 013061F 54 High Limit 013062F 013062F 55 Flue Sensor 013063F 013063F 56 Water Gasket Kit Includes 56a 56b and 56c 10pcs ea 013000F 013000F 57 Flue Exhaust Gas Gasket Kit Includes 57a and 57b 013001F 013001F 58 Nat to Pro Gas Conversion Kit 013052F 013053F For gas conversions consult the factory for information 63 Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 00 and 5 00 for installation of through the wall vented gas appliances as follows a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In additio
51. FIELD SUPPLIED o d 31 Fig 30 a total intake length INTAKE b total flue length EXHAUST 1 MIN g m ommu TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION 12 300 mm OVER E MAXIMUM SNOW LEVEL R2 AN 24 en WHICHEVER IS SREATER a total intake length INTAKE b total flue length EXHAUST gt 2 2 4 LU SUPPLIED 2 HE 2 FIELD SUPPLIED Fig 31 asm ommu TWO PIPES SINGLE WALL V SEALED COMBUSTION OPERATION SA Kk x i J Ki K WHICHEVER IS GREATER EXHAUST HE INTAKE x SUPPLIED 2 E E 2 s OB 32 Fig 32 a total intake length 0 b total flue length EXHAUST min 12 EXHAUST o TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION INTAKE a SUPPLIED 2 H 2 FIELD SUPPLIED O Bom 12 300 mm 12 y 12 300 mm 300 mm minimum minimum LY 300 m mm minimum A NG Pag mm minimum NB VT 33 CONNECTING THE CONDENSATE WATER DRAIN Install the condensate drain flexible pipe 0 825 21mm female flexible rubber connection with a suitable gradient min 2 5 Discharge condensate from the boiler into the drainage system either directly or if required via a neutralization unit not supplied 1 CONDENSATE CONNECTION The condensate drain of the boiler is equipped with a built in siphon
52. G Ibs hr 4 02 5 55 kg hr 1 82 2 52 Gas Rate min LPG Ibs hr 1 20 1 28 kg hr 0 54 0 58 Emissions CO2 setting 10 0 10 0 NOx max ppm lt 20 lt 20 NOx min ppm lt 15 lt 20 CO max without air ppm lt 200 lt 200 CO min without air ppm lt 40 lt 35 Injector size Injector LPG E black coated 0 15 inch 3 9 mm 10 19 inch 5 0 mm BOILER FAN SPEEDS The boiler fan speeds require to be checked and or adjusted prior to making any adjustments to the gas valve or if the main PCB has been replaced ATTENTION Gas type and boller fan speed output must be set according to the specific appliance specification Raypak accepts no responsibility if the gas type and or fan speed is not correctly adiusted according to the respective specification as detailed on the boiler data badge ADJUSTING GAS PRESSURE The gas pressure can not be adjusted as the boiler is equipped with a pneumatic gas valve CHECKING ADJUSTING THE APPLIANCE FAN SPEEDS Move the selector switch to the OFF position and remove the 3 selector knobs ABSOLUTE MAX FAN SPEED Locate the MAX trim pot Fig 2 and gently adjust clockwise or counter clockwise to achieve the correct fan speed see table below NOTE The display shows the fan RPMin multiples of 1000 i e 2 5 2500RPM ABSOLUTE MIN FAN SPEED Locate the MIN trim pot Fig 2 and gently adjust clockwise or counter clockwise to achieve the correct fan speed see table below NOTE The d
53. INSTALLATION amp OPERATING INSTRUCTIONS NINETY PLUS XPak 85 XPak 120 WARNING If the information in this manual is not follovved exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids or other combustable 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 shuld be maintained in legible condition and kept adjacent to the boiler or in a safe place for future reference BA AVERTISSEMENT Assurez vous de bien suivres les instructions donn es dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommage mat riel toute blessure ou la mort Ne pas entreposer ni utiliser d essence ni d autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ou de tout autre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareils Ne touchez
54. LL MOUNTED XPAK BOILER XPak boilers are wall mounted Use only the XPak boiler wall mounting instructions included in the box WARNING The wall must be capable of carrying the weight of the boiler and its related components The weights of the boiler are approximately XPak 85 82 Ibs 37 kg XPak 120 93 Ibs 42 kg Failure to comply with above could result in severe personal injury death or substantial property damage 2 GENERAL PIPING INFORMATION CAUTION Use two wrenches when tightening water piping at boiler using one wrench to prevent the boiler return line or supply line from turning Failure to support the boiler piping connections to prevent them from turning could cause damage to boiler components 3 XPAK WALL MOUNTING INSTRUCTIONS WARNING This boiler is heavy and awkward to lift It is recommended and safer to install the boiler with two people Use caution as to not drop the boiler which could cause personal injury Verify that the boiler is securely mounted before leaving the boiler unsupervised NOTICE The XPak boiler control module uses temperature sensors to provide both high limit protection and modulating temperature control The PCB also provides low water protection using a water pressure switch minimum 6 5 psi 0 45 bar and blocked flue switch Some codes jurisdictions may require additional external controls for high limit and or low water cutoff protection
55. N DD 1391184 vy kiNs abejjon Mo M un c TWNDIS NV4 Du SR Pad y ber Gr a ee 4h 57 1 CE 2 A 5 NI Ca auser L M 1 HO LVLSOWH3HL IX Se da LINT HOOTAHJANN 2100 2 z lz SEENEN i SLOWEY XL LAY DEE 74 O ie 2 qas LON NAHM adWNr EX LMS aki 1VLSOWHAHL NOOY vid E T O 5 HOLIMS x CN AHNSSAHd ed k 9 P Wa HALVA SE 7 IVISONH3HL i ld SS YNVL J D l HOSN3S CN 20714 IN Fig 40 38 8 START UP PROCEDURE There are several steps involved in starting up the boiler 46260002 POI ney np 9 919AN09 zajuoway UONISOd ej g 81I210 suas l suep G l ZUNOY E U IJ J U R 18p9901d 1 5 lasedde ap uonejuewuiI e zodno9 Z sseq snid 266 uoynoq l z ulnol p El 2INeJadwa ej g je sowlay l z lb ki L 1134VddV 7 ZV 30 NOISSINGV 1 34 LNINNOI JUANO anod jee ue 286 euueA Zeb ap Inassluino no lienb uelaiuy9e un z j dde jIe1edde zeb ep uoissiwpe 18dn09 juawwo9 s inu ul SUOIJONIJSUI s l ZEAINS ue sed jeu s eu laJedde KA einelodue R e soWiay z lb H LL uolsu snos laledde Z N VM OL Iney np 9 918AN09 l zajuowa NO SUE ej 8
56. PM 5 72 6 2 ltr hr 1 300 1 400 Pump residual head at max flow rate n W C 60 22 44 11 mbar 150 110 Primary vvater content CAN G 0 70 0 84 USG 0 85 1 0 Tir 32 3 8 Boiler VVater Temperature Adjustable high limit range high temp radiators heating F 104 176 C 40 80 Adjustable high limit range low temp space heating E 68 113 C 20 45 DHW production set point F 95 140 C 35 60 Max boiler temperature F 194 E 90 Electric Data Electric rate voltage V Hz 120 60 Current less than A 1 19 1 25 Electric consumption pump included W 133 141 Electrical protection rating IP IPX5D Fuses A VAC 4 250 Flue Gas Values CO2 setting natural gas A Yo 8 5 CO2 setting LPG E Yo 10 0 NOx max A ppm lt 20 lt 20 NOx min A ppm lt 15 lt 15 CO Q max A without air ppm lt 135 lt 170 CO min A without air ppm lt 15 lt 25 NOx max E ppm lt 20 lt 20 NOx min E ppm lt 15 lt 20 CO max E without air ppm lt 200 lt 220 CO min E without air ppm lt 40 lt 35 10 XPak 85 XPak 120 Boiler flue gas connection in 2 3 8 2 3 8 mm 60 60 Combustion air connection outer dia in 4 4 mm 100 100 Free fan unit feed pressure IN vv C 0 26 0 18 Pa 65 45 Flue gas
57. PPLES ON THE APPLIANCE GAS VAL VE ARE TIGHT AND CHECKED FOR TIGHTNESS ENSURE THE APPLIANCE FLUE SYSTEM IS INSTALLED CORRECTLY AND IS PROPERLY SECURED ENSURE ALL PIPE WORK IS RE CHECKED FOR SOUNDNESS REATTACH APPLIANCE CASING COMPLETE CHECKLIST Complete details of the boiler controls installation and commissioning in the checklist at the back of this book It is important that the checklist is correctly completed and handed to the user Failure to install and commission the appliance to the manufacturers instructions may invalidate the warranty 17 INSTRUCTING THE USER Hand over all documentation supplied with this appliance including these instructions and explain the importance of keeping them in a safe place Explain to the user how to isolate the appliance from the gas water and electricity supplies and the locations of all drain points Show the user how to operate the appliance and any associated controls correctly Show the user the location of any isolating valves and the location of all manual air release points Explain to the user how to turn off the appliance for both long and short periods and advise on the necessary precautions to prevent freeze damage Explain to the user that for continued safe and efficient operation the appliance must be serviced annually by a qualified service person 18 WARRANTY To validate the appliance warranty it s necessary to register the appliance detail
58. TIONS AT ELEVATION Rated inputs are suitable for up to 4 500 ft elevation see technical data table Consult the factory for installations at altitudes over 4 500 ft above sea level No hardware changes are required to the boilers for installations up to 10 000 ft adjustments may be required COMPLETION On completion of the combustion analysis check and or any gas valve adjustment setthe HTG trim pot to the corresponding value as detailed in the fan speed table Reattach the 3 selector knobs Remove the test probe from the test point and reattach the sealing screws and or cap 57 IMPORTANT A GAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED REPLACED OR DISTURBED XPAK LPG LABEL 1 Fill in the enclosed LPG label with all the information required and affix the label as close as possible to existing rating plate 2 Affix the enclosed RED color label over the existing YELLOW color label under the boiler near to the boiler gas connection SEQUENCE OF THE IGNITION SYSTEM Switch on the boiler as follows Open the gas tap under the boiler by turning it counterclockwise Turn on the general switch of the system and then after lowering the flap turn the function selector to summer X winter or winter tank temperature EF depending on the chosen operating mode The boiler start to run according the automatic sequence heat request fan start up tachometer check ignition trials gas
59. UFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation 64 LIMITED WARRANTY MODULATING CONDENSING BOILER XPAK HEATING BOILERS MODELS 85 amp 120 SCOPE OFWARRANTY Raypak Inc Raypak warrants to the first retail purchaser of the XPAKHeating Boiler that was delivered with this limited warranty certificate the Boiler that the Boiler will be free from defects in materials and workmanship under normal use and service for the Applicable Warranty Periods specified below Under this Limited Warranty Raypak will at its option repair or
60. Y VALVE WIRING CONNECTION XPak boiler can manage an external 3 way valve field supplied the terminal strip M3a output is 120V 60 Hz see electric diagram Logic of the boiler managing 3 vvay valve 1 Boiler configuration in DHVV case A and case B see Fig 61 for boiler jumper configuration 2 Once the jumper has set in DHW mode tank with probe or tank with thermostat when there is a heat request from the sensor or from the thermostat there is povver out 120V 60 Hz to the boiler terminal strip M3a Fig 35 3 The output to the 3 way valve DHW pin is continuously supply up to the heat is satisfied 4 The room thermostat request is independent from the DHVV request Priority is alvvays given to DHVV production 5 The 3 vvay valve is always powered even if there is no DHW demand VVARNING The 3 vvay valve is continuously povvered even if there is no heat request from the tank VViring connections 3 vvay valve Suggested source Honeywell VC6011 actuator VCZMK6000 VViring the valve as per diagram Fig 38 Follovv the installation of the piping referring to the diagram shovving the logic of vvorking Fig 38 The connections colors and schematic refer to the Honeywell VC6011 actuator VCZMK6000 14 REMOTE CONTROL CONNECTION The boiler can be fully remoted using an open therm plus remote control use only Raypak REC 08 Part No 013073 When the control is installed with the boiler displa
61. a 3 way valve for DHW indirect storage tank controlled either with a tank thermostat or a tank sensor accessories Dear Costumer Thank you for choosing the XPak boiler This Raypak product provides more efficiency and greater comfort to the living space thanks to its unique features The new patented aluminum heat exchanger provides ultra low emissions higher efficiency and easier recycling after the boiler life CONTENTS 1 2 3 4 5 D 8 VVARNINGS PAY ATTENTION TO THESE TERMS GENERAL SAFETY TIME TEMPERATURE RELATIONSHIPS IN SCALDS BEFORE INSTALLATION REGULATIONS AND GUIDELINES INTRODUCTION TECHNICAL DATA PRINCIPLE COMPONENTS MODE OF OPERATION AT REST MODE OF OPERATION SAFETY DEVICES BANNED MATERIAL STATEMENT MANUAL HANDLING STATEMENT XPAK INTERNAL HYDRAULIC CIRCUIT PIPING CONNECTIONS DIMENSIONS AND CONNECTIONS PACKAGING AND TRANSPORTATION 1 Scope of delivery 2 Transporting the boiler 3 Boiler box content INSTALLATION PREPARE XPAK LOCATION Installations must comply with Before locating the XPak boiler Clearances for service access Residential garage installation Exhaust vent and intake air vent Prevent combustion air contamination When removing an existing boiler from an existing common vent system PREPARE XPAK 1 Remove XPak boiler from box 2 Placing the wall mounted XPak boiler 3 XPak wall mounting instructions 4 Installatio
62. al Warranty Exclusions and Terms below is three 3 years from the date of original installation or thirty seven months 37 months from the date that the residential Boiler was shipped from Raypak s factory based on Raypak s records whichever comes first This Applicable Warranty Period does not apply to Boiler fans in commercial installations as defined in Additional VVarranty Exclusions and Terms below ALL OTHER COMPONENTS OF THE BOILER Except as otherwise specified above for the heat exchangers and residential Boiler fan the Applicable Warranty Period for all components in the Boiler is one 1 year from date of the Boiler s original installation or thteen 13 months from date that the Boiler was shipped from Raypak s factory based on Raypak s records whichever comes first SATISFACTORY PROOF OF ORIGINAL INSTALLATION DATE SUCH AS INSTALLER S INVOICE IS REQUIRED THIS WARRANTY WILL BE VOID IF THE BOILER RATING PLATE IS ALTERED OR REMOVED ADDITIONAL WARRANTY EXCLUSIONS AND TERMS This Limited Warranty does NOT apply 1 if the Boiler has been moved from its original place of installation or if the original purchaser no longer owns the property where the original installation was made 2 to damage malfunctions or failures resulting from improper installation operation or maintenance of the Boiler in accordance with the manufacturer s instructions 65 NO OP UW 8 9 to damage malfunctions or failures r
