Raypak 88AR–398A Installation & Operating Instructions Manual

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Page 1

INSTALLATION & OPERATING

CUS

INSTRUCTIONS

Models 88AR–398A

Type H

AVERTISSEMENT: Assurez-vous de bien suivre

WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

les instructions données dans cette notice pour réduire au minimum le risqué d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible 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.

Ne pas entreposer ni utilizer d’essence ou ni d’autres vapeurs ou liquids inflammables à proimité de cet appareil ou de tout autre appareil.

CE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAS:

Ne pas tenter d’allumer d’appareil. • Ne touchez á aucun interrupteur; ne pas vous• server des téléphones se trouvant dans la bâtiment. Appelez immédiatement votre fournisseur de• gaz depuis un voisin. Suivre les instructions du fournisseur. Si vous ne pouvez rejoinder le fournisseur,• appelez le service es incendies.

L’installation et l’entretien doivent être assurés par un installeur qualifié ou par le fournisseur de gaz.

Catalog No. 1000.66B Effective: 06-01-16 Replaces: 12-08-15 P/N 241556 Rev. 3

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Rev. 3 reflects the following: Changes to: Minor changes to pages 8, 17, 22, 29, 37, 38, 39, 40, 52, 55, 58, 59, 66 and 67. Updated Wiring Diagram

on page 47.

Additions: Information under Condensate Management on page 37. Deletions: Information under Ignition Control Functions on page 39.

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CONTENTS

WARNINGS 4

Pay Attention to These Terms 4

BEFORE INSTALLATION 5

Product Receipt 5 Model Identification 6 Ratings and Certifications 6 Installations at Elevation 6 Component Locations 7 General Information 7

BOILER DIMENSIONS 8

Time/Temperature Relationships in Scalds 9

INSTALLATION 9

Installation Codes 9 Equipment Room 10 Clearances 10 Combustion and Ventilation Air 11 Direct Vent 14 Conventional Combustion Air Supply 14 Water Piping 15 Hydronic Heating 16 System Sensor Installation 16 Applications and Modes 17 Heater Flow Rates and Pressure Drops 17 MODE 1 Water Plumbing 18 MODE 2 Water Plumbing 19 MODE 3 Water Plumbing 20 Gas Supply 21 Gas Supply Connection 21 Equivalent Pipe Length 21 Gas Supply Pressure 22 Electrical Power Connections 22 Making the Electrical Connections 23 Field Wiring Connections 24 Heating System Sensor Installation 25 Venting 28 Venting Installation Tips 31 Venting Configurations 31 Condensate Management 37 Freeze Protection 38 Controls 39

Outdoor Reset Concept 45

WIRING DIAGRAM 47

Converting Natural to Propane Gas 48 Gas Valve & Combustion Settings 49

START-UP 50

Pre Start-up 51 Pre Start-up Check 51 Initial Start-up 51 Preparation 51 Start-Up 52 Lighting Instructions 54 To Turn Off Gas to Appliance 54

TROUBLESHOOTING 55

XPak FT Error Codes 55 Heater Errors 55 Heater Faults 55 Sensor Resistance Values 55 XPak FT Fault Text 56

MAINTENANCE 58

Suggested Minimum Maintenance Schedule 58 Preventive Maintenance Schedule 58 Combustion Chamber Cleaning Instructions 60

APPENDIX 61

Inside Air Contamination 61 Important Instructions for the Commonwealth of Massachusetts 62

WARRANTY 63 START-UP CHECKLIST 64 ILLUSTRATED PARTS LIST 65

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WARNINGS

Pay Attention to These Terms

ndicates the presence of immediate hazards which will cause severe

DANGER:

I personal injury, death or substantial property damage if ignored.

WARNING:

CAUTION:

NOTE:

DANGER: Make sure the gas on which the boiler

will operate is the same type as that specified on the boiler rating plate.

WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical 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.

WARNING: To minimize the possibility of improper operation, serious personal injury, fire, or damage to the boiler:

Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

WARNING: Both natural gas and propane have an odorant added to aid in detecting a gas leak. Some people may not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar with the smell of natural gas or propane, ask your local gas supplier. Other conditions, such as "odorant fade," which causes the odorant to diminish in intensity, can also hide, camouflage, or otherwise make detecting a gas leak by smell more difficult.

WARNING: UL-recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications wherein there is a potential for an explosive mixture of fuel gas to accumulate and their installation should be in accordance with the detector manufacturer's recommendations and/or local laws, rules, regulations, or customs.

• 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: Vent connectors serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure. If an XPak FT an existing unit, the vent system MUST be verified to be of the correct size and of one of the Category IV vent materials identified in this manual. If it is NOT, it MUST be replaced.

boiler is installed to replace

WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the

State of California to cause cancer, birth defects or other reproductive harm.

WARNING: This appliance produces condensate from the flue products that is acidic and highly corrosive. Raypak recommends the use of a condensate neutralizer kit to avoid long-term damage to the drainage system and to meet local code requirements.

WARNING: Risk of electrical shock. More than one disconnect switch may be required to de-energize the equipment before servicing.

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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.

OTE: 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. Open the bleedle valve until all air is purged.

AVERTISSEMENT: N’utilisez pas cette Chaudière si une partie de celle-ci s’est retrouvée sous l’eau. Appelez immédiatement un technician de service qualifié pour inspecter la Chaudière et pour remplacer toute partie du système de contrôle et toute commande de gaz s’étant retrouvée sous l’eau.

OTE: Minimum 18 AWG, 105°C, stranded wire

must be used for all low voltage (less than 30 Volts)

xternal connections to the unit. Solid conductors

e should not be used because they can cause

xcessive tension on contact points. Install conduit

e as appropriate. All high voltage wires must be the same size (105°C, stranded wire) as the ones on the unit or larger.

AVERTISSEMENT: En cas de surchauffe ou de non fermeture de la vanne d’alimentation en gaz, n’éteignez ou ne débranchez pas l’alimentation électrique de la chaudière. Coupez plutôt l’alimentation en gaz á l’extérieur de la chaudière.

BEFORE INSTALLATION

Raypak strongly recommends that this manual be reviewed thoroughly before installing your XPak FT boiler. Please review the General Safety information before installing the unit. Factory warranty does not apply to units 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 your local Raypak representative or visit our website at www.raypak.com.

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 unit it is suggested that you visually check for external damage to the shipping carton. If the carton is damaged, make a note to that effect on the Bill of Lading when signing for the shipment. Next, remove the boiler from the carton. Report any damage to the carrier immediately.

On occasion, items are shipped loose. Be sure that you receive the correct number of packages as indicated on the Bill of Lading.

Claims for shortages and damages must be filed with the carrier by consignee. Permission to return goods must be received from the factory prior to shipping. Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted. All returned goods are subject to a restocking charge.

When ordering parts, you must specify the model and serial number of the 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. Parts will be replaced in kind only per Raypak’s standard warranties.

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Model Identification

he model identification number and boiler serial num-

T ber are found on the rating plate located on the inside upper right panel and also on inlet air decal. The model number has the form H7-198AR or similar

epending on the unit size and configuration. The let-

d ter in the first group of characters identifies the application (H = Hydronic Heating). The number which follows identifies the firing mode (7 = electronic modulation). The second group of characters identifies the size of the unit (three numbers representing the approximate MBTUH input), and, where applicable, a letter indicating the manufacturing series.

Ratings and Certifications

Standards:

• ANSI Z21.13 · CSA 4.9 - latest edition, GasFired Hot Water Boilers

• SCAQMD Rule 1146.2

All units are National Board Registered, and designcertified 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 Engineers (ASME) Boiler and Pressure Vessel Code and bears the ASME “H” stamp. This boiler also complies with the latest edition of the ASHRAE 90.1 Standard.

Fig 1: Boiler Carton Contents

Items Included:

1. (1) XPak FT Boiler

2. (1) Wall Mount Bracket

3. (6) Lag Screws

4. (2) Hold Down Brackets

5. (6) Washers

6. (1) Full-Scale Heater Template

7. (1) T & P Gauge

8. (1) Condensate Trap & Hose

9. (2) System Sensor

10. (1) Outdoor Sensor

11. (1) Installation & Operating Instructions Manual

12. (1) Propane Orifice Kit (Models 88AR & 108AR ONLY)

Installations at Elevation

WARNING: Altering any Raypak pressure vessel

by installing replacement heat exchangers or any ASME parts not manufactured and/or approved by Raypak will instantly void the ASME and CSA ratings of the vessel and any Raypak warranty on the vessel. Altering the ASME or CSA ratings of the vessel also violates national, state, and local approval codes.

Rated inputs are suitable for up to 2,000 ft elevation without de-rating. Consult your local representative or the factory for installations at altitudes over 2,000 ft above sea level. No hardware changes are required to the boilers for installations up to 10,000 ft (adjustments may be required).

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Component Location

General Information

AFUE Rating

Model

88AR 17.0 85 95 12.0 1” ½” ½” 2”/3”** 2”/3”**

108AR 22.0 110 95 13.0 1” ½” ½” 3” 3”

198AR 39.8 199 95 28.4 1-1/4” ¾” ¾” 3” 3”

278AR 55.0 275 95 36.6 1-1/4” ¾” ¾” 3” 3”

398A 39.9 399 96* 39.9 1-1/2” ¾” ¾” 3”/4”*** 3”/4”***

*Model 398A value is a Thermal Efficiency. **Model 88AR has a 3" standard vent size, but can be reduced to 2" with a shorter run. (See page 31 for details) ***Model 398A has a 4" standard vent size, but can be reduced to 3" with a shorter run. (See page 31 for details)

Input (MBH)

Min Max

Fig 2: Component Locations

Minimum

Operating

% Nat Pro Flue Intake

Input

(MBH)

Table A: Basic Data

Water Conn. (NPT)

Gas conn. (NPT) Vent Size (inches)

Page 8

Dimensions

3.79

WATER INLET

GAS SUPPLY CONNECTION

WATER OUTLET

CONDENSATE

OUTLET

AIR INLET

PRV

FLUE OUTLET

Fig 3: Boiler Dimensions

Model

88AR/

108AR

198AR/

278AR

398A 21.4 38.6 22.1 2.7 4.0 10.1 12.0 13.0 8.9 2.6 15.3 4.0 2.1

A B C D E F H J K L M N P

16.4 35.8 16.5 2.1 2.7 6.3 7.8 9.5 5.5 1.5 4.6 2.8 2.3

18.6 36.2 19.4 2.0 3.1 8.2 10.0 11.3 7.1 1.7 12.3 3.6 2.3

Table B: Basic Data

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odel No.

8AR

Boiler Water Volume

(gallons)

108AR 2.9

198AR 5.2

278AR 4.5

398A 5.9

Table C: Heater Water Volume

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.

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.

INSTALLATION

Installation Codes

Installations must follow these codes:

Local, state, provincial, and national codes, laws,• regulations and ordinances National Fuel Gas Code, ANSI Z223.1/NFPA 54 –•

atest edition (NFGC)

l National Electrical Code, ANSI/NFPA 70 - latest• edition (NEC) Standard for Controls and Safety Devices for• Automatically Fired Boilers, ANSI/ASME CSD-1, (CSD-1) when required For Canada only: CAN/CSA B149 Natural Gas• and Propane Installation Code and CSA C22.1 C.E.C. Part 1 (C22.1)

CAUTION: This boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the structure. When such locations cannot be avoided, it is recommended that a suitable catch pan, adequately drained, be installed under the appliance. The pan must not restrict air flow.

Water Temp.

Time to Produce

Serious 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

Table D: Time to Produce Serious Burn

Page 10

Fig 4: Wall Mount Installation

Equipment Room

Install CO detectors per local regulations. Boiler requires yearly maintenance, see chapter “Checks, adjustments and fault finding”.

Operating Limits of the boiler: Max. Boiler Outlet Temperature: 200°F (99°C) Max. Operating Pressure: 80 psi (5.5 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.

In addition, the unit shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation or service.

NOTE: Use of this boiler in construction areas where fine particulate matter, such as concrete or dry-wall dust, is present may result in damage to the boiler that is not covered by the warranty. If operated in a construction environment, a clean source of combustion air must be provided directly to the boiler.

Clearances Indoor Installations

When installed according to the listed minimum clearances from combustible construction, these boilers can be serviced without removing permanent structural construction around the unit. However, for ease of servicing, we recommend a clearance of at least 24 in. in front, on the rear and 24 in. above the top of the boiler. This will allow the unit to be serviced in its installed location without movement or removal of the heater.

Service clearances less than the minimum may require removal of the unit to service either the heat exchanger or the burner components. In either case, the boiler must be installed in a manner that will enable the unit to be serviced without removing any structure around the boiler.

Min.

