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  5. Installation & Operating Instructions Manual

Raypak XPAK 120 Installation & Operating Instructions Manual - 6 - Installation

Other manuals for XPAK 120: User's Information Manual
Manual is about: Raypak Boiler User Manual

Summary of XPAK 120

  • Page 2

    2 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, st...

  • Page 3

    3 contents 1 - warnings 4 pay attention to these terms 4 2 - general safety 6 time/temperature relationships in scalds 6 3 - before installation 6 4 - regulations and guidelines 7 5 - introduction 8 technical data 10 principle components 12 mode of operation (at rest) 12 mode of operation 12 safety ...

  • Page 4: 1 - Warnings

    4 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. Note : minimum 18 awg, 105°c, stranded wire must be used for all low voltage (less tha...

  • Page 5

    5 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 wa...

  • Page 6: 3 - Before Installation

    6 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. (ref...

  • Page 7: 4 - Regulations And

    7 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 boiler...

  • Page 8: 5 - Introduction

    8 xpak 85 fig. 1 g f r p c 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 automat...

  • Page 9

    9 fig. 1a a pressure gauge b green led c 2-digit led display d red led e temperature selector space heating f mode selector switch g temperature selector domestic hot water f off/reset - select this position when the boiler needs to be reset or switched off. Summer mode - the domestic hot water func...

  • Page 10

    10 technical data tab. 1 xpak 85 xpak 120 input - 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 / 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 / 80°c - 30°c) btu...

  • Page 11

    11 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 w. C. 0.26 0.18 pa 65 45 flue gas mass flow rate at rated full load (a) lbs/hr 90.39 123.17 kg/hr 41 55.87 flue gas mass flow rate at rated ful...

  • Page 12

    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 w...

  • Page 13

    13 piping connections (fig. 3) legend a - boiler in connection 3/4” npt - male b - boiler out connection 3/4” npt - male c - gas supply connection 3/4” npt - female d - pressure relief valve drain connection 3/4” npt - female e - condensate connection Ø (rubber flexible) 0.825” (21 mm) female f - bo...

  • Page 14

    14 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...

  • Page 15

    15 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...

  • Page 16: 6 - Installation

    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 attempt to install the...

  • Page 17

    17 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 =...

  • Page 18

    18 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 ha...

  • Page 19

    19 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 ta...

  • Page 20

    20 fig. 10 fig. 9.

  • Page 21

    21 fig. 11 fig. 12.

  • Page 22

    22 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 ...

  • Page 23

    23 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 ma...

  • Page 24

    24 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 provisi...

  • Page 25

    25 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) - left side intake air (factory sealed with two screws) for two pipes solutions (fig. 16 pos. 2) - ri...

  • Page 26

    26 4. Minimum clearances from vent/air inlet termination u.S. Installations1 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...

  • Page 27

    27 fig. 24 fig. 23 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) pos. 1 mounting clip (set of 4) 3.94” (100 mm) for coaxial pos. 2 (fig. 24) 90° elbow 3” (80 ...

  • Page 28

    28 fig. 25 fig. 26 a = total intake length = intake b = total flue length = exhaust a = total intake length = intake b = total flue length = exhaust two pipes single wall sealed combustion operation two pipes single wall sealed combustion operation.

  • Page 29

    29 fig. 28 fig. 27 a = total intake length = 0 b = total flue length = exhaust a = total intake length = intake b = total flue length = exhaust a = 0 two pipes single wall sealed combustion operation two pipes single wall room air dependent operation.

  • Page 30

    30 stainless steel 3” vent system 1 us + canada vent system - room air independent operation (sealed combustion operation) - fig. 12-14-15-17 vent system diameter 3” vent system material stainless steel two pipes vent adaptors (included with the boiler) - - adaptor 80 mm > 3” (included with the boil...

  • Page 31

    31 fig. 29 a = total intake length = intake b = total flue length = exhaust description diagram drawing p/n 013040 two pipes vent adaptors fig. 29-30-31-32 (included with the boiler) pos. 1 p/n 013040 adaptor 80 mm > 3” fig. 29-30-31-32 (included with the boiler 1 pcs) pos. 2 two pipes single wall s...

  • Page 32

    32 fig. 31 fig. 30 a = total intake length = intake b = total flue length = exhaust two pipes single wall sealed combustion operation two pipes single wall sealed combustion operation a = total intake length = intake b = total flue length = exhaust.

  • Page 33

    33 fig. 32 two pipes single wall sealed combustion operation a = total intake length = 0 b = total flue length = exhaust.

  • Page 34: 7 - Electrical Connections

    34 fig. 34 fig. 33 b 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 l...