63. al controls using PVC insulated cable 18 AWG x3C 105 C 221 F All wiring must be installed in accordance with requirements of National Electrical Code and any additional national state or local code requirements having jurisdiction All wiring must be N E C Class 1 The boiler must be electrically grounded in accordance with the National Electrical Code ANSI NFPA No 70 latest edition In Canada installation must conform to CSA C22 1 Canadian Electrical Code Part 1 and any local codes 3 FIELD WIRING The electrical junction box has a 24 volt terminal compartment and 120 volt terminal compartment Each terminal connection is clearly marked to ensure correct installation Fig 33 Electrical supply 120V terminal block Optional devices 24V terminal block Fig 34 34 4 CASING REMOVAL Fig 33 To gain internal access to the appliance you must first remove the casing proceed as outlined below remove the 3 screws B located at the Left Right Front of the underside of the casing lift the casing upward to disengage it from the top locating hooks and then remove store the casing and screws B safely until required Re fit in the reverse order 5 APPLIANCE TERMINAL BLOCK The appliance terminal block is located on the rear of the control panel Remove the casing Gently pull the control panel forwards and down Locate the terminal block cover see Fig 34 NOTICE
64. ale i Fig 15 23 COMBUSTION AIR AND VENTILATION OPENINGS Provisions for combustion and ventilation air must be made in accordance with section 5 3 Air for Combustion and Ventilation of the National Flue Gas Code ANSI Z223 1 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 Installation Codes or applicable provisions of the local building codes CAUTION BOILER DAMAGE AND OPERATIONAL FAILURES Due to insufficient or lacking openings for combustion air and or ventilation of the boiler room Provisions for combustion air and ventilation are always required regardless whether the combustion air is taken from the outside sealed combustion or inside room air for combustion Insufficient ventilation of the boiler room can lead to high air temperatures This can result in boiler damage Make sure that intake and exhaust openings are sufficiently sized and no reduction or closure of openings takes place When the problem is not resolved do not operate the boiler Please note these restrictions and its dangers to the operator of the boiler WARNING BOILER DAMAGE Due to contaminated air Boiler must be clear and free from combustible materials gasoline and other flammable vapors and liquids and corrosive liquids and vapors Never use chlorine and hydrocarbon containing chemicals such as spray chemicals solution and cleaning agents paints glues etc in the vicinity of the boiler Do not s
65. ate for the pipe connection dimensions Connect the pipes so that they are free from strain 6 EXPANSION TANK AND MAKE UP WATER 1 Ensure expansion tank size will handle boiler and system water volume and temperature Allow 2 gallons for the boiler and its piping CAUTION Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve Eventual failure can result due to excessive make up water addition 2 Expansion tank must be located near to the boiler as shown in Piping XPak installation diagrams No valve is to be placed between the boiler and the expansion tank 7 SIZING SPACE HEAT SYSTEM PIPING Size the piping and components in the space heating system using recognized design methods NOTICE The boiler when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel with the boiler and with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 17 8 BOILER WITH DHW TANK Connect the external hot vvater tank according to the Installation ins
66. certified together with the XPak boiler as a constructional unit The XPak boiler may also be vented vertically or horizontally using a metallic AL29 4C special stainless steel Suggested sources ProTech System Inc or room air dependent venting system UL ULC listed for category IV For a more detailed description of the direct vent and single wall vent system please refer to the following installation Instructions NOTICE Brick or masonry surfaces directly behind the horizontal vent termination should be protected with a rust resistant sheet metal plate Fig 16 Tab 5 FasNseal stainless steel vent Country US CANADA Diameter 3 Material Stainless steel Single wall Maximum Equivalent Length 3 80 mm De rate less 2 De rate less 5 XPak 85 XPak 120 XPak 85 XPak 120 fl 40440 16416 1304130 1154115 7 mj 12412 545 40440 35 35 Always follow XPak Installation Instructions Select vent material based on Country of the installation Vent configuration Preferred material Necessary maximum equivalent length NOTICE The minimum covering wall thickness is 1 25 mm The maximum covering wall thickness is 16 406 mm 1 Gasket in EPDM peroxide 58 F 50 C 302 F 150 C 2 Adapter in PP polypropylene male female 80 mm gt 3 GASKET FITTEDN O TO 7 Fig 17 L 80 mm
67. ch per foot back to the boiler This allows the condensate to drain away NOTICE Do not use cellular core pipe Aminimum clearance of 4 feet horizontally from and in no case above and below unless a 4 foot horizontal distance is maintained from electric meters gas Below are approved examples of vertical and horizontal venting installation Place pipe supports every 5 feet 1525 mm of horizontal run beginning with support near boiler Periodic cleaning of the vent terminal and air intake screens is mandatory The minimum covering wall thickness is 1 25 mm The maximum covering wall thickness is 16 406 mm For Direct venting properly reassembele and reseal the vent and air intake systems CAUTION Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure 7 12 300 mm P minimum a ae 12 300 mm minimum IF 12 300 mm L L minimum 12 300 mm minimum Fig 15A VENT SYSTEMS 1 FLUE GAS SYSTEM Raypak coaxial PP Polypropylene Aluminium concentric flue gas fresh air systems Raypak coaxial Alu Alu concentric flue gas fresh air systems and two pipe aluminum systems for room air independent operation sealed combustion and air dependent operation and side wall venting are tested to ANSI ANSI 221 13b 2007 CSA 4 9b 2007 standards and are
68. crease to maximum or modulate to suit the set requirement When the appliance reaches the desired temperature the burner will shut down and the boiler will perform a three minute post purge timer delay When the request for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance SAFETY DEVICES When the appliance is in use safe operation is ensured by a water pressure switch that monitors system water pressure and will de activate the pump when lockout condition is reached fan and burner should the system water pressure drop below the rated tolerance blocked flue switch that monitors flue pressure and will de activate the pump when lockout condition is reached fan and burner should the flue pressure increase over the rated tolerance fan speed sensor to ensure safe operation of the burner a high limit thermostat that over rides the temperature control circuit to prevent or interrupt the operation of the burner flame sensor that will shut down the burner when no flame signal is detected a sensor that interrupts the operation of the appliance if the condensate pipe becomes blocked apressure relief valve which releases excess pressure from the primary circuit a flue sensor that controls the flue temperature continuously checking to be right according the output a flue thermostat that over rides the temperature control circuit to pre
69. ction The boiler setting depends from the jumper JP position Fig 63 CASE A factory set heating only external water tank with thermostat adjustment inapplicable jumper in position 3 CASE B heating only external water tank with sensor to adjust the temperature of the domestic hot water in the water tank turn the temperature selector clockwise to increase and counterclockwise to decrease jumper in position 2 5 WORKING THE BOILER If a programmable timer or ambient thermostat are mounted these must be switched on and adjusted to higher than ambient temperature in order to allow the boiler to start The boiler remains on standby until the burner ignites as a result of a demand for heat The green indicator LED B Fig 52 located on the left hand side of the panel lights up to indicate the flame is present The boiler continues to work until the selected temperatures have been reached It then returns to stand by while displaying delivery temperature In the event of a starting or operating fault the boiler performs a SAFETY STOP the green indicator LED on the control panel goes out a fault code flashes on the display Fig 53 and a red indicator LED D lights up in the event of a shutdown To identify the fault codes and reset the boiler consult the Indicator LEDs and faults section 6 RESET FUNCTION To reset the boiler turned the function selector to Fig 54 then move it to the required
70. d approximately 120VAC If so proceed to next stage Connect test leads between the Neutral amp Ground connections at the boiler terminal strip Fig 35 The meter should read less than 1 VAC If so polarity is correct REVERSED POLARITY OR SUPPLY FAULT Repeat the above tests at the appliance isolator if testing reveals correct polarity and or supply at the isolator re check wiring and connections between the isolator and the boiler If tests on the isolator also reveal reversed polarity or a supply fault consult the local electricity supplier for advice RESISTANCE TO GROUND CHECK Isolate the boiler from the electrical supply and using a suitable multi meter carry out a resistance test Connect test leads between the Live amp Ground connections at the appliance terminal strip Fig 35 If the meter reads other than infinity there is a fault that must be isolated carry out a detailed continuity check to identify the location of the fault These series of checks must be carried out before attempting any troubleshooting procedures on the appliance On completion of any task that required the disconnection and re connection of any electrical wiring or component these checks must be repeated 48 FAULT FINDING Before attempting any faultfinding the electrical checks must be carried out Isolate the appliance from the electrical supply Disconnect any external controls from terminal plug Fig 35 and insert a jumper between
71. disassembled CHANGE THE GAS INJECTOR Slacken and unscrew upper gas valve pipe locate and remove the two screws shown as A Locate and remove the natural gas injector B inside the pipe insert the LPG injector black coating Replace in the reverse order Check and adjust burner pressure settings WARNING A gas tightness check must be carried out if any gas carryng components have been removed replaced or disturbed Fig 1 CHECKING THE RELATIONSHIP OF THE IGNITER TO MAIN BURNER Remove the burner assembly as indicated in the boiler manual Servicing instructions Check the distance between the burner and the two electrodes according the distances indicated in Fig 1A Replace in the reverse order Fig 1A TECHNICAL DATA LPG Gas pressure XPak 85 XPak 120 Input 0 2000 ft 7 0 610 m Btu hr 25 600 87 000 27 300 119 500 kW 7 5 25 5 8 0 35 0 nput 2000 4500 ft 610 1375 m Btu hr 25 600 82 900 27 300 114 300 kW 7 5 24 3 8 0 33 5 Gas supply pressure LPG n w C 11 11 kPa 2 75 2 75 Min gas supply pressure LPG in 8 8 kPa 1 99 1 99 Max gas supply pressure LPG in 13 13 kPa 3 24 3 24 Burner pressure max min n vv C 1 92 0 24 2 00 0 16 kPa 0 48 0 06 0 50 0 04 Fig 3 Rate Gas Rate max LP
72. e desired position In case of frequent pressure drops call your local Service Technician For alarm AL91 The boiler has an internal self diagnostic system that can advise if it is necessary to clean the main heat exchanger alarm code AL91 after 2500 hours of working in particular conditions After the heat exchanger cleaning using the cleaning kit Raypak Part No 013142F it is necessary to reset the hour meter with the following instructions Switch off the electric supply to the boiler Remove the knob of the main selector Switch on the boiler while pressing the CO button for at least 4 seconds Fig 59 To check if the counter has been reset switch OFF and ON the boiler main supply after the lighting of all the segments of the display the value of the counter will appear NOTICE The reset counter procedure must be carry on after every heat exchanger deep cleaning and in any case after heat exchanger replacement NOTICE To check the hours of the counter switch off the main supply than switch on After the lighting of all the elements of the display a number will appear multiply for 100 to get the hours 18 1800 hours 01 100 hours 45 11 CHECKS ADJUSTMENTS AND FAULT FINDING 1 CHECKING APPLIANCE OPERATION When carrying out any repairs or servicing to the appliance the relevant commissioning procedure must be undertaken to ensure the continued safe operation of the appliance Particular attention