Boiler Side

Clearances

from

Combustible

Minimum

Service

Clearances

Surfaces

Right Side 0” 1”

Left Side 0” 1”

Top 0” 24”

Front Open 24”

Vent 1” 1”

Bottom 6” 12”

Table E: Clearances — Indoor Installations

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min

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imme

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ll lo

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ile

)

is reco

in cold climates t

mmended that the in

Vent

lie

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o minimize swe

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mb io

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ila

(

n n s

f a

r ir

ion

)

ke ven

ating.

t w

(

s t

ir b a

h S

e h

Venting not shown for clarity. Boiler must be vented per

instructions in this manual

Fig. 5: Minimum Clearances from Combustible

Surfaces

Fig 6: Indoor Air Duct

Page 12

Fig 7: Two Vertical Air Ducts - Floor

Fig 8: Single Air Duct

Fig 9: Two Vertical air Ducts - Ceiling

Fig 10: Two Horizontal Air Ducts

Page 13

U.S. Installations

Canadian Installations

Clearance above grade, veranda, porch, deck, or balcony

1 ft (30 cm) 1 ft (30 cm)

Clearance to window or door that may be opened

4 ft (1.2 m) below or to side

of opening; 1 foot (30 cm)

above opening

3 ft (91 cm)

C Clearance to permanently closed window * *

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the terminal

5 ft (1.5 m) *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner 6 ft (1.83 m) *

Clearance to each side of center line extended above meter/regulator assembly

3 ft (91 cm) within a height

15 ft above the me-

ter/regulator assembly

I Clearance to service regulator vent outlet * 6 ft (1.83 m)

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance

4 ft (1.2 m) below or to side

of opening; 1 ft (30 cm)

above opening

3 ft (91 cm)

K Clearance to mechanical air supply inlet

3 ft (91 cm) above if within

10 ft (3 m) horizontally

6 ft (1.83 m)

Clearance above paved sidewalk or paved driveway located on public property

7 ft (2.13 m)

7 ft (2.13 m) t

Clearance under veranda, porch, deck or balcony

* 12 in. (30 cm) TT

In accordance with the current ANSI Z223.1/NFPA 54 N ational Fuel Gas Code

In accordance with the current CAN/CSA-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 term inal and

underside of veranda, porch, deck or balcony is greater than 1 ft (30 cm)

* Clearances in accordance with local installation codes and the requirements of the gas supplier

Fig. 11: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table F: Vent/Air Inlet Termination Clearances

Page 14

Direct Vent

If outside air is drawn through the intake pipe directly

o the unit for combustion:

1. Install the combustion air ducting kit.

. Install combustion air direct vent in accordance

with Fig. 24 (horizontal) or Fig. 26 (vertical) of this manual.

3. Ventilation of the space occupied by the boiler(s) is recommended and can be provided by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area should be at least 1 in² of free area per 20,000 BTUH (111 mm² per kW) of total input rating of all equipment in the room when the opening is communicating directly with the outdoors or through vertical duct(s). The total cross-sectional area should be at least 1 in² of free area per 10,000 BTUH (222 mm² per kW) of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct(s). Damage to the equipment due to inadequate ventilation of the space is not a warrantable failure.

4. In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of a motorized sealed damper on the air intake to prevent the circulation of cold air through the boiler during non-operating hours.

Conventional Combustion Air Supply

U.S. Installations

All Air from Inside the Building

The confined space shall be provided with TWO permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for a room large in comparison (NFGC). 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 in.2 per 1,000 BTUH (2,225 mm2 per kW) of the total input rating of all gas utilization equipment in the con- fined space, but not less than 100 in.2 (645 cm2). One opening shall commence within 12 in. (305 mm) of the top, and one opening shall commence within 12 in. (305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 in. (76 mm) in any direction.

ll Air from Outdoors

The confined space shall communicate with the out-

oors in accordance with one of the methods below.

d The minimum dimension of air openings shall not be less than 3 in. (76 mm) in any direction. Where ducts are used, they shall be of the same cross-sectional

rea as the net free area of the openings to which they

a connect.

1. Two permanent openings, one commencing within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

a. Where directly communicating with the out-

doors or where communicating to the outdoors through vertical ducts, each open- ing shall have a minimum free area of 1 in. per 4,000 BTUH (550 mm2per kW) of total input rating of all equipment in the enclosure.

b. Where communicating with the outdoors

through horizontal ducts, each opening shall have a minimum free area of 1 in.2per 2,000 BTUH (1,100 mm2per kW) of total input rating of all equipment in the enclosure.

2. One permanent opening, commencing within 12 in. (305 mm) of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 in. (25 mm) from the sides, top and bottom and 6 in. (152 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors, and shall have a minimum free area of:

a. 1 in.2per 3,000 BTUH (740 mm2per kW) of

the total input rating of all equipment located in the enclosure, and

b. Not less than the sum of the areas of all vent

connectors in the confined space.

WARNING: Do not use the “one permanent opening” method if the equipment room is under negative-pressure conditions.

Page 15

Canadian Installations

. Ventilation of the space occupied by the boiler

shall be provided by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area of

uch an opening(s) shall be at least 10% of the

s area required in 2. and 3. (below), but in no case shall the cross-sectional area be less than 10 in.2 (65 cm2).

CAUTION: All combustion air must be drawn from the air outside of the building; the mechanical equipment room must communicate directly with the outdoors.

2. For boilers using a barometric damper in the vent system, there shall be a permanent air supply opening(s) having a cross section area of not less than 1 in. to and including 1 million BTUH, plus 1 in.2per 14,000 BTUH (160 mm2per kW) in excess of 1 million BTUH. This opening(s) shall be either located at or ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down and terminated 18 in. (450 mm) from the floor, but not near piping. This air supply opening requirement shall be in addition to the air opening for ventilation air required in 1. (above).

3. For heaters when air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator, drafthood or similar flue gas dilution device installed in the same space, in addition to the opening for ventilation air required in 1., there shall be a permanent air supply opening(s) having a total cross-sectional area of not less than 1 in.2for each 30,000 BTUH (74 mm2per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere with the intended purpose of the opening(s) for ventilation air referred to in 1. This opening(s) can be ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down 18 in. (450 mm) from the floor, but not near piping.

WARNING: Care must be taken to ensure that the equipment room is not under negative pressure conditions.

per 7,000 BTUH (320 mm2per kW) up

Water Piping

NOTE: Refer to the VERSA IC®Applications Guide

(Catalog #5000.72) for detailed instructions regarding the various applications supported by the

ERSA IC control system.

General

The boiler should be located so that any water leaks will not cause damage to the adjacent area or structures.

CAUTION: This boiler requires forced water circulation when the burner is operating. See Table H for minimum and maximum flow rates. The pump must be interlocked with the boiler to prevent heater operation without water circulation.

WARNING: Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur. Refer to local codes.

Relief Valve Installation and Piping

The boiler is supplied with a Section IV “H” stamped relief valve sized for the full input of the unit. Relief valve discharge piping shall provide no less than the cross-sectional area of the relief valve outlet and must be routed to a safe point of discharge. Installation must comply with all national, state and local codes.

Temperature & Pressure Gauge

The temperature and pressure gauge is shipped loose for field installation and must be installed within 12 inches of the boiler outlet (if possible) in an easily readable location. Installation must comply with ASME Section IV as well as all applicable national, state and local codes.

Hydrostatic Test

Unlike many types of heaters, this boiler does not require hydrostatic testing prior to being placed in operation. The heat exchanger is ASME certified for 80 PSI maximum working pressure. However, Raypak does recommend hydrostatic testing of the piping connections to the unit and the rest of the system prior to operation. This is particularly true for hydronic systems using expensive glycol-based anti-freeze. Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply.

4. Refer to the B149 Installation Code for additional information.

Page 16

eaks must be repaired at once to prevent damage to

L the heater. NEVER use petroleum-based stop-leak compounds.

o perform hydrostatic test:

. Connect fill water supply. With bleed valve open,

fill boiler with water. When water flows from bleed valve, shut off water. Close bleed valve. Carefully fill the rest of the system, making sure to eliminate any entrapped air by using high-point vents. Close feed valve. Test at standard operating pressure for at least 24 hours.

2. Make sure constant gauge pressure has been maintained throughout test.

3. Check for leaks. Repair if found.

Hydronic Heating

Pump Selection

In order to ensure proper performance of your boiler system, you must install a correctly-sized pump. Raypak recommends designing for a ∆T within the range of 20°F to 60°F (8°C to 19°C). See Table H for acceptable flow rates for each model (∆T is the temperature difference between the inlet and outlet water when the heater is firing at full rate).

System Sensor Installation

The System Sensor (S3) is required for all selectable modes unless the unit’s firing rate will be controlled by an external source such as our Temp Tracker MOD+ Hybrid sequencer. Proper placement and method of installation are critical for proper operation of the system. (See Fig. 12) The sensor must be installed in a drywell in conjunction with heat conductive compound as shown in the following images. The drywell must be installed no more than 5 equivalent feet of pipe/tubing downstream of the de-coupler and installed in such a way that ensures the sensor bulb is in the flow path.

CAUTION: Be careful when installing the drywell not to over-tighten the well as this can damage the well and may prevent the sensor from fitting properly.

NPT Fitting

Thermal Paste

Drywell

System Sensor (S3)

Boiler Model

Standard Boiler Pump*

Pump HP

H7-88AR TACO 007 1/25

H7-108AR TACO 007 1/25

H7-198AR TACO 010 1/8

H7-278AR TACO 012 1/8

H7-398A TACO 012 1/8

* Pump selection based on 30° ∆T with up to 50 eq. ft. of tubing.

Table G: Pump Selection

NOTE: The 50 eq. feet of tubing typically represents

25 linear feet of tubing and 25 eq. feet of fittings.

Fig 12: System Sensor Installation

Three-Way Valves

Three-way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used.

Page 17

Applications & Modes

The VERSA IC Control system is designed for a wide range of applications. The installer/design engineer should refer to the following Modes to determine which best fits the intended application and functionality for

he unit being installed.

The XPak FT has three modes available to them to address the various applications the units can be applied to.

Mode 1

This mode is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4). The system temperature is controlled by the System sensor (S3). The Boiler Pump (P1) runs during any call for heat. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the warm weather shut down (WWSD) temperature setting (if utilized). The Boiler Pump and System Pump are delayed “off” as user-defined in the ADJUST menu. See Fig. 13 for piping example.

Mode 2

This mode is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4) with indirect DHW on the system loop (with or without priority). The system temperature is controlled by the System sensor (S3). The Indirect DHW sensor (S5) determines the indirect call/tank setpoint. The system temperature is boosted to Target Max when using the Indirect DHW sensor (S5) during an indirect call for heat. Priority mode toggles off the System Pump (P2) when an indirect call for heat is present. The Boiler Pump (P1) runs during any call for heat. The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The boiler

ump (P1) and System Pump (P2) delay “off” as user-

P defined in the ADJUST menu. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD

emperature setting (if utilized) unless an indirect call

t for heat is present with priority. See Fig. 14 for piping

xample.

Mode 3

This mode is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4) with indirect DHW on the boiler loop (with priority). The system temperature is controlled by the Supply sensor (S3) whenever the indirect call for heat is not active. The DHW Supply sensor (S5) determines the indirect call/tank setpoint. During an indirect call for heat the boiler firing rate is determined by the water temperature at the Indirect Supply sensor (S6) and the Target Max setting when using the Indirect DHW sensor (S5).

The Boiler Pump (P1) runs during all heat calls regardless of priority. The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The Boiler Pump (P1) and System Pump (P2) delay “off” as user-defined in the ADJUST menu. The system pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect call for heat is present. See Fig. 15 for piping example.

WARNING: All potable water heating with this boiler must be by an indirect heat exchanger. Only non-potable water will go through the boiler.

System flow must exceed 120% of boiler flow.

Model

No.

H7-88A 8.1 5.4 20 5.4 3.3 4.0 2.3 3.2 1.8 2.7 1.4 60

H7-108A 10.5 7.4 20 7.0 4.5 5.2 3.2 4.2 2.4 3.5 2.0 60

H7-198A 18.9 11.6 20 12.6 6.2 9.5 4.3 7.6 3.5 6.3 3.0 60

H7-278A 26.1 20.3 20 17.4 10.1 13.1 6.5 10.5 4.9 8.7 4.0 60

H7-398A 38.3 14.1 20 25.5 7.4 19.2 5.0 15.3 4.0 12.8 3.4 60

Notes: Basis for minimum flow is ∆T . Basis for maximum flow is GPM.

MAXIMUM

FLOW

GPM ΔP (ft) ΔT GPM ΔP (ft) GPM ΔP (ft) GPM ΔP (ft) GPM ΔP (ft) ΔT

Water Flow Rates

30°F

∆T

Table H: Heater Rates of Flow and Pressure Drops

40°F

∆T

50°F

∆T

MINIMUM

FLOW

Page 18

Fig 13: MODE 1 - Single Boiler - Primary/Secondary Piping

Page 19

Fig 14: MODE 2 - Single Boiler - Primary/Secondary Piping

with Indirect DHW on System Loop

Page 20

Fig 15: MODE 3 - Single Boiler - Primary/Secondary Piping

with Indirect DHW on Boiler Loop

Page 21

Gas Supply

ANGER: Make sure the gas on which the unit will

operate is the same type as specified on the rating plate.

Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve located outside the boiler jacket. It is recommended that a union be installed in the gas supply piping adjacent to the boiler for servicing. Refer to Table J for maximum pipe lengths.

Gas Supply Connection

CAUTION: The boiler must be disconnected from

the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 PSI (3.45 kPa).

The boiler must be isolated from the gas supply piping system by closing the upstream manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1/2 PSI (3.45 kPa). Relieve test pressure in the gas supply line prior to re-connecting the boiler and its manual shut-off valve to the gas supply line. FAIL-

URE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. Over-pressurized gas

valves are not covered by warranty. The boiler and its gas connections shall be leak-tested before placing the appliance in operation. Use soapy water for leak test. DO NOT use an open flame.

Fig. 16: Gas Supply Connection

CAUTION: Do not use Teflon tape on gas line pipe

thread. A pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.

CAUTION: Support gas supply piping with hangers, not by the boiler or its accessories. Make sure the gas piping is protected from physical damage and freezing, where required.

