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.
CONTENTS 1 - WARNINGS PAY ATTENTION TO THESE TERMS 4 4 2 - GENERAL SAFETY TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 6 6 3 - BEFORE INSTALLATION 6 4 - REGULATIONS AND GUIDELINES 7 5 - 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.
1 - WARNINGS PAY ATTENTION TO THESE TERMS DANGER: Indicates the presence of immediate hazards which will cause 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.
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.
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.
Ratings and Certifications Standards: • 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 designcertified and tested by the Canadian Standards Association (CSA) for the U.S. and Canada.
5 - INTRODUCTION XPAK 85 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.
Fig. 1A A B C G A B C D E F G E D F 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. 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).
TECHNICAL DATA Input - Output Input - (0 - 2000 ft / 0 - 610 m) Input - (2000 - 4500 ft / 610 - 1375 m) Output (176°F - 86°F / 80°C - 30°C) Energy Guide AFUE Gas Gas supply pressure Natural Gas (A) Min. gas supply pressure Natural Gas (A) Max. gas supply pressure Natural Gas (A)** Gas supply pressure LPG (E) Min. gas supply pressure LPG (E) Max.
Boiler flue gas connection in mm Combustion air connection outer dia. in mm Free fan unit feed pressure in w. c. Pa Flue gas mass flow rate at rated full load (A) lbs/hr kg/hr Flue gas mass flow rate at rated full load (E) lbs/hr kg/hr Flue gas mass flow rate at rated partial load (A) lbs/hr kg/hr Flue gas mass flow rate at rated partial load (E) lbs/hr kg/hr Condensate flow rate (A) at max - 122/86 °F (50/30°C) USG/hr ltr/hr Condensate flow rate (A) at min.
PRINCIPLE COMPONENTS BANNED MATERIAL STATEMENT: 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.
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 Ø (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 - female 0.825” (21 mm) female 7/16” (11 mm) F 4.73” 120 mm 2.55” 65 mm A B 1.76” 45 mm C D E Fig.
DIMENSIONS AND CONNECTIONS (Fig. 4) Recommended minimum service clearances water 4-7/8” (124 mm) gas 6-13/16” (173 mm) 6” (150 mm) 150 mm 30-3/4” (781 mm) 1” (25 mm) 50 mm 8-5/8” (219 mm) 12” (300mm) 1” 50 (25 mmmm) 150 mm from casing or 25 mm above flue elbow (whichever is applicable) 5-1/2” (140 mm) 14-1/8” (359 mm) 30-3/4” (781 mm) XPak 85 = 15-3/4” (400 mm) XPak 120 = 17-3/4” (451 mm) = 1” (25 mm) Fig.
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 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.
6 - INSTALLATION PREPARE XPAK LOCATION 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. 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.
2. PLACING THE WALL-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 lbs (37 kg). XPak 120 = 93 lbs (42 kg). Failure to comply with above could result in severe personal injury, death or substantial property damage 3.
8. BOILER WITH DHW TANK - Connect the external hot-water tank according to the Installation instructions of the hot-water tank and fittings concerned. Domestic Hot Water Production via DHW 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.
XPAK INSTALLATION DIAGRAMS NOTICE: The following illustrations are simplified conceptual illustrations only. Key for installation sample diagrams 1. XPak boiler 2. Gas shut off valve 3. Expansion vessel 4. Radiators 5. Under floor heating 6. Pressure relief valve discharge pipe 7. Indirect DHW tank 8. 3-way valve 9. Room thermostat (24V) 10. Remote control (Raypak) 11. Condensate drain pipe 12. Valve ball 13. Hydraulic manifold box package 14. High limit thermostat floor heating 15. Outdoor sensor 16.
Fig. 9 Fig.
Fig. 11 Fig.
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.
BOILER TEMPLATE (Fig. 15) Wall Mounting Information XPak comes with a template, which allows you to easily mark the location of the screws for the mounting bracket and the location of the flue gas pipe on the wall (Raypak coaxial PP vent system only). The connection to the gas circuits must be made on site, 3/4” gas cock is supplied with the boiler. Wall stud 16" C/C 4,53" Hole for 60/100mm coaxial vent 3" vent adaptor (supplied) 1.