73. e gas valve slacken and unscrevv upper gas valve pipe please note that the gas injector is located in this upper part Disconnect the compensation pipe C Locate and remove the two retaining screws D locate and remove the four gas valve retaining screws E Replace in the reverse order Check and adjust burner pressure settings WARNING A GAS TIGHTNESS CHECK MUST BE CARRIED OUT NOTICE The gas valve sticker WARNING VALVE IS NOT FIELD SERVICEABLE means the valve can be adjusted but not disassembled Fig 71 XPak 85 XPak 120 Fig 72 INJECTOR Fig 72 Slacken and unscrew upper gas valve pipe locate and remove only two screws D Locate and remove the injector F inside the pipe Replace in the reverse order Check and adjust burner pressure settings WARNING A GAS TIGHTNESS CHECK MUST BE CARRIED OUT ELECTRODES amp CONDENSATE SENSOR Fig 73 Unclip and remove the air chamber front and right hand side covers Disconnect the electrode leads and ancillary wiring from their respective connectors Remove the retaining screws A for spark and sensing electrodes and remove Remove the retaining nut C for condensate sensor D and remove Fig 73 53 FLUE FAN amp MIXER Fig 74 Unclip and remove the air chamber front and the right hand side covers Slacken the gas pipe A at the air box connection and swing ro
74. e should the valve discharge Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length Discharge line must pitch downward from the valve and terminate no more than 6 150 mm above the floor drain where any discharge will be clearly visible The discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 F 190 C or greater Do not pipe the discharge to any place where freezing could occur Do not plug or place any obstruction in the discharge line Test the operation of the valve after filling and pressurizing system by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly replace it with a new relief valve For boilers installed with only a pressure relief valve the separate storage vessel must have a temperature and pressure relief valve installed This relief valve shall comply with the standard for Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA4 4 Failure to comply with the above guidelines could result in failure of the relief valve to operate resulting in possibility of severe personal injury death or substantial property damage NOTICE When using oxygen permeable pipes e g for floor heating systems you must separate the system using heat exchangers Thoroughly flush all pipes and radiators Refer to the installation templ
75. ed refit and rotate in any direction the main selector switch FREEZE PROTECTION This function is only active when there are no requests for heating or DHW If the temperature drops below 43 F 6 C the boiler will operate on minimum power until the temperature of the primary thermistor reaches 95 F 35 C Thereafter the pump amp fan will post purge for 30 seconds ANTI CYCLE FUNCTION The anti cycle function ensures the burner remains switched off for at least 3 minutes after the set point hysteresis set point 9 F 5 C PUMP ANTI SEIZE FUNCTION When there has been no heating or DHW request for 24 hours the anti seize cycle is activated The pump will be activated for a period of 30 seconds ACTUATOR ANTI SEIZE FUNCTION When there has been no heating or DHW request for 24 hours the anti seize cycle is activated The divertor valve actuator 3 way valve will cycle briefly to the heating position and then back to the DHW position 5 HEATING MODE With the selector switch in the ON position 3 E and any additional controls time clock programmer room thermostat etc calling for heat the appliance will operate in the heating mode The pump and fan will be activated via the flow temperature sensor When the fan is sensed to be operating correctly blower signal the ignition sequence commences Ignition is sensed by the electronic circuitry to ensure flame stability at the burner Once successful ignition
76. eding with the conversion Installation Codes Installations must follow these codes e Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition NFGC e For Canada only CAN CSA B149 Natural Gas and Propane Installation Code and CSA C22 1 C E C Part 1 C22 1 WARNING XPak boilers are shipped ready to fire natural gas ONLY You must install the propane orifice and regulate the gas valve if the boiler will be connected to propane Failure to comply could result in severe personal injury death or substantial property damage Pipe sizing for natural gas Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Propane supply pressure requirements 1 Adjust propane supply regulator provided by gas supplier for 13 w c maximum pressure 2 Pressure required at gas valve inlet pressure port Maximum 13 w c with no flow lockup or 8 vv c minimum with boiler operating 56 any other appliances that it serves GAS SUPPLY INSTALLATION The entire installation including the meter must be purged and checked for gas tightness CONVERTING THE BOILER GAS TYPE To convert the boiler to another gas type it is necessary to change the gas injector adjust the fan speed and the gas valve NOTICE The gas valve sticker WARNING VALVE IS NOT FIELD SERVICEABLE means the valve can be adjusted but not
77. eld supplied C To gas supply Open z position Closed position f7 w L Fig 14 NOTICE When installing the gas supply connection it must comply with local regulations or if such regulations do not exist with the National Fuel Gas Code ANSI Z 223 1 In Canada the gas supply connection must comply with local regulations or if such regulations do not exist with CAN CSA B149 Natural Gas and Propane Installation Code A sediment trap must be provided upstream of the gas controls Gas Pipe Capacity for different pipe sizes Tab 3 Length of Gas Volume Capacity pipe feet ft5 h 3 4 1 1 1 4 1 1 2 10 278 520 1 060 1 600 20 190 350 730 1 100 30 152 285 590 890 40 130 245 500 760 50 115 215 440 670 75 93 175 360 545 100 79 160 305 480 150 64 120 250 380 Maximum pipe capacity in ft3 hr based on a specific gravity of 60 42 mbar and a inlet gas pressure of 14 inches W C 35 mbar or less and a pressure drop of 0 3 inches W C 20 mbar Equivalent length for pipe fittings in feet Tab 4 Steel pipe Equivalent length for Pipe Fittings in feet diameter Type of pipe fitting in inches 190 Elbovv Tee Gate valve Gas cocks flovv thru branch Equivalent length in feet 3 4 2 1 4 1 0 5 1 25
78. ended that it is checked and serviced at regular intervals It is essential that any worn or failed component be replaced only with a genuine XPak spare parts t should be remembered that although certain generic components may look similar they will be specific to an individual appliance or product range Use of non genuine XPak spare parts could invalidate your warranty and may pose a potential safety hazard The frequency of servicing will depend upon the particular installation conditions but in general once per year should be sufficient It is the law that any servicing work is carried out by competent person such as a Raypak Technician an approved service agent or other suitably qualified personnel The following instructions apply to the appliance and its controls but it should be remembered that the central heating and the domestic hot water systems would also require attention from time to time 2 ROUTINE ANNUAL SERVICING Check the operation of the boiler and ensure it functions as described in Section 11 Checks adjustments and fault finding Thoroughly inspect the boiler for signs of damage or deterioration especially the flue system and the electrical apparatus Check and adjust if necessary the system design pressure see pg 63 ref 10 Carry out an analysis of the flue gases pg 73 and visually check the condition of the entire flue assembly Check that the burner and main heat exchanger are
79. er If it s necessary to remove the air box side cover locate and remove the 4 securing screws Fig 68 PUMP ASSEMBLY Fig 69 Locate and remove the 2 securing screws A at the rear of the pump assembly Disconnect the flow pipe B only for XPak 120 from the combustion chamber connection slacken the pipe at the hydraulic assembly and swing rotate clear of the pump assembly Disconnect and remove the pump outlet pipe C from the pump assembly combustion chamber connection Locate and remove the pressure gauge securing pin D and disconnect the pressure gauge from the pump assembly Disconnect the electrical wiring from the pump s electrical connection point E Remove locking pin F from pump base and lift pump assembly clear of the hydraulic manifold The pump assembly can now be removed from the appliance Replace carefully in the reverse order PRESSURE RELIEF VALVE Fig 69 Disconnect the outlet pipe L and the flow pipe M from the safety valve remove pressure release valve Replace in the reverse order LOWER AUTOMATIC AIR RELEASE VALVE Fig 69 Locate and remove the AAV locking pin G from the pump assembly and remove the AAV assembly H Replace in the reverse order TOP AUTOMATIC AIR RELEASE VALVE Fig 70 Remove the drain pipe A Unscrew the top AAV B Replace in the reverse order Loctite or similar should be used as a thread sealant for the AAV XPak 85 XPak 120 Fig 69
80. ernal water tank it provides domestic hot water The display indicates the boiler flow temperature Winter mode tank temperature F The boiler produces hot water for heating and if connected to an external water tank with a sensor it provides domestic hot water The display indicates the storage tank temperature 2 HOW TO READ THE DISPLAY TEMPERATURE dot in the middle means hundred Fig 43 dot on RIGHT side means DHW mode Fig 44 example rature To increase or decrease the temperature with respect to the value automatically calculated by the PCB turn the heating water selector Fig 50 clockwise to increase and counterclockwise to decrease Adjustment settings range from comfort levels 5 to 5 which are indicated on the digital display when the knob is turned 4 ADJUSTING DOMESTIC HOT WATER TEMPERATURE IF A STORAGE TANK WITH SENSOR AND 3 WAY VALVE IS INSTALLED When turning the knob the required temperature automatically appears on the digital display The domestic hot water adjustment ranges lies between 95 F 35 C and 140 F 60 C When choosing the temperature both for heating and domestic hot water the display shows the value being selected About 4 seconds after the selection has been made the modification is recorded and the display returns to the delivery or domestic hot water temperature read by the probe Priority is always given to DHW produ
81. ervice is needed DO NOT RETURN THIS DOCUMENT TO RAYPAK KEEP IT WITH YOUR BOILER OR BUSINESS RECORDS Name of Owner Name of Installer Owners Address Installers Address Date of Boiler Installation Telephone Number of Installer Model Number of Your Boiler Serial Number of Your Boiler 66 START UP CHECKLIST FOR FAN ASSISTED RAYPAK PRODUCTS This start up checklist is to be completely filled out by the service technician starting up the Raypak Boiler for the first time All nformation may be used for vvarranty purposes and to ensure that the installation is correct Additionally this form vvill be used to record all equipment operation functions and required settings GASSUPPLYDATA CLEARANCES Regulator Model amp Size CFH Front Clearance n Gas Line Size in room In NPT Right Side Clearance n Length of Gas Line Eq Ft Left Side Clearance n Gas Shut Off Valve Type Rear Clearance n Ball Lube cock Overhead Clearance n Sediment Trap YIN Port Std Full ELECTRICAL Voltage Supply VAC No Load Load Voltage 24 VAC VAC Voltage Com to Ground VAC VISUAL INSPECTION OF COMPONENTS Operating Control Setting deg F Verify inspection was done and condition of components are in good working order with a yes Wiring Harness Y N Burner s flame Y N Remote flame sense Y N Sketch plumbing on reverse side WATER SUPPLY Flow Rate in GPM or Delta T If Avail Measure flow rate at full
82. essure fall belovv an acceptable level the appliance may malfunction or sustain damage 13 FINAL FLUSHING OF THE HEATING SYSTEM The system shall be flushed Cleaners or chemicals used must be suitable for Aluminum heat exchangers and shall be from a reputable manufacturer and shall be administered in strict accordance with the manufacturers instructions NOTICE Chemicals used to clean the system and or inhibit corrosion must be pH neutral i e they should ensure that the level of the pH in the system water remains neutral Premature failure of certain components can occur if the level of pH in the system water is out of normal levels 14 SETTING THE BOILER OPERATING TEMPERATURE The flow outlet temperature can be adjusted between 104 176 F 40 80 C depending on the boiler configuration via the Heating thermostat knob Fig 1A If the 3 way valve is connected the flow outlet temperature to the tank can be adjusted between 95 140 F 35 60 C via the DHVV temperature selector Fig 1A 15 REGULATING THE CENTRAL HEATING SYSTEM Fully open all radiator and circuit valves and run the appliance for both heating and hot water until heated water is circulating If conditions are vvarm remove any thermostatic heads Adiust radiator return valves and any branch circuit return valves until the individual return temperatures are correct and are approximately equal 41 16 FINAL CHECKS ENSURE ALL TEST NI
83. esulting from misuse neglect alteration accident fire flood and the like to damage malfunctions or failures resulting from sediment or lime buildup freezing or other conditions causing inadequate water circulation to damage malfunctions or failures resulting from high velocity flow exceeding boiler design rates to damage malfunctions or failures resulting from connected systems devices such as pump or controller to damage malfunctions or failures resulting from use of accessories or other components that are not authorized in writing by Raypak for use in conjunction with the Boiler system to damage malfunctions or failures resulting from failure to eliminate air from or replenish water in the connected water system to damage malfunctions or failures resulting from chemical contamination of combustion air or use of chemically contaminated combustion air including but not limited to contaminants such as chlorine gas halogenated hydrocarbons and Freon 10 to damage malfunctions or failures resulting from ingestion by the Boiler of drywall sheetrock or plasterboard dust and particles lint or dirt 11 to Boilers that have been installed by anyone other than a heating professional whose principal occupation is the sale and installation of heating plumbing and or air conditioning equipment For purposes of this Limited Warranty a residential installation is defined as the installation of a Boiler in any of the following residen