N: Natural Gas 1000 BTU/FT٨3 .60 Specific Gravity @ 0.5” WC pressure Drop

P: Propane Gas 2500 BTU/FT٨3 1.53 Specific Gravity @ 0.5” WC pressure Drop

Model

88AR

108AR

198AR

278AR

398A

Input

(KBTU)

88 35 75 135 305 440 990

110 20 50 90 205 290 720 1045

199 15 30 65 95 220 365 880 830

275 15 35 50 120 205 460 425 980

399 20 25 60 100 230 220 485

1/2” 3/4” 1” 1-1/4” 1-1/2”

N P N P N P N P N P

Maximum Equivalent Pipe Length

Table J: Maximum Equivalent Pipe Length

Page 22

Gas Supply Pressure

minimum of 4.5 in. WC upstream gas pressure

A under full load and a maximum gas supply pressure setpoint of 10.5 in. WC under load and no-load conditions for natural gas. A minimum of 8.0 in. WC

pstream gas pressure under full load and a maximum

u gas supply pressure setpoint of 13.5 in. WC is required

or propane gas. The gas pressure regulator(s) sup-

f plied on the boiler is for low-pressure service. If upstream pressure exceeds 1/2 PSI at any time, an intermediate gas pressure regulator, of the lockup type, must be installed. This regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the boiler gas controls.

When connecting additional gas utilization equipment to the gas piping system, the existing piping must be checked to determine if it has adequate capacity for the combined load. The gas valve pressure regulator on the boiler is nominally preset as noted in Table K.

During normal operation, carbon dioxide should be 8.8 to 10.5% at full fire for natural gas and between 10.2 and 10.8% for propane gas. Carbon monoxide should be ‹200 ppm.

Manifold Pressure (in. WC)

Model

No.

88AR -.1” WC -.1” WC

108AR -.1” WC -.1” WC

198AR -2.0” WC -1.4” WC

278AR -2.1” WC -2.0” WC

398A -3.4” WC -3.0” WC

Table K: Manifold Gas Pressure Settings

CAUTION: For proper operation, no more than a 30% drop in gas supply pressure from no-load to fullload conditions is acceptable. Under no circumstances should the pressure be outside the listed operational range.

Natural Gas Propane Gas

High High

Electrical Power Connections

Installations must follow these codes:

• National Electrical Code and any other national, state, provincial or local codes or regulations having jurisdiction.

• Safety wiring must be NEC Class 1.

• Heater must be electrically grounded as required by the NEC.

• In Canada, CSA C22. 1 C.E.C. Part 1.

The XPak FT 88AR-398A boilers are wired for 120 VAC single-phase 60 Hz power. Consult the wiring diagram shipped with the unit. Before starting the boiler, check to ensure proper voltage to the boiler and pump(s).

The expected current draw for the boiler is less than 5 amps. The pump load is additional.

The boiler pump (up to ¼ HP) and the indirect DHW pump (up to ¼ HP) get their power supply directly from the boiler power supply. The system pump relay is rated for pilot duty only. An indirect DHW pump larger than ¼ HP or 5A must use a separate power supply and run the power through an external field-supplied pump contactor. Use appropriately-sized wire as defined by NEC, CSA and/or local codes. All primary wiring should be 125% of minimum rating. The indirect and system pumps outputs are fuse-protected.

If any of the original wire as supplied with the boiler must be replaced, it must be replaced with 105°C wire or its equivalent.

All 120VAC field wiring connections to the XPak FT are made inside the rear wiring box as shown in Fig. 17. Low-voltage wiring is connected to the VERSA control board and the Platform Ignition Module (PIM) at the front of the unit. Sensors, enable/disable contacts, (optional) 0-10 VDC control wiring, and cas- cade connections are wired into the VERSA and PIM field wiring plugs. See the wiring diagram on page 47.

Page 23

Check the Power Source

(12 AWG)

ABK

(12 AWG)

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

s appropriate. All high voltage wires must be the

a same size (105°C, stranded wire) as the ones on the unit or larger.

Fig. 18: Multi-meter

Making the Electrical Connections

Refer to Fig. 17–25.

1. Verify that circuit breaker is properly sized by referring to the boiler’s rating plate. A dedicated circuit breaker should be provided and sized for the boiler and all pumps powered through it.

NOTE: Current draw noted on rating plate does not include pump current.

Fig. 17: Wiring Connections

WARNING: Using a multi-meter, check the

following voltages at the circuit breaker panel prior to connecting any equipment. Make sure proper polarity is followed and house ground is proven. (See Fig. 17.)

Check the power source:

AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum

2. Turn off all power to the boiler. Verify that power has been turned off by testing with a multi-meter prior to working with any electrical connections or components at the J-box inside the unit.

3. Observe proper wire colors while making electrical connections. Many electronic controls are polarity sensitive. Components damaged by improper electrical installation are not covered by warranty.

4. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code.

5. Install boiler controls, thermostats, or building management systems in accordance with the applicable manufacturers’ instructions.

6. Conduit must not be used as the earth ground.

NOTE: A grounding electrode conductor shall be used to connect the equipment grounding conductors, the equipment enclosures, and the grounded service conductor to the grounding electrode.

Page 24

Field Wiring Connections

DANGER: SHOCK HAZARD

Make sure electrical power to the boiler is disconnect-

d to avoid potential serious injury or damage to

e components.

CAUTION: Wiring errors can cause improper and dangerous operation. See the wiring diagram in this manual. Verify proper operation after servicing.

Fig. 19: Electrical Wiring

Wiring the Thermostat

Connect the Enable/Disable terminals to the PIM (shown in Fig. 20). Alternately, any dry contact closure (including a remote thermostat) across these terminals will enable the XPak FT unit to run. Caution should be used to ensure neither of the terminals becomes connected to ground.

Fig. 20: XPak FT Single Boiler Control

Page 25

Heating Sensor Installation

1. Only use the System sensor provided with the unit.

2. The sensor wires can be extended up to 500'

sing a shielded 2-conductor cable.

3. Do not run sensor wires in conduit with line voltage wiring.

4. Install a 3/8" ID 1/2 NPT immersion well.

5. If installing the system sensor on the supply, insert the sensor in a well with heat paste no more than 5' feet past the boiler loop outlet on the common supply header but before any major takeoffs. The sensor must be located where it sees the output of all the boiler stages. If a boiler is piped so that the sensor does not see its output, the VERSA IC will

not sequence the boilers correctly.

Heating System Sensor

Sensor Probe

Immersion Well 3/8” ID 1/2 NPT

Fig 21: System Sensor (S3)

Common Supply Pipe

3. Use a minimum 18 AWG wire for runs of up to 150 feet.

4. Mount the outdoor sensor on an exterior surface of

he building, preferably on the north side in an

t area that will not be affected by direct sunlight and that will be exposed to varying weather conditions.

Wiring the Indirect Sensor (S5)

1. There is no indirect sensor connection required if an indirect water heater is not used in the installation.

2. When the Indirect DHW call for heat is active, the PIM communicates this to the VERSA. The VERSA calculates the optimal operation and sends the firing rate and pump output requests to the PIM so it can activate the Indirect DHW pump and Boiler pump if needed.

NOTE: Alternately, a thermostat contact closure can be used in lieu of the sensor for indirect operation. Connect the thermostat to the terminals marked IND REMOTE THERMOSTAT.

CAUTION: Sensor and control wiring must NOT be run in conduit or chases with line voltage.

If an optional Indirect DHW sensor is connected to J2-1 and J2-2 the PIM will pass this signal to the VERSA. This allows the VERSA to optimize the Indirect DHW demand to maintain the Indirect DHW setpoint. The Indirect DHW thermostat switch closure is not required when using the Indirect DHW sensor. If a VERSA is not present the PIM shall activate the Indirect DHW pump whenever the Indirect DHW call is active. The Boiler pump may also be activated based on the Indirect DHW piping configuration setting.

NOTE: If the System Sensor (S3) can not sense the correct water temperature, the VERSA IC will not provide comfortable heat levels.

WARNING: Use only the System and Outdoor Air sensors included with the control.

Wiring the Outdoor Sensor (S4)

1. There is no connection required if an outdoor sensor is not used in this installation.

2. If using an Outdoor Sensor, connect the sensor wires to the terminals marked OUTDOOR SENSOR (see wiring diagram). Caution should be used to ensure neither of these terminals becomes connected to ground.

3. Connect the indirect tank sensor to the terminals marked INDIRECT DHW SENSOR (see wiring diagram). Caution should be used to ensure neither of these terminals becomes connected to ground.

Wiring the Optional 0–10 Volt Building Control Signal

1. A signal from an energy management system may be connected to the XPak FT boiler. This signal should be a 0-10 volt positive DC signal, and an energy management system can be used to control either the setpoint temperature or the firing rate of the XPak FT boiler.

Page 26

VERSA

MASTER

Fig. 22: XPak FT Cascade System Wiring

2. To enable this remote control function, set dip switch 5 to the UP position on the PIM. Dip switch 5 Toggles between an EMS (UP) signal or a demand signal from the VERSA (DOWN). Dip switch 2 on the PIM toggles between a Direct Drive (UP) input and a Target Temperature (DOWN) setpoint.

3. For a 4-20 mA application, refer to the VERSA IC Applications Guide.

4. Connect an Energy Management system or other auxiliary control signal to the terminals marked 010V (+ /-) on the PIM (see Fig. 20). Caution should be used to ensure that the +0-10V connection does not create a short to ground.

Wiring the Cascade System Communication Bus

1. Designate the primary boiler as the master boiler/boiler1 by leaving DIP switch 2 on the VERSA in the ON position. All other VERSA controls require DIP switch 2 to be toggled OFF, designating them as followers. Follower VERSA’s are ignored by their corresponding PIM’s. Use standard 18 AWG wire to connect the master VERSA to the PIM on the followers. A total of 3 followers can be connected to the VERSA on the master. For systems requiring more than 4 connected boilers, an external sequencer such as the Raypak Temp-Tracker Mod+ Hybrid can be used.

2. It is recommended that the shortest length cable possible be used to reach between the boilers. Do not run unprotected cables across the floor or where they will become wet or damaged. Do not run communication cables parallel with, or close to or against, high voltage (120 volt or greater) wiring. Raypak recommends that the total maximum length of each set of communication bus cables not exceed 200 feet.

3. Route the FT_BUS wires from the front along the right rail and out the bottom of the cabinets.

4. Connect the FT_BUS wires to the PIM by pressing down on the slots with a small screwdriver and then inserting the wires into the holes. See Fig.

23.

Fig. 23: FT_BUS Wire Connection

Page 27

(12 AWG)

Fig. 24: XPak FT Cascade Master Pumps

(12 AWG)

Cascade System Pump and Sensor Wiring

1. On the boiler designated as the Master, connect the system pump wiring to the terminal block at the rear of the unit. Connect to terminals 10, 11, and 12 (See Fig. 24). The output is rated for pilot duty only (2A maximum).

Cascade Follower Pump and Sensor Wiring

. Once the primary boiler has been identified, addi-

tional boilers will be designated as follower boilers. Ensure DIP switch 2 on each follower VERSA is set to the OFF/Down position (See Fig. 25)

2. For each follower boiler, connect the boiler pump wires to the terminal block at the rear of each unit. Connect to terminals 4, 5, and 6 as shown in Fig.

24.

2. Connect the boiler pump wires to the terminal block at the rear of their unit. Connect to terminals 4, 5, and 6 (See Fig. 24).

3. Connect the system supply sensor to terminals 3

Fig. 25: VERSA Follower

and 4 on the J2 connector located on the Master PIM (See Fig. 20).

Modbus BMS Communication

The VERSA IC control is equipped as standard with a communications port for connectivity to building automation via Modbus protocol. Refer to the VERSA IC Applications Guide (Catalog No. 5000.72) for fur-

4. Connect the Outdoor sensor (if used) to terminals 5 and 6 on the J2 connector located on the Master PIM (See Fig. 20).

ther information.

5. Connect the Enable/Disable wiring to terminals 9 and 10 on the J1 connector located on the Master PIM (See Fig. 20). This connection must be provided through dry contacts closure.

NOTE: This dry contacts closure can come from a room thermostat or a remote relay. No power of any kind should be applied to either of these terminals.

Page 28

Alarm Connection

The Alarm Contacts are 3A rated dry contacts on a normally-open relay that close during fault or lockout conditions, and the maximum voltage across the contacts is 30 VAC or 30 VDC. Connections are made at

he supplied alarm contacts (spade terminals).

In a cascade system, the alarm output of the master boiler will be active if either the master boiler or follower(s) have a lockout condition. The alarm output of the follower boilers will only energize if a lockout condition occurs on that specific boiler.

Venting

CAUTION: Proper installation of flue venting is

critical for the safe and efficient operation of the boiler.

WARNING: Contact the manufacturer of the vent

aterial if there is any question about the appliance

m categorization and suitability of a vent material for application on a Category IV vent system. Using improper venting materials can result in personal injury, death or property damage.

se only PVC or CPVC vent material (in Canada,

U ULC-S636 approved plastic material must be used) or special gas vent pipes listed for use with Category IV gas burning heaters, such as the AL29-4C stainless steel vents offered by Heat Fab Inc. (800-772-0739), Protech System, Inc. (800-766-3473), Z-Flex (800654-5600) or American Metal Product (800-423-4270). Pipe joints must be positively sealed. Follow the vent manufacturer’s installation instructions carefully.

DuraVent approved to be used on XPak FT products.

polypropylene vent material is also

General

Appliance Categories

Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent.

Category I – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category II – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

Category III – A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category IV – A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

See Table M for appliance category requirements.

NOTE: For additional information on appliance categorization, see the ANSI Z21.13 Standard and the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes.

Vent installation shall be in accordance with Part 7, Venting of Equipment, of the NFGC, ANSI Z223.1/NFPA 54, Section 7, Venting Systems and Air Supply for Appliances, of the B149 Code, or applicable provisions of the local building codes.