COMBUSTION AIR VENTILATION OPENINGS AND INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM 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.
VENT SYSTEMS 1 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 Z21.13b 2007 – CSA 4.9b 2007 standards and are certified together with the XPak boiler as a constructional unit.
4. MINIMUM CLEARANCES FROM VENT/AIR INLET TERMINATION Fig. 20 V = vent terminal X = air supply inlet \\\ = area where terminal is not permitted Tab. 6 A B Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened U.S. Installations1 Canadian Installations2 1 ft (30 cm) 1 ft (30 cm) 4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) * * 5 ft (1.
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 > 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.
Fig. 25 TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION a = total intake length = INTAKE b = total flue length = EXHAUST Fig.
TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION Fig. 27 a = total intake length = INTAKE b = total flue length = EXHAUST TWO PIPES SINGLE WALL ROOM AIR DEPENDENT OPERATION Fig.
Stainless Steel 3” Vent System1 US + CANADA Vent System - Room Air independent Operation (Sealed Combustion Operation) - Fig. 12-14-15-17 Tab. 7 Vent System diameter Vent system material 3” Stainless steel Two pipes vent adaptors (included with the boiler) adaptor 80 mm > 3” (included with the boiler 1 pcs) for flue - - Field supplied Field supplied Order No. Order No. 45° elbow EqL = 2 ft / 0,6m 90° elbow EqL = 3 ft / 0,9m Field supplied Order No. Bird Screen c/w Termination Venting support2 dia.
DESCRIPTION DIAGRAM P/N 013040 Two pipes vent adaptors (included with the boiler) Fig. 29-30-31-32 Pos. 1 P/N 013040 adaptor 80 mm > 3” (included with the boiler 1 pcs) Fig. 29-30-31-32 Pos. 2 Fig.
Fig. 30 a = total intake length = INTAKE b = total flue length = EXHAUST Fig.
Fig.
CONNECTING THE CONDENSATE 7 - ELECTRICAL CONNECTIONS Devices such as outdoor sensor, 3-way valve, tank sensor, tank WATER DRAIN thermostat, remote controls are all connected to the external Install the condensate drain flexible pipe (Ø 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.
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.
Tab. 9 11. TERMINAL STRIP DETAILS Description Technical specifications Indications M3 Main supply 120 VAC – 60 Hz The main supply cable must be anchored to the boiler frame (Fig. 39) and pass through the strains relief (field supplied). Cable as specified in the electrical supply. M3a 3-way valve: Connections for DHW external 3-way valve 120 VAC – 60 Hz M4 Outdoor sensor 12 K Ohm B3760 M4 Remote control Open therm plus protocol Only Raypak Part No.
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. Fig. 36 Connection Specification – Wire 22 AWG maximum to 100 ft (30 m). Outdoor Sensor is connected in the junction box on the XPak.
WIRING FUNCTIONAL DIAGRAM Fig.
TO TURN OFF GAS TO APPLIANCE to OPEN Gas Valve CLOSED If you then smell gas, STOP! Follow "B" in the safety information above this label. If you don't smell gas, go to next step. 8. Turn gas shutoff valve counterclockwise to open valve. Handle will be parallel to pipe. 9. Install top cover. 10. Turn on all electric power to appliance. 11.Set thermostat to desired setting. 12.
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 company. 2. If pH differs from above, consult local water treatment company for treatment needed.
- 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. Fig. 42a A 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.
16. FINAL CHECKS - ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS VALVE 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.
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 management functions. 1. SWITCHING ON THE APPLIANCE Switch on the boiler as follows: - Open the gas tap under the boiler by turning it counterclockwise (Fig.
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.
Open position D red indicator LED fault Fig. 46 Fig. 47 DHW mode Fig. 48 Heating mode Fig. 53 Fig. 49 Fig. 54 B green indicator LED boiler status Fig. 55 Fig. 50 Fig. 51 Fig. 56 Fig.