84. f components 4 Component removal procedure LPG INSTRUCTIONS PROPANE GAS EXPLODED DIAGRAMS IMPORTANT INSTRUCTIONS FOR THE COMMONWEALTH OF MASSACHUSETTS LIMITED PARTS WARRANTY START UP CHECKLIST FOR FAN ASSISTED RAYPAK PRODUCTS 59 64 65 67 1 VVARNINGS PAY ATTENTION TO THESE TERMS DANGER ndicates the presence of immediate hazards vvhich vvill cau se severe personal injury death or substantial property damage if ignored CAUTION This boiler requires forced water circulation when the burner is operating See minimum and maximum flow rates Severe damage will occur if the boiler is operated without proper water flow circulation WARNING Indicates the presence of hazards or unsafe practices which could cause severe personal injury death or substantial property damage if ignored CAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored NOTICE Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards DANGER Make sure the gas on which the boiler will operate is the same type as that specified on the boiler rating plate and on the coloured sticker near the boiler gas connection WARNING Should overheating occur or the gas supply valve fail to shut do not turn off or disconnect the electrica
85. g appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MAN
86. ges must be filed with the carrier by consignee Permission to return goods must be received from Raypak 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 boiler 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 and will be replaced in kind only per Raypak s standard warranty Model Identification The model identification number and boiler serial number are found on the boiler rating plate located on the casing right side Also the boiler serial number can be found on the back page of this manual and inside the front control panel flap Ratings and Certifications Standards e Gas fired hot water boiler for either direct vent installation or for installation using indoor combustion air Design according to ANSI Z21 13b 2007 CSA 4 9b 2007 Fired low pressure hot water boilers Category IV SCAQMD Rule 1146 2 All Raypak boilers are National Board Approved and design certified and tested by the Canadian Standards Association CSA for the U S and Canada Each boiler is constructed in accordance with Section IV of the American Society of Mechanical
87. h If external controls are to be added to the system they must be connected to the appliance as shown in the following diagrams For advice on controls that are not featured in this book please contact Raypak technical department 8 EXTERNAL WIRING LIMITATIONS Any external wiring must remain within the limits as detailed in the table below CONNECTION MAX LENGTH Outdoor air sensor 100 ft 30 metres Room thermostat 100 ft 30 metres Remote control connection 100 ft 30 metres 9 CONNECTING THERMOSTAT 1 Connect room thermostat or end switch terminal strip is 24V Fig 35 ref M4a 2 Install thermostat on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television direct sunshine or fireplaces 10 OTHER DEVICES Contact Raypak technical department should you require more specific information on the suitability of a particular control Further guidance on the recommended practice for the installation of external controls can be found IMPORTANT The boiler must always be supplied with a permanent 120V electrical supply Always remove the link on M4a terminal strip on the appliance low voltage 24V terminal strip whenever additional controls are connected to the appliance Do not connect any controls or auxiliary equipment to the 24V terminal strip other than that approved supplied by the manufacturer 35 11 TERMINAL STRIP DETAILS Tab 9
88. he 40 system the pressure gauge will begin to rise Once the gauge has reached 15 p s i 1 bar close both valves and begin venting all manual air release valves starting at the lowest first It may be necessary to go back and top up the pressure until the entire system has been filled Inspect the system for water tightness fixing any leaks WARNING Eliminate all system leaks Continual fresh make up water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating heat exchanger and causing heat exchanger failure 5 The system may have residual substances that could affect water chemistry After the system has been filled and leak tested verify water pH and chlorine concentrations are acceptable CAUTION It is important that you purge the system of air to avoid damage to the heater 5 PURGE AIR FROM BOILER MANUAL AIR RELEASE Fig 42 When the boiler has been filled for the first time or the system has been drained and refilled it will be necessary to release any air that may have become trapped within the appliance heat exchanger Slacken the bleed screw using a 7 16 11mm open ended spanner until water is released and then close IMPORTANT THERE ARE NO OTHER MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE WARNING Never open the Manual Air Vent while the boiler is hot Allow boiler to cool to room temperature to avoid scalding while pu
89. idential garage per ANSI Z223 1 paragraph 5 1 9 Mount the boiler with a minimum of 18 inches above the floor of the garage to the bottom of the boiler to ensure the burner and ignition devices will be no less than 18 inches above the floor Locate or protect the boiler so it cannot be damaged by a moving vehicle 5 EXHAUST VENT AND INTAKE AIR VENT XPaks are rated ANSI Z21 13b 2007 CSA 4 9b 2007 Fired low pressure steam and hot water boilers Category IV pressurized vent likely to condense in the vent Also installations with air dependent operation are allowed providing proper openings in the room are provided 16 NOTICE To prevent combustion air contamination when considering exhaust vent and intake air vent termination Intake and exhaust may be vented vertically through the roof or out a side wall The intake and exhaust venting methods are detailed in the Venting Section Do not attemptto install the XPak Boiler using any other means Be sure to locate the boiler such that the air intake and exhaust vent piping can be routed through the building and properly terminated The air intake and exhaust vent piping lengths routing and termination method must all comply with the methods and limits given in the Venting section 6 PREVENT COMBUSTION AIR CONTAMINATION Install intake air piping for the XPak as described in the Venting section Do not terminate exhaust in locations that can allow contamination of in
90. iler manual air release System drain Check thermostat circuit s Testing for gas leaks Initial flushing of the system 10 Pre operation checks 11 Initial lighting 12 Checking gas pressure and combustion analysis 13 Final flushing of the heating system 14 Setting the boiler operating temperature 15 Regulating the central heating system 16 Final checks 17 Instructing the user 18 Warranty OANDARWN START UP AND OPERATION Switching on the appliance How to read the display temperature Adjusting heating water temperature with an outdoor probe connected Adjusting domestic hot water temperature if a storage tank with sensor and 3 way valve is installed Working the boiler Reset function Switching off Indicator LEDs and faults SO x D xo CHECKS ADJUSTMENTS AND FAULT FINDING Checking appliance operation Appliance modes of operation Selector switch in the off stand by position On board functions Heating mode DHW mode Boiler fan speeds Checking the CO2 and adjusting the gas valve Gas valve maximum setting 10 Gas valve minimum setting 11 Combustion analysis test 12 External faults 13 Electrical checks 14 Component values amp characteristics 15 Boiler configuration 16 Setting the outdoor reset curve with outdoor sensor 17 Fault codes OANDARWN SERVICING INSTRUCTIONS 1 General 2 Routine annual servicing 3 Replacement o
91. ion Code plumbing or waste water codes and other codes as applicable Clearances from combustible material must be strictly adhered to Manufacturers instructions must NOT be interpreted in anyway as overriding statutory obligations The XPak family comprises a range of high efficiency hot water boilers with outputs ranging from 87 000 Btu hr 25 5 kW to 119 500 Btu hr 35 kW Each appliance is provided with a fan powered flue outlet with an annular co axial combustion air intake that can be rotated horizontally through 360 degrees for various horizontal or vertical applications The XPak can also be used with two pipe flue vent system These appliances are designed for use with a sealed system only consequently they are not intended for use on open vented systems This booklet is an integral part of the appliance It is therefore necessary to ensure that the booklet is handed to the person responsible for the property in which the appliance is located installed A replacement copy can be obtained from Raypak customer services General layout Fig 1 1 Water pressure switch Pump Bottom auto air vent AAV Gas injector Condense trap Return sensor H stamp main heat exchanger Main heat exchanger Flue thermostat 10 Flue sensor 11 Flue gas analysis test point 12 Flue outlet amp air intake 13 Blocked flue switch 14 Top automatic air vent 15 Flow sensor 16 High limit thermostat 17 Ignition transformer 18 Sensing
92. ipped with an internal 3 speed pump PUMP DUTY Fig 6 below shows the flow rate available after allowing for pressure loss through the appliance for system requirements When using this graph apply only the pressure loss of the system The graph is based on a 36 F 20 C temperature differential CAUTION The XPak should not be operated as a potable Hot Water Boiler The XPak should not be operated in a open system 10 PROCEDURE SUMMARY 1 Connect the system return marked In 2 Connect the system supply marked Out 3 Install a Back Flow preventor on the Cold Feed Make Up Water line 4 Install a Pressure Reducing Valve if required on the Cold Feed Make Up Water line 15 PSI 1 bar nominal on the system return Check Pressure Gauge which should read minimum pressure of 12 PSI 0 8 bar 5 Install an Expansion Tank on the system supply Consult the tank manufacturer s instruction for specificinformation relating to expansion tank installation Size the expansion tank for the required system volume and capacity no valve is to be placed between the boiler and the expansion tank 6 Install an Air Elimination Device on the system supply if required the boiler has two auto air vents built in 7 Install a drain valve at the lowest point of the system Note The XPak has a proper internal drain valve see Fig 42a 8 The Safety Relief Valve is installed at the factory Pipe the discha
93. isplay shows the fan RPM in multiples of 1000 i e 2 5 2500RPM IGNITION FAN SPEED ATTENTION Do this operation only after the adjusting of absolute max and min fan speed Locate the IGN trim pot Fig 2 and gently adjust clockwise or counter clockwise to achieve the correct fan speed see table below NOTE The display shows the fan RPM in multiples of 1000 i e 2 5 2500RPM HEATING FAN SPEED Locate the HTG trim pot Fig 2 and gently adjust clockwise or counter clockwise to achieve the correct fan speed see table below NOTE The display shows the fan RPM in multiples of 1000 i e 2 5 2500RPM FAN SPEED rpm TABLE MODEL MAX MIN HTG IGN XPak85 5 700 1 900 5 700 3 700 XPak120 5 400 1 400 5 400 3 700 ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYZER CHECKING THE CO2 AND ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYZER Isolate the boiler from the electrical supply and remove the appliance casing Set the flue gas analyzer to read CO2 andinsert the probe into the flue analysis test point A air B flue Fig 3 Restore the electrical supply to the boiler and switch the boiler to the OFF mode To adjust the gas valve you must first ensure that the fan speed potentiometers trim pots have been set correctly Remove the 3 selector knobs locate and
94. ith ndirect vvater tank vvith thermostat to control sensor to control DHVV DHVV temperature temperature Fig 61 Im Fig 62 Fig 63 16 SETTING THE OUTDOOR RESET CURVE WITH OUTDOOR SENSOR Outdoor temperature reset only works with the outdoor air sensor connected therefore after installation connect the outdoor air sensor to the relative connections on the boiler terminal board Fig 35 This enables the outdoor temperature reset function The user can program the desired supply temperature based on the heat transmitter that will be used in the installation Once the outdoor sensor is connected to the control board the water temperature of the boiler will adjustto run the boiler more efficiently and provide greater comfort to the living space NOTICE The DHVV temperature is independent from the outdoor air sensor Selecting the offset heating curve Fig 65 The offset heating curve maintains a theoretical ambient tempe rature of 68 F 20 C at outdoor temperatures ranging from 68 F to 4 F 20 C to 20 C The choice of the curve depends on the rated minimum outdoor temperature of the geographical area and the rated delivery temperature on the type of system and must be carefully calculated by the installer using the following formula using the correct values in F or C Nominal flow Temp Tshift TME 68 F 20 C min
95. l supply to the boiler Instead shut off the gas supply at a location external to the boiler WARNING Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water AVERTISSEMENT En cas de surchauffe ou de non fermeture de la vanne d alimentation en gaz n eteignez ou ne debranchez pas l alimentation lectrique de la chaudi re Coupez plut t l alimentation en gaz l ext rieur de la chaudi re AVERTISSEMENT N utilisez pas cette chaudi re si une partie de celle ci s est retrouv e sous l eau Appelez imm diatement un technicien de service qualifi pour inspecter la chaudi re et pour remplacer toute partie du syst me de contr le et toute commande de gaz s tant retrouv e sous l eau WARNING To minimize the possibility of improper operation serious personal injury fire or damage to the boiler e Always keep the area around the boiler free of combustible materials gasoline and other flammable liquids and vapors Boiler should never be covered or have any blockage to the flow of fresh air to the boiler WARNING Risk of electrical shock More than one disconnect switch may be required to de energize the equipment before servicing WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals k