WARNING: Do not use foam core or cellular core PVC/CPVC pipe for venting.

WARNING: DO NOT insulate PVC or CPVC vent pipe.

CAUTION: When using stainless steel vent in a climate where freezing may occur, a double wall vent pipe must be used.

CAUTION: The inlet water temperature to the XPak FT must not exceed 170ºF at any firing rate to use the PVC venting option. The venting system must conform to local codes and/or the current National Fuel Gas Code ANSI Z223.1/NFPA 54. The system setpoint must not exceed 180°F.

Support of Vent Stack

The weight of the vent stack or chimney must not rest on the heater vent connection. Support must be provided in compliance with applicable codes. The vent should also be installed to maintain proper clearances from combustible materials. Use insulated vent pipe spacers where the vent passes through combustible roofs and walls.

Page 29

ombustion

COMBUSTIONCOMCOMBUCOMBUSCOMBUSTCOMBUSTICOMBUSTIOCOMBUSTION TEST PORT

COMBUSTION TEST PO

COMBUSTION TEST PORT

3 O-RING

COMBUSTION TEST PORT

3 O-RING

GASKETS

COMBUSTION TEST PORT

3 O-RING GASKETS

Air Supply

xhaust

Configuration

Heater

Venting

Category

Vertical Venting

From Inside Building (Non-Direct Venting)

Horizontal Through-

the-Wall Venting

Vertical Venting

From Outside Building

(Direct Venting)

Horizontal Through-

the-Wall Venting

* Only Duravent®polypropylene is approved for the XPak FT product.

Table L: Venting Category Requirements

ertified Vent

Materials

(Canada Only: ULC-

636 PVC and CPVC)

Stainless Steel,

AL29-4C,

Sch 40 PVC or CPVC

Polypropylene*

Combustion

Air Inlet Material

Galvanized Steel,

PVC, ABS,

CPVC

WARNING: Condensate is acidic and highly corrosive. The drain line must not be allowed to freeze. Take appropriate measures.

NOTE: During winter months check the vent cap and make sure no blockage occurs from build-up of snow or ice.

Vent Terminal Location

1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.

2. Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury.

3. Gases may form a white vapor plume in winter. The plume could obstruct a window view if the termination is installed near windows.

4. The bottom of the vent terminal and the air intake shall be located at least 12 in. above grade, including normal snow line.

5. Single-wall Category IV metal vent pipe shall not be used outdoors in cold climates for venting gasfired equipment without insulation.

6. Through-the-wall vents for Category IV appliances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

Fig. 26: 3 in 1 Multi-Vent Connector

The Multi-vent connector is capable of using stainless steel (SST), Polypropylene or PVC/CPVC pipe. Before installing vent pipe, verify which o-ring gasket will be used and dispose of the other two.

6. Locate and guard vent termination to prevent accidental contact by people or pets.

7. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area.

9. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations.

10. Locate or guard vent to prevent condensate from damaging exterior finishes. Use a 300-series stainless steel backing plate against brick or masonry surfaces.

Page 30

11. DO NOT extend exposed vent pipe outside of

VENT CAPS STACKED VERTICALLY

FLUE GASES MOVING IN PARALLEL

VENT CAPS ALL AT SAME ELEVATION

FLUE GASES MOVING TOWARD EACH OTHER

VENT CAPS AT STAGGERED ELEVATIONS

FLUE GASES MOVING TOWARD EACH OTHER

1” MINIMUM (TYP)

2” MINIMUM (TYP)

1” MINIMUM (TYP)

DISCHARGE

4’-0” MIN.

(TYP)

4’-0” MIN.

(TYP)

DISCHARGE

uilding beyond the minimum distance required

b for the vent termination. Condensate could freeze and block vent pipe.

.S. Installations

Refer to the latest edition of the National Fuel Gas

ode.

Vent termination requirements are as follows:

1. Vent must terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, window or gravity air inlet to the building.

2. The vent must not be less than 7 ft above grade when located adjacent to public walkways.

3. Terminate vent at least 3 ft above any forced air inlet located within 10 ft.

4. Vent must terminate at least 4 ft horizontally, and in no case above or below unless 4 ft horizontal distance is maintained, from electric meters, gas.

5. Terminate vent at least 6 ft away from adjacent walls.

6. DO NOT terminate vent closer than 5 ft below roof overhang.

7. The vent terminal requires a 12 in. vent terminal clearance from the wall.

8. Terminate vent at least 1 ft above grade, including normal snow line.

9. Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane.

Installations in Canada

Refer to latest edition of the B149 Installation Code.

A vent shall not terminate:

1. Directly above a paved sidewalk or driveway which is located between two single-family dwellings and serves both dwellings.

2. Less than 7 ft (2.13 m) above a paved sidewalk or paved driveway located on public property.

3. Within 6 ft (1.8 m) of a mechanical air supply inlet to any building.

4. Above a meter/regulator assembly within 3 ft (915 mm) horizontally of the vertical centerline of the regulator.

WARNING: The Commonwealth of Massachusetts requires that sidewall-vented heaters, installed in every dwelling, building or structure used in whole or in part for residential purposes, be installed using special provisions as outlined on page 62 of this manual.

5. Within 6 ft (1.8 m) of any gas service regulator vent outlet.

Fig. 26: Vent Cap Configurations

6. Less than 1 ft (305 mm) above grade level.

7. Within 3 ft (915 mm) of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building or the combustion air inlet of any other appliance.

8. Underneath a verandah, porch or deck, unless the verandah, porch or deck is fully open on a minimum of two sides beneath the floor, and the distance between the top of the vent termination and the underside of the verandah, porch or deck is greater than 1 ft (305 mm).

Page 31

odel

No.

ertified Vent

Material

Vent and

ntake Air

Vent Size

(in.)

Vertical Vent Height1 (ft)

Min. Max.

Combustion

ir Intake

Pipe

Material

Vertical Air

Inlet Max.

Length* (ft)

88AR

(Canada Only:

ULC-S636 PVC

and CPVC)

108AR

198AR

278AR

Stainless Steel,

AL29-4C,

ANSI/ASTM D1785

Sch 40 PVC,

3 100 100

Galvanized

PVC, ABS,

ANSI/ASTM F441

398A

Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. * Subtract 10 ft per elbow. Max. 7 elbows. ** Only Duravent polypropylene is approved for the XPak FT product.

Model No.

Sch 40 CPVC

Polypropylene**

Table M: Category IV Vertical Vent & Vertical Direct Vent

Size

(in.)

3 60 60

4 100 100

Approved

Intakes

Approved Plastic

Terminals

Approved SS Terminals

88AR

3" PVC/CPVC Elbow

108AR

198AR

278AR

398A 4

PVC 90° Elbow,

Sch 40

Galvanized 90°

Elbow,

SS 90° Elbow,

ABS 90° Elbow

Sch 40*,

Duravent

Polypropylene

4" PVC/CPVC Tee

Sch 40*,

Duravent

FasNSeal®FSTT 3

FasNSeal®FSTT 4

Polypropylene

Steel,

CPVC

*Must be ULC-S636 materials in Canada.

Table N: Horizontal Vent and Air Intake Terminals

Venting Installation Tips

Support piping:

• Horizontal runs—At least every 5 ft (1.5 m)

• Vertical runs—Use braces

• Under or near elbows

NOTE: Ensure adequate clearances to allow annual inspection of the venting system.

Venting Configurations

For heaters connected to gas vents or chimneys, vent installations shall be in accordance with the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes.

CAUTION: This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer’s instructions. Failure to install a condensate drain in the venting system will void all warranties on this boiler. Condensate is acidic and highly corrosive. The drain line must not be allowed to freeze. Take appropriate measures.

Vertical Venting (Category IV)

Installation

The maximum and minimum venting length for this Category IV appliance shall be determined per the NFGC (U.S.) or B149 (Canada).

Page 32

The minimum flue pipe diameter for conventional venting is: 3 in. (76 mm) for Models 88AR (2” optional), 108AR, 198AR and 278AR, and 4 in. (102 mm) for Models 398A (3” optional).

The connection from the appliance vent to the stack must be as direct as possible and shall be the same diameter as the vent outlet. The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot from the heater to the vent terminal. The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints.

The vent terminal should be vertical and should terminate outside the building at least 2 ft above the highest point of the roof that is within 8 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft hori-zontal distance is maintained) electric meters, gas meters, regulators and relief equipment.

WARNING: Vent connectors serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure. If an XPak FT boiler is installed to replace an existing boiler, the vent system MUST be verified

o be of the correct size and of Category IV AL29-4C

t vent material, approved PVC/CPVC construction, or DuraVent

polypropylene (in Canada, ULC- S636 approved plastic materials must be used). If it is NOT, it MUST be replaced..

NOTE: For extractor sizing, typical CO2 levels are

9.0% for natural gas and 10.5% for propane gas and flue temperatures of less than 180°F.

At the 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:

The distance of the vent terminal from adjacent public walkways, adjacent buildings, open windows and building openings must be consistent with the NFGC (U.S.) or B149 (Canada). Vents supported only by flashing and extending above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads.

Common Venting

The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters. This is covered in the NFGC under “Engineered Vent Systems”. Table O provides volumes of flue products at full fire for the calculation of appropriate vent and extractor sizing for common venting.

CAUTION: A listed vent cap terminal suitable for connection to the Cat IV vent materials, adequately sized, must be used to evacuate the flue products from the boilers.

WARNING: An extractor is required when multiple heaters are vented through a common vent pipe. The extractor must operate when one or more units are firing.

(a) Seal any unused openings in the common venting

system.

(b) Visually inspect the venting system for proper size

and horizontal pitch and make sure there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

NOTE: Vent and intake piping must be supported so that the weight of the venting is not transfered to the unit. Horizontal runs of vent and intake piping must be supported to prevent sagging.

NOTE: While a drain connection is required in the vent of all XPak FT installations, the drain can be accomplished in several different ways. The figures in this manual show the drain in a vent tee, however, this can also be accomplished using an inline collector for condensing stacks or an inline vertical or horizontal collector available from several of the listed vent manufacturers.

WARNING: Condensate is acidic and highly corrosive.

Page 33

oid all warranties on this boiler. The drain line must

v not be allowed to freeze. Take appropriate measures.

Installation

These installations utilize the heater-mounted blower to draw combustion air and to vent the combustion products to the outdoors. The combustion air intake and the vent are installed horizontally through the wall to the outdoors. Adequate ventilation air must be supplied to the equipment room in accordance with the NFGC (U.S.) or B149 (Canada).

The total length of the horizontal through-the-wall direct vent system should not exceed 200 equivalent ft in length. If combined vent/intake run exceeds 200 equivalent ft, an appropriately sized variable-speed extractor must be used. Each elbow used is equal to 10 ft of straight pipe with a maximum of 4 elbows each on the air intake and vent.

ermination

The vent cap MUST be mounted on the exterior of the

uilding. The vent cap cannot be installed in a well or

b below grade. The vent cap must be installed at least 1 ft above ground level and above normal snow levels. Only Raypak-approved vent caps may be used. The

ent terminal must be located NO CLOSER than 12”

v off the wall.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

The vent cap is not considered in the overall length of the venting system.

The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight. The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that:

1. The vent must be installed with condensate drains as directed by the vent manufacturer.

2. The vent must be installed with a slight upward slope of not less than 1/4 inch per foot of horizontal run to the vent terminal.

Page 34

Horizontal Through-the-Wall Direct Venting (Category IV)

Fig. 27: Horizontal Through-the-Wall Venting

Fig. 28: Horizontal Through-the-Wall Direct

Venting

Fig. 29: Horizontal Through-the-Wall Venting w/ Single Termination

Page 35

Fig. 30: Direct Vent - Vertical

Fig. 31: Vertical Venting w/ Stainless

Termination Cap

Fig. 32: Direct Venting w/ Elbow Terminations Fig. 33: Vertical Concentric Venting

Page 36

Fig. 34: Vertical - Elbow Vent Termination

Fig. 35: Vertical - Stainless Termination Cap

Fig. 36: Vertical - Concentric Vent Termination

Fig. 37: Vertical - Stainless Tee Termination

Page 37

Direct Vent—Horizontal

Installation

These installations utilize the heater-mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors.

The total length of air supply pipe cannot exceed the distances listed in Table M. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in any arrangement that does not exceed the lengths shown in Table M.

The vent cap is not considered in the overall length of the venting system.

Care must be taken during assembly that all joints are sealed properly and are airtight.

Combustion air supplied from outdoors must be free of

articulate and chemical contaminants. To avoid a

p blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.

Condensate Management

he condensate must be drained properly to protect

T the appliance and drainage system. The condensate from the boiler is acidic. Its pH is between 3.2 and 4.5. Raypak recommends treating the condensate with a Condensate Treatment kit (Z-12). The treatment kit is connected to the drain system and contains limestone (calcium carbonate) chips to raise the pH level of the condensate. The kit may be added to avoid long-term damage to the drainage system and to meet local code requirements. The pH level of the effluent entering a sanitary drain must be 5.0 or higher.

The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that:

1. The vent must be installed with a condensate drain as directed by the vent manufacturer.

2. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of horizontal run to the vent terminal.

CAUTION: This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer’s instructions. Failure to install a condensate drain in the venting system will void all warranties on this boiler. Note that the condensate is acidic and highly corrosive.

Termination

The vent cap MUST be installed on the exterior of the building. The vent cap cannot be installed in a well or below grade. The vent cap must be installed at least 1 ft above ground level and above normal snow levels.

Vent pipe condensate drains are also required for installation of the XPak FT. Follow vent manufacturer instructions for location of condensate drains in the vent. The vent condensate should also be routed through a treatment kit, as required by local code requirements.