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 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.
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. 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.
Compensation pipe connection Fig. 60 Maximum pressure adjustment screw Minimum pressure adjustment screw NOTE: The gas valve sticker “WARNING: VALVE IS NOT FIELD SERVICEABLE” means the valve can be adjusted but not disassembled. 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.
JUMPER IN POSITION 5: unused Select KT by turning the trimmer located under the domestic hot water temperature knob (A).
OUTDOORTEMPERATURE RESET CURVES (°C) (°F) 212 194 176 FLOW TEMPERATURE 158 140 122 104 86 68 (°C) 68 59 50 41 32 23 14 5 -4 (°F) OUTDOOR TEMPERATURE FLOW TEMPERATURE Fig.
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.
12 - SERVICING INSTRUCTIONS 1. GENERAL To ensure the continued safe and efficient operation of the boiler, it is recommended 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. It should be remembered that although certain generic components may look similar, they will be specific to an individual appliance or product range.
XPak 85 E B A C D Fig. 70 WATER PRESSURE SWITCH (Fig. 69) Locate and remove the screw (I) from the water pressure switch. Remove the wiring. Carefully remove the switch. Replace in the reverse order. E XPak 120 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. E RETURN SENSOR (RETURN THERMISTOR) (Fig.
FLUE FAN & 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/rotate 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.
CONDENSATE TRAP REMOVAL (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. A 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).
13 - LPG INSTRUCTIONS This instruction must be 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 manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction.
TECHNICAL DATA - LPG Gas pressure Input - (0 - 2000 ft / 0 - 610 m) Input - (2000 - 4500 ft / 610 - 1375 m) Gas supply pressure LPG Min. gas supply pressure LPG Max. gas supply pressure LPG Burner pressure (max-min) Rate Gas Rate max LPG Gas Rate min LPG Emissions CO2 setting NOx @ max NOx @ min CO @ max without air CO @ min without air Injector size Injector LPG (E) - black coated Btu/hr kW Btu/hr kW in w. c. kPa in w. c. kPa in w. c. kPa in w. c. kPa XPak 85 25,600 - 87,000 7.5 - 25.5 25,600 - 82,900 7.
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.
14 - EXPLODED DIAGRAMS Drawing 1 2 1 12a 6 3 8 4 11 9 10 7 12a 5 59
Drawing 2 19 17 18 56a 56b 12b 56a 14 15 13 16 60
Drawing 3 XPAK 85 XPAK 120 25 25 22 28 22 26 28 12d 21d 26 12d 21d 56a 21c 12d 21b 28 24b 24c 21c 23 56a 24b 24c 56c 24d 56a 23 27 24e 21a 12c 20 24d 24e 24a 24a 61
Drawing 4 30 29 31 47 45 34 40 33 56a 35 43 41 57b 36 30 37 44 46 38 32 57 42 39 58 57b 52 Drawing 5 53 Drawing 5 Drawing 5 50 49 51 48 55 53 54 52 62
CALL OUT DESCRIPTION XPak85 XPak120 1 2 3 4 5 6 7 8 9 10 11 12 Electric/Case Components Jacket Front Boiler Mounting Bracket Control Panel Control Panel Cover Control Panel Door PC Board Control Knob Control Panel Hinge Pressure Gauge Wire Harness Kit - (Includes Complete Set of Boiler Harnesses) Control Panel Fuse Kit - (Includes Complete Set of Fuses) Retainer Clip Kit - (Includes 12a {20pcs}, 12b {1 pc}, 12c {10 pcs} and 12d {10 pcs}) 13 14 15 16 17 18 19 Water Pressure Switch Bypass Valve Distribu
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.
LIMITED WARRANTY MODULATING - CONDENSING BOILER XPAK HEATING BOILERS MODELS 85 & 120 TM SCOPE OF WARRANTY: 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.
3. 4. 5. 6. 7.
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 information may be used for warranty purposes and to ensure that the installation is correct. Additionally this form will be used to record all equipment operation functions and required settings.
Your XPak serial number for future reference www.raypak.com Raypak, Inc.