96. le 0 825 21 mm female 7 16 11 mm Fig 3 13 DIMENSIONS AND CONNECTIONS Fig 4 Recommended minimum service clearances q Ka XPak 85 15 3 4 400 mm XPak 120 17 3 4 451 mm ee E o PE Fig 4 li E E m N N 30 3 4 781 mm E E E o NG A to aN x o 5 2 g D gt m 5 1 2 8 5 8 140mm 219mm T 14 1 8 359 mm XPak 85 3 15 16 97 mm 1 25 mm XPak 120 4 1 2 114 mm 1 25 mm Minimum Clearances to Combustibles Top 0 Front 0 AL CL Rear 0 Left 0 Right 0 AL Alcove CL Closet Note The XPak boiler has passed the zero inches vent clearance to combustibles testing requirements provided by the boiler Harmonized Standard ANSI Z21 13b 2007 CSA 4 9b 2007 and therefore is listed for zero clearance to combustibles when vented with a single wall special venting system AL29 4C material or UL ULC listed gas vent material The zero inches vent clearance to combustibles for the XPak boiler supercedes the clearance to combustibles listing that appears on the special venti
97. ler set parameter 51 1 this parameter can only be modified from the remote control unit Fig 67 available only from Raypak technical service When the contact is closed the heat request is made by the delivery probe on the basis of the external temperature in order to maintain the rated ambient temperature at the DAY level 68 F 20 C When the contact opens it does not stop the heat request but reduces parallel shift the temperature curve to the NIGHT level 61 F 16 C This activates the night mode Though flow temperature is automatically calculated by the boiler the user may manually override it By modifying HEATING on the user interface C Fig 13 2 the HEATING SET POINT will no longer be available but just a value that can be set from 5 to 5 as required Please note that the number displayed is a comfort level 5 means feel hotter 5 means feel colder Modifications to this value do not directly change flow tempera ture but affect the calculation made to automatically determine its value by modifying the reference temperature of the system 0 68 F 20 C for DAY level 61 F 16 C for NIGHT level If a remote control Raypak REC 08 is installed refer to instructions for setting the outdoor sensor using 49 OUTDOORTEMPERATURE RESET CURVES CF C 212 100 19
98. mote Control RECO8 To comply with safety regulations the control is set when shipped from the factory CAUTION Hotter water increases the risk of scalding There is a hot water scald potential if the thermostat is set too high 3 BEFORE INSTALLATION Raypak strongly recommends that this manual be reviewed thoroughly before installing your XPak boiler Please review the General Safety information before installing the boiler Factory warranty does not apply to boilers 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 qualified installer service agency or gas supplier If after reviewing this manual you still have questions which this manual does not answer please contact the manufacturer or your local Raypak representative Thank you for purchasing a Raypak product We hope you will be satisfied with the high quality and durability of our equipment Product Receipt On receipt of your boiler it is suggested that you visually check for external damage to the shipping package If the package is damaged make a note to that effect on the Bill of Lading when signing for the shipment Remove the boiler 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 dama
99. n the installing plumber or gastfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heatin
100. n steps XPAK PIPING Relief valve General piping information Separate low water cutoff Backflow preventer Fitting the heating circuit supply and return pipes Expansion tank and make up water Sizing space heat system piping Boiler with DHW tank Waterside Flow primary circuit 10 Procedure summary 11 Fill and purge heating system XPAK INSTALLATION DIAGRAMS MAKING THE GAS CONNECTION BOILER TEMPLATE COMBUSTION AIR AND VENTILATION OPENINGS INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM VENT SYSTEMS 1 Flue gas system 2 Boiler supply 3 Installations of supplied vent components 4 Minimum Clearances from Vent Air Inlet Termination CONNECTING THE CONDENSATE WATER DRAIN 1 Condensate Connection MODUN 0 ELECTRICAL 5 External connection board connections Electrical supply Field wiring Casing removal Appliance terminal block Connecting the electrical supply 120V External wiring External wiring limitations Connecting thermostat 10 Other devices 11 Terminal strip details 12 Outdoor sensor connection 13 3 way valve wiring connection 14 Remote control connection WIRING FUNCTIONAL DIAGRAM ODNDOUOAWNSs START UP PROCEDURE SA 9 10 11 12 13 14 COMMISSIONING Check control water chemistry Freeze protection when used The heating system Initial filling of the system Purge air from bo
101. nal block cover 120V Pass the cable through the cable anchorage point on the control panel Pass the cable through the Strain Relief Bushings field supplied Fig 39 The boiler is equipped with 4 holes in the lower support Chose the circle holes in the case of using Heyco Flex Metallic SR 7K 2 Fig 39 ref 2 Chose the non circle holes in the case of using Strain Relief Bushings 1 2 HFC Z 1 2 Fig 39 ref 1 Connect the supply cable wires LIVE NEUTRAL amp GROUND to their corresponding terminals L N amp G on the appliance 120V terminal block When connecting the GROUND wire ensure that it s left slightly longer about 1 in 20 mm that the others this will prevent strain on the GROUND wire should the cable become taut Do not remove the link wire unless additional external controls are to be fitted The securing screw on the cable anchorage should now be tightened Fig 37 This must be done before the control panel is reinstalled in the upright position The appliance casing screws and lower cover can now be reinstalled NOTICE It is the installer s responsibility to ensure that the appliance is properly grounded Raypak cannot be held responsible for any damages or injuries caused as a result of incorrect ground wiring 7 EXTERNAL WIRING The appliance comes with a factory installed room thermostat link to allow basic operation of the boiler via the mode selector switc
102. ng system label 14 PACKAGING AND TRANSPORTATION 1 SCOPE OF DELIVERY The boiler is delivered fully assembled When receiving the delivery check if the packaging is intact Check that all the items listed in Table 2 are included in the delivery 2 TRANSPORTING THE BOILER CAUTION The boiler may be damaged when it is improperly secured Only transport the boiler using the right transportation equipment such as a handtruck with a fastening belt or special equipment for maneuvering steps During transportation the boiler must be secured on the transportation equipment to prevent it from falling off Protect all parts against impacts if they are to be transported Observe the transportation markings on the packaging Packaged boilers must always be lifted and carried to their destination by two people or you must use a handtruck or special equipment to transport them to their destination Transport the boiler to the room where it is to be installed 3 BOILER BOX CONTENT Table 2 User s Instructions Installation Instructions Wall Mounting Template Top manual air vent drain pipe oa Gas shut off valve Flue gas adaptors including vent adaptor for two pipes vent system intake air adaptor for two pipes 3 adaptor 4 screws LPG conversion kit injector black coated LPG sticker LPG conversion labelling Conversion ins
103. nown to the State of California to cause cancer birth defects or other reproductive harm 4 NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts external connections to the unit Solid conductors should not be used because they can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones on the unit or larger NOTE When the boiler has been filled for the first time or the system has been drained and refilled it will be necessary to release any air that may have become trapped within the appliance heat exchanger Loosen the bleed screw until water is released and then close IMPORTANT THERE ARE NO OTHER MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE The following instructions must be observed The boiler must only be used for its designated purpose observing the Installation Instructions Only use the boiler in the combinations and with the accessories and spares listed Other combinations accessories and consumables must only be used if they are specifically designed for the intended application and do not affect the system performance and the safety requirements Maintenance and repairs must only be carried out by authorized professionals You must report the installation of a condensing gas boiler to the relevant gas utility company and have i
104. ntegral pump Fan Water pressure switch Condensate level sensor Pressure gauge Pressure relief valve Flue thermostat Flue sensor Blocked flue svvitch MODE OF OPERATION AT REST VVhen the appliance is atrest and there are no requests for heating or hot vvater the follovving functions are active 2 stage freeze protection system the freeze protection system protects the appliance against the risk of freeze damage The first stage enables activation of the pump should the tempera ture of the appliance fall to 43 F 6 C Should the first stage become active the appliance will function on minimum 25 power until it reaches 95 F 35 C Anti seize function the anti seize function enables the pump to be energized for short periods when the appliance has been inactive for more than 24 hours MODE OF OPERATION When there is a request for heat and or hot water via the programmer time clock and or any external control the pump and fan are started the fan speed will modulate until the correct signal voltage is received at the control PCB At this point an ignition sequence is enabled Ignition is sensed by the electronic circuitry to ensure flame stability at the burner Once successful ignition has been achieved the electronic circuitry increases the gas rate to 75 of the MAX Heating set by the corresponding HTG trimmer fora period of 15 minutes Thereafter the boilers output will either in
105. opening and ignition start up 58 Compensation pipe connection Fig 4 O O Maximum screw Minimum screw 14 EXPLODED DIAGRAMS Drawing 1 59 Drawing 2 60 Drawing 3 XPAK 85 XPAK 120 61 Drawing 4 57b 53 Drawing 5 m O 52 Drawing 5 Drawing 5 62 CALL OUT DESCRIPTION XPak85 XPak120 Electric Case Components See Drawing 1 1 Jacket Front 012831F 012832F 2 Boiler Mounting Bracket 013004F 013004F 3 Control Panel 012829F 012829F 4 Control Panel Cover 012827F 012827F 5 Control Panel Door 012833F 012833F 6 PC Board 012828F 012828F 7 Control Knob 012830F 012830F 8 Control Panel Hinge 012834F 012834F 9 Pressure Gauge 012826F 012826F 10 Wire Harness Kit Includes Complete Set of Boiler Harnesses 012836F 012999F 11 Control Panel Fuse Kit Includes Complete Set of Fuses 013003F 013003F 12 Retainer Clip Kit Includes 12a 20pcs 12b 1 pc 12c 10 pcs and 12d 10 pcs 013011F 013011F Hydraulic Components 1 See Drawing 2 13 Water Pressure Switch 013005F 013005F 14 Bypass Valve 013006F 013007F 15 Distribution Header 013008F 013008F 16 Vent Plug 013009F 013009F 17 PRV 45 013012F 013012F 18 PRV Adapter 013013F 013013F 19 PRV Discharge Plumbing Kit 013010F 013010F Hydraulic Com
106. or heating Outdoor sensor Tank thermostat Tank sensor Mixing valve anti scald Radiator valve Condense neutralizer Tank drain valve Tank pressure relief valve Pump CONDARWN gt o ek tr OONOUROM O N N N N DN O N R 3 way mixing valve Pressure gauge Bypass radiator NN oun Fig 7 Fig 8 sum uu Fo m h u Fig 9 E e 4 Fig 10 20 LUBID MAKING THE GAS CONNECTION DANGER Only carry out work on gas conduits and fittings if you are licensed for such work Determine proper size gas pipe for the installation using Table 3 and Table 4 Do not forget the pipe fitting losses and observe proper size of the fittings Install the furnished 3 4 female gas cock on the gas connection 3 4 male on the boiler Fig 13 Connect the gas pipe to the gas cock so that it is free from any strain CAUTION The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa Fig 13 A Manual main gas shutoff valve supplied B Coupling fi
107. or is turned to the digital display indicates Fig 55 unless the anti freeze phase AF Fig 56 is in progress or the combustion analysis function is activated CO Fig 58 7 SWITCHING OFF For short absences weekends brief journeys etc turn the function selector to Q OFF RESET As the boiler remains powered with the gas tap open it is protected by the following systems Freeze protection Heating The function starts if the temperature measured by the flow sensor falls below 43 F 6 C In this mode a heat demand is generated and the burner ignites at minimum power This is maintained until the temperature of the water flow reaches 95 F 35 C 43 Domestic hot water with connection to an external water tank with probe The function starts if the temperature measured by the water tank probe falls below 40 F 4 C In this mode a heat demand is generated and the burner ignites at minimum power This is maintained until the temperature of the delivery water reaches 95 F 35 C NOTICE During the freeze protection mode AF flashes on the display Fig 56 circulator anti block if the boiler remains inactive the circulator performs a 30 second operating cycle every 24 hours If the boiler is planned not to be used for a long period proceed as follows move the function selector to OFF RESET turn the main system switch to off 8 INDICATOR LEDS AND FAULTS Green indicator