The treatment kit must be sized to the condensate generated by the appliance and the vent.

The condensate drain line must not be allowed to freeze. Take appropriate measures.

Expected max condensate volume:

88AR 0.9 GPH 108AR 1.1 GPH 198AR 2.0 GPH 278AR 2.8 GPH 398A 4.0 GPH

The vent cap MUST NOT be installed with any combustion air inlet directly above a vent cap. This vertical spacing would allow the flue products from the vent cap to be pulled into the combustion air intake installed above. This type of installation can cause non-warrantable problems with components and poor operation of the boiler due to the recirculation of flue products. Multiple vent caps installed in the same horizontal plane must have a 4 ft clearance from the side of one vent cap to the side of the adjacent vent cap(s).

Page 38

Freeze Protection

o enable freeze protection, DIP switch position 7 (on

T the PIM) must be turned on (UP position). This is the default position.

f the water temperature drops below 45˚F on the

I Outlet or Inlet sensors, the Boiler pump is enabled. The pump is turned off when both the Inlet and Outlet temperatures rise above 50˚F.

If either the Outlet or Inlet temperature drops below 38°F, the VERSA starts the burner at the minimum firing rate. The burner cycle will terminate when both the Inlet and Outlet temperatures rise above 42°F.

CAUTION: In general, the condensate piping from the appliance must have a downward slope of ¼” per horizontal foot. Condensate drain traps must be primed with water to prevent gas flue leaks.

reatment kits should be checked at least once per

T year, to ensure that the pH of the effluent is 5.0 or higher, and the chips should be replenished as necessary. When replacing the chips, they should be no smaller than ¾” to avoid blockage in the condensate piping. Fig. 38 is a visual guide only. Follow the manufacturer’s instructions for the installation of the treatment kit and condensate drains.

WARNING: Installation, adjustment and service of controls, including timing of various operating functions, must be performed by a qualified installer, service agency or the gas supplier. Failure to do so may result in control damage, malfunction, property damage, personal injury, or death.

CAUTION: This appliance has provisions to be connected to more than one supply source. To reduce the risk of electric shock, disconnect all such connections before servicing.

CAUTION: Risk of electric shock: More than one disconnect switch may be required to de-energize the equipment before servicing.

Fig. 38: Visual Guide for Condensate Piping

Page 39

Controls

Ignition Control Functions

When there is a call for heat, and all safeties are

losed, then the combustion air blower starts to purge

c air from the combustion chamber. After the pre-purge,

he igniter is energized. The ignition module will lock-

t out after failing to light 3 times during a call for heat. To reset the lockout, press and release the RESET button located on the user interface. The con- trol will automatically reset after 1 hour. When in lockout the control will run the blower through a post- purge cycle.

NOTE: Ignition modules are common for all model sizes. However, model-specific operating parameters are defined by their respective ID cards.

High Limit — Manual Reset

he heater is equipped with a fixed-setting manual-

T reset high limit temperature device as standard, set at 200ºF, and it may have an additional optional adjustable manual reset high temperature device.

Standard

The fixed-setting manual-reset high limit is built into the PIM, and utilizes a dual element sensor located on the outlet. To reset a high limit lock-out, press and release the RESET button located on the user interface.

Optional

The optional adjustable-setting manual-reset high limit is located behind the front panel. To reset a high limit lockout, press the reset button on the adjustable manual reset limit as well as the reset button located on the user interface.

Flue Temperature Limit

The heater is equipped with a fixed-setting manualreset high limit temperature device on the vent, for use with non-metallic vent material. The high temperature limit is located inside the unit near the vent adapter. The VERSA monitors the limit and displays any fault associated with the limit on the user interface. To reset the limit, access it and press down on the red button.

The unit is provided with a limit rated for PVC vent material. A higher-rated limit is provided when using DuraVent®polypropylene venting. The limit is removed when using Category IV stainless steel venting.

Fig. 39: Flue Temperature Limit

Page 40

Test/Reset

PRESSPRESS TO START

PRESS T

PRESS TO ST

PRESS TO STAR

PRESS TO START

Low Water Cut-Off (Model 398A Only)

The standard low water cut-off automatically shuts

own the burner whenever water level drops below the

d level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Manual reset is required to restore operation

Fig. 40: Low Water Cut-Off

All-In-One Low Water Cut-Off (Models 88AR-278AR)

The standard low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe.

This device will automatically reset once the correct water level is restored. The VERSA control will continue to maintain lockout for 15 minutes (soft lockout). During that time, press ‘RESET’ to restart the unit.

pressure drops below the factory setting of 3.0 in. WC for natural gas or propane gas.

The high gas pressure switch connection mounts downstream of the gas valve. Special ports are located on the backside of the gas valve and are accessible from the front or top of the boiler (to reset the gas pressure switch), as necessary. If the gas pressure regulator in the valve fails, the high gas pressure switch automatically shuts down the burner.

The High gas pressure switch shuts down the boiler if the gas supply pressure rises above the factory setting of 3.0” WC for either natural or propane gas.

Fig. 42: High/Low Gas Pressure Switch

Operation of either the High or Low Gas Pressure Switch will turn on an LED inside the switch housing. Push the top of the plastic switch housing as shown in Fig. 42 to reset a tripped pressure switch. The LED will go out when the switch is reset.

These safety devices can emit small amounts of fuel gas, and must be piped to a safe discharge location outdoors, per local code requirements.

Fig. 41: Low Water Cut-Off

High & Low Gas Pressure Switches (Field Add-On)

The low gas pressure switch connection mounts upstream of the gas valve (on the inlet flange to the gas valve) and is accessible through the removable access panels on the front of the boiler to reset the gas pressure switch, as necessary. It is used to ensure that sufficient gas pressure is present for proper valve/regulator performance. The low gas pressure switch automatically shuts down the boiler if the gas supply

Blocked Vent Switch

The heater is equipped with a blocked vent pressure switch to prevent the operation of the boiler when a significant amount of air flow is blocked at the vent. The switch is located at the left rear of the unit.

Fig. 43: Blocked Vent Switch

Page 41

User Interface

The user interface consists of several Menu options. Press the MENU button to scroll through the different menus in the interface. Press the ITEM button to scroll through available items within a selected menu. And,

he UP and DOWN buttons allow for setting changes

t to items in the ADJUST menu. Refer to Fig. 44 for display and key locations.

View Menu

The VIEW menu is the default menu. See Table P. It displays sensor temperatures, the modulation rate of the blower, heater cascade status, pump operation

nd CFH information. Some of the items displayed are

a mode-specific and are only observable when its corresponding mode is active.

For detailed descriptions of the various screens, consult the VERSA IC Control Applications Guide (Catalog No. 5000.72).

Adjusting the XPak FT Setpoint

To adjust the setpoint on the XPak FT:

Use the MENU key to scroll to the ADJUST menu, then use the ITEM key to scroll to the SETPOINT item. Adjust the Setpoint using the UP and DOWN arrow keys. Minimum is 50°F, Maximum is 192°F, and the default is 180°F for H models.

Setup Menu

To change settings use the MENU key to scroll to the ADJUST menu. The ADJUST menu allows the

installer to make adjustments to items shown in Table Q.

Refer to the VERSA IC Control Applications Guide (Catalog #5000.72) for detailed setup instructions.

Item Application Description

OUTDOOR MODE 1, 2, 3 Outdoor air temperature, available when TARGET = RSET in ADJUST menu.

Target MODE 1, 2, 3

SUPPLY MODE 1, 2, 3 Current system supply temperature

IND SUPPLY MODE 3 Current temperature being supplied to the indirect system

Boil OUTLET All Current boiler outlet temperature

Boil INLET All Current boiler inlet temperature

Boil ΔT All Current temperature difference between boiler outlet and boiler inlet

DHW SUPPLY MODE 2, 3 Current indirect DHW supply temperature

BOILER STATUS All IDLE, PREP, IGN, MOD RATE %, POST, SOFT

Fig. 44: User Interface

Current target temperature, available when TARGET = SETP in ADJUST menu (Defautl), (EMS /MODB)

Table P: View Menu

Page 42

Item Application Range Description Default User

TARGET MODE 1, 2, 3 RSET <> SETP RSET = Outdoor Reset, SETP =Setpoint SETP

MODE MODE 1, 2, 3 1, 2, 3 Piping and application configuration. 1

SETPOINT MODE 1, 2, 3 50°F to 192°F

OUT START MODE 1, 2, 3 35°F to 85°F Outdoor starting temperature - outdoor reset 70°F

OUT DESIGN MODE 1, 2, 3 -60°F to 45°F Outdoor design temperature - outdoor reset 10°F

Boil START MODE 1, 2, 3 35°F to 150°F

Boil DESIGN MODE 1, 2, 3 70°F to 200°F

TARGET MAX MODE 1, 2, 3 100°F to 192°F Maximum target system temperature 192°F

TARGET MIN MODE 1, 2, 3 OFF, 50°F to 190°F Minimum target system temperature 50°F

TARGET DIFF MODE 1, 2, 3 2°F to 42°F Differential for target system temperature 10°F

IND SENSOR MODE 1, 2, 3 OFF <> ON

IND SETP MODE 2, 3 OFF, 50°F to 180°F

DHW DIFF MODE 2, 3 2°F to 10°F

IND SUPPLY MODE 2, 3 OFF, 50°F to PIM value*

Boiler target temperature while a heat

demand is present for setpoint operation

Starting boiler target temperature when the outdoor temperature is at outdoor start out-

door reset

Design boiler target temperature when the

outdoor temperature is at outdoor design

outdoor reset

Selects whether a DHW sensor is used for

indirect DHW tank

Target Indirect DHW Tempererature (IND

Sensor = ON, to enable this setting)

Differential for the target indirect DHW tank

temperature, Requires IND Sensor = ON

Target boiler temperature for the DHW heat

exchanger during indirect DHW operation,

requires IND Sensor = OFF

180°F

70°F

180°F

OFF

140F

6°F

180°F

DHW

PRIORITY

PRI OVR MODE 2, 3 Au, 0:10hr to 2:00hr

SYS PURGE All OFF, 0:20min to 20:00min

MIX TYPE All H (BOIL <> PLNT)

MIX TARGET All 50°F TO 140°F Inlet Target Temperature 120F

MIX LOCK All ON <>OFF

MIX TRIM All -5 to 5

MIX SPEED All FAST <> MED <> SLOW This setting defines speed of response. MED

MIX INV All ON <>OFF

WWSD MODE 1, 2, 3 40°F to 100°F

UNITS All deg F <> deg C Show units using icons in display deg F

MODBUS All OFF<>MNTR<>TEMP<>RATE

ADDRESS All 1 to 247 ModBus slave address 1

DATA TYPE All RTU <> ASCI Modbus data type RTU

BAUD RATE All 2400<>9600<>19K2<>57K6<>115K 19K2

PARITY All NONE<>EVEN<>ODD EVEN

* Fixed values based on the ID card.

MODE 2 OFF <> ON

Selects whether or not Indirect DHW priority

is active during indirect DHW operation

Sets the length of the indirect DHW priority

override time

Sets the length of the system pump post

purge

Selects the type of control depending on

pipe configuration for CWP

The equipment will trigger a warning when

“MIX Target” is not reached within 7 min-

utes. MIX LOCK = ON Alarm and lockout,

MIX LOCK = OFF Alarm only

This adjustment is for various types and

sizes of units as well as various actuator

motor speeds and types supplied by Raypak

This option is related to the use of spring return actuators with a proportional valve

The system warm weather shutdown tem-

perature outdoor reset, requires TARGET =

REST

ModBus Operating Mode: Off, Monitor, Temp

Control, Rate Control

OFF

1:00hr

seconds

H BOIL

OFF

70°F

OFF

Table Q: Adjust Menu

Page 43

Boiler View Menu

The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information

Item Application

BOILER 1 ALL Enables Boiler for operation

BOILER 2 CASCADE Enables Boiler for cascade operation

BOILER 3 CASCADE Enables Boiler for cascade operation

BOILER 4 CASCADE Enables Boiler for cascade operation

IDLE=no CFH PREP=pre-purge or inter-purge between trials for ignition IGN=trial for

ignition BURN=burner operating POST=post purge HARD=a hard lockout fault has

occurred requiring manual reset (Ignition Lockout or manual high limit) and SOFT=a

IGNITION ALL

LIMIT TEMP ALL Current Outlet -Limit temperature N/A

EMS Vdc ALL Current EMS signal in Volts DC N/A

FIRE RATE ALL PIM N/A

SPEEDX 1000 ALL Blower speed in revolutions per minute (rpm) x 1000 N/A

OUTLET MAX Mode 1, 2, 3

OPERATOR ALL Operator Potentiometer setting on PIM N/A

DIFF ALL Current auto differential – Fixed by PIM N/A

Pump Post ALL Sets the length of the boiler pump purge N/A

FLAME CUR ALL Flame current in micro-amps (µA) N/A

soft lockout fault has occurred which interrupts the heating cycle (any safety other

than ignition or manual high limit).

The CFH will resume after the soft lockout fault has been corrected and a 15 min.

Defines Max Outlet temperature offset above Target Setpoint (Press and hold up and

down arrows for 3 seconds to enable adjustment), see Versa IC manual, catalog

Description User

N/A

waiting period has expired.

5000.72.

MASS ALL Thermal mass recovery, see Versa IC manual, catalog 5000.72.