  • Page 35

    35 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 ...

  • Page 36

    36 remote control external sensor 0t+ m4 -t° m2 tank thermostat v room thermostat (jumper when not used) tank sensor -t° m4a m3b m3a m3 underfloor heating limit thermostat or condensate pump alarm (jumper when not used) low voltage high voltage 120v n l f= fuse 4af pcb fuse=4at cod. 20003227 3w blue...

  • Page 37

    37 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 livi...

  • Page 38

    38 wiring functional diagram fig. 40

  • Page 39: 8 - Start-Up Procedure

    39 8 - start-up procedure there are several steps involved in starting up the boiler. For your safety read before opera ting w arning : if y ou do not f ollo w these instr uctions e xactly , a fire or e xplosion ma y result causing proper ty damage , personal injur y, or loss of lif e. A. This appli...

  • Page 40: 9 - Commissioning

    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 s...

  • Page 41

    41 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 and relay in the external circuit one at a time and check th...

  • Page 42

    42 16. Final checks - ensure all test nipples 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 com...

  • Page 43: 10 - Start-Up and Operation

    43 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 fol...

  • Page 44

    44 fig. 45 a pressure gauge b green led c 2-digit led display d red led e temperature selector space heating f mode selector switch g 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 insta...

  • Page 45

    45 fig. 46 fig. 47 dhw mode heating mode fig. 48 fig. 49 fig. 50 fig. 51 fig. 52 fig. 53 fig. 54 fig. 55 fig. 56 fig. 57 closed position b green indicator led boiler status open position d red indicator led fault for al41 faults if the pressure on the water gauge located on the control panel is less...

  • Page 46

    46 5. Heating mode with the selector switch in the on position ( - - f ) 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 s...

  • Page 47

    47 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...

  • Page 48

    48 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 standard heating range °f (°c) 104-176 (40-80) floor heating ran...

  • Page 49

    49 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);...

  • Page 50

    50 outdoor temperature reset curves outdoor reset correction night setback outdoor temperature flo w tempera ture fig. 65 fig. 66 fig. 67 68 59 50 41 32 23 14 5 -4 212 194 176 158 140 122 104 86 68 outdoor temperature flo w tempera ture 86 77 68 59 50 41 32 23 14 5 -4 194 176 158 140 122 104 86 68 5...

  • Page 51

    51 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/n...

  • Page 52

    52 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 remo...

  • Page 53

    53 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. Flow sensor (primary thermistor) (fig. 1) unclip and remove the air chamber front cover. Unclip the primary thermistor from...

  • Page 54

    54 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 co...

  • Page 55

    55 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. Flue c...

  • Page 56: 13 - Lpg Instructions

    56 13 - lpg instructions lpg instructions propane gas: caution: the gas supply shall be shut off prior to disconnecting the electrical power, before proceding with the conversion. Installation codes installations must follow these codes: • local, state, provincial, and national codes, laws, regulati...

  • Page 57

    57 technical data - lpg gas pressure xpak 85 xpak 120 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 / 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 in w. C. 11 11 kpa...

  • Page 58

    58 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 ...

  • Page 59: 14 - Exploded Diagrams

    59 14 - exploded diagrams drawing 1 5 7 9 3 12a 4 6 8 12a 1 10 2 11.

  • Page 60

    60 drawing 2 17 18 56a 56a 14 15 56b 13 16 12b 19.

  • Page 61

    61 drawing 3 12d 12d 23 24c 24e 24d 24b 22 28 26 21d 56a 21c 56a 56c 21a 28 21b 24a 20 27 12c 25 23 24b 24c 24e 24d 24a 22 21d 26 28 56a 21c 12d xpak 120 xpak 85 25.

  • Page 62

    62 drawing 5 drawing 4 30 30 29 39 38 37 36 43 56a 47 42 31 33 34 40 35 41 32 44 57b 45 46 52 drawing 5 57 53 drawing 5 57b 58 49 55 51 53 52 50 48 54.

  • Page 63

    63 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...

  • Page 64: Massachusetts

    64 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 instal...

  • Page 65

    65 limited warranty modulating - condensing boiler xpak tm heating boilers models 85 & 120 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...

  • Page 66

    66 3. To damage, malfunctions or failures resulting from misuse, neglect, alteration, accident, fire, flood and the like; 4. To damage, malfunctions or failures resulting from sediment or lime buildup, freezing, or other conditions causing inadequate water circulation; 5. To damage, malfunctions or ...

  • Page 67

    67 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 thi...

  • Page 68: Www.Raypak.Com

    Your xpak serial number for future reference www.Raypak.Com raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (805) 278-5468.