108. pany 2 If pH differs from above consult local water treatment company for treatment needed Hardness less than 7 grains 1 Consult local water treatment companies for unusually hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm 2 Do not use the heater to directly heat swimming pool or spa water 3 Do not fill heater or operate with water containing chlorine in excess of 200 ppm Clean system to remove sediment 1 You must thoroughly flush the system without heater connected to remove sediment The high efficiency heat exchanger can be damaged by buildup or corrosion due to sediment 2 Flush system until water runs clean and you are sure piping is free of sediment Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions to verify inhibitor level and that other fluid characteristics are satisfactory 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions 2 FREEZE PROTECTION WHEN USED WARNING NEVER use automotive or standard glycol antifreeze even ethylene glycol made for hydronic systems Use only freeze prevention fluids certified by fluid manufacturer as suitable for use with aluminum heate
109. ponents 2 See Drawing 3 20 Pump 013014F 013015F 21 Plumbing Kit Includes 21a 21b 21c and 21d 013016F 013017F 22 Air Vent 013018F 013018F 23 Condensate Reservoir 013019F 013019F 24 Condensate Plumbing Kit Includes 24a 24b 24c 24d and 24e 013020F 013021F 25 Air Venting Plug Kit 013022F 013023F 26 High Limit 013024F 013024F 27 Pump Plug 013025F 013025F 28 Water Detector 013026F 013026F Burner Components Air Box See Drawing 4 29 Air Chamber Access Panel 013037F 013038F 30 Air Chamber Side 013027F 013027F 31 Intake Air Flue Adapters 013040F 013040F 32 Combustion Air Blower 013028F 013028F 33 Burner Assembly 013029F 013029F 34 gniter 013030F 013030F 35 Condensate Electrode Kit 013031F 013031F 36 Outlet Gas Manifold 013032F 013033F 37 Gas Valve Kit 013034F 013034F 38 nlet Gas Manifold 013035F 013035F 39 Gas Shut Off Valve 013036F 013036F 40 Burner Observation Port Kit 013039F 013039F 41 Air Gas Manifold 013041F 013041F 42 Manifold Gas Blovver Inlet 013042F 013064F 43 Gas Orifice Nat 013043F 013044F 43 Gas Orifice Pro 013045F 013046F 44 Combustion Air Mixer 013047F 013048F 45 Flame Sensor 013049F 013049F 46 Blovver Heat Shield 013050F 013050F 47 gnition Transformer 013051F 013051F Combustion Chamber Components Flue Drain See Drawing 5 48 Heat Exchanger Assembly 013054F 013055F 49 Flue Exhaust Condensate Collector 013056F 013057F 50 Flue Exhaust Condensate Collector Adapter 013058F 013058F 51 Air Pressure Switch 013059
110. position and check that the red indicator LED has gone out At this point the boiler starts automatically if correct operating conditions have been restored when the burner ignites the green indicator led lights up and the digital display indicates the instantaneous operating temperature Fig 43 Heating mode 60 F Fig 44 DHW mode Deeg omo 40 F 140 F NOTICE NOTICE Simply turning the selector to does not reset the boiler If the boiler continues not to work call your local Service Technician For temperature over 199 F 93 C the display shows 99 Adjusting heating water temperature To adjust the heating water temperature turn the knob marked INN Fig 50 clockwise to increase and counterclockwise to decrease When turning the knob the required temperature automatically appears on the digital display NOTICE Depending on the type of system it is possible to pre select the suitable temperature range standard systems 104 176 F 40 80 C floor systems 68 113 F 20 45 C For further details consult the Boiler configuration Fig 61 3 ADJUSTING HEATING WATER TEMPERATURE WITH AN OUTDOOR PROBE CONNECTED When an outdoor probe is connected the value of the delivery temperature is automatically chosen by the system which rapidly adjusts ambient temperature to the changes in outdoor tempe In normal operating conditions when the function select
111. press the CO button The appliance will now operate in CO mode for approximately 15 minutes GAS VALVE MAXIMUM SETTING Locate and gently turn the HTG trim pots until the maximum value max fan speed is obtained and check that it corresponds with the appropriate CO2 value Maximum for the respective boiler If the CO2 reading is correct proceed to gas valve minimum setting However If the CO2 reading is incorrect the maximum gas pressure must be adjusted as follows Using a suitable screwdriver very slowly turn the maximum adjustment screw Fig 4 clockwise to decrease counter clockvvise to increase until the correct value is displayed on the CO2 analyzer allow time for the analyzer to stabilize GAS VALVE MINIMUM SETTING Locate and gently turn the HTG trim pot until the minimum value min fan speed is obtained and check that it corresponds with the appropriate CO2 value Minimum for the respective appliance lf the CO2 reading is correct rotate the HTG trim pot until the correct value is obtained for the respective appliance see fan speed table and proceed However If the CO2 reading is incorrect the minimum gas pressure must be adjusted as follows Using a suitable screwdriver very slowly turn the minimum adjustment screw Fig 4 clockwise to increase counter clockwise to decrease until the correct value is displayed on the CO2 analyzer allow time for the analyzer to stabilize INSTALLA
112. ptor for room air dependent operation Straight Pipe 3 28 ft 1 m 3 94 100 mm coaxial 90 Elbow 3 94 100 mm coaxial Mounting Clip set of 4 Vertical vent termination 3 80 mm single wall Pos 1 Pos 2 Fig 24 Pos 2 Fig 25 26 27 28 Pos 2 Fig 29 30 31 32 Pos 3 Fig 25 26 28 Pos 3 Pos 4 Flg 25 26 28 Pos 4 Fig 23 Pos 5 Pos 6 Fig 28 Pos 6 Fig 24 Pos 7 Pos 8 Fig 25 26 27 Pos 8 Fig 24 Pos 9 Fig 28 Pos 9 Fig 24 Pos 10 Fig 24 Pos 10 Fig 25 26 27 28 Pos 11 Fig 28 VERTICAL COAXIAL Fig 24 SEALED COMBUSTION OPERATION VERTICAL COAXIAL SEALED COMBUSTION OPERATION 27 Fig 25 a total intake length INTAKE b total flue length EXHAUST TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION D EXHAUST T t IRO e Fig 26 a total intake length INTAKE b total flue length EXHAUST TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION OS Ra i 1 H INTAKE 28 Fig 27 a total intake length INTAKE b total flue length EXHAUST E38 LG TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION 9 4 EXHAUST INTAKE oom EXHAUST L wm INTAKE v Fig 28 a total intake length 0
113. rawl or attic that freely communicate with the outdoors The minimum dimension of air openings shall be no less than 3 inches 75 mm 1 Where directly communicating with the outdoors each open ing shall have a minimum free area of 1 square inch per 4 000 Btu hr of total input rating of all equipment in the enclosure 2 Where communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr of total input rating of all equipment in the enclosure 3 Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 Btu hr of total input rating of all equipment in the enclosure 4 Where ducts are used they shall be of the same cross sectional area as the free area of the opening to which they connect 24 INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM NOTICE Consult local and state codes pertaining to special building code and fire department requirements Adhere to national code requirements NOTICE Observe the listed maximum lengths of vent system which are boiler model dependent The maximum permissible lengths are listed in the main specification Tab 5 An optional concentric vent air intake body can be used for the installation of a vertical venting system as well as for a horizontal venting system The concentric vent air intake body can be ordered through Raypak
114. respective boiler see the data table for values f the CO2 reading is correct proceed to gas valve minimum setting However if the CO2 reading s incorrect the maximum gas pressure must be adiusted as follovvs Using a suitable screvvdriver very slowly turn the maximum pressure adiustment screvv Fig 60 clockvvise to decrease counter clockvvise to increase until the correct value is displayed on the CO2 analyzer allovv time for the analyzer to stabilize 10 GAS VALVE MINIMUM PRESSURE SETTING Locate and gently tum the HTG trim pot until the minimum value min fan speed is obtained and check that it corresponds with the appropriate CO2 value Minimum for the respective appliance If the CO2 reading is correct rotate the HTG trim pot until the correct value is obtained for the respective appliance see fan speed Tab 10 However if the CO2 reading is incorrect the minimum gas pressure must be adjusted as follows Remove the sealing screw Using a suitable screwdriver very slowly turn the minimum pressure adjustment screw Fig 60 clockwise to increase counter clockwise to decrease until the correct value is displayed on the CO2 analyzer allow time for the analyzer to stabilize COMPLETION On completion of the combustion analysis check and or any gas valve adjustment set the HTG trim pot to the corresponding value as detailed in the fan speed table Reattach the 3 selector knobs Remove the
115. rge of the safety relief valve to prevent injury in the event of pressure relief Pipe the discharge to a maximum of 6 152 mm above the floor to a drain Provide piping that is the same size as the safety relief valve outlet Never block the outlet of a safety relief valve 11 FILL AND PURGE HEATING SYSTEM CAUTION For installation that incorporates standing Iron Radiation and systems with manual vents at the high points Follow above section and starting with the nearest manual air vent open vent until water flows out then close vent Repeat procedure working your way toward furthest air vent It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present Annual cleaning of the strainer may be necessary WARNING Use only inhibited propylene glycol solutions which are specially formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems Glycol mixtures should not exceed 40 1 Glycol in hydronic applications which is specially formulated for this purpose includes inhibitors that prevent the glycol from attacking metallic system components Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level 2 The glycol solution should be tested atleast once a year and as recommended by the glycol manufacturer 3 Anti freeze solutions expand more than water Allowances must
116. rging Fill the system and watch that system pressure rises to correct cold fill pressure After the system has operated for a while eliminate any residual air 6 SYSTEM DRAIN Fig 42a Use a open ended wrench dimensions 7 16 11 mm to drain the water inside the boiler attach the rubber pipe supplied to the drain valve A locate the wrench hole under the boiler fit the wrench to the valve gently rotate the wrench counterclockwise drain the boiler close the valve rotating the wrench clockwise remove the rubber pipe from the valve once the valve as been closed DANGER The system water temperature could be very hot be sure when the valve is opening that the rubber pipe is well attached Frontal water flushing can occur and cause instant severe burns or death from scalds Fig 42 Fig 42a 7 CHECK THERMOSTAT CIRCUIT S 1 Disconnect the two external wires connected to the boiler thermostat terminals low voltage terminal strip M4a 2 Connect a voltmeter across these two incoming wires Close each thermostat zone valve andrelay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring 5 Once the external thermostat circuit wiring is checked and corrected if necessary
117. rise and exceeds the set point by 9 F 5 C hysteresis the burner will shut down A new ignition sequence will be enabled when the 3 minute anti cycle has been performed and the temperature at the primary thermistor has dropped 9 F 5 C hysteresis below the set point NOTICE When the request for heating and or hot water has been satisfied the appliance pump and fan may continue to circulate to dissipate any residual heat within the appliance 6 DHW MODE With the selector switch in either the hot water only or heating amp hot water position the appliance will operate in the hot water mode whenever a tank sensor thermostat is in request If there is a request the pump and fan will be activated via the flow tempe rature sensor When the fan is sensed to be operating correctly blower signal the ignition sequence commences Ignition is sensed by the electronic circuitry to ensure flame stability at the burner Once successful ignition has been achieved the electronic circuit allows the gas rate to achieve the modulation value OFF reset position a O NZ Fig 58 Freeze protection mode active Combustion analysis mode active Normal DHW request example 140 F 60 C 46 NOTICE When the request for heating and or hot water has been satisfied the boiler pump and fan may continue to circulate to dissipate any residual heat within the boiler
118. rity for further information Maximum water temperatures occur just after the boiler s burner has shut off 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 WARNING This boiler cannot supply hot water for use by individuals directly A heat exchanger must be used in conjunction with this boiler to meet DHW needs A DANGER Water temperature over 125 F 50 C 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 TIME TEMPERATURE RELATIONSHIPS IN SCALDS The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications Water Time to Produce Serious Temperature Burn 120 F More than 5 minutes 125 F 1 1 2 to 2 minutes 130 F About 30 seconds 135 F About 10 seconds 140 F Less than 5 seconds 145 F Less than 3 seconds 150 F About 1 1 2 seconds 155 F About 1 second Table courtesy of The Shriners Burn Institute The temperature of the water in the boiler can be regulated by using the Raypak Re