IDENTITY ALL Identifies the unit as boiler, water heater or pool heater N/A

IGN TYPE ALL PIM Board type N/A

ID CARD ALL Identifies Raypak Identity Card N/A

SW ID ALL PIM Software identification number N/A

ERROR CODE ALL Current Error Code N/A

Table R: Boiler View Menu

Page 44

Monitor Menu

he Monitor Menu records and displays critical Boiler information, such as, Cycle times, Run times, and

T Maximum/Minimum temperature readings depending on the setup.

Item Application Description

RUN TIME Burner 1 All Burner run time (hours). Press UP/DOWN for 1 sec to clear.

Cycles Burner All Number of burner cycles. Press UP/DOWN for 1 sec to clear.

RUN TIME Boiler pump All Boiler pump run time (hours). Press UP/DOWN for 1 sec to clear.

RUN TIME System pump All System pump run time (hours). Press UP/DOWN for 1 sec to clear.

RUN TIME DHW pump MODE 2, 3 DHW pump run time (hours). Press UP/DOWN for 1 sec to clear.

OUTLET HI All

OUTLET LO All

INLET HI All

INLET LO All

DELTA T All

OUTDOOR HI MODE 1, 2, 3

OUTDOOR LO MODE 1, 2, 3

SYSTEM HI All

SYSTEM LO All

IND HI MODE 1, 2, 3

IND LO MODE 1, 2, 3

Records the highest boiler outlet temperature. Press UP/DOWN for 1 sec to clear.

Records the lowest boiler outlet temperature. Press UP/DOWN for 1 sec to clear.

Records the highest boiler inlet temperature. Press UP/DOWN for 1 sec to clear.

Records the lowest boiler outlet temperature. Press UP/DOWN for 1 sec to clear.

Captures the highest Delta T Temperature recorded Press UP & DOWN buttons for 3 sec to clear this entry

Records the highest outdoor temperature. Press UP/DOWN for 1 sec to clear.

Records the lowest outdoor temperature. Press UP/DOWN for 1 sec to clear.

Records the highest supply temperature. Press UP/DOWN for 1 sec to clear.

Records the lowest supply temperature. Press UP/DOWN for 1 sec to clear.

Records the highest Indirect supply temperature. Press UP/DOWN for 1 sec to clear.

Records the lowest Indirect supply temperature. Press UP/DOWN for 1 sec to clear.

Table S: Monitor Menu

Page 45

Toolbox Menu

he Toolbox Menu logs all error codes from the VERSA and PIM, as well as other functions. Up to 15 error codes

T can be logged for a maximum of 24 days.

tem

Lookup Active Error Look up and display the active error info.

USER TEST

MAX HEAT

P/N 104901 Software number of the Raypak VERSA

DEFAULTS

HISTORY

lookup logged error

Select ON to start the function. The setting returns to default after the test is run.

(See Page 52 for details.)

Select ON to start the function. The setting will time out to OFF after 24 hours or can

be set to OFF again by the user. (See VERSA IC Applications Guide for details.)

Resets to factory settings. Press UP and DOWN for 1 second to show CLR and load

factory defaults to all settings. This will also clear all history.

Displayed when an error code is present. 1 indicates the most recent error code.

Press UP and DOWN for 1 second to clear the error logs.

Table T: Toolbox Menu

Outdoor Reset Concept

The Temperature controller can change the System Set Point based on outdoor temperature (Outdoor Reset). The temperature controller varies the temperature of the circulating heating water in response to changes in the outdoor temperature. The heating water temperature is controlled through the modulation and/or sequencing of the cascade.

The Temperature controller can also control the system circulating pump with an adjustable Outdoor Cutoff. When the outdoor temperature is above the Outdoor Cutoff, the pump is turned off and no heating water is circulated through the system. When the outdoor temperature drops below the Outdoor Cutoff, the system pump relay is activated and the heating water circulates through the system. The temperature of the heating water is controlled by the Reset Ratio, Water Offset, and changes with the outdoor temperature.

Reset Ratio/Outdoor Reset

When a building is being heated, heat escapes through the walls, doors, and windows to the colder outside air. The colder the outside temperature, the more heat escapes. If you can input heat into the building at the same rate that it is lost out of the building, then the building temperatures will remain constant. The Reset Ratio is an adjustment that lets you achieve this equilibrium between heat input and heat loss.

escription

The starting point for most systems is the 1.00 (OD):1.00 (SYS) (Outdoor Temperature: Heating Water Temperature) ratio. This means that for every degree the outdoor temperature drops, the temperature of the heating water will increase one degree. With the VERSA, both ends of the slope are adjustable. It is factory-set at 70°F water temperature (Boil START) at 70°F outdoor air (OUT START), and 180°F water temperature (Boil DESIGN) at 10°F outdoor air (OUT DESIGN).

Each building has different heat loss characteristics. A very well insulated building will not lose much heat to the outside air, and may need a Reset Ratio of 2.00 (OD):1.00 (SYS) (Outdoor: Water). This means the outdoor temperature would have to drop 2 degrees to increase the water temperature 1 degree. On the other hand, a poorly insulated building may need a Reset Ratio of 1.00 (OD):2.00 (SYS). This means that for each degree the outdoor temperature dropped the water temperature will increase 2 degrees. The VERSA control Reset Ratio allows for full customization to match any building’s heat loss characteristics.

A heating curve that relies not only on Outdoor temperature but also on the type of radiation will improve heat comfort. The user can fine-tune these adjustments based on the specific building need.

Page 46

RESET RATIO

The control uses the four following settings to determine the reset ratio:

Boiler Start (Boil START)

he Bo il START temp er ature is the theo re tical bo iler s upply water t em perat ure that th e heat in g system re qu ires whe n the out door air

temperature equals the OUT START temperature setting. The Boil START is typically set to the desired building temperature.

utdoor Start (OUT START)

The OUT START temperature is the outdoor air temperature at which the control provides the Boil START water temperature to the system. The OUT START is typically set to the desired building temperature.

Outdoor Design (OUT DESIGN)

The OUT DESIGN is the outdoor air temperature that is the typical coldest annual temperature where the building is located. This temperature is used when completing heat loss calculations for the building.

Boiler Design (Boil DESIGN)

The Boil DESIGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the OUT DESIGN temperature.

Warm Weather Shut Down (WWSD)

When the outdoor air temperature rises above the WWSD setting, the co ntrol tu rns on the WWSD se gment in the display. Wh en the co ntrol is in Warm Weather Shut Down, the Dem 1 segment is displayed if there is a heat demand. However, the control does not operate the boiler to satisfy this demand. The control continues to respond to DHW demands.

Decreasing Outdoor Temperature

Increasing Water Temperature

Boil

START

OUT

DESIGN

Boil DESIGN

START

OUT

RESET RATIO =

(OUTDOOR START – OUTDOOR DESIGN)

(BOILER DESIGN – BOILER START)

Reset Ratio

The controller uses the following four settings to calculate the Reset Ratio (RR):

For example, when using the default values, the RR is:

RR = (70 - 10) / (180 - 70) = 0.55

Therefore, the RR is 0.55:1 (Outdoor:Water).

Fig. 45: Reset Ratio

Page 47

WIRING

DIAGRAM

Fig. 46: Wiring Diagram

Page 48

CONVERTING NATURAL TO

ROTATERROTROTAROTATROTATE TO OFF

ROTATETROTATE TO OFF

RUBBERRRUBBER GROMMET

RUBBERGRUBBER GRO

RUBBER GROM

RUBBER GROMM

RUBBER GROMME

RUBBER GROMMET

PROPANEPPROPROPPROPAPROPA NPROPAN E ORIFICE

PROPANE ORIFICE

ASSEMBLEDASSEMBLED ORIFICE IN

ASSEMBLED ORIFICE IN

GROMMET

ASSEMBLED ORIFICE IN G

ASSEMBLED ORIFICE IN GRO

ASSEMBLED ORIFICE IN GROM

ASSEMBLED ORIFICE IN GROMM

ASSEMBLED ORIFICE IN GROMME

ASSEMBLED ORIFICE IN GROMMET

GASGAS VALV E

GASVGAS VAL

GAS VALV E

PROPANEPPROPROPPROPAPROPANPROPAN E ORIFICE

PROPANE ORIFICE

RUBBERRRUBBER GROMMET

RUBBERGRUBBER GRO

RUBBER GROM

RUBBER GROMM

RUBBER GROMME

RUBBER GROMMET

ALLEN

RUBBER GROMMET

ALLEN

SCREWS

RUBBER GROMMET

ALLEN SCREWS

BLOWER/

RUBBER GROMMET

ALLEN SCREWS

RUBBER GROMMET

ALLEN SCREWS

BLO

RUBBER GROMMET

ALLEN SCREWS

BLOW

RUBBER GROMMET

ALLEN SCREWS

BLOWE

RUBBER GROMMET

ALLEN SCREWS

BLOWER

RUBBER GROMMET

ALLEN SCREWS

BLOWER/

VENTURI

RUBBER GROMMET

ALLEN SCREWS

BLOWER/ VENTURI

ROTATERROTROTAROTATROTATE TO OFF

ROTATE T

ROTATE TO OFF

ENTURIVENTURI

UNION

VENTUR

UNION

GAS VALVEGAS GAS VAGAS VALVGAS VALVE ASSEMBLY

GAS VALVE ASSEMB

GAS VALVE ASSEMBLY

BLOWER

GAS VALVE ASSEMBLY

BLO

GAS VALVE ASSEMBLY

BLOW

GAS VALVE ASSEMBLY

BLOWE

GAS VALVE ASSEMBLY

BLOWER

SCREW

GAS VALVE ASSEMBLY

BLOWER

SCREW

GAS VALVE ASSEMBLY

BLOWER

SCREW

VENTURIVENTURI

PROPANE GAS

These instructions are intended for boilers manufactured for Natural Gas. The instructions must be

ollowed by a trained qualified technician or manufac-

f turing representative.

1. Turn power OFF to the boiler.

2. Remove screws holding top panel in place (located above boiler).

3. Turn Supply Gas OFF and/or turn the Manual Valve to the OFF position (see Fig 47).

Fig. 49: Rubber Seal & Propane Orifice

10. Re-install grommet in between Venturi and Valve assembly.

11. Re-install Allen screws to secure Gas Valve assembly.

12. Tighten union to secure supply line to Gas valve.

13. Turn manual valve back on.

14. See “Gas Valve Adjustment” before running boiler.

For Models 198AR thru 398A

6. Loosen the Venturi union from the Manifold nipple (see Fig 50).

Fig. 47: Shut-Off Valve & Venturi Location

88AR thru 108AR

4. Disconnect Gas Valve power harness.

5. Loosen union above Manual Valve.

For Models 88AR & 108AR (orifice supplied)

6. Remove the two Allen screws holding the Gas Valve to the Venturi/Blower assembly (see Fig 48).

Fig. 48: Gas Train Assembly 88AR thru 108AR

7. Remove the Gas Valve assembly. This will reveal the rubber grommet between the Gas Valve and Venturi assembly.

8. Remove the rubber grommet.

9. Insert the Propane orifice inside this grommet. There is a thin slot allocated for the orifice to slip into. (see Fig 49).

Fig. 50: Shut-off Valve & Venturi Location

198AR thru 398A

7. Remove the Gas Valve assembly and set aside.

8. Remove the (3) screws holding the Natural Gas Venturi to the Blower (see Fig 51).

Fig. 51: Gas Train Assembly 198AR thru 398A

Page 49

9. Replace the Natural Gas Venturi with the Propane

BLOWERBBLOBLOWBLOWEBLOWER

SCREW

BLOWER

SCREW

BLOWER

SCREW

VENTURIVENTURI

HI FIRE THROTTLEHI FIRE THHI FIRE THROHI FIRE THROTHI FIRE THROTTHI FIRE THROTTLHI FIRE THROTTLE (

FLAT SCREWDRIVER)

HI FIRE THROTTLE (FL

HI FIRE THROTTLE (FLA

HI FIRE THROTTLE (FL

AT SCREWDRIVER)

LO FIRE OFFSET

HI FIRE THROTTLE (FL

AT SCREWDRIVER)

HI FIRE THROTTLE (FL

AT SCREWDRIVER)

LO FIRE OFFSET

(

ALLEN WRENCH)

HI FIRE THROTTLE (FL

AT SCREWDRIVER)

LO FIRE OFFSET (ALLEN WRENCH)

GAS VALVEGAS GAS VAGAS VALVGAS VALVE

Venturi (see Fig 52).

Fig. 53: Setting Hi Fire Throttle / LO Fire Offset

Fig. 52: Propane Venturi

10. Re-install (3) screws to secure the Propane Venturi to Blower.

11. Re-install Gas Valve assembly to Venturi by securing the union between them.

12. Tighten union to secure supply line to Gas valve.

13. Turn manual valve back on.

14. See “Gas Valve Adjustment” before running boiler.

GAS VALVE ADJUSTMENT

A Gas Valve adjustment is required to attain optimal performance from the boiler when replacing one or converting gas. These instructions must be followed by a trained qualified technician or manufacturing representative.

Valve adjustment throttle locations are indicated on Figure 53.

CAUTION: Adjust the proper throttle on Hi Fire and/or Offset on LO Fire. Adjustment of the LO fire offset while the heater is running on Hi Fire may cause the valve to work improperly and vice versa.

Setting Hi Fire Throttle:

1. Turn the needle down (clockwise) until the needle bottoms out.

2. Follow Table U below for the number of 360° counter-clockwise turns needed for each model and Gas Type.

3. Once adjustment is made, turn heater on.

4. Adjust 0-10 VDC SIGNAL to 10 VDC.

5. Wait until “FIRE RATE” reaches 100%.

6. Adjust Hi Fire Throttle (see Fig. 53)) to get within the combustion range required.

Setting LO Fire Offset (while heater is running on LO Fire):

1. Adjust 0-10 VDC signal to 1 VDC.

2. Wait until Blower RPM reaches 1300 RPM.

3. Using an Allen wrench turn the Offset slightly clockwise to increase CO2values (see Fig. 53).

4. Adjust 0-10 VDC signal back to 10 VDC.

5. Verify combustion is still within range given in Table U. Adjust if necessary.

GAS VALVE & COMBUSTION SETTINGS - NATURAL GAS

Model

88AR 3-1/2 108AR 3-1/2 198AR 4-1/2 -2.0 ± 0.1"WC 278AR 5-3/4 -2.1 ± 0.1"WC

398A 5 -3.4 ± 0.2"WC

Model

88AR 3-1/2 108AR 3-1/2 198AR 4 -1.4 ± 0.1"WC

Turns Manifold

-0.1 ±0.05"WC

GAS VALVE & COMBUSTION SETTINGS - PROPANE GAS

Turns Manifold

-0.1 ±0.05"WC

278AR 4-1/4 -2.0 ± 0.1"WC

398A 4 -3.0 ± 0.2"WC

HI Fire LO Fire

CO2(%) CO (ppm) CO2(%)

MIN NOMINAL MAX MAX MIN NOMINAL MAX

8.8 9.4 10.5 200 8.5 9.1 10.8

HI Fire LO Fire

CO2(%)

MIN NOMINAL

10.2 10.5 10.8 200 9.9 10.2 10.5

Table U: Gas Valve Settings

CO (ppm)

MAX MAX

MIN NOMINAL MAX

CO2(%)

CO (ppm)

Less than

100

CO (ppm)

Less than

100

Page 50

NOTE: The wiring diagrams in this manual show all

tandard options. Refer to the large wiring diagram

s provided with your boiler for options installed on your specific unit(s).

START-UP

WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Pre Start-up

• If you cannot reach your gas supplier, call the fire epartment.

• Use only your hand to close the gas supply shutoff

valve inside the boiler. Never use tools. If the knob will not turn by hand, do not try to repair it, call a

ualified service technician. Forced or attempted

q repair may result in a fire or explosion. Do not use this appliance if any part has been

•

under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

• Check around unit for debris and remove com-

bustible products, i.e. gasoline, etc.

Filling System (Heating Boilers)

Fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal system operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent.

Venting System Inspection

1. Check all vent pipe connections and flue pipe material.

2. Make sure vent terminations are installed per code and are clear of all debris or blockage.

For Your Safety

This appliance has a direct spark igniter. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand.

BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell near the floor because some gas is heavier than air and will settle on the floor.

Pre Start-up Check

1. Verify the boiler is filled with water.

2. Check system piping for leaks. If found, repair immediately.

3. Vent air from system. Air in system can interfere with water circulation.

4. Purge air from gas line to boiler.

Initial Start-up

Required tools

• (1) 12-0-12 (24” scale) U-tube manometer

• (2) 6-0-6 (12” scale) U-tube manometer

• Screwdrivers (assorted sizes and shapes)

• (1) Crescent wrench (8” or 10”)

• (1) Multi-meter

(Metric Allen wrenches will be required for servicing the gas valve, but not during start-up)

NOTE: Digital manometers are not recommended.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any telephone in your building.

• Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.

Page 51

Preparation

WARNING: Do not turn on gas at this time.

Check Power Supply

ith multi-meter at incoming power, check voltage

W between:

Hot - Common (≈120 VAC)

Hot - Ground (≈120 VAC)

Common - Ground (< 1 VAC)

WARNING: If Common - Ground is > 1 VAC, STOP: Contact electrician to correct ground failure. Failure to do this may burn out 120V-24V transformer, or may cause other safety control damage or failure.

NOTE: While attaching manometers, any cap or bleedle valves removed should be retained for reinstallation later.

ttach Manometers to Measure Pressures

1. Turn off main gas shutoff valve. . Attach a 24” scale manometer to the supply pres-

sure test port on the gas valve to the heater (see Fig. 54).

. Attach a 12” scale manometer to the offset pres-

sure testport for Models 88AR-108AR. For Models 198AR-398A attach manometer to manifold pressure tap (see Fig. 54).

Check Gas Supply Pressure

1. Slowly turn on main gas shut-off valve.

2. Read the gas supply pressure from the manome-

ter; minimum supply pressure for natural gas is 4.5 in. WC, recommended supply is 7.0 in. WC, minimum supply pressure for propane gas is 8.0 in. WC, recommended supply is 11.0 in. WC (dynamic readings, full fire input).

3. If the gas pressure is greater than 14.0 in. WC,

turn off the main gas shut-off valve.

Fig. 54: Gas Pressure Measurement Locations

Page 52

Start-Up

. Turn power on.

2. Turn on the boiler, approximately 45 seconds after the blower starts, the igniter should start to spark.

3. The boiler ignites at 3000 RPM (as indicated on the LCD display of the user interface).

4. This boiler is equipped with a three-try ignition module, it will try for ignition up to three times before going into lockout.

5. Wait until the controller indicates a percentage on the firing rate display screen. This may take several minutes.

Manifold Check

1. Check manifold gas pressure at the manifold pressure tap. This pressure should read per the values in Table U, on page 49.

User Test

Set DIP #1 on the VERSA IC control to “ON”. Set

• USER TEST = ON in the 'ToolBox' Menu to start

he user test function.

• USER TEST is displayed in the Title Field.

• UP keystrokes are used to advance through the user test.

• The Boil MIN/MAX steps for burner operation are only run for enabled boilers.

• Local Heat/DHW/EMS demands must be present for burner operation.

• On the first press of the Up button, the test step is held and "HOLD" is flashed at 1Hz.

• On the second press of the Up button, the test step is incremented.

• If boiler outlet temperature reaches the PIM HiLimit, the boiler will be ramped down to keep the temperature in a safe range.

• Press of the Up button from Boiler Max will End the User Test function.

2. Valves should be within the specified ranges given on Table U, on page 49.

Number Field

SYS System Pump relay turns on.

DHW DHW Pump relay turns on.

PMP 1 System and Boiler Pump relays turn on.

Boil 1 Ignite Boiler Burner.

Min 1 Hold Boiler at Min Fire.

Max 1 Ramp Boiler to Max Fire and hold.

Output Action

Table V: User Test Fields

Page 53

Safety Inspection

1. Check all thermostats and high limit settings.

2. During the following safety checks leave manometers hooked up, check and record.

. If other gas-fired appliances in the room are on the

same gas main, check all pressures on the XPak FT with all other equipment running.

4. Check thermostats for ON-OFF operation.

5. Check high limits for ON-OFF operation.

6. While in operation, check flow switch operation (if

equipped).

7. Check the low gas pressure switch (if provided). (For proper adjustment, use the attached manometers, if available, to set pressure. The scales on the switch are approximate only.) Low gas pressure switch (if provided) must be set at

3.0 in. WC for natural gas and propane gas.

8. Make sure that the high gas pressure switch (optional) is set to 3.0 in. WC for both natural gas and propane gas.

Post Start-Up Check

. Verify that the boiler and heat distribution units or

2. Confirm that the manual air vent was opened duing

3. Verify that air has been purged from the system.

4. Verify that air has been purged from the gas pip-

5. Confirm that the proper start-up procedures were

6. Inspect burner to verify flame.

7. Test safety controls: If boiler is equipped with a low

8. Check to see that the high limit control is set

Finishing

Record all data on the “Start-up Checklist” located at the back of this manual.

2. Disconnect the manometers and reconnect the cap on the air intake and reinsert or close the sealing screws into the bleedle valves.

3. Start-up is complete and the boiler should be operating properly.

9. Check that the boiler is cycled with the thermostat.

10. Observe several operating cycles for proper oper-

storage tank are filled with water.

the venting procedure.

ing, and that the piping has been checked for leaks.

followed.

water cut-off or additional safety controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when controls are tested. When safety devices are restored, burners should re-ignite after pre-purge time delay.

above the design temperature requirements of the system. For multiple zones: Check to make sure the flow is adjusted as required in each zone.

Raise the setting on the thermostat to the highest setting and verify that the boiler goes through the normal start-up cycle. Reduce to the lowest setting and verify that the boiler goes off.

ation.

Follow-Up Safety checks must be recorded as performed. Turn

boiler on. After main burner ignition:

1. Cycle unit several times and re-check readings.

2. Remove all manometers and replace caps and screws.

3. Check for gas leaks.

11. Set the boiler thermostat to desired temperature.

12. Review all instructions shipped with this boiler with owner or maintenance person, return to envelope and give to owner or place the instructions inside front panel on boiler.

Page 54

Fig. 55: Boiler Lighting Shut Off Instructions

Page 55

TROUBLESHOOTING

XPak FT Error Codes

f any of the sensors detect an abnormal condition or

I an internal component fails during the operation of the XPak FT, the display may show an error code. This code may either be the result of a temporary condition

n which case the display will revert to its normal read-

i out when the condition is corrected, or it may be the result of a condition that the controller has evaluated as not safe to restart the unit. In this case, the unit control will be locked out, requiring the maintenance person to manually reset the control by pressing and releasing the RESET key.

WARNING: When servicing or replacing any components of this unit be certain that:

• The gas is off.

• All electrical power is disconnected.

Sensor Resistance Values

Water Sensor / Outdoor Sensor

Water Temperature

(°F)

32 32550

41 25340

Resistance (ohms)

Heater Errors

When an error condition occurs, the controller will display an error code on the display module. These error codes and several suggested corrective actions are included in the XPak FT Fault Text section on the following page.

Heater Faults

1. When a fault condition occurs, the controller will flash a red light on the PIM and display the error code on the user interface. The alarm output will also be activated. Most fault conditions will also cause the boiler pump to run in an attempt to cool the unit.

2. Note the error code, either through the flash code on the PIM and/or from the Toolbox menu on the user interface, and reference the explanation of the fault along with troubleshooting steps in the XPak FT fault text section.

3. Press and release the RESET key to clear the fault on the user interface and resume operation. Be sure to observe the operation of the unit for a period of time to ensure correct operation and no reoccurrence of fault code(s).

50 19870

59 15700

68 12490

77 10000

86 8059

95 6535

104 5330

113 4372

122 3605

131 2989

140 2490

149 2084

158 1753

167 1481

176 1256

185 1070

194 915

203 786

DANGER: When servicing or replacing components that are in direct contact with the water, be certain that:

• There is no pressure in the boiler. (Pull the release on the relief valve. Do not depend on the pressure gauge reading).

• The boiler water is not hot.

• The electrical power is off.

212 667

Table W: Sensor Resistance Values

Page 56

3/16”

WARNING: Do not use this appliance if any part has been under water. Improper or dangerous operation may result. Contact a qualified service

echnician to inspect the boiler and to repair or

t replace any part of the boiler that has been under water prior to placing the boiler back in operation.

CAUTION: Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. See wiring diagram.

CAUTION: If overheating occurs or the gas supply fails to shut off, do not turn off electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of boiler damage. Instead, shut off the gas supply to the boiler at the gas service valve.

XPak FT Fault Text

Error Display

If there is an active error, then it is displayed as the first item in the Toolbox Menu and it is the default display for the control until the error is resolved.

NOTE: If receiving a NO FLAME, check the gap spacing between points on the electrode by holding two quarters together and sliding them through the gap. There should be no resistance.

Fig. 56: Direct Spark Igniter

Error Item Description and Troubleshooting

OUTLET SEN Check the outlet water sensor and its wiring.

LIMIT SEN Check the high limit sensor and its wiring.

INLET SEN Check the inlet sensor and its wiring.

GAS PRESS Check PIM wiring.

IGNITION Reset control, push and release RESET button

LIMIT TRIP Boiler temperature tripped the high limit.

FLAME False flame detected. Shut off gas supply, recycle power.

ID CARD Identity card, check ID card and wiring.

IGN CTRL Internal control fault. Reset power, replace control.

DELTA T

Temperature difference between the inlet and outlet exceeded the set point. Check water flow.

LOW 24VAC Low 24 VAC power. Check power supply wiring and transformer.

BLOW SPEED Blower speed out of range. Check blower wiring and blower.

Table X: Error Display

Page 57

LED Error Code Listing

ctive errors detected are indicated by LED lights on the PIM.

LED Code Error Mode Recommended Troubleshooting

Off Normal Operation

Red LED steady ON, Green Power

ID Card Fault

LED OFF

Steady ON Internal Control Failure Perform a power and system reset. If fault remains, replace PIM.

1 flash N/A N/A

2 flashes False Flame Error Check for proper gas valve closure. Clean burner and electrodes.

3 flashes Ignition Lockout Fault Check the gas supply. See table for more information.

4 flashes N/A N/A

Check that the proper ID card is securely connected. Perform a power and system restart.

5 flashes Low Voltage Fault

Check the 24 VAC input voltage. The voltage must be above 18.0 VAC.

6 flashes N/A N/A

7 flashes Hi-Limit Fault Check for proper water flow. Check hi-limit and outlet sensor.

8 flashes Sensor Fault See VERSA for fault identification. Check sensor wiring.

9 flashes N/A N/A

10 flashes N/A N/A

11 flashes Blower Speed Fault Verify tachometer signal and connection on J5.

12 flashes N/A N/A

13 flashes

14 flashes

Hi-Temperature Delta Fault

Ft-Bus Communications Fault

15 flashes Safety Circuit Open

Check pump operation. Confirm proper water flow across heat exchanger.

Verify VERSA is connected and operating. Check the cable between the VERSA and PIM.

Confirm all safeties are functioning normally. Check continuity at the PIM at J8 plug, pins 5 and 6.