119. rs verified in fluid manufacturer s literature Throroughly clean and flush any system that has used glycol before installing the new XPak Boiler Provide XPak boiler owner with a material safety data sheet MSDS on the fluid used if requested 1 Determine freeze protection fluid quantity using total system water content following fluid manufacturer s instructions Remember to include expansion tank water content 2 Local codes may require back flow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level 3 THE HEATING SYSTEM The appliance contains components that may become damaged or rendered inoperable by oils and or debris that are residual from the installation of the system consequently it is essential that the system be flushed in accordance with the following instructions 4 INITIAL FILLING OF THE SYSTEM Ensure both flow and return service valves are open remove appliance casing as described identify the automatic air release valves AAV and loosen the dust cap s by turning the cap counterclockwise one full turn Ensure all manual air release valves located on the heating system are closed Fill the system via proper filling method field supplied As water enters t
120. s and water fitting In addition a handtruck with a fastening belt is very useful Disposal Dispose of the boiler packaging in an environmentally sound manner Dispose of components of the heating system e g boiler or control device that must be replaced by handing them in to an authorized recycling facility 2 GENERAL SAFETY To meet domestic hot water use needs the high limit safety control on this boiler is adjustable up to 140 F 60 C Water temperatures over 125 F 50 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 50 C Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat The most energy efficient operation will result when the temperature setting is the lovvest that satisfies the needs of the application Water temperature over 125 F 50 C can cause instant severe burns or death from scalds Children disabled and elderly are at highest risk of being scalded e Feel water before bathing or showering Temperature limiting valves are available NOTE When this boiler is supplying general purpose hot water for use by individuals a thermostatically 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 autho
121. s with us The warranty can be registered in several ways see last pages of this manual for details 42 10 START UP AND OPERATION XPak wall mounted condensing boiler is designed for the production of heating and domestic hot water if a storage tank is connected The control panel contains the main boiler control and manage ment functions 1 SWITCHING ON THE APPLIANCE Switch on the boiler as follows Open the gas tap under the boiler by turning it counterclockwise Fig 46 Turn on the general switch of the system and then after lowering the flap turn the function selector to summer Ft winter 3 or winter tank temperature EF Fig 54 depending on the chosen operating mode Pump cycle mode when power is restored to the boiler and or the boiler is powered for the first time the boiler will enter a 2 minute purge cycle whereby only the pump will run for 15 seconds then off for 15 seconds and will not fire until this period has elapsed To interrupt the purge cycling remove the knob of the main selector switch and press the CO button Fig 59 Off reset Select this position when the boiler needs to be reset or switched off Summer mode The domestic hot water function provided by the water tank is activated The display indicates the storage tank temperature only with the external water tank connected with a sensor Winter mode 3 The boiler produces hot water for heating and if connected to an ext
122. see chapter Checks adjustments and fault finding Operating Limits of the boiler Max boiler temperature 194 F 90 C Max operating pressure 45 psi 3 1 bar The hot water distribution system must comply with all applicable codes and regulations When replacing an existing boiler it is important to check the condition of the entire hot water distribution system to ensure safe operation 5 INTRODUCTION The XPak boiler is a wall hung fan assisted direct vent heating boiler only These boilers by design incorporate electronic ignition circulating pump pressure relief valve pressure gauge and automatic bypass As supplied the boiler will automatically modulate to provide central heating outputs between 25 600 87 000 Btu hr 7 5 25 5 kW XPak 85 and 27 300 119 500 Btu hr 8 35 kW XPak 120 IMPORTANT It is the law that all gas appliances are installed by a competent person It is in your own interest and that of safety to ensure that the law is complied with The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 The installation should conform with CGA B149 INSTALLATION CODE and or local installat
123. should be made to ensure gas tightness water tightness and the electrical integrity of the appliance 2 APPLIANCE MODES OF OPERATION NOTICE There must be sufficient system water pressure min 7 psi 0 5 bar to ensure the water pressure switch is activated If there is insufficient system pressure the pump and fan will be prevented from operating and the low pressure fault code will be displayed The 2 digit display can show several different modes of operation 3 SELECTOR SWITCH IN THE OFF STAND BY POSITION When the selector switch is in the Off reset position the following functions are active Active functions Freeze protection system Pump anti seize 4 ON BOARD FUNCTIONS THERMOREGULATION When an outdoor air sensor is connected to the appliance the electronic circuitry will automatically adjust the flow outlet temperature to suit local weather conditions in order to maintain comfort and efficiency A specific operating curve that is most suited to the system type and geographical area can also be selected Fig 65 CO FUNCTION the CO function when activated will allow the appliance to run at maximum and minimum output while a combustion analysis check is being carried out While the CO function is active all other functions are disabled minimum power operating period anti cycle set point etc Once enabled the CO function will remain active for a 15 minute period or until the function is manually deactivat
124. st of the replacement part RESIDENTIAL WARRANTY The table below lists the portion of the replacement part s cost that the original homeowner will be responsible to pay Years into Warranty of List Price First 10 0 11 20 12 30 13 40 14 50 15 55 16 60 17 65 18 70 19 75 20 80 XPAK Commercial Extruded Aluminum Heat Exchanger The Applicable Warranty Period for the aluminum heat exchanger of the Boiler in a commercial installation as defined in Additional Warranty Exclusions and Terms below is five 5 years after the original installation date of the Boiler During the first three 3 years of the Applicable Warranty Period Rheem will pay for 100 of the cost of the replacement part or repair excluding labor and transportation costs For years 4 and 5 of the Applicable Warranty Period for the commercial aluminum heat exchanger Raypak will provide a replacement part for a defective part provided that the warranty claimant pays the following percentages of the cost of the replacement part COMMERCIAL WARRANTY The table below lists the portion of the replacement part s cost that the original owner will be responsible to pay Years into Warranty of List Price First 3 0 4 20 5 30 RESIDENTIAL BOILDER FAN The Applicable Warranty Period for the fan of a Boiler in a residential installation as defined in Addition
125. t approved You are only allowed to operate the condensing gas boiler with the combustion air flue gas system that has been specifically designed and approved for this type of boiler Please note that local permission for the flue system and the condensate water connection to the public sewer system may be required You must also observe The local building regulations stipulating the installation rules The local building regulations concerning the air intake and outlet systems and the chimney connection The regulations for the power supply connection The technical rules laid down by the gas utility company concerning the connection of the gas burner fitting to the local gas main The instructions and standards concerning the safety equipment for the water space heating system The Installation Instructions for building heating systems The boiler must be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the boiler or to lower floors of the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the boiler The pan must not restrict combustion air flow The boiler must be installed such that the gas ignition system components are protected from water dripping spraying rain etc during boiler operation and service The boiler must not be installed on carpeting
126. take air WARNING You must pipe outside air to the boiler air intake for sealed combustion operation Ensure that the intake air will not contain any of the contaminants below Contaminated air willdamage the boiler resulting in possible severe personal injury death or substantial property damage For example do not pipe intake air vent near a swimming pool Also avoid areas subject to exhaust fumes from laundry facilities These areas may contain contaminants 7 WHEN REMOVING AN EXISTING BOILER FROM AN EXISTING COMMON VENT SYSTEM Do not install the XPak boiler into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible severe personal injury death or substantial property damage WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death Atthe time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a b Seal any unused openings in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine there is non blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe
127. tate away from the fan assembly To remove the mixer B locate and remove the three screws C To remove the fan D disconnect the electrical connections attached to the fan locate and remove the four screws E Gently ease the fan from its location Replace in the reverse order Ensure all seals are in good condition taking care to ensure they are replaced correctly BURNER Fig 75 Unclip and remove the air chamber front and the right hand side covers Slacken the gas pipe A at the air box connection and swing rotate of the fan assembly Locate and remove the 3 internal nuts B which secure the fan assembly in position C to the heat exchanger D Disconnect the electrode leads and ancillary wiring from their respective connectors Remove the retaining screws A fig 73 for sensing electrode and remove Remove the retaining nut C fig 73 for condensation sensor D fig 73 and remove Gently ease the fan assembly out of its location Once the assembly has been removed the burner E can be withdrawn from the heat engine Ensure the seal F is in good condition taking care to ensure it is replaced correctly Replace in the reverse order BLOCKED FLUE PRESSURE SWITCH IGNITION TRANSFORMER Fig 73 Disconnect the compensation pipe G Disconnect the electric wiring from the pressure switch ignition transformer Remove the two screw F on the upper part of the combustion chamber Remove the screw l Remove the press
128. ter 3 Vent system material Stainless steel Adaptor for room air dependent operation 3 013102 Order No adaptor 80 mm gt 3 included with the boiler 1 pcs ULC UL listed Stainless steel Vent material 45 elbow EqL 2 ft 0 6m Field supplied Order No 90 elbow EqL 3 ft 0 9m Bird Screen c w Termination Field supplied Order No Venting support dia 3 Field supplied Order No 1 Stainless steel vent material must be ULC UL listed stainless steel AL29 4C for category IV boilers Sources FasNseal Protech System Inc 2 Order Mounting Clip for each straight length of vent pipe installed boiler can not support weight of vent system 3 Provide a proper air opening in the room size according indication pg 7 Do not exceed maximum equivalent vent length Always follow XPak Venting System Installation Instructions 30 DESCRIPTION DIAGRAM DRAWING P N 013040 Two pipes vent adaptors included with the boiler Fig 29 30 31 32 Pos 1 P N 013040 adaptor 80 mm gt 3 included with the boiler 1 pcs Fig 29 30 31 32 Pos 2 Fig 29 a total intake length INTAKE b total flue length EXHAUST TWO PIPES SINGLE WALL SEALED 10 0 MIN 250 mm 0 mm EXHAUST COMBUSTION OPERATION MIN i 12 300 mm OVER MAXIMUM SNOVV LEVEL OR 24 600 mm WHICHEVER IS T GREATER INTAKE 3 3 SUPPLIED 2 H 5 2
129. test probe from the test point and reattach the sealing screws and or cap DANGER A GAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED REPLACED OR DISTURBED 11 COMBUSTION ANALYSIS TEST A combustion analysis check can easily be carried out on the boiler via the test points located on the top of the appliance Insert the flue gas analyzer probe into the flue gas test point Pos B in Fig 59a Operate the boiler in CO mode and compare the values with those shown in Tab 1 Nat Gas or Section 13 LPG If different adjust the gas valve accordingly 12 EXTERNAL FAULTS Before carrying out any troubleshooting or component replacement ensure the fault is not attributable to any aspect of the installation INSTALLATION FAULTS Possible cause Check wiring check electrical supply Check external controls Check external controls Symptom No display ignition No hot water No heating Fault code Possible cause 10 Check gas supply check flue system check polarity check condensate 47 Maximum pressure adjustment Compensation pipe connection O H a B Minimum pressure adiustment Fig 60 screw NOTE The gas valve sticker WARNING VALVE IS NOT FIELD SERVICEABLE means the valve can be adjusted but not disassembled
130. the control panel cover A after turning off the main switch Fig 62 Locate the JP positioning Fig 63 JUMPER IN POSITION 1 Fig 61 The position nr 1 of the jumper indicates the boiler heating tem perature pre selection of the most suitable heating temperatu re adjustment field according to the type of system Jumper not inserted factory set case 1 Standard system radiators 104 176 F 40 80 C Jumper inserted case 2 Floor system radiant heating 68 113 F 20 45 C NOTICE The boiler has been factory configured for standard systems JUMPER IN POSITION 2 Jumper inserted heating indirect water tank with sensor JUMPER IN POSITION 3 Jumper inserted heating indirect water tank with thermostat factory set JUMPER IN POSITION 4 unused JUMPER IN POSITION 5 unused JUMPER IN POSITION 6 unused The boiler is supplied standard with the jumper in position 3 standard heating indirect water tank with thermostat if you wish to use an external water tank with sensor move this jumper from position 3 to position 2 case B Fig 61 if you wish to have low temperature for floor space heating move the not inserted jumper in position 1 Fig 61 CASE A CASE B radiators floor heating radiators floor heating factory set 6f5 a 6f5 o 6 o Blo D F D D D D D D D D D D D 25 ie ED ile GO ndirect vvater tank vv
131. the two wires at the room thermostat connections Fig 35 ref M4a NOTICE Restore the electrical supply to the boiler and turn the main selector switch to the heating request position amp The boiler should now function Should the boiler fail to respond the internal fuses and connectors should be checked to ensure integrity and continuity 14 COMPONENT VALUES 8 CHARACTERISTICS Standard Heating Range F C Floor Heating Range F C CH limited power at 75 COMPONENT VALUE Fan 120VAC Pump 120VAC 3 way valve field supplied 120VAC Ignition transformer 120VAC Gas valve 120VAC Room thermostat connection 24 Vdc NTC sensor dry contact 10Kohm NTC sensor wet contact 10Kohm FUNCTION VALUE 104 176 40 80 68 113 20 45 15 Min Heating OFF hysteresis F C SP 8 5 Heating ON hysteresis F C SP 8 5 Anti cycle delay 3 min Pump over run 30 sec Low output min output 96 Min 25 CO function max temp F C 203 95 CO re light temp F C 167 75 CO function time 15 min Flow NTC max temp F C 203 95 High limit thermostat F C 221 105 Maximum differential F C 95 35 IGNITION CONTROL VALUE Ignition attempts before L O lockout 5 Re ignition attempts after loss of flame signal 5 15 BOILER CONFIGURATION The electronic board contains a series of jumpers that can be used to configure the boiler access these by loosening the fasteners B and removing
132. tial spaces a Single family detached dwelling b Two family attached dwelling or c Dwelling unit of a residential building in which each dwelling unit has an individual Boiler For purposes of this Limited Warranty a commercial installation is defined as the installation of a Boiler in any site other than a Single family detached dwelling b Two family attached dwelling or c Dwelling unit of a residential building in which each dwelling unit has an individual Boiler HOW TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of installation and description of the problem The installer must then notify a Raypak distributor for instructions regarding the claim If neither the installer nor the distributor is available immediately notify Raypak at 800 278 5300 supplying model number serial number date of original installation and a description of the problem Proper authorization MUST be obtained PRIOR to any repairs for the Limited Warranty to apply This Limited Warranty is VOID if the Boiler is repaired or altered in any way by ANY persons or agencies other than those authorized by Raypak Raypak reserves the right at all times to inspect or require the return of the defective Boiler or component part and to verify warranty coverage at its factory The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable
133. tore and use these chemicals in the boiler room Avoid excessive dust formation and build up NOTICE When one expects contaminated combustion air near swimming pools chemical cleaning operations and hair salons sealed combustion operation is recommended DANGER FIRE DANGER Due to flammable materials or liquids Do not store flammable materials and liquids in the immediate vicinity of the boiler All Air from Inside the Building room air The room shall be provided with two permanent openings communicating directly with an additional room s The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of 1 square inch per 1 000 Btu per hour of total input rating of all gas utilization equipment in the confined space but no less than 100 square inches One opening shall commence within 12 inches 305 mm of the top and one opening shall commence within 12 inches 305 mm of the bottom of the enclosure The minimum dimension of air openings shall be not less than 3 inches 75 mm All Air from Outdoor sealed combustion The room shall be provided with two permanent openings one commencing within 12 inches 305 mm from the top and one commencing within 12 inches 305 mm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces c
134. tructions Pos Parts Quantity Packaging 1 Boiler with casing 1 1 box 2 Wall bracket 1 3 Technical documents 1 including Refer to Fig 5 for Boiler box contents Fig 5 R 15 6 INSTALLATION PREPARE XPAK LOCATION 1 INSTALLATIONS MUST COMPLY WITH Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 latest edition National Electrical Code For Canada only B149 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes NOTICE The XPak boiler gas manifold and controls meet safe lighting and other performance criteria as specified in ANSI Z21 13b 2007 CSA 4 9b 2007 2 BEFORE LOCATING THE XPAK BOILER 1 Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power Check area around boiler Remove any combustible materials gasoline and other flammable liquids WARNING Failure to keep boiler area clear and free of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial propert
135. tructions of the hot vvater tank and fittings concerned Domestic Hot Water Production via DHVV Storage Tank XPak boilers can be used in conjunction with the stand alone DHW storage tanks The boiler can control the DHW tank temperature directly from the boiler control panel In case a tank sensor is installed see boiler configuration jumpers Fig 61 adjust the tank temperature via the DHW selector The display shows the tank temperature if main selector in proper position Boiler can accept also a DHW tank controlled by a thermostat see boiler configuration jumpers Fig 61 in this case the DHW set point can not be adjusted on the control panel but only on the tank thermostat field supplied Both cases the supplied water temperature to the tank is 176 F 80 C and it goes ahead with priority over heating until the tank request is satisfied either the sensor or the termostat open The boiler can control a 3 way valve directly from the boiler control panel see 3 way installations Fig 38 Refer to electrical connections for 3 way valve installation Size and select the DHW storage tank based on the forecast DHW consumption of the building in question If different method of DHW production are used the boiler flow temperature is set as heating mode see boiler configuration jumpers Fig 61 9 WATERSIDE FLOW PRIMARY CIRCUIT The boiler is designed only for closed loop forced circulation hot water heating systems XPak is equ
136. ul A Inlet air adapter supplied 1 7 16 25 7 l XPak 12 j 17 81 TT 227 H D XPak 85 16 75 H Boiler outline CENTER LINE My OF BOILER TD UI WARNING 74 m This boiler is heavy and awkward to lift It is s NA recommended and safer to install the boiler with two Aji 5i Z people Use caution as to not drop this boiler which NA could cause personal injury Verify that the boiler is securely mounted before leaving the boiler unsupervised l Ensure there is adequate clearances for mounting the boiler details given in i installation instructions i he wall mount bracket is designed forja stud spacing of 16 inches from i center For other stud spacing a solid mounting surface must be provided by i he installer 1 Do not mount the boiler to a hollow wall Be sure to mount the boiler the i studs only I Mount the wall bracket using 4 5 16 lag screws Ensure the bracket is level when mounted i H Extreme care is needed to ensure the bplts are secured in the studs i Hang the boiler on the bracket and secure the bottom of the boiler with two 2 additional lag screws 3 14 UY XPak i 120 i 3 35 138 XPak 85 IN sr NPT male OUT aw NPT male Pressure relief valve drain N 3 4 NPT female Condensale piping flexible supplied Ke Gas shut off valve supplied N 1 4 holes for earthquake restraint 2 places 0 25 female N 3 4 NPT fem
137. ure switch Replace in reverse order Remove the two screw H remove the ignition transformer Replace in reverse order MAIN HEAT EXCHANGER Fig 76 77 Unclip and remove the three air chamber covers front left hand right hand sides Disconnect all the wiring connections Fig 76 slacken the gas pipe A at the air box connection and swing rotate of the fan assembly Disconnect the flow B return C and condensation connections on the heat exchanger Locate and remove the 4 screws that secure the heat exchanger to the combustion chamber D Move the heat exchanger to the right and disconnect it from the flue collector E The heat exchanger can now be lifted up and removed from the boiler Fig 77 to remove the fan burner assembly A locate and remove the 3 external nuts B Replace in the reverse order Ensure all seals are in good condition taking care to ensure they are replaced correctly AUTOMATIC BYPASS Fig 78 Disconnect and remove the flow pipe 1 at the connection to the pressure relief valve at heating manifold and at the connection to the air chamber Using a hooked piece of wire carefully withdraw the bypass cartridge 2 Ensure all seals are in good condition taking care to ensure they are replaced correctly Replace in the reverse order ensuring the cartridge is facing the correct way Fig 77 Fig 78 54 CONDENSATE TRAP REMOVAL
138. vent or interrupt the operation of the burner 12 BANNED MATERIAL STATEMENT No banned materials or substances have been used in the manufacture or production of this appliance or its inherent components MANUAL HANDLING STATEMENT CAUTION This appliance may require 2 or more persons to lift or carry it to the installation location due to the weight of the appliance it may be necessary for two people to lift and attach the appliance to its mounting To avoid the possibility of injury during the installation servicing or cleaning of this appliance care should be taken when handling component edges XPAK INTERNAL HYDRAULIC CIRCUIT FIG 2 top flow auto air temperature valve sensor manualair release return temperature sensor main heat pa exchanger WI pressure relief valve bottom auto air valve D pressure switch pump ES Si x drain valve automatic bypass Heating Heating pressure return low relief valve Fig 2 PIPING CONNECTIONS FIG 3 Legend A boiler in connection B boiler out connection C gas supply connection D pressure relief valve drain connection E condensate connection rubber flexible F boiler drain valve open ended spanner dimension 3 4 NPT male 3 4 NPT male 3 4 NPT female 3 4 NPT fema
139. warranty conditions satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts manufactured by others but Raypak will apply any such warranty as may be provided by the parts manufacturer EXCLUSIVE WARRANTY LIMITATION OF LIABILITY The Limited Warranty is the only warranty given by Raypak No one is authorized to make any other warranties on Raypak s behalf ANY IMPLIED WARRANTIES INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIOD SPECIFIED ABOVE RAYPAK S SOLE LIABILITY WITH RESPECT TO ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS LIMITED WARRANTY OR IN CONTRACT TORT OR NEGLIGENCE OR OTHERWISE FOR CLAIMS FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING NO LIABILITY FOR DAMAGE FROM WATER LEAKAGE ALL OF WHICH ARE EXPRESSLY EXCLUDED Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential damages so the above limitation or exclusion may not apply to you THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE We suggest you immediately record the model and serial number and date of original installation and retain this Limited Warranty Certificate in the event warranty s
140. y damage The XPak must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service If the new XPak is to replace an existing boiler check for and correct any existing system problems such as System leaks ncorrectly sized expansion tank Lack offreeze protection in heating vvater causing system and boiler to freeze and leak Excessive glycol vvhich vvill affect the boiler system operation 3 CLEARANCES FOR SERVICE ACCESS 1 See figure for recommended service clearances f you do not provide minimum clearances shown it might not be possible to service the boiler without removing it from the space VVARNING The space must be provided vvith combustion ventilation air openings correctly sized for all other appliances located in the same space as the XPak boiler The boiler internal front cover must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room in the case of sealed combustion operation This is particularly important if the boiler is located in the same room as other appliances Failure to comply with the above vvarnings could result in severe personal iniury death or substantial property damage 4 RESIDENTIAL GARAGE INSTALLATION Precautions Take the follovving special precautions vvhen installing the XPak in a residential garage If the boiler is located in a res
141. y shows as per Fig 36 No operation can be made on the boiler control panel once the remote control is installed All the boiler settings can be made only by Remote Control once it is connected See Remote Control instruction for setting and use Fig 36 Fig 37 3VVAY VALVE Fig 38 BOILER OUT BOILER OUT ee E gt 5 2 f H o U fo j J 100 0 m DT E Ce gt o Fig 39 Main supply cable 3 way valve cable Choose one of the two options for the strain relief that XPak allows 1 Straight Thru Heyco HFC Z 1 2 Listed under UL File E 206446 2 Strain Relief Bushings Heyco SR 7K 2 Listed under UL File E 15331 CSA LR8919 37 WIRING FUNCTIONAL DIAGRAM ITAVSIAGY SI NOILIINNO 9 N 1 ILON je sowiay 1 OLN 1osuss Mo su AO L OMS Josuas ajesuapuo9 s god UGW XLLAY AYINI sanina OUEUUD pasnun LX M p ds ue Bune y Joj Jowwi Ave 92d 0 uollo uuoo 91X72X p ds ue uolubi 10 Jawwi NG LL 824 0 UONDBUUOD GNO NO andyno wnwiulw 10 JeWUWUIIL 18W10JSUEI 824 cHL indino wnwixew 10 Jewwii J9WJ0 SUEJ uou OSL SSES SATVA

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