Table Y: PIM LED Error Codes

Page 58

MAINTENANCE

Suggested Minimum Maintenance Schedule

Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency.

Maintenance as outlined below may be performed by the owner.

Daily

1. Check that the area where the boiler is installed is free from combustible materials, gasoline, and other flammable vapors and liquids.

2. Check for and remove any obstruction to the flow of combustion or ventilation air to boiler.

. Check that area is free from combustible materi-

als, gasoline, and other flammable vapors and liquids.

. Check for and remove any obstruction to the flow

of combustion or ventilation air to boiler.

5. Follow pre-start-up check in the Start-up section.

6. Visually inspect burner flame. It should be light blue at full input. Remove and visually inspect direct spark igniter and sensor for damage, cracking or debris build-up.

7. Check operation of safety devices. Refer to manu-

facturers’ instructions.

8. Follow oil-lubricating instructions on pump (if re-

quired). Over-oiling will damage pump. Water-lubricated circulators do not need oiling.

Monthly

1. Check for piping leaks around pumps, mixing valves, relief valves, and other fittings. If found, repair at once. DO NOT use petroleum-based stop-leak compounds.

2. Visually inspect burner flame.

3. Visually inspect venting system for proper function, deterioration or leakage.

4. Visually inspect for proper operation of the con-

densate drains in the venting, and the internal condensate trap. Clean trap as necessary. If leaks are observed, repair at once.

5. Check air vents for leakage.

Yearly (Beginning Of Each Heating Season)

Schedule annual service call by qualified service agency.

1. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent

is normal.

2. Visually inspect venting system for proper func-

tion, deterioration or leakage. Ensure that condensate drain is inspected and ensure that condensate is being directed to appropriate condensate management system or drain, as required by local codes.

9. To avoid potential of severe burn, DO NOT REST HANDS ON OR GRASP PIPES. Use a light touch; return piping will heat up quickly.

10. Check blower and blower motor.

11. Check for piping leaks around pumps, relief valves and other fittings. Repair, if found. DO NOT use petroleum-based stop-leak.

Periodically

1. Check relief valve. Refer to manufacturer’s

instructions on valve.

2. Test low water cut-off (if equipped). Refer to manufacturer’s instructions.

Preventive Maintenance Schedule

The following procedures are recommended and are good practice for all XPak FT installations.

Daily

1. Check gauges, monitors and indicators.

2. Check instrument and equipment settings. (See “Post Start-Up Check”.)

3. Check burner flame. (Should see light blue flame at full input rate).

Page 59

Monthly

. Check flue, vent, stack, or dampers.

2. Check drip leg and gas strainers.

. Test high and low gas pressure interlocks (if

equipped). (See “Safety Inspection”.)

Semi-Annually

1. Recalibrate all indicating and recording gauges.

2. Check flame failure detection system components.

3. Check firing rate control by checking the manifold pressure. (See “Manifold Check”.)

4. Check piping and wiring of all interlocks and shutoff valves.

Annually

1. Test flame failure detection system.

2. Test high limit and operating temperature. (See “Post Start-Up Check”.)

3. Check flame sensor.

4. Refer to Table U for gas valve combustion readings.

3. Check flame failure detection system. (See “Post Start-Up Check”.) Verify high and low fire flame signal, compare to start-up data.

4. Check igniter. Clean and verify spark gap (see Fig. 56).

5. Check fan speed and manifold pressure. (See “Blower Check” and “Manifold Check”.)

6. Test safety/safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV.

5. Check valve coil for 60-cycle hum or buzz. Check for leaks at all valve fittings using a soapy water solution (while unit is operating). Test other operating parts of all safety shut-off and control valves and increase or decrease settings (depending on the type of control) until the safety circuit opens. Reset to original setting after each device is tested.

6. Perform leakage test on gas valves, if required by local codes.

7. Inspect and clean burner using shop air.

8. Clean the combustion chamber coil, using the procedure on the following page.

As Required

1. Recondition or replace low water cut-off device (if equipped).

Page 60

WARNING:

The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can

e converted to cristobalite in very high temperature

b applications. The International Agency for Research

n Cancer (IARC) has concluded that “Crystalline

o silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group1).”:

Combustion Chamber Cleaning Instructions

Before beginning this procedure, you must have on hand the following items:

a nylon, stainless steel or brass brush (not steel)

– – “Rydlyme” (recommended for best results) or

“CLR”

– Gloves, eye protection

Avoid breathing dust and contact with skin and • eyes.

Use NIOSH certified dust respirator (N95).• This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website at

http://www.cdc.gov/niosh/homepage.html.

NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.

Wear long-sleeved, loose fitting clothing, gloves,•

and eye protection.

Apply enough water to the combustion chamber•

lining to prevent dust.

Wash potentially contaminated clothes• separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid:

Eye: Irrigate immediately Breathing: Fresh air.

1. Shut down the XPak FT boiler by using the following steps:

a. Close the gas valve, shut down the unit and

wait for the unit to be cool to the touch.

b. Disconnect the condensate piping from the out-

side connection, (not from the XPak FT boiler side), so the flow from condensate reservoir can be observed.

c. Disconnect electrical connections from the gas

valve, spark electrode and flame rectification probe and combustion blower.

d. Disconnect the gas line by loosening union

above the shut-off valve.

e. Disconnect the wiring connected to the com-

bustion blower motor.

f. Remove the 10mm nuts from the burner plate

assembly.

g. Remove the valve/blower/burner assembly

with refractory from the heat exchanger.

2. Using a spray bottle filled with the recommended product “RYDLYME” or “CLR”, spray liberally on the heat exchanger, making sure the solution penetrates and funnels down through the condensate system. If the condensate system is blocked, let the chemical penetrate for at least 15 minutes or until it drains.

3. Use the nylon, stainless steel or brass brush (do not use steel) to scrub heat exchanger to remove any buildup, then vacuum the debris from the heat exchanger.

4. Spray the heat exchanger with clear water, making sure to confine the spray to the area being cleaned. Flush the combustion chamber with fresh water until clear water runs from the condensate drain. At this point, the XPak FT should be ready to be reassembled.

a. Inspect gaskets. b. Re-install the burner assembly.

Page 61

2. You want to reduce infiltration into your building

BLOWER/BBLOBLOWBLOWEBLOWERBLOWER/ VENTURI

BLOWER/ VENTURI

LOW ERBBLOBLOWBLOWEBLOWER

ASKET

OWER

GASKET

ENSORSENSOR

ND SCREWS

SENSO

AND SCREWS

GNITERIGNITER

ND SCREWS

IGNITE

AND SCREWS

EAT EXCHANGERHEHEAHEAT EXHEAT EXCHANGER

DOOR PLATE

AT EXCHANGER

DOOR PL

AT EXCHANGER

DOOR PLAT

AT EXCHANGER

DOOR PLATE

BURNER GASKETBBURNER GASKET

BURNE RBBURNER A

ND SCREWS

BURNER AND SCREWS

OOR PLATEDOOR PLDOOR PLATDOOR PLATE

GASKET

DOOR PLAT

GASKET

REFRACTORYREFRREFRACREFRACTREFRACTOREFRACTORREFRACTORY

HEATHEHEAT EXCHANGER

HEATEHEAT EXC

HEAT EXCH

HEAT EXCHA

HEAT EXCHAN

HEAT EXCHANG

HEAT EXCHANGE

HEAT EXCHANGER

through openings around windows and doors.

3. You are using AL29-4C stainless steel vent pipe, which is more corrosion-resistant than standard metallic vent pipe. In extremely contaminated ar-

as, this may also experience deterioration.

Products causing contaminated combustion air:

• spray cans containing chloro/fluorocarbons

• permanent wave solutions

• chlorinated waxes/cleaners

• chlorine-based swimming pool chemicals

• calcium chloride used for thawing

• sodium chloride used for water softening

• refrigerant leaks

• paint or varnish removers

• hydrochloric acid/muriatic acid

• cements and glues

• antistatic fabric softeners used in clothes dryers

• chloride-type bleaches, detergents, and cleaning solvents found in household laundry rooms

• adhesives used to fasten building products

• similar products

Fig. 57: Heat Exchanger Components Removal

APPENDIX

Inside Air Contamination

Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high efficiency systems. The boiler can be supplied with corrosion-resistant, non-metallic intake air vent material. You may, however, choose to use outside combustion air for one or more of these reasons:

Areas where contaminated combustion air commonly exists:

• dry cleaning/laundry areas

• metal fabrication plants

• beauty shops

• refrigeration repair shops

• photo processing plants

• auto body shops

• plastic manufacturing plants

• furniture refinishing areas and establishments

• new building construction

• remodeling areas

• open pit skimmers

Check for areas and products listed above before installing boiler. If found:

• remove products permanently, OR

• install TruSeal direct vent.

1. Installation is in an area containing contaminants listed below which will induce acidic condensation.

Page 62

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

hrough – 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 addition, the installing plumber or gasfitter 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 heating 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".

(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) MANUFACTURER 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.

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.

Page 63

LIMITED PARTS WARRANTY XPak FT®– TYPE H

MODELS 88AR-398A

COPE

Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under

ormal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts

emoval or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.

HEAT EXCHANGER WARRANTY

pace Heating (Closed Loop System)

en (10) year limited warranty from date of heater installation. This warranty applies only to boilers utilized in closed loop heating systems and hot water sup-

T ply boilers that have been properly installed based upon manufacturer’s installation instructions.

ear of Claim 0-5 6789

Y Percentage to be paid by purchaser 0 % 20% 40% 60% 80% Thermal Shock Warranty

wenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large changes exceeding

T 150°F between the water temperature at intake and heater temperature, or operating at heater temperatures exceeding 215°F).

ANY OTHER PART MANUFACTURED BY RAYPAK

ne (1) year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records, whichever comes

O first.

SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED.

ADDITIONAL WARRANTY EXCLUSIONS

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;

. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding heater design rates;

5. Failure of connected system devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the heater system;

7. Failing to eliminate air from, or replenish water in, the connected water system;

8. Chemical contamination of combustion air or use of chemical additives to water.

PARTS REPLACEMENT

Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer.

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 his Raypak distributor for instructions regarding the claim. If either is not available, contact Service Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be received from Raypak before replacement of any part.

EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY

This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. 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. You may also have other rights which may vary from state to state. We suggest that you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective date of the warranty (date of installation) must be presented; otherwise, the effective date will be based on the date of manufacture plus thirty (30) days.

Original Owner

Mailing Address

City State Zip Code

Daytime Telephone Number

RAYPAK, INC • 2151 Eastman Avenue • Oxnard, CA 93030-9786 • (805) 278-5300 • Fax (800) 872-9725 • www.raypak.com

Model Number

Serial Number

Date of Installation

Installation Site

Contracor/Installer

Page 64

START-UP CHECKLIST FOR THE XPAK FT

This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater 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.

GAS SUPPLY DATA CLEARANCES

Regulator Model & Size _________ / ______CFH Front Clearance _______________In. G

as Line Size (in room) ________________In. NPT Right Side Clearance _______________In. Length of Gas Line ________________Eq Ft Left Side Clearance _______________In. Low Gas Pressure Setting ________________In. WC Rear Clearance _______________In. High Gas Pressure Setting ________________In. WC Overhead Clearance _______________In. Gas Shut-Off Valve Type ________________ ( Ball, Lube cock)

ELECTRICAL

ediment Trap ________________Y/N Voltage Supply (VAC) No Load______ Load_____ Port _______Std______Full Voltage -24 VAC _______________VAC Voltage Com to Ground _______________VAC

VISUAL INSPECTION OF COMPONENTS

Verify inspection was done and condition of components are in good working order with a “yes”

Auto High Limit Setting

Manual Reset High Limit Setting

_______________deg F

Wiring Harness _________________ Y/N Operating Control Setting _______________deg F Burner/s (flame) _________________ Y/N Refractory (visual) _________________ Y/N Sketch plumbing on reverse side Remote fla me sense _________________ Y/N

WATER SUPPLY

Covers in place for outdoor _________________ Y/N Flow Rate in GPM or De lta T _______________If Avail

Measure flow rate at full fire

VENTING

Pump Off Delay setting _______________Minutes

Vent Size: _____________ Stack Height:_______ Low Water Cutoff _______________Test Category: _________ sketch vent on reverse side *** Number of Tanks and Size Qty____ _______Gallons Vent Material: __________________ Plumbing Size _______________ Vent Termination Type: __________________ Pump Size: _________(boiler) Pump HP: ______ Combustion Air Openings: Low __________ in2 Impeller trim____________ Pump Model___________ Ventilation air High __________ in2 Louvers __________________ Screens________________

EMISSIONS SETTINGS AND TEST INFORMATION Nominal Factory Recommended Settings

Air Intake Pressure _________________In. WC See manual or card tag Supply Gas Pressure Verify stable pressure static &

_________________In. WC

dynamic condition

See manual or card tag

Manifold Gas Pressure _________________In. WC See manual or card tag

The following measurements must be obtained with a Combustion Analyzer.

NOX _________________PPM Less than 20 PPM (If required by Certifying Agency) CO _________________PPM Less than 150 PPM

CO2 _________________% See manual

Model Number: ______________________________ Serial Number: _______________________________ *** Note: draw venting with details, such as extractors, barometric dampers, blast dampers or draft inducers

Site Altitude Above Sea Level __________________Ft.

Job Name _______________________________________________________________________________________

Address _________________________________________________________________________________________

Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; Roof______; 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) 278-5496 in order to ensure warranty consideration Attn: Service Manager

High Low

N/A

Page 65

ILLUSTRATED PARTS LIST

Page 66

Page 67

Page 68

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468

Litho in U.S.A.

Raypak 88AR–398A Installation & Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual