Raypak XPAK120 Installation Manual

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CATALOG NO. 2100.52A Effective: 05-22-13 Replaces: 06-01-09

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Subject to technical changes! Slight changes may be made to the illustrations, process steps and technical data as a result of our policy of continuous improvement.

About these instructions

These Installation Instructions contain important information for the safe and professional installation, start-up and maintenance of the boiler with boiler capacities 87,000 and 120,000 btu/hr. These Installation Instructions are intended for qualified installers, who have the necessary training and experience for working on heating and gas systems.

About the XPak

The boiler was designed for heating water for a space heating system and generating hot water e.g. for domestic purposes. The boiler can be fitted with a remote control or an On/Off room thermostat (24 V), external sensor and with a 3-way valve for DHW indirect storage tank controlled either with a tank thermostat or a tank sensor (accessories).

Dear Costumer, Thank you for choosing the XPak boiler. This Raypak product provides more efficiency and greater comfort to the living space, thanks to its unique features. The new patented aluminum heat exchanger provides ultra low emissions, higher efficiency and easier

recycling after the boiler life.

Rev. A reflects the following: Changes to: ASME Mark on page 1, AFUE values on page 10, piping diagrams on pages 19-21, Flue Gas

System on page 25, Warranty on pages 65-66. Additions: Fig. 32A on page 33.

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CONTENTS

1 - WARNINGS 4

PAY ATTENTION TO THESE TERMS 4

2 - GENERAL SAFETY 6

TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 6

3 - BEFORE INSTALLATION 6

4 - REGULATIONS AND GUIDELINES 7

5 - INTRODUCTION 8

TECHNICAL DATA 10 PRINCIPLE COMPONENTS 12 MODE OF OPERATION (AT REST) 12 MODE OF OPERATION 12 SAFETY DEVICES 12 BANNED MATERIAL STATEMENT 12 MANUAL HANDLING STATEMENT 12 XPAK INTERNAL HYDRAULIC CIRCUIT 12 PIPING CONNECTIONS 13 DIMENSIONS AND CONNECTIONS 1 4 PACKAGING AND TRANSPORTATION 15

1. Scope of delivery 15

2. Transporting the boiler 15

3. Boiler box content 15

6 - INSTALLATION 16

PREPARE XPAK LOCATION 16

1. Installations must comply with 16

2. Before locating the XPak boiler 16

3. Clearances for service access 16

4. Residential garage installation 16

5. Exhaust vent and intake air vent 16

6. Prevent combustion air contamination 16

7. When removing an existing boiler from an existing common 16 vent system

PREPARE XPAK 16

1. Remove XPak boiler from box 16

2. Placing the wall-mounted XPak boiler 17

3. XPak wall mounting instructions 17

4. Installation steps 17

XPAK PIPING 17

1. Relief valve 17

2. General piping information 17

3. Separate low water cutoff 17

4. Backflow preventer 17

5. Fitting the heating circuit supply and return pipes 17

6. Expansion tank and make-up water 17

7. Sizing space heat system piping 17

8. Boiler with DHW tank 18

9. Waterside Flow (primary circuit) 18

10.Procedure summary 18

11.Fill and purge heating system 18

XPAK INSTALLATION DIAGRAMS 19 MAKING THE GAS CONNECTION 22 BOILER TEMPLATE 23 COMBUSTION AIR AND VENTILATION OPENINGS 24 INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM 24 VENT SYSTEMS 25

1. Flue gas system 25

2. Boiler supply 25

3. Installations of supplied vent components 25

4. Minimum Clearances from Vent/Air Inlet Termination 26

CONNECTING THE CONDENSATE WATER DRAIN 34

1. Condensate Connection 34

7 - ELECTRICAL CONNECTIONS 34

1. External connection board connections 34

2. Electrical supply 34

3. Field wiring 34

4. Casing removal 35

5. Appliance terminal block 35

6. Connecting the electrical supply (120V) 35

7. External wiring 35

8. External wiring limitations 35

9. Connecting thermostat 35

10.Other devices 35

11 .Terminal strip details 36

12.Outdoor sensor connection 3 7

13.3-way valve wiring connection 3 7

14.Remote control connection 37

WIRING FUNCTIONAL DIAGRAM 38

9 - COMMISSIONING 40

1. Check/control water chemistry 40

2. Freeze protection (when used) 40

3. The heating system 40

4. Initial filling of the system 40

5. Purge air from boiler manual air release 40

6. System drain 40

7. Check thermostat circuit(s) 41

8. Testing for gas leaks 41

9. Initial flushing of the system 41

10. Pre-operation checks 4 1

11. Initial lighting 41

12. Checking gas pressure and combustion analysis 41

13. Final flushing of the heating system 41

14. Setting the boiler operating temperature 41

15. Regulating the central heating system 41

16.Final checks 42

17.Instructing the user 42

18.Warranty 42

10 - START-UP AND OPERATION 43

1. Switching on the appliance 43

2. How to read the display temperature 43

3. Adjusting heating water temperature with an outdoor probe connected 43

4. Adjusting domestic hot water temperature (if a storage tank with sensor and 3-way valve is installed) 43

5. Working the boiler 43

6. Reset function 43

7. Switching off 43

8. Indicator LEDs and faults 44

11 - CHECKS, ADJUSTMENTS AND FAULT FINDING 46

1. Checking appliance operation 46

2. Appliance modes of operation 46

3. Selector switch in the off/stand by position 46

4. On-board functions 46

5. Heating mode 46

6. DHW mode 46

7. Boiler fan speeds 47

8. Checking the CO2 and adjusting the gas valve 47

9. Gas valve maximum setting 47

10 .Gas valve minimum setting 47

11.Combustion analysis test 47

12. External faults 47

13. Electrical checks 48

14.Component values & characteristics 48

15 .Boiler configuration 48

16.Setting the outdoor reset curve with outdoor sensor 49

17 .Fault codes 51

12 - SERVICING INSTRUCTIONS 52

1. General 52

2. Routine annual servicing 52

3. Replacement of components 52

4. Component removal procedure 52

13 - LPG INSTRUCTIONS 56

PROPANE GAS 56

14 - EXPLODED DIAGRAMS 59

IMPORTANT INSTRUCTIONS FOR THE COMMONWEALTH OF MASSACHUSETTS 64

LIMITED PARTS WARRANTY 65

START-UP CHECKLIST FOR FAN-ASSISTED RAYPAK PRODUCTS 67

8 - START-UP PROCEDURE 39

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1 - WARNINGS -

PAY ATTENTION TO THESE TERMS

DANGER:

Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored.

WARNING:

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

CAUTION:

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

NOTICE:

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

DANGER: Make sure the gas on which the boiler will operate is the same type as that specified on the boiler rating plate and on the coloured sticker near the boiler gas connection.

WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the boiler. Instead, shut off the gas supply at a location e xternal to the boiler.

WARNING: Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water.

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

AVERTISSEMENT: N’utilisez pas cette chaudière si une partie de celle-ci s’est retrouvée sous l’eau. Appelez immédiatement un technicien 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.

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

• Always keep the area around the boiler free of combustible materials, gasoline, and other flammable liquids and vapors.

• Boiler should never be covered or have any blockage to the flow of fresh air to the boiler.

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

WARNING - CALIFORNIA PROPOSITION

65: This product contains chemicals known to the State of

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

CAUTION: This boiler requires forced water circulation when the burner is operating. See minimum and maximum flow rates. Severe damage will occur if the boiler is operated without proper water flow circulation.

NOTE: Minimum 18 AWG, 105°C, stranded wire must be used for all low voltage (less than 30 volts) external connections to the unit. Solid conductors should not be used because they can cause excessive tension on contact points. Install conduit as appropriate. All high voltage wires must be the same size (105°C, stranded wire) as the ones on the unit or larger.

NOTE: When the boiler has been filled for the first time or the system has been drained and refilled, it will be necessary to release any air that may have become trapped within the appliance heat exchanger. Loosen the bleed screw until water is released and then close. IMPORTANT, THERE ARE NO OTHER MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE.

The following instructions must be observed

– The boiler must only be used for its designated purpose,

observing the Installation Instructions.

– Only use the boiler in the combinations and with the

accessories and spares listed.

– Other combinations, accessories and consumables must only

be used if they are specifically designed for the intended application and do not affect the system performance and the safety requirements.

– Maintenance and repairs must only be carried out by

authorized professionals.

– You must report the installation of a condensing gas boiler to

the relevant gas utility company and have it approved.

– You are only allowed to operate the condensing gas boiler

with the combustion air/flue gas system that has been specifically designed and approved for this type of boiler.

– Please note that local permission for the flue system and the

condensate water connection to the public sewer system may be required.

You must also observe:

– The local building regulations stipulating the installation rules. – The local building regulations concerning the air intake and

outlet systems and the chimney connection. – T he regulations for the power supply connection. – The technical rules laid down by the gas utility company

concerning the connection of the gas burner fitting to the local

gas main. – The instructions and standards concerning the safety

equipment for the water/space heating system. – The Installation Instructions for building heating systems. – The boiler must be located in an area where leakage of the

tank or connections will not result in damage to the area

adjacent to the boiler or to lower floors of the structure. When

such locations cannot be avoided, it is recommended that a

suitable drain pan, adequately drained, be installed under

the boiler. The pan must not restrict combustion air flow. – The boiler must be installed such that the gas ignition system

components are protected from water (dripping, spraying, rain

etc.) during boiler operation and service. – The boiler must not be installed on carpeting. – The boiler must only be installed on a wall. – Do not restrict or seal any air intake or outlet openings. – If you find any defects, you must inform the owner of the system

of the defect and the associated hazard in writing.

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DANGER

if flammable gas explodes. Beware if you smell gas: there may be an explosion hazard!

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

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other boiler.

What to do if you smell gas

- Do not try to light any boiler.

- Do not touch any electrical switch; do not use any phone in your building.

- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

- 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.

Observe these instructions as general warnings:

– Chemicals used to clean the system and/or inhibit corrosion

must be pH neutral, i.e. they should ensure that the level of the pH in the system water remains neutral. Premature failure of certain components can occur if the pH level in the system water is out of normal levels.

– Raypak recommends that an inhibitor - suitable for use with

aluminum heat exchangers - is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers instructions.

– A properly sized expansion tank must be installed in the boiler

system. No valve is to be placed between the boiler and the expansion tank.

– When the boiler has been filled for the first time or the system

has been drained and refilled, it will be necessary to purge any air that may have become trapped within the appliance heat exchanger.

NOTE: Glycol in the system must not exced 40%.

Observe these instructions for space heating water:

– Thoroughly flush the system prior to filling.

Only use untreated main water to fill and top off the system.

– Do not use water softners in the system. – Do not use inhibitors or other additives! – The maximum permissible flow rate of the XPAK 85 this is 5.7

GPM (1,300 ltr/hr), for the XPAK 120 is 6.2 GPM (1,400 ltr/hr).

– When using oxygen-permeable pipes, e.g. for floor heating

systems, you must separate the system using heat exchangers. Unsuitable heating system water promotes the formation of sludge and corrosion. This may damage the heat exchanger or affect its operation.

– A properly sized expansion tank must be installed in the boiler

system.

T ools, materials and additional equipment

For the installation and maintenance of the boiler you will need the standard tools for space heating, gas and water fitting. In addition, a handtruck with a fastening belt is very useful.

Disposal – Dispose of the boiler packaging in an environmentally sound

manner.

– Dispose of components of the heating system (e. g. boiler or

control device), that must be replaced, by handing them in to an authorized recycling facility.

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2 - GENERAL SAFETY

T o meet domestic hot water use needs , the high limit safety control on this boiler is adjustable up to 140°F (60°C).Water temperatures over 125°F (50°C) can cause instant severe burns or death from scalds. When supplying general purpose hot water, the recommended initial setting for the temperature control is 125°F (50°C). Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat. The most energy-efficient operation will result when the temperature setting is the lowest that satisfies the needs of the application. Water temperature over 125°F (50°C) can cause instant severe burns or death from scalds. Children, disabled and elderly are at highest risk of being scalded.

• Feel water before bathing or showering.

• Temperature limiting valves are available. NOTE: When this boiler is supplying general purpose hot

water for use by individuals, a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information.

Maximum water temperatures occur just after the boiler’s burner has shut off. To determine the water temperature being deliv ered, turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer.

WARNING: This boiler cannot supply hot water for use by individuals directly. A heat exchanger must be used in conjunction with this boiler to meet DHW needs.

TIME/TEMPERATURE RELATIONSHIPS IN SCALDS

The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

Water Time to Produce Serious

Temperature Burn

120°F More than 5 minutes 125°F 1-1/2 to 2 minutes 130°F About 30 seconds 135°F About 10 seconds 140°F Less than 5 seconds 145°F Less than 3 seconds 150°F About 1-1/2 seconds 155°F About 1 second

Table courtesy of The Shriners Burn Institute The temperature of the water in the boiler can be regulated by

using the Raypak Remote Control REC08. To comply with safety regulations, the control is set when shipped from the factory.

CAUTION: Hotter water increases the risk of scalding! There is a hot water scald potential if the thermostat is set too high.

3 - BEFORE INSTALLATION

Raypak strongly recommends that this manual be reviewed thoroughly before installing your XPak boiler. Please review the General Safety information before installing the boiler. Factory warranty does not apply to boilers that have been improperly installed or operated. (Refer to the warranty at the back of this manual.) Installation and service must be performed by a qualified installer, service agency or gas supplier. If, after reviewing this manual, you still have questions which this manual does not answer, please contact the manufacturer or your local Raypak representative. Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.

Product Receipt

On receipt of your boiler it is suggested that you visually check for external damage to the shipping package. If the package is damaged, make a note to that effect on the Bill of Lading when signing for the shipment. Remove the boiler from the shipping packaging. Report any damage to the carrier immediately. On occasion, items are shipped loose. Be sure that you receive the correct number of packages as indicated on the Bill of Lading. Claims for shortages and damages must be filed with the carrier by consignee. Permission to return goods must be received from Raypak prior to shipping. Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted. All returned goods are subject to a restocking charge. When ordering parts, you must specify the model and serial number of the boiler. When ordering under warranty conditions, you must also specify the date of installation. Purchased parts are subject to replacement only under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted and will be replaced in kind only per Raypak’ s standard warranty.

Model Identification

The model identification number and boiler serial number are found on the boiler rating plate located on the casing right side. Also the boiler serial number can be found on the back page of this manual and inside the front control panel flap.

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Ratings and Certifications

Standards:

• Gas fired hot water boiler for either direct vent installation or for installation using indoor combustion air. Design according to: ANSI Z21.13b 2007 – CSA 4.9b 2007 – Fired low pressure hot water boilers. Categor y IV.

• SCAQMD Rule 1146.2

All Raypak boilers are National Board Approved, and designcertified and tested by the Canadian Standards Association (CSA) for the U.S. and Canada. Each boiler is constructed in accordance with Section IV of the American Society of Mechanical Engineers (ASME) Boiler Pressure Vessel Code and bears the ASME H stamp. This boiler also complies with the latest edition of the ASHRAE 90.1 Standard.

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

Installations at Elevation

Rated inputs are suitable for up to 4,500 ft elevation (see technical data table). Consult the factory for installations at altitudes over 4,500 ft above sea level. No hardware changes are required to the boilers for installations up to 10,000 ft (adjustments may be required).

4 - REGULATIONS AND

GUIDELINES

The installation must be conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI Z223.1. In Canada, installation must be in accordance with the requirements of CAN/CSA B149.1, Natural Gas and Propane Installation Code. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. Install CO detectors per local regulations. Boiler requires yearly maintenance, see chapter “Checks, adjustments and fault finding”.

Operating Limits of the boiler:

Max. boiler temperature: 194°F (90 °C) Max. operating pressure: 45 psi (3.1 bar)

The hot water distribution system must comply with all applicable codes and regulations. When replacing an e xisting boiler, it is important to check the condition of the entire hot water distribution system to ensure safe operation.

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5 - INTRODUCTION

The XPak boiler is a wall hung, fan assisted, direct vent, heating boiler only. These boilers – by design – incorporate electronic ignition, circulating pump, pressure relief valve, pressure gauge, and automatic bypass. As supplied, the boiler will automatically modulate to provide central heating outputs between 25,600 - 87,000 Btu/hr (7.5-25.5 kW) - XPak 85 and 27,300 - 119,500 Btu/hr (8-35 kW) XPak 120.

IMPORTANT

It is the law that all gas appliances are installed by a competent person. It is in your own interest and that of safety to ensure that the law is complied with.

• The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

• The installation should conform with CGA B149 INST ALLATION CODE and/or local installation Code, plumbing or waste water codes and other codes as applicable.

• Clearances from combustible material must be strictly adhered to.

• Manufacturers instructions must NOT be interpreted in anyway as overriding statutory obligations.

The XPak family comprises a range of high-efficiency hot water boilers with outputs ranging from 87,000 Btu/hr (25.5 kW) to 119,500 Btu/hr (35 kW). Each appliance is provided with a fan powered flue outlet with an annular co-axial combustion air intake that can be rotated – horizontally – through 360 degrees for various horizontal or vertical applications. The XPak can also be used with two pipe flue vent system. These appliances are designed for use with a sealed system only; consequently they are not intended for use on open vented systems. This booklet is an integral part of the appliance. It is therefore necessary to ensure that the booklet is handed to the person responsible for the property in which the appliance is located/ installed. A replacement copy can be obtained from Raypak customer services.

XPAK 120

XPAK 85

General layout (Fig. 1)

1 Water pressure switch 2 Pump 3 Bottom auto air vent (AAV) 4 Gas injector 5 Condense trap 6 Return sensor 7 H stamp main heat exchanger 8 Main heat exchanger 9 Flue thermostat 10 Flue sensor 11 Flue gas analysis test point 12 Flue outlet & air intake 13 Blocked flue switch 14 Top automatic air vent 15 Flow sensor 16 High limit thermostat 17 Ignition transformer 18 Sensing Electrode 19 Spark Electrode 20 Top automatic air vent drain pipe 21 Condensate level sensor 22 Cylindric Burner 23 Fan assembly 24 Mixer 25 Gas modulator coil 26 Gas valve 27 Pressure relief valve R Boiler IN connection F Boiler OUT connection G Gas connection P Pressure relief valve drain C Condensate drain pipe

Fig. 1

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Fig. 1A

A Pressure gauge B Green led C 2-digit LED display D Red led E Temperature selector space heating F Mode selector switch G Temperature selector Domestic Hot Water

Off/reset - Select this position when the boiler needs to be

reset or switched off.

Summer mode - The domestic hot water function provided by the water tank is activated. The display indicates the storage tank temperature (only with the external water tank connected with a sensor).

Winter mode - The boiler produces hot water for heating and, if connected to an external water tank, it provides domestic hot water. The display indicates the boiler flow temperature.

Winter mode tank temperature - The boiler produces hot water for heating and, if connected to an external water tank

with a sensor, it provides domestic hot water. The display indicates the storage tank temperature.

Temperature selector DHW- Move the temperature selector clockwise to increase the hot water temperature in the water tank or counter-clockwise to reduce the temperature (working only if a tank sensor is connected).

Temperature selector Heating - Move the temperature selector clockwise to increase the heating temperature or counterclockwise to reduce the temperature.

2-digit LED display - Displays the temperature according the mode selector switch. During a fault condition, the appropriate code will be displayed (refer to the installation instructions regarding fault codes).

Green LED lit - Boiler is working/responding to a heating/ tank request (flame ON).

Red LED lit - Boiler has identified a fault and has shut down. Refer to installation instructions on how to reset.

Pressure gauge - Ensure the system pressure is set correctly (minimum 7 p.s.i. (0.45 bar))

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TECHNICAL DATA

Tab. 1

Input - Output

Input - (0 - 2000 ft / 0 - 610 m) Btu/hr 25,600 - 87,000 27,300 - 119,500

kW 7.5 - 25.5 8.0 - 35.0

Input - (2000 - 4500 ft / 610 - 1375 m) Btu/hr 25,600 - 82,900 27,300 - 114,300

kW 7.5 - 24.3 8.0 - 33.5

Output (176°F - 86°F / 80°C - 30°C) Btu/hr 25,200 - 76,600 26,600 - 108,300

kW 7.4 - 22.5 7.8 - 31.7

Energy Guide

AFUE % 90.3 90.5

Gas

Gas supply pressure Natural Gas (A) in w. c. 6.82

kPa 1.70

Min. gas supply pressure Natural Gas (A) in w. c. 3.5

kPa 0.87

Max. gas supply pressure Natural Gas (A)** in w. c. 10.5

kPa 2.62

Gas supply pressure LPG (E) in w. c. 11

kPa 2.75

Min. gas supply pressure LPG (E) in w. c. 8

kPa 1.99

Max. gas supply pressure LPG (E)** in w. c. 13

kPa 3.24

Gas Rate max natural rh/3tf)A( sag 10.12177.78

sm3/hr 34.394.2

Gas Rate min natural gas (A) ft3/hr 26.14 28.01

sm3/hr 97.047.0

Gas Rate max LPG (E) lbs/hr 55.520.4

kg/hr 25.228.1

Gas Rate min LPG (E) lbs/hr 82.102.1

kg/hr 85.045.0

System Data

Minimum relief valve capacity lbs/hr 87 119.50 Maximum operating pressure 54.i.s.p

bar 3.1

Minimum operating pressure p.s.i. 6.52

bar 0.45

Recommended system pressure p.s.i. 15

bar 1

Boiler max flow rate (ltr/hr) GPM 5.72 6.2

ltr/hr 004,1003,1

Pump residual head at max flow rate in w. c. 60.22 44.11

mbar 150 110

Primary water content CAN G 0.70 0.84

USG 0.85 1.0 ltr 3.2 3.8

Boiler Water Temperature

Adjustable high limit range - high temp. (radiators heating)* °F 104 - 176

°C 40 - 80

Adjustable high limit range - low temp. (space heating)* °F 68 - 113

°C 20 - 45

DHW production - set point °F 95 - 140

°C 35 - 60

Max boiler temperature °F 194

°C 90

Electric Data

Electric rate voltage V - Hz 120 - 60 Current less than A 1.19 1.25 Electric consumption (pump included) W 133 141 Electrical protection rating D5XPIPI Fuses A - VAC 4 - 250

Flue Gas Values

CO2 setting natural gas (A) % 8.5% CO2 setting LPG (E) % 10.0% NOx @ max (A) ppm < 20 < 20 NOx @ min (A) ppm < 15 < 15 CO @ max (A) without air ppm < 135 < 170 CO @ min (A) without air ppm < 15 < 25 NOx @ max (E) ppm < 20 < 20 NOx @ min (E) ppm < 15 < 20 CO @ max (E) without air ppm < 200 < 220 CO @ min (E) without air ppm < 40 < 35

XPak 85 XPak 120

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XPak 85 XPak 120

Boiler flue gas connection in 2 3/8 2 3/8 Combustion air connection outer dia. in 4 4 Free fan unit feed pressure in w. c. 0.26 0.18 Flue gas mass flow rate at rated full load (A) lbs/hr 90.39 123.17 Flue gas mass flow rate at rated full load (E) lbs/hr 88.89 121.18 Flue gas mass flow rate at rated partial load (A) lbs/hr 26.58 28.48 Flue gas mass flow rate at rated partial load (E) lbs/hr 25.08 27.99 Condensate flow rate (A) at max - 122/86 °F (50/30°C)USG/hr 0.37 0.41 Condensate flow rate (A) at min. - 122/86 °F (50/30°C) USG/hr 0.13 0.16 Flue temperature at boiler return temp. 86°F/30°C °F 186.0 170.0

at full load (A) °C 86.0 77.0 Flue temperature at boiler return temp. 86°F/30°C °F 163.0 165.0 at partial load (A) °C 73.0 74.0 Flue temperature at boiler return temp. 140°F/60°C °F 194.0 186.0 at full load (A) °C 90.0 86.0

Max flues length de-rate less 2%

Max length horizontal coaxial 60/100 mm ft 6.5 6.5 Max total length 2 pipe 3” (80 mm) (air + flues) ft 40+40 16+16

Max flues length de-rate less 5%

Max length horizontal coaxial 60/100 mm ft 26 26 Max total length 2 pipe 3” (80 mm) - (air + flues) ft 130+130 115+115

Minimum Clearances To Combustibles

Top - front - rear in 0 - 0 - 0 Left - right - vent pipe in 0 - 0 - 0

Recommended Minimum Service Clearances

Top - front - rear in 12 - 24 - 0 Left - right in 1 - 1

Pipe Connections

Gas supply connection (shut off valve) i n 3/4 NPT - female Boiler in connection in 3/4 NPT - male Boiler out connection in 3/4 NPT - male Pressure relief valve in 3/4 NPT - female Condensate connection diameter (rubber flexible) in 0.825 female

Boiler drain valve - open-ended wrench dimension in 7/16

Boiler Dimensions And Weight

Height x Width x Dept in 30.7 x 15.75 x 14.1 30.7 x 17.7 x 14.1 Weight net lb s 73 8 0

Components

Burner Stainless Steel Main heat exchanger ASME approved extruded aluminum Gas valve SIT 848 Pump Groundfos UPM 15-52 Groundfos UPM 15-62 Pressure relief valve Watts M350 - M2 ASME approved Fan MVL RG 128 3-way valve for DHW tank (field supply) Honeywell VC6011 + VCZMK6000 Injector Natural Gas (A) Ø 0.20 inch (5.1 mm) 0.26 inch (6.7 mm) Injector LPG (E) - black coated Ø 0.15 inch (3.9 mm) 0.19 inch (5.0 mm)

mm 60 60 mm 100 100 Pa 65 45 kg/hr 41 55.87 kg/hr 40.32 54.97 kg/hr 12.06 12.92 kg/hr 11.88 12.70 ltr/hr 1.41 1.56 ltr/hr 0.48 0.6

m2 2 m 12+12 5+5

m 7.8 7.8 m 40+40 35+35

mm 0 - 0 - 0 mm 0 - 0 - 0

mm 300 - 600 - 0 mm 25 - 25

mm 21 female mm 11

mm 780 x 400 x 358 780 x 450 x 358 kg 33 36

notes

*See jumpers configurations for heating temperature range setting **If the gas supply pressure exceeds the maximum gas supply pressure value, a separate gas pressure regulator must be installed upstream of the heating system.

Page 12

PRINCIPAL COMPONENTS

A fully integrated electronic control board featuring electronic temperature control, anti-cycle control, pump over-run, actuator anti-block function, self-diagnostic fault indicator, full air/gas modulation.

- Radial aluminum heat exchanger.

- Electronic ignition with flame supervision

- Integral pump

- Fan

- Water pressure switch

- Condensate level sensor

- Pressure gauge

- Pressure relief valve

- Flue thermostat

- Flue sensor

- Blocked flue switch

MODE OF OPERATION (AT REST)

When the appliance is at rest and there are no requests for heating or hot water, the following functions are active:

- 2-stage freeze protection system – the freeze protection system

protects the appliance against the risk of freeze damage. The first stage enables activation of the pump should the temperature of the appliance fall to 43°F (6 become active, the appliance will function on minimum +25% power until it reaches 95°F (35

- Anti-seize function – the anti-seize function enables the pump

to be energized for short periods, when the appliance has been inactive for more than 24-hours.

C). Should the first stage

C).

BANNED MATERIAL STATEMENT:

No banned materials or substances have been used in the manufacture or production of this appliance or its inherent components

MANUAL HANDLING STATEMENT:

CAUTION: This appliance may require 2 or more persons to lift or carry it to the installation location; due to the weight of the appliance it may be necessary for two people to lift and attach the appliance to its mounting. To avoid the possibility of injury during the installation, servicing or cleaning of this appliance, care should be taken when handling component edges.

XPAK INTERNAL HYDRAULIC CIRCUIT (FIG. 2)

MODE OF OPERATION

When there is a request for heat and/or hot water, via the programmer/time clock and/or any external control, the pump and fan are started, the fan speed will modulate until the correct signal voltage

is received at the control PCB. At this point an ignition sequence is enabled. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry increases the gas rate to 75% of the MAX Heating (set by the corresponding HTG trimmer) for a period of 15 minutes. Thereafter, the boiler’s output will either increase to maximum or modulate to suit the set requirement. When the appliance reaches the desired temperature the burner will shut down and the boiler will perform a three-minute post purge (timer delay). When the request for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

SAFETY DEVICES

When the appliance is in use, safe operation is ensured by:

- a water pressure switch that monitors system water pressure

and will de-activate the pump (when lockout condition is reached), fan and burner should the system water pressure drop below the rated tolerance;

- blocked flue switch that monitors flue pressure and will de-

activate burner should the flue pressure increase over the rated tolerance;

- fan speed sensor to ensure safe operation of the burner;

- a high limit thermostat that over-rides the temperature control

circuit to prevent or interrupt the operation of the burner;

- flame sensor that will shut down the burner when no flame signal

is detected;

- a sensor that interrupts the operation of the appliance if the

condensate pipe becomes blocked;

- a pressure relief valve which releases excess pressure from the

primary circuit;

- a flue sensor that controls the flue temperature continuously

checking to be right according the output;

- a flue thermostat that over-rides the temperature control circuit

to prevent or interrupt the operation of the burner.

the pump (when lockout condition is reached), fan and

temperature

pump

return

sensor

bottom

auto air

valve

pressure

switch

automatic

bypass

flow

temperature

sensor

pressure

relief valve

drain valve

top

auto air

valve

manual air

release

main heat

exchanger

Fig. 2

Heating

return

Heating

flow

pressure

relief valve

Page 13

PIPING CONNECTIONS (FIG. 3)

Legend

A - boiler in connection 3/4” NPT - male B - boiler out connection 3/4” NPT - male

C - gas supply connection 3/4” NPT - female D - pressure relief valve drain connection 3/4” NPT - female E - condensate connection Ø (rubber flexible) 0.825” (21 mm) female F - boiler drain valve - open-ended spanner dimension 7/16” (11 mm)

Fig. 3

2.55” 65 mm

4.73” 120 mm

1.76” 45 mm

Page 14

DIMENSIONS AND CONNECTIONS (Fig. 4)

Recommended minimum service clearances

1” (25 mm)

5-1/2”

(140 mm)

12” (300mm)

30-3/4” (781 mm)

6” (150 mm)

14-1/8” (359 mm)

8-5/8”

(219 mm)

water 4-7/8” (124 mm)

gas 6-13/16” (173 mm)

XPak 85 = 15-3/4” (400 mm)

XPak 120 = 17-3/4” (451 mm)

30-3/4” (781 mm)

= =

1” (25 mm)

Fig. 4

1” (25 mm)

XPak 85= 3-15/16“ (97 mm) XPak 120= 4-1/2“ (114 mm)

Minimum Clearances to Combustibles

Top=0 Front =0 AL, CL Rear=0 Left=0 Right=0

AL = Alcove CL = Closet

Note: The XPak boiler has passed the zero inches vent clearance to combustibles testing requirements provided by the boiler Harmonized Standard ANSI Z21.13b 2007 – CSA 4.9b 2007 and therefore is listed for zero clearance to combustibles when vented with a single wall special venting system (AL29-4C material) or UL/ULC-listed gas vent material. The zero inches vent clearance to combustibles for the XPak boiler supersedes the clearance to combustibles listing that appears on the special venting system label.

Page 15

PACKAGING AND TRANSPORTATION

1. SCOPE OF DELIVERY

The boiler is delivered fully assembled.

- When receiving the delivery, check if the packaging is intact.

- Check that all the items listed in Table 2 are included in the delivery.

2. TRANSPORTING THE BOILER

CAUTION: The boiler may be damaged when it is improperly

secured.

- Only transport the boiler using the right transportation

equipment, such as a handtruck with a fastening belt or special equipment for maneuvering steps.

- During transportation the boiler must be secured on the

transportation equipment to prevent it from falling off.

- Protect all parts against impacts if they are to be

transported.

- Observe the transportation markings on the packaging.

- Packaged boilers must always be lifted and carried to

their destination by two people, or you must use a handtruck or special equipment to transport them to their destination.

- Transport the boiler to the room where it is to be installed.

3. BOILER BOX CONTENT (Table 2)

Pos. Parts Quantity Packaging

1 Boiler with casing 1 1 box 2 Wall bracket 1 3 Technical documents 1

including:

- User’s Instructions

- Installation Instructions

- Wall Mounting Template

4 Top manual air vent drain pipe 1 5 Gas shut off valve 1 6 Flue gas adaptors including: 1

- vent adaptor for two pipes vent system

- intake air adaptor for two pipes

- 3” adaptor

- 4 screws

7 LPG conversion kit 1

- injector black coated

- LPG sticker

- LPG conversion labelling

- Conversion instructions

8 1Outside air sensor

Refer to Fig. 5 for Boiler box contents.

Wall stud

"61 C/C

4,53"Hole for 60/100mm coaxial vent

3" vent adaptor (supplied)

1.5" inside 3"

Inlet air either right or left

Exhaust vent adapter (supplied)

Screw (2x) (supplied)

14.17"

16.25"

XPak 120 - 17.81"

XPak 85 - 15.75"

CENTER LINE OF BOILER

WARNING

This boiler is heavy and awkward to lift. It is recommended and safer to install the boiler with two people. Use caution as to not drop this boiler which could cause personal injury. Verify that the boiler is securely mounted before leaving the boiler unsupervised.

Ensure there is adequate clearances for mounting the boiler (details given in installation instructions). The wall mount bracket is designed for a stud spacing of 16 inches from center. For other stud spacing a solid mounting surface must be provided by the installer. Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only. Mount the wall bracket using 4 5/16" lag screws. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the studs. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) additional lag screws.

5.90"

3.14"

3.35" 1.38"

NPT male

IN 3/4"

OUT 3/4"

NPT male

Condensate piping exible (supplied) 4/5" female

Ø1/4" holes for earthquake restraint (2 places)

inside 3.15"

Inlet air adapter (supplied)

Screw (2x) (supplied)

Gas shut o valve (supplied) 3/4" NPT female

3" inlet air adapter (not supplied)

Pressure relief valve drain 3/4" NPT female

XPak 120

Screw (2x) (tted)

XPak 85

XPak 120

XPak 85

Boiler bracket

3.54"

(supplied)

Ø1/4" holes for 5/16" lag screws (4 places)

Boiler outline

30.71" Boiler height

XPak 120

XPak 85

Fig. 5

Page 16

6 - INSTALLATION

PREPARE XPAK LOCATION

1. INSTALLATIONS MUST COMPLY WITH:

- Local, state, provincial, and national codes, laws, regulations and ordinances.

- National Fuel Gas Code, ANSI Z223.1 – latest edition.

- National Electrical Code.

- For Canada only: B149 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

NOTICE: To prevent combustion air contamination when considering exhaust vent and intake air vent termination. Intake and exhaust may be vented vertically through the roof or out a side wall.

The intake and exhaust venting methods are detailed in the Venting Section. Do not attempt to install the XPak Boiler using any other means. Be sure to locate the boiler such that the air intake and exhaust vent piping can be routed through the building and properly terminated. The air intake and exhaust vent piping lengths, routing and termination method must all comply with the methods and limits given in the Venting section.

NOTICE: The XPak boiler gas manifold and controls meet safe lighting and other performance criteria as specified in ANSI Z21.13b 2007 – CSA 4.9b 2007

2. BEFORE LOCATING THE XPAK BOILER

1. Check for nearby connection to:

- System water piping

- Venting connections

- Gas supply piping

- Electrical power

2. Check area around boiler. Remove any combustible materials,

gasoline and other flammable liquids.

WARNING: Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

3. The XPak must be installed so that gas control system

components are protected from dripping or spraying water or rain during operation or service.

4. If the new XPak is to replace an existing boiler, check for and

correct any existing system problems such as:

- System leaks.

- Incorrectly-sized expansion tank.

- Lack of freeze protection in heating water causing system and boiler to freeze and leak.

- Excessive glycol which will affect the boiler system operation.

3. CLEARANCES FOR SERVICE ACCESS

1. See figure for recommended service clearances. If you do not

provide minimum clearances shown, it might not be possible to service the boiler without removing it from the space.

WARNING: The space must be provided with combustion/ ventilation air openings correctly sized for all other appliances located in the same space as the XPak boiler. The boiler internal front cover must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room in the case of sealed combustion operation. This is particularly important if the boiler is located in the same room as other appliances. Failure to comply with the above warnings could result in sev ere personal injury, death or substantial property damage.

4. RESIDENTIAL GARAGE INSTALLATION

Precautions Take the following special precautions when installing the XPak in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1, paragraph 5.1.9:

- Mount the boiler with a minimum of 18 inches above the floor

of the garage to the bottom of the boiler to ensure the burner and ignition devices will be no less than 18 inches above the floor.

- Locate or protect the boiler so it cannot be damaged by a

moving vehicle.

5. EXHAUST VENT AND INTAKE AIR VENT

XPaks are rated ANSI Z21.13b 2007 – CSA 4.9b 2007 – Fired low pressure steam and hot water boilers. Category IV.(pressurized vent, likely to condense in the vent). Also installations with air dependent operation are allowed providing proper openings in the room are provided.

6. PREVENT COMBUSTION AIR CONTAMINATION

Install intake air piping for the XPak as described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.

WARNING: You must pipe outside air to the boiler air intake for sealed combustion operation. Ensure that the intake air will not contain any of the contaminants below. Contaminated air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. For example, do not pipe intake air vent near a swimming pool. Also avoid areas subject to exhaust fumes from laundry facilities. These areas may contain contaminants.

7. WHEN REMOVING AN EXISTING BOILER FROM AN EXISTING COMMON VENT SYSTEM

Do not install the XPak boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.

WARNING: Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

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. a. Seal any unused openings in the common venting system. b. Visually inspect the venting system for proper size and horizontal

pitch and determine there is non blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

c. Insofar as is practical, close all building doors and windows and

all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow the

lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Any improper operation of the common venting system should

be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 — latest edition. Correct by resizing to approach the minimum size as determined using the appropriate tables in Table 13 of ANSI Z223.1 2006 of that code. Canadian installations must comply with B149 Installation Code.

PREPARE XPAK

CAUTION: CAUTION:

CAUTION: Cold weather handling — If boiler has been

CAUTION: CAUTION:

stored in a very cold location (below 0°F (-18°C)) before installation, handle with care until the plastic components come to room temperature.

1. REMOVE XPAK BOILER FROM BOX

1. XPak is heavy and awkward to lift. Care must be taken to place it in a safe location prior to installation on the wall to prevent damage to the bottom mechanical connections.

Page 17

2. PLACING THE WALL-MOUNTED XPAK BOILER

XPak boilers are wall mounted. Use only the XPak boiler wall mounting instructions included in the box.

WARNING: The wall must be capable of carrying the weight of the boiler and its related components. The weights of the boiler are approximately: XPak 85 = 82 lbs (37 kg). XPak 120 = 93 lbs (42 kg). Failure to comply with above could result in severe personal injury, death or substantial property damage

3. XPAK WALL MOUNTING INSTRUCTIONS

WARNING: This boiler is heavy and awkward to lift. It is

recommended and safer to install the boiler with two people. Use caution as to not drop the boiler which could cause personal injury. Verify that the boiler is securely mounted before leaving the boiler unsupervised.

The wall must be vertically plumb and capable of carrying the weight of the XPak and its related components. The building frame (studs) must be 16" on center. If not, you must use 1/2" minimum plywood 24" x 48", fastened with at least (14) #12 x 3" (3/16" x 3") round head tapping screws to the frame of the building to provide proper support for the boiler. Alternate methods of mounting must not be used. (ex. toggle bolts, hollow wall anchors) or any other fastener other than #12 x 3" (3/16" x 3") round head tapping screws.

CAUTION: If the XPak is not vertically plumb, improper and unsatisfactory operation may occur. This will cause excessive condensation build-up causing unnecessary maintenance and nuisance fault codes.

4. INSTALLATION STEPS

Prior to lifting the XPak Boiler onto the wall, use the enclosed template to level and locate the wall bracket. Mount the wall bracket using lag screws. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the studs. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) additional lag screws. This will provide additional strength and support to the XPak boiler.

XPAK PIPING

1. RELIEF VALVE

The XPak has a pressure relief valve factory fitted. Connect discharge piping to safe disposal location, following guidelines in the WARNING below:

WARNING: To avoid water damage or scalding due to relief valve operation:

- Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the valve discharge.

- Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length.

- Discharge line must pitch downward from the valve and terminate no more than 6” (150 mm) above the floor drain where any discharge will be clearly visible. The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375 °F (190°C) or greater.

- Do not pipe the discharge to any place where freezing could occur.

- Do not plug or place any obstruction in the discharge line.

- Test the operation of the valve after filling and pressurizing system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.

- For boilers installed with only a pressure relief valve, the separate storage vessel must have a temperature and pressure relief valve installed. This relief valve shall comply with the standard for Relief Valves for Hot Water Supply Systems, ANSI Z21.22/CSA4.4.

- Failure to comply with the above guidelines could result in failure of the relief valve to operate, resulting in possibility of severe personal injury, death or substantial property damage.

2. GENERAL PIPING INFORMATION

CAUTION: Use two wrenches when tightening water piping

at boiler, using one wrench to prevent the boiler return line or supply line from turning. Failure to support the boiler piping connections to prevent them from turning could cause damage to boiler components.

NOTICE: The XPak boiler control module uses temperature sensors to provide both high limit protection and modulating temperature control. The PCB also provides low water protection using a water pressure switch (minimum 6.5 psi (0.45 bar)) and blocked flue switch. Some codes/jurisdictions may require additional external controls for high limit and/or low water cutoff protection.

3. SEPARATE LOW WATER CUTOFF

A low water cutoff may be required by state local code or some insurance companies. Check code requirements before installation of the XPak boiler. If required:

- Use a low water cutoff designed for hydronic installations

- Follow low water cutoff manufacturer’s instructions

NOTICE:

A hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be provided with a low water cut off device either as apart of the boiler or at the time of the boiler installation.

4. BACKFLOW PREVENTER

Use a backflow preventer specifically designed for hydronic boiler installations. This valve should be installed on the cold water fill supply line per local codes.

5. FITTING THE HEATING CIRCUIT SUPPLY AND RETURN PIPES

NOTICE:

- To protect the entire heating system Raypak recommends installing a filter in the return circuit. When connecting the boiler to an existing heating system this filter must definitely be installed.

- Install shut-off valves immediately before and after the dirt particle filter to enable the filter to be cleaned.

- Install a filling and drain cock in the heating system supply pipe if required.

- Also install a safety valve in the system.

NOTICE: When using oxygen-permeable pipes, e. g. for floor heating systems, you must separate the system using heat exchangers.

- Thoroughly flush all pipes and radiators.

- Refer to the installation template for the pipe connection dimensions.

- Connect the pipes so that they are free from strain.

6. EXPANSION TANK AND MAKE-UP WATER

1. Ensure expansion tank size will handle boiler and system water volume and temperature. Allow 2 gallons for the boiler and its piping.

CAUTION: Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve. Eventual failure can result due to excessive make-up water addition.

2. Expansion tank must be located near to the boiler as shown

in Piping “XPak installation diagrams”. No valve is to be placed between the boiler and the expansion tank.

7. SIZING SPACE HEAT SYSTEM PIPING

- Size the piping and components in the space heating system

using recognized design methods.

NOTICE:

- The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler and with appropriate valves to prevent the chilled medium from entering the boiler.

- The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

Page 18

8. BOILER WITH DHW TANK

- Connect the external hot-water tank according to the Installation instructions of the hot-water tank and fittings concerned.

Domestic Hot Water Production via DHW Storage Tank

XPak boilers can be used in conjunction with the stand-alone DHW storage tanks. The boiler can control the DHW tank temperature directly from the boiler control panel. In case a tank sensor is installed (see boiler configuration jumpers Fig. 61) adjust the tank temperature via the DHW selector. The display shows the tank temperature if main selector in proper position. Boiler can accept also a DHW tank controlled by a thermostat (see boiler configuration jumpers Fig. 61), in this case the DHW set point can not be adjusted on the control panel but only on the tank thermostat (field supplied). Both cases the supplied water temperature to the tank is 176°F (80°C) and it goes ahead with priority over heating until the tank request is satisfied (either the sensor or the termostat open). The boiler can control a 3-way valve directly from the boiler control panel (see 3-way installations Fig. 38). Refer to electrical connections for 3-way valve installation. Size and select the DHW storage tank based on the forecast DHW consumption of the building in question. If different method of DHW production are used, the boiler flow temperature is set as heating mode (see boiler configuration jumpers Fig. 61).

9. WATERSIDE FLOW (PRIMARY CIRCUIT)

The boiler is designed only for closed loop, forced circulation hot water heating systems. XPak is equipped with an internal 3 speed pump.

PUMP DUTY

Fig. 6 below shows the flow-rate available – after allowing for pressure loss through the appliance – for system requirements. When using this graph, apply only the pressure loss of the system. The graph is based on a 36°F (20°C) temperature differential.

required system volume and capacity, no valve is to be placed between the boiler and the expansion tank.

6. Install an Air Elimination Device on the system supply if required, the boiler has two auto air vents built in.

7. Install a drain valve at the lowest point of the system. Note: The XPak has a proper internal drain valve. (see Fig. 42a)

8. The Safety Relief Valve is installed at the factory. Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a maximum of 6” (152 mm) above the floor to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the

outlet of a safety relief valve.

11. FILL AND PURGE HEATING SYSTEM

CAUTION: For installation that incorporates standing Iron

Radiation and systems with manual vents at the high points. Follow above section and starting with the nearest manual air vent, open vent until water flows out, then close vent. Repeat procedure, working your way toward furthest air vent. It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present. Annual cleaning of the strainer may be necessary.

WARNING: Use only inhibited propylene glycol solutions which are specially formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems. Glycol mixtures should not exceed 40%.

1.Glycol in hydronic applications which is specially formulated for this purpose includes inhibitors that prevent the glycol from attacking metallic system components. Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level.

2.The glycol solution should be tested at least once a year and as recommended by the glycol manufacturer.

3.Anti-freeze solutions expand more than water. Allowances must be made for this expansion in the system design.

CAUTION: The XPak should not be operated as a potable Hot Water Boiler. The XPak should not be operated in a open system.

10. PROCEDURE SUMMARY

1. Connect the system return marked “In”.

2. Connect the system supply marked “Out”.

3. Install a Back Flow preventor on the Cold Feed Make-Up Water line.

4. Install a Pressure Reducing Valve if required on the Cold Feed Make-Up Water line, 15 PSI (1 bar) nominal on the system return. Check Pressure Gauge which should read minimum pressure of 12 PSI (0.8 bar)

5. Install an Expansion Tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to expansion tank installation. Size the expansion tank for the

6 5

Residual head (ftwc)

0.6 0

0 20 41 61 81 102 122 142 163 183 203 224 244 264 285 305

XPak 85

3rd speed

2nd speed

1st speed

Flow rate (gph)

Fig. 6

CAUTION: It is highly recommended that you carefully follow the glycol manufacturer’s recommended concentrations, expansion requirements and maintenance recommendations (pH additive breakdown, inhibitor reduction, etc.). You must carefully calculate the additional friction loss in the system as well as the reduction in heat transfer co-efficients; pH must be maintained between 6-8.

6 5

Residual head (ftwc)

0.6 0

0 20 41 61 81 102 122 142 163 183 203 224 244 264 285 305

XPak 120

3rd speed

2nd speed

1st speed

Flow rate (gph)

Page 19

XPAK INSTALLATION DIAGRAMS

NOTICE: The following illustrations are simplified conceptual

illustrations only.

Fig. 7

Fig. 8

Page 20

Fig. 9

Fig. 10

Page 21

Fig. 11

Fig. 12

Page 22

MAKING THE GAS CONNECTION

DANGER: Only carry out work on gas conduits and fittings if

you are licensed for such work.

- Determine proper size gas pipe for the installation using Table 3 and and observe proper size of the fittings.

- Install the furnished 3/4” female gas cock on the gas connection (3/4” male on the boiler) (Fig. 13).

- Connect the gas pipe to the gas cock so that it is free from any strain.

CAUTION: The boiler and its individual shutoff valve must

be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa).

Fig. 13

A- Manual main gas shutoff

valve (supplied) B- Coupling (field supplied) C- To gas supply

Table 4. Do not forget the pipe fitting losses

A B

position

Fig. 14

Open

Closed

position

NOTICE: When installing the gas supply connection, it must comply with local regulations or, if such regulations do not e xist, with the National Fuel Gas Code, ANSI Z 223.1. In Canada, the gas supply connection must comply with local regulations or, if such regulations do not exist, with CAN/CSA B149, Natural Gas and Propane Installation Code. A sediment trap must be provided upstream of the gas controls.

Gas Pipe Capacity for different pipe sizes

Length of Gas Volume Capacity

pipe (feet) (ft3/h)

Ta b . 3

3/4” 1” 1 1/4” 1 1/2”

10 278 520 1,060 1,600 20 190 350 7 3 0 1,100 30 152 285 590 890 40 130 245 500 760 50 115 215 440 670

75 93 175 360 545 100 7 9 160 305 480 150 6 4 120 250 380

* Maximum pipe capacity in ft3/hr, based on a specific gravity of 60 (42

mbar) and a inlet gas pressure of 14 inches W.C. (35 mbar) or less and a pressure drop of 0.3 inches W.C. (20 mbar)

Equivalent length for pipe fittings in feet

Ta b. 4

Steel pipe Equivalent length for Pipe Fittings in feet

diameter Type of pipe fitting

in inches 90° Elbow Tee Gate valve Gas cocks

(flow thru

branch)

Equivalent length in feet

3/4 2.1 4.1 0.5 1.25

1 2.6 5.2 0.6 1.60 1 1/4 3.5 6.9 0.8 2.15 1 1/2 4.0 8.0 0.9 2.50

NOTICE: The boiler must be isolated from the gas supply

piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

Page 23

BOILER TEMPLATE (Fig. 15)

Boiler bracket (supplied)

Ø1/4" holes for 5/16" lag screws (4 places)

1.5"

Wall stud

3.54"

Exhaust vent adapter (supplied)

3" vent adaptor (supplied)

Inlet air either right or left

C/C16"

inside 3"

Screw (2x) (supplied)

14.17"

16.25"

XPak 120 - 17.81"

XPak 85 - 15.75"

4,53" Hole for 60/100mm coaxial vent

3" inlet air adapter (not supplied)

inside 3.15"

Screw (2x) (supplied)

Inlet air adapter (supplied)

XPak 120

Screw (2x) (fitted)

Wall Mounting Information

XPak comes with a template, which allows you to easily mark the location of the screws for the mounting bracket and the location of the flue gas pipe on the wall (Raypak coaxial PP vent system only). The connection to the gas circuits must be made on site, 3/4” gas cock is supplied with the boiler .

XPak 85

30.71" Boiler height

Boiler outline

CENTER LINE OF BOILER

WARNING

XPak 120

XPak 85

IN 3/4"

NPT male

Ø1/4" holes for earthquake restraint (2 places)

5.90"

OUT 3/4"

3.35" 1.38"

NPT male

Condensate piping flexible (supplied)

0.825” female

4/5" female

3.14"

Pressure relief valve drain 3/4" NPT female

Gas shut off valve (supplied) 3/4" NPT female

XPak 120

XPak 85

Fig. 15

Page 24

COMBUSTION AIR AND VENTILATION OPENINGS

Provisions for combustion and ventilation air must be made in accordance with section 5.3, Air for Combustion and Ventilation, of the National Flue Gas Code, ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149, Installation Codes, or applicable provisions of the local building codes.

CAUTION: BOILER DAMAGE AND OPERATIONAL FAILURES !

Due to insufficient or lacking openings for combustion air and/or ventilation of the boiler room. Provisions for combustion air and ventilation are always required, regardless whether the combustion air is taken from the outside (sealed combustion) or inside (room air for combustion). Insufficient ventilation of the boiler room can lead to high air temperatures.

This can result in boiler damage. – Make sure that intake and exhaust openings are sufficiently

sized and no reduction or closure of openings takes place. – When the problem is not resolved, do not operate the boiler. – Please note these restrictions and its dangers to the operator

of the boiler.

WARNING: BOILER DAMAGE !

Due to contaminated air. – Boiler must be clear and free from combustible materials,

gasoline and other flammable vapors and liquids, and

corrosive liquids and vapors. Never use chlorine and

hydrocarbon containing chemicals (such as spray

chemicals, solution and cleaning agents, paints, glues etc)

in the vicinity of the boiler. – Do not store and use these chemicals in the boiler room. – Avoid excessive dust formation and build-up.

NOTICE: When one expects contaminated combustion air (near swimming pools, chemical cleaning operations and hair salons), sealed combustion operation is recommended.

DANGER: FIRE DANGER !

Due to flammable materials or liquids. – Do not store flammable materials and liquids in the

immediate vicinity of the boiler.

All Air from Inside the Building (room air)

The room shall be provided with two permanent openings communicating directly with an additional room(s). The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1,000 Btu per hour of total input rating of all gas utilization equipment in the confined space, but no less than 100 square inches. One opening shall commence within 12 inches (305 mm) of the top, and one opening shall commence within 12 inches (305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 inches (75 mm).

All Air from Outdoor (sealed combustion)

The room shall be provided with two permanent openings, one commencing within 12 inches (305 mm) from the top, and one commencing within 12 inches (305 mm) from the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. The minimum dimension of air openings shall be no less than 3 inches (75 mm).

1. Where directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr of total input rating of all equipment in the enclosure.

2. Where communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr of total input rating of all equipment in the enclosure.

3. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 Btu/hr of total input rating of all equipment in the enclosure.

4. Where ducts are used, they shall be of the same cross-sectional area as the free area of the opening to which they connect.

INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM

NOTICE: Consult local and state codes pertaining to special

building code and fire department requirements. Adhere to national code requirements.

NOTICE: Observe the listed maximum lengths of vent system, which are boiler model dependent. The maximum permissible lengths are listed in the main specification Tab. 5.

An optional concentric vent/air intake body can be used for the installation of a vertical venting system as well as for a horizontal venting system. The concentric vent/air intake body can be ordered through Raypak Inc. The boiler can also be operated with separate air intake and exhaust piping. The termination shall be at least 4 ft (1220 mm) for the U.S. and 6ft. (1830 mm) for Canada away from a gas utility meter, service regulator or the like (for room air applications only). The termination shall terminate at least 4 ft (1220 mm) below, 4 ft (1220 mm) horizontally from, or 1 ft (305 mm) above any door, window, or gravity air inlet into any building. Vent must be at least 12 inches (305 mm) above grade, anticipated snow line or roof surface (Canada 18” (457 mm) minimum). Vent termination must be at least 7 ft (2135 mm) above a public walkway (see Fig. 20). Vent must be 3 ft (915 mm)above any forced air intake within 10 ft (3050 mm) (see Fig. 20). Do not extend exposed vent pipe outside the building beyond recommended distance. Condensate could freeze and block vent pipe. Vent should terminate at least 3 ft (915 mm) away from adjacent walls, inside corners and below roof overhang. It is not recommended to terminate vent above any door or window, condensate can freeze causing ice formations. Do not use chimney as a raceway if another boiler or fireplace is vented into or through chimney. All vent pipes must be glued, except for the flue gas adapter which is fix into place and the first connection to the flue gas adapter. Installed you can slide the pipe onto the adapter, properly supported and the exhaust pipe must be pitched a minimum of a ¼ inch per foot back to the boiler. This allows the condensate to drain away.

NOTICE:

- Do not use cellular core pipe.

- A minimum clearance of 4 feet horizontally from and in no case above and below, unless a 4-foot horizontal distance is maintained, from electric meters, gas Below are approved examples of vertical and horizontal venting installation

- Place pipe supports every 5 feet (1525 mm) of horizontal run, beginning with support near boiler.

- Periodic cleaning of the vent terminal and air-intake screens is mandatory.

- The minimum covering wall thickness is 1" (25 mm).

- The maximum covering wall thickness is 16" (406 mm).

- For Direct venting properly reassembele and reseal the vent and air-intake systems.

CAUTION: Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

Fig. 15A

Page 25

VENT SYSTEMS

1. FLUE GAS SYSTEM

Raypak coaxial PP (Polypropylene/Aluminium) concentric flue gas/fresh air systems, Raypak coaxial Alu/Alu concentric flue gas/fresh air systems and two-pipe aluminum systems for room air independent operation (sealed combustion) and air dependent operation and side wall venting are tested to ANSI ANSI Z21.13b 2007 – CSA 4.9b 2007 standards and are certified together with the XPak boiler as a constructional unit. The XPak boiler may also be vented vertically or horizontally, using a metallic AL29-4C sources: ProTech System Inc., or room air dependent venting system (UL/ULC listed for category IV). For a more detailed description of the direct vent and single-wall vent system, please refer to the following installation Instructions. See Fig. 32A (pg. 33) for special instructions on XPak 85 boilers.

NOTICE:

Brick or masonry surfaces directly behind the horizontal vent termination should be protected with a rust-resistant sheet metal plate.

Tab. 5

Country US + CANADA

Diameter 3”

Material Stainless steel

Single wall Maximum Equivalent Length 3” (80 mm)

Horizontally/ vertically vented (air+flues)

special stainless steel - Suggested

FasNseal stainless steel vent

XPak 85

40+40ft

12+12m

XPak 120 XPak 85 XPak 120

16+16

5+5

De-rate less 5%De-rate less 2%

130+130 115+115

40+40 35+35

Fig. 16

1 Gasket in EPDM (peroxide) -58°F (-50°C) – 302°F (150°C) 2 Adapter in PP (polypropylene) male/female 80 mm > 3”

Always follow XPak Installation Instructions. Select vent material based on

- Country of the installation

- Vent configuration

- Preferred material

- Necessary maximum equivalent length

NOTICE:

The minimum covering wall thickness is 1” (25 mm) The maximum covering wall thickness is 16” (406 mm)

2. BOILER SUPPLY

XPak boilers are supplied with the following vent components and they are certified together with the XPak boiler as a constructional unit.

- 60/100 mm vent exit (Fig. 16 pos. 1)

- Left side intake air (factory sealed with two screws) for two pipes solutions (Fig. 16 pos. 2)

- Right side intake air (factory sealed with two screws) for two pipes solutions (Fig. 16 pos. 3)

- Vent adaptor for two pipes vent system – 80 mm dia exit (Fig. 16 pos. 5) (Fig. 19)

- Intake air adaptor for two pipes vent system – 80 mm dia exit (Fig. 16 pos. 6) (Fig. 18)

- 3” adaptor (inside diameter 3”) (Fig. 16 pos 4, Fig. 17)

- Paper template to fix the boiler and the flues (Fig. 15)

3. INSTALLATIONS OF SUPPLIED VENT COMPONENTS

In the case of installations using two pipes or room dependent air the following instructions must be observed.

1. Install the vent adapter (Fig. 19) to the boiler vent connection

(Fig. 16 pos. 1)

2. Use the two supplied screws to ensure the closing between

the adapter and boiler (Fig. 16 pos. 5)

3. Insert the 3” adapter (Fig. 17) into the vent adapter (Fig. 19) in

the case using 3” vents

4. Install the air adapter (Fig. 18) to the boiler air connection (choose

right or left installation (Fig. 16 pos. 2 - 3), using the two supplied screws (Fig. 16 pos. 6) in the case of two pipes, room sealed vent installation.

Fig. 17

Fig. 18

Fig. 19

Page 26

4. MINIMUM CLEARANCES FROM VENT/AIR INLET TERMINATION

Fig. 20

V = vent terminal X = air supply inlet \\\ = area where terminal is not permitted

Tab. 6

U.S. Installations1 Canadian Installations2

A Clearance above grade, veranda,

porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm)

B Clearance to window or door that may 4 ft (1.2m) below or to side of

be opened opening; 1 foot (30 cm) above 3 ft (91 cm)

opening C Clearance to permanently closed window * * D Vertical clearance to ventilated soffit located above 5 ft (1.5m) *

the terminal within a horizontal distance of 2 ft (61cm)

from the centerline of the terminal E Clearance to unventilated soffit ** F Clearance to outside corner ** G Clearance to inside corner 6 ft (1.83m) * H Clearance to each side of center line * 3 ft (91 cm) within a height

extended above meter/regulator assembly 15 ft above the meter/ regulator

assembly I Clearance to service regulator vent outlet * 6 ft (1.83m) J Clearance to non-mechanical air supply inlet to 4 ft (1.2m) below or to 3 ft (91 cm)

building or the combustion air inlet to any other side of opening; 1 ft appliance (30 cm) above opening

K Clearance to mechanical air supply inlet 3 ft (91 cm) above if within 6 ft (1.83m)

10 ft (3m) horizontally

L Clearance above paved sidewalk or paved driveway 7 ft (2.13m) 7 ft (2.13m) t

located on public property

M Clearance under veranda, porch, deck or balcony * 12 in. (30 cm) TT

1 In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code 2 In accordance with the current CAN/CGA-B149 Installation Codes t Vent terminal shall not ter minate directly above sidewalk or paved driveway located between 2 single family dwellings that ser ves both dwellings TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and underside of veranda, porch, deck or balcony is greater than 1 ft (30cm) * Clearances in accordance with local installation codes and the requirements of the gas supplier

Page 27

NOTICE: The following illustrations are simplified conceptual illustrations only.

Legend for illustrations 23-24-25-26-27-28-29-30-31-32

Two pipes vent adaptors (included with the boiler) Pos. 1 Mounting Clip (set of 4) 3.94” (100 mm) for coaxial Pos. 2 (Fig. 24) 90° Elbow 3” (80 mm) single wall Pos. 2 (Fig. 25-26-27-28) Adaptor 80 mm > 3” (included with the boiler 1 pcs) Pos. 2 (Fig. 29-30-31-32) 45° Elbow 3” (80 mm) single wall Pos. 3 (Fig. 25-26-28) V ertical vent termination 3.28 ft (1 m) 3.94” (100 mm) coaxial Pos. 3 Straight Pipe 1.64 ft (0.5 m) 3” (80 mm) single wall Pos. 4 (FIg. 25-26-28) Roof Flashing flat universal Pos. 4 (Fig. 23) Straight Pipe 3.28 ft (1 m) 3” (80 mm) single wall Pos. 5 Straight Pipe 6.56 ft (2 m) 3” (80 mm) single wall Pos. 6 (Fig. 28) Roof Flashing sloping universal Pos. 6 (Fig. 24) 45° Elbow 3.94” (100 mm) coaxial Pos. 7 Horizontal inlet air vent 2.82 ft (0.86 m) 3” (80 mm) single wall Pos. 8 (Fig. 25-26-27) Straight Pipe 1.64 ft (0.5 m) 3.94” (100 mm) coaxial Pos. 8 (Fig. 24) Adaptor for room air dependent operation Pos. 9 (Fig. 28) Straight Pipe 3.28 ft (1 m) 3.94” (100 mm) coaxial Pos. 9 (Fig. 24) 90° Elbow 3.94” (100 mm) coaxial Pos. 10 (Fig. 24) Mounting Clip (set of 4) Pos. 10 (Fig. 25-26-27-28) Vertical vent termination 3” (80 mm) single wall Pos. 11

Fig. 23

SEALED COMBUSTION OPERATION

VERTICAL COAXIAL

Fig. 24

VERTICAL COAXIAL

SEALED COMBUSTION OPERATION

Page 28

Fig. 25

a = total intake length = INTAKE b = total flue length = EXHAUST

TWO PIPES SINGLE WALL

SEALED COMBUSTION OPERATION

Fig. 26 a = total intake length = INTAKE

b = total flue length = EXHAUST

TWO PIPES SINGLE WALL

SEALED COMBUSTION OPERATION

Page 29

Fig. 27

a = total intake length = INTAKE b = total flue length = EXHAUST

TWO PIPES SINGLE WALL

SEALED COMBUSTION OPERATION

Fig. 28

a = total intake length = 0 b = total flue length = EXHAUST

TWO PIPES SINGLE WALL

ROOM AIR DEPENDENT OPERATION

a = 0

Page 30

Stainless Steel 3” Vent System

US + CANADA

Vent System - Room Air independent Operation (Sealed Combustion Operation) - Fig. 12-14-15-17

Tab. 7

Vent System diameter 3” Vent system material Stainless steel

Two pipes vent adaptors (included with the boiler) - adaptor 80 mm > 3” (included with the boiler 1 pcs) for flue - adaptor 80 mm > 3” for intake air Field supplied Order No. Combustion air intake vent material ULC/UL listed

Stainless steel Vent material 45° elbow EqL = 2 ft / 0,6m Field supplied Order No. 90° elbow EqL = 3 ft / 0,9m Bird Screen c/w Termination Field supplied Order No. Venting support

stainless steel vent material must be ULC/UL listed, stainless steel AL29-4C® for category IV boilers. Sources FasNseal – Protech

System Inc.

Order Mounting Clip for each straight length of vent pipe installed, boiler can not support weight of vent system

allowable material for combustion air ABS – CPVC – PVC or stainless steel

dia. 3” Field supplied Order No.

- Do not exceed maximum equivalent vent length.

- Always follow XPak Venting System Installation Instructions.

Field supplied Order No.

Stainless Steel Vent System

US + CANADA

Vent System - Room Air Dependent Operation - Fig. 13-16-18

Vent System diameter 3” Vent system material Stainless steel Adaptor for room air dependent operation adaptor 80 mm > 3” (included with the boiler 1 pcs) - ULC/UL listed

Stainless steel Vent material 45° elbow EqL = 2 ft / 0,6m Field supplied Order No. 90° elbow EqL = 3 ft / 0,9m Bird Screen c/w Termination Field supplied Order No.

Venting support

Stainless steel vent material must be ULC/UL listed, stainless steel AL29-4C® for category IV boilers. Sources FasNseal –

Protech System Inc.

Order Mounting Clip for each straight length of vent pipe installed, boiler can not support weight of vent system

Provide a proper air opening in the room (size according indication pg. 7)

dia. 3” Field supplied Order No.

- Do not exceed maximum equivalent vent length.

- Always follow XPak Venting System Installation Instructions.

013102 Order No.

Tab. 8

Page 31

DESCRIPTION DIAGRAM DRAWING

P/N 013040

Two pipes vent adaptors Fig. 29-30-31-32 (included with the boiler) Pos. 1

P/N 013040

adaptor 80 mm > 3” Fig. 29-30-31-32 (included with the boiler 1 pcs) Pos. 2

Fig. 29

a = total intake length = INTAKE b = total flue length = EXHAUST

TWO PIPES SINGLE WALL

SEALED COMBUSTION OPERATION

Page 32

Fig. 30

a = total intake length = INTAKE b = total flue length = EXHAUST

TWO PIPES SINGLE WALL

SEALED COMBUSTION OPERATION

Fig. 31

a = total intake length = INTAKE b = total flue length = EXHAUST

TWO PIPES SINGLE WALL

SEALED COMBUSTION OPERATION

Page 33

Fig. 32

a = total intake length = 0 b = total flue length = EXHAUST

TWO PIPES SINGLE WALL

SEALED COMBUSTION OPERATION

Fig. 32A

XPAK 85 ONLY:

If using two pipe single-wall sealed combustion with CPVC vent, add polypropylene adapters as shown. Field-supplied.

Page 34

CONNECTING THE CONDENSATE WATER DRAIN

Install the condensate drain flexible pipe (Ø 0.825” - 21mm female flexible rubber connection) with a suitable gradient (min.

2.5%). Discharge condensate from the boiler into the drainage system, either directly or (if required) via a neutralization unit (not supplied).

1. CONDENSATE CONNECTION

The condensate drain of the boiler is equipped with a built-in siphon trap in order to keep flue gases from being discharged via the condensate drain.

The condensate formed both in the condensing boiler and in the flue gas pipe must be discharged into the public sewage system in accordance with all applicable local regulations. The condensate produced by a gas-fired heating system has a pH value between 3 and 4. Some local codes may require the use of a separate neutralization unit to treat the aggressive and corrosive condensate. Raypak offers a Condensate Neutralizer Kit (Z-12 option) for use when managing the condensate is desired or required. Order part number 013141. With a neutralization unit installed, all condensate from the boiler and the flue gas pipe enters into the neutralization unit where it is treated and released into the public sewage system with a safe pH value of above 6.5. The use of neutralization granulate (performing the neutralizing process) is dependent on the operation of the heating system. To deter mine the required refill amount, check granulate level several times during the first year of operation. In some cases one granulate fill may last an entire year. The condensate discharge outlet to the drainage system connection must be clearly visible. It must be installed with a suitable gradient and provided with a stench trap. If the condensate outlet of the boiler is lower than the drain, a condensate pump must be used (see electrical wiring to loch out the boiler in the case of failure of the condensate pump - alarm 21). Only corrosion-resistant materials may be used for condensate drainage purposes (e.g. braided hose). Do not use galvanized materials or materials containing copper for piping, couplings etc. Please note that other requirements may apply depending on local regulations and/or project-specific details. It is advisable to contact your local waterworks office (authority responsible for waste water regulations) well before commencing with the installation of the neutralization unit in order to establish details of local regulations that apply.

NOTICE: Pipe ventilation must take place between the siphon trap and the neutralization unit (if applicable).

7 - ELECTRICAL CONNECTIONS

Devices such as outdoor sensor, 3-way valve, tank sensor, tank thermostat, remote controls are all connected to the external connection board. The electrical connections to the boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI/NFPA-70. Installations should also conform with CSA C22.1 Canadian Electrical Code Part 1 if installed in Canada.

1. EXTERNAL CONNECTION BOARD CONNECTIONS

A qualified electrician should connect the electrical supply to the appliance. If controls – external to the appliance – are required, a competent person must undertake the design of any external electrical circuits. ANY EXTERNAL CONTROL OR WIRING MUST BE SERVED FROM THE SAME ISOLATOR AS THAT OF THE APPLIANCE. Wiring to the appliance must be rated for operation in contact with surfaces up to 194°F (90°C).

WARNING: ELECTRICAL SHOCK HAZARD — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

AVERTISSEMENT: RISQUE DE CHOC ÉLECTRIQUE — Pour votre sécurité, coupez l'alimentation électrique au niveau du tableau de distribution avant d'effectuer tout raccordement électrique afin d'éviter un risque éventuel de choc électrique. La non-observation du dernier point peut provoquer de graves blessures ou la mort.

NOTICE: Wiring must be N.E.C. Class 1. If original wiring as supplied with heater must be replaced, use only TEW 221°F (105 °C) wire or equivalent. Heater must be electrically grounded as required by National Electrical Code ANSI/ NFPA 70 — latest edition.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

2. ELECTRICAL SUPPLY

The boiler requires a 120V 60Hz power supply. Ensure the electrical supply is properly polarized.

The boiler must be grounded.

There must only be one common isolator, providing complete electrical isolation for the boiler and any external controls using PVC insulated cable 18 AWG x3C 105 °C /221°F. All wiring must be installed in accordance with requirements of National Electrical Code and any additional national, state, or local code requirements having jurisdiction. All wiring must be N.E.C. Class 1. The boiler must be electrically grounded in accordance with the National Electrical Code, ANSI/NFPA No. 70-latest edition. In Canada, installation must conform to CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

3. FIELD WIRING

The electrical junction box has a 24 volt terminal compartment and 120 volt terminal compartment. Each terminal connection is clearly marked to ensure correct installation.

Optional devices (24V) terminal block

Fig. 34Fig. 33

Electrical supply (120V)

terminal block

Page 35

4. CASING REMOVAL (Fig. 33)

To gain internal access to the appliance you must first remove the casing, proceed as outlined below:

- remove the 3 screws (B) located at the Left/Right/Front of the underside of the casing

- lift the casing upward to disengage it from the top locating hooks and then remove

- store the casing and screws (B) safely until required. Re-fit in the reverse order.

5. APPLIANCE TERMINAL BLOCK

The appliance terminal block is located on the rear of the control panel. Remove the casing. Gently pull the control panel forwards and down. Locate the terminal block cover (see Fig. 34).

NOTICE: The appliance comes with a f actory installed jumper for room thermostat connection to allow basic operation of the boiler via the mode selector switch. If it is anticipated that external controls will be required please refer to the wiring diagrams (remove room thermostat jumper if there is the remote control installed on the low voltage terminal strip - M4 Fig. 35).

External connection board connections

Make all electrical connections inside the external connection box.

- Open the cover of the external connection box (Fig. 34).

Connecting incoming power

The boiler must be electrically grounded in accordance with local codes, or in absence of local codes, with the National Electrical Code, ANSI/INFPA 70 and/or the CSA C22.1, Electrical Code.

Boiler terminal strip (Fig. 35)

The XPak terminal strip is divided in two separated area: low voltage and high voltage area. The high voltage area is dedicated to:

- connections incoming power: ground neutral line, a fuse (4A) is factory fit directly on the terminal strip, 3 pins - M3

- connection for 3-way DHW valve (field supplied) 3 pins - M3a

The low voltage area is dedicated to:

- external sensor (2 pins - M4)

- remote control (2 pins - M4)

- DHW tank sensor (2 pins - M4a)

- DHW tank thermostat (2 pins - M2)

- Room thermostat (2 pins - M4a) factory jumper

- External alarm (3 pins - M3b) factory jumper

7. EXTERNAL WIRING

The appliance comes with a factory installed room thermostat link to allow basic operation of the boiler via the mode selector switch. If external controls are to be added to the system, they must be connected to the appliance as shown in the following diagrams. For advice on controls that are not featured in this book, please contact Raypak technical department.

8. EXTERNAL WIRING LIMITATIONS

Any external wiring must remain within the limits as detailed in the table below

CONNECTION MAX. LENGTH

Outdoor air sensor 100 ft (30 metres) Room thermostat 100 ft (30 metres) Remote control connection 100 ft (30 metres)

9. CONNECTING THERMOSTAT

1. Connect room thermostat or end switch, terminal strip is 24V (Fig. 35 ref. M4a)

2. Install thermostat on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, direct sunshine or fireplaces.

10. OTHER DEVICES

Contact Raypak technical department should you require more specific information on the suitability of a particular control. Further guidance on the recommended practice for the installation of external controls, can be found.

IMPORTANT

- The boiler must always be supplied with a permanent 120V

electrical supply.

- Always remove the link on M4a terminal strip on the appliance

low voltage 24V terminal strip whenever additional controls are connected to the appliance.

- Do not connect any controls or auxiliary equipment to the 24V

terminal strip, other than that approved/supplied by the manufacturer.

6. CONNECTING THE ELECTRICAL SUPPLY (120V)

Unhook and remove the terminal block cover (120V). Pass the cable through the cable anchorage point on the control panel. Pass the cable through the Strain Relief Bushings (field supplied) (Fig. 39). The boiler is equipped with 4 holes in the lower support .

- Chose the circle holes in the case of using Heyco-Flex Metallic (SR 7K-2) (Fig. 39 ref. 2).

- Chose the non-circle holes in the case of using Strain Relief Bushings (1/2” HFC-Z 1/2) (Fig. 39 ref. 1).

Connect the supply cable wires (LIVE, NEUTRAL & GROUND) to their corresponding terminals (L, N & G) on the appliance - 120V terminal block. When connecting the GROUND wire, ensure that it’s left slightly longer (about 1 in (20 mm)) that the others, this will prevent strain on the GROUND wire should the cable become taut. Do not remove the link wire unless additional external controls are to be fitted. The securing screw on the cable anchorage should now be tightened (Fig. 37). This must be done before the control panel is reinstalled in the upright position. The appliance casing, screws and lower cover can now be reinstalled.

NOTICE: It is the installer’s responsibility to ensure that the appliance is properly grounded. Raypak cannot be held responsible for any damages or injuries caused as a result of incorrect ground wiring.

Page 36

11. TERMINAL STRIP DETAILS

Terminal Description Technical Indications

strip specifications

reference

Tab. 9

M3 Main supply 120 VAC – 60 Hz The main supply cable must be anchored to the

boiler frame (Fig. 39) and pass through the strains relief (field supplied). Cable as specified in the electrical supply.

M3a 3-way valve:

Connections for DHW Model: Honeywell VC6011 (actuator) + VCZMK6000 external 3-way valve 120 VAC – 60 Hz (Cartridge valve)

The 3-way valve cable must be anchored to the boiler frame (Fig. 39) and pass through the strains relief (field

High voltage (Fig. 35)

supplied) (Fig. 39). Cable as specified in the electrical

supply. M4 Outdoor sensor 12 K Ohm B3760 M4 Remote control Open therm plus protocol Only Raypak Part No. 013073

M4a Room thermostat 24 VDC Volt free (Jumper when not used) M4a Tank sensor 10 K Ohm B3435 Immersion type.

for DHW If the boiler is installed with a tank sensor, the Jumper

on the PCB must be in position 2 (Fig. 61)

M2a Tank thermostat On/off (NO) Volt free

for DHW If the boiler is installed with a tank termostat, the

Jumper on the PCB must be in position 3 (Fig. 61)

M3b Under-floor heating limit On/off (NC) Volt free.

Low voltage (Fig. 35)

thermostat and condensate This is a generic input to lock out the boiler. Jumper when

(generic available alarm) not used). If the contact will be

open the alarm number 21

will appear on the display and the boiler is lock out

REMOTE CONTROL

0T+

Fig. 35

EXTERNAL

SENSOR

-t°

LOW VOLTAGE

TANK

THERMOSTAT

ROOM

THERMOSTAT

(jumper when

not used)

UNDERFLOOR HEATING LIMIT

THERMOSTAT OR

CONDENSATE PUMP ALARM

(jumper when not used)

TANK

SENSOR

-t°

M4a

M3b

HIGH VOLTAGE

M3a

PCB fuse=4AT

BROWN (CLOSED)

BLUE (COMMON)

BLACK(OPEN)

120V

Cod. 20003227

F= fuse 4AF

Page 37

12. OUTDOOR SENSOR CONNECTION

The user can program the desired supply temperature based on the outdoor temperature. Once the outdoor sensor is connected to the control board, the water temperature of the boiler will adjust to run the boiler more efficiently and provide greater comfort to the living space.

Connection Specification – Wire 22 AWG maximum to 100 ft (30 m). Outdoor Sensor is connected in the junction box on the XPak. Route wires from the terminal strip to your outdoor sensor, which will allow the user to change the temperature going to the Central Heating loop automatically. Place the outdoor sensor preferably to the north or northwest or to the side which will be affected by changing weather conditions outside. NOTE: Do not locate the sensor in the direct sunlight.

13. 3-WAY VALVE WIRING CONNECTION

XPak boiler can manage an external 3-way valve (field supplied), the terminal strip (M3a) output is 120V – 60 Hz (see electric diagram).

Logic of the boiler managing 3-way valve

1. Boiler configuration in DHW (case A and case B), see Fig. 61 for boiler jumper configuration.

2. Once the jumper has set in DHW mode (tank with probe or tank with thermostat), when there is a heat request from the sensor or from the thermostat, there is power out (120V – 60 Hz) to the boiler terminal strip M3a (Fig. 35).

3. The output to the 3-way valve DHW pin is continuously supply up to the heat is satisfied.

4. The room thermostat request is independent from the DHW request (Priority is always given to DHW production).

5. The 3-way valve is always powered, even if there is no DHW demand.

Fig. 36

Fig. 37

WARNING: The 3-way valve is continuously powered even if there is no heat request from the tank.

Wiring connections 3-way valve Suggested source: Honeywell VC6011 (actuator) + VCZMK6000 Wiring the valve as per diagram Fig. 38. Follow the installation of the piping referring to the diagram showing the logic of working Fig. 38. The connections colors and schematic refer to the Honeywell VC6011 (actuator) + VCZMK6000.

14. REMOTE CONTROL CONNECTION

The boiler can be fully remoted using an open therm plus remote control (use only Raypak REC 08 Part No 013073). When the control is installed with the boiler display shows as per Fig. 36. No operation can be made on the boiler control panel once the remote control is installed. All the boiler settings can be made only by Remote Control once it is connected. See Remote Control instruction for setting and use.

Choose one of the two options for the strain relief that XPak allows

Fig. 38

Main supply cable

Straight-Thru:

Heyco HFC-Z 1/2

Strain Relief

Bushings:

Heyco SR 7K-2

Fig. 39

3 way valve

cable

Listed under UL File #E-206446

Listed under UL File

#E-15331 CSA

LR8919

Page 38

WIRING FUNCTIONAL DIAGRAM

Fig. 40

Page 39

8 - START-UP PROCEDURE

There are several steps involved in starting up the boiler.

instructions du fornisseur

fournisseur, appelez le service des

incendies.

d'admission du gaz qu'à la main; ne

jamais utiliser d'outil. Si la manette reste

coincée, ne pas tenter de la réparer;

appelez un technicien qualifié. Le fait de

forcer la manette ou de la réparer peut

déclencher une explosion ou un incendie.

dans l'eau, même partiellement. Faites

inspecter l'appareil par un technicien

qualifié et remplacez toute partie du

système de contrôle et toute commande

qui ont été plongés dans l'eau.

- Si vous ne pouvez rejoindre le

C.Ne poussez ou tournez la manette

D. N'utilisez pas cet appareil s'il a été plongé

INSTRUCTIONS D'ALLUMAGE

l'étape "B" des instructions de sécurité

sur la portion supérieure de cette

étiquette. S'il n'y a pas d'odeur de gaz,

passez à l'étape suivante.

gaz dans le sense antihoraire à la

position "marche" (ON)

8. Tourner le bouton de commande de

9. Remontez le couvercle du haut

10. Mettez l'appareil sous tension

11. Réglez le thermostat à la température

désirée

suivez les instructions intitulées

"Comment couper l'admission de gaz

de l'appareil" et appelez un technicien

qualifié ou le fournisseur de gaz.

12. Si l'appareil ne se met pas en marche,

vanne gaz en arret

pour

Cod. 20003235

ouvrir

dans le sens horaire à la position "arret"

4. Tournez le bouton de commande de gaz

5. Remontez le couvercle du haut.

POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE

Il est muni d'un dispositif d'allumage qui

allume automatiquement le brûleur. Ne

tentez pas d'allumer le brûleur

manuellement.

tout autour de l'appareil pour déceler une

odeur de gaz. Reniflez près du plancher,

AVERTISSEMENT: Quiconque ne respecte pas à la lettre les instructions dans la

présente notice risque de déclencher un incendie ou une explosion entraînant des

dommages, des blessures ou la mort.

A.Cet appareil ne comporte pas de veilleuse.

knob. Never use tools. If the handle will

call the fire department.

not turn by hand, don't try to repair it,

- If you cannot reach your gas supplier,

C. Use only your hand to turn the gas control

B. AVANT DE FAIRE FONCTIONNER, reniflez

call a qualified service technician. Force

or attempted repair may result in a fire

car certains gaz sont plus lourds que l'air

or explosion.

D. Do not use this appliance if any part has

et peuvent s'accumuler au niveau du sol.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR

been under water. Immediately call a

qualified service technician to inspect the

vous servir des téléphones se trouvant

DE GAZ:

- Ne pas tenter d'allumer l'appareil

- Ne touchez à aucun interrupteur; ne pas

appliance and to replace any part of the

control system and any gas control which

has been under water.

dans le bâtiment

de gaz depuis un voisin. Suivez les

- Appelez immédiatement votre fournisseur

1. ARRÊTEZ! Lisez les instructions de

If you then smell gas, STOP! Follow "B"

sécurité sur la portion supérieure de cette

étiquette

2. Réglez le thermostat à la température la

in the safety information above this label.

If you don't smell gas, go to next step.

plus basse

l'appareil

3. Coupez l'alimentation électrique de

to open valve. Handle will be parallel to

pipe.

8. Turn gas shutoff valve counterclockwise

9. Install top cover.

vanne gaz en marche

veilleuse. Il est muni d'un dispositif

d'allumage qui allume automatiquement

le bruleur. Ne tentez pas d'allumer le

bruleur manuallement.

dans le sens horaire à la position "arret"

(OFF)

échapper tout le gaz. Si vous sentez une

odeur de gaz, ARRÊTEZ! Passez à

4. Cet appareil ne comporte pas de

10. Turn on all electric power to appliance.

the instructions "To Turn Off Gas To

11.Set thermostat to desired setting.

12.If the appliance will not operate, follow

5. Retirez le couvercle du haut

6. Tournez le bouton de la vanne de gaz

7. Attendre cinq (5) minutes pour laisser

Appliance" and call your service

technician or gas supplier.

Gas Valve CLOSED

pour

fermer

to OPEN

COMMENT COUPER L'ADMISSION DE GAZ L'APPAREIL

plus basse

1. Réglez le thermostat à la température la

2. Coupez l'alimentation électrique de

valve. Handle will be perpendicular to pipe.

Do not force.

4. Turn gas shut off valve clockwise to close

l'appareil s'il faut procéder à l'entretien

3. Retirez le couvercle

5. Install top cover.

FOR YOUR SAFETY READ BEFORE OPERATING

Fig. 41

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury, or loss of life.

A. This appliance does not have a pilot. It

is equipped with an ignition device

which automatically lights the burner. Do

not try to light the burner by hand.

B. BEFORE OPERATING smell all around

the appliance area for gas. Be sure to

smell next to the floor because some

gas is heavier than air and will settle on

the floor.

WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance.

- Do not touch any electric switch; do not

OPERATING INSTRUCTIONS

Follow the gas supplier's instructions.

use any phone in your building.

a neighbor's phone.

- Immediately call your gas supplier from

on this label.

1. STOP! Read the safety information above

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an

ignition device which automatically lights

the burner. Do not try to light the burner

by hand.

5. Remove top cover.

6. Turn gas shutoff valve clockwise to close

TO TURN OFF GAS TO APPLIANCE

Gas Valve OPEN

to CLOSE

valve. Handle will be perpendicular to

pipe. Do not force.

7. Wait five (5) minutes to clear out any gas.

if service is to be performed.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance

3. Remove top cover.

Page 40

9 - COMMISSIONING

1. CHECK/CONTROL WATER CHEMISTRY

WARNING: Do not use petroleum-based cleaning or sealing

compounds in heater system. Damage to elastomer seals and gaskets in system could occur, resulting in substantial property damage.

Water pH between 6.0 and 8.0

1. Maintain heater water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by water treatment company.

2. If pH differs from above, consult local water treatment company for treatment needed.

system the pressure gauge will begin to rise. Once the gauge has reached 15 p.s.i. (1 bar) close both valves and begin venting all manual air release valves, starting at the lowest first. It may be necessary to go back and top-up the pressure until the entire system has been filled. Inspect the system for water tightness, fixing any leaks.

WARNING: Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure.

Hardness less than 7 grains.

1. Consult local water treatment companies for unusually hard water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm.

2. Do not use the heater to directly heat swimming pool or spa water.

3. Do not fill heater or operate with water containing chlorine in excess of 200 ppm.

Clean system to remove sediment

1. You must thoroughly flush the system (without heater connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment.

2. Flush system until water runs clean and you are sure piping is free of sediment.

Test/replace freeze protection fluid

1. For systems using freeze protection fluids, follow fluid manufacturer’s instructions to verify inhibitor level and that other fluid characteristics are satisfactory.

2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer’s instructions.

2. FREEZE PROTECTION (WHEN USED)

WARNING: NEVER use automotive or standard glycol

antifreeze, even ethylene glycol made for hydronic systems. Use only freeze-prevention fluids certified by fluid manufacturer as suitable for use with aluminum heaters, verified in fluid manufacturer’s literature.

Throroughly clean and flush any system that has used glycol before installing the new XPak Boiler. Provide XPak boiler owner with a material safety data sheet (MSDS) on the fluid used (if requested).

1. Determine freeze protection fluid quantity using total system water content, following fluid manufacturer’s instructions. Remember to include expansion tank water content.

2. Local codes may require back flow preventer or actual disconnect from city water supply.

3. When using freeze protection fluid with automatic fill, install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

5. The system may have residual substances that could affect water chemistry. After the system has been filled and leak tested, verify water pH and chlorine concentrations are acceptable.

CAUTION: It is important that you purge the system of air to avoid damage to the heater.

5. PURGE AIR FROM BOILER

MANUAL AIR RELEASE (Fig. 42)

When the boiler has been filled for the first time or the system has been drained and refilled, it will be necessary to release any air that may have become trapped within the appliance heat exchanger . Slacken the bleed screw using a 7/16” (11mm) openended spanner until water is released and then close. IMPORTANT, THERE ARE NO OTHER MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE.

WARNING: Never open the Manual Air Vent while the boiler is hot. Allow boiler to cool to room temperature to avoid scalding while purging.

Fill the system and watch that system pressure rises to correct cold-fill pressure. After the system has operated for a while, eliminate any residual air.

6. SYSTEM DRAIN (Fig. 42a)

Use a open-ended wrench (dimensions 7/16” (11 mm)) to drain the water inside the boiler:

- attach the rubber pipe supplied to the drain valve (A)

- locate the wrench hole under the boiler

- fit the wrench to the valve

- gently rotate the wrench counterclockwise

- drain the boiler

- close the valve rotating the wrench clockwise

- remove the rubber pipe from the valve once the valve as been

closed DANGER: The system water temper ature could be very hot,

be sure when the valve is opening that the rubber pipe is well attached. Frontal water flushing can occur and cause instant severe burns or death from scalds.

3. THE HEATING SYSTEM

The appliance contains components that may become damaged or rendered inoperable by oils and/or debris that are residual from the installation of the system, consequently it is essential that the system be flushed in accordance with the following instructions.

4. INITIAL FILLING OF THE SYSTEM

Ensure both flow and return service valves are open, remove appliance casing as described, identify the automatic air release valves (AAV) and loosen the dust cap/s by turning the cap counterclockwise one full turn. Ensure all manual air release valves located on the heating system are closed. Fill the system via proper filling method (field supplied). As water enters the

Fig. 42

Page 41

Fig. 42a

7. CHECK THERMOSTAT CIRCUIT(S)

1. Disconnect the two external wires connected to the boiler thermostat terminals (low voltage terminal strip M4a).

2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and correct the external wiring.

5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to boiler low voltage terminal strip. Allow the boiler to cycle.

8. TESTING FOR GAS LEAKS

Prior to start-up of the boiler you must check the external tightness of the gas supply valve and confirm this in the start-up report. Inspect the entire installation including the gas meter.

WARNING: Before starting the XPak, and during initial operation, smell near the floor and around the heater for gas odorant or any unusual odor. Remove heater front door and smell interior of heater enclosure. Do not proceed with startup if there is any indication of a gas leak. Repair any leak at once.

WARNING: LPG boiler only — Your propane supplier mixes an odorant with the LPG to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the LPG supplier verify the correct odorant level in the gas.

WARNING:

- Cover endangered positions before leak testing.

- Do not spray the leak testing agent onto cables, plugs or electrical connection lines.

- Do not allow it to drip onto them either.

DANGER: Leaks may be caused to pipes and screw connections during commissioning and maintenance activities.

- Carry out a proper leak test.

- Only use approved leak detection agents for leak detection.

- Disconnect the heating system from the power supply.

- Check the exterior tightness of new pipe sections up to and including the direct sealing point on the gas burner

fitting.

- Ensure the 4 AMP fuses are installed;

- Ensure the system has been filled, vented, and the pressure set to 15 p.s.i. (1 bar);

- Ensure the flue system has been installed properly and in accordance with the instructions;

- Ensure all appliance service valves are open.

11. INITIAL LIGHTING AND IGNITION SAFETY SHUTOFF

DEVICE TEST

Ensure the electrical supply to the appliance is switched on. Ensure any external controls are switched to an ‘ON’ position and are calling for heat. Move the selector switch to the ON position ( appliance will now operate.

NOTICE:

After installation, the boiler must be turned ON and the thermostat set for CFH and operated with the manual gas shut-off valve below the unit closed. Allow the boiler to go through its 5 ignition tries and then lock out. The display should indicates the alarm code 10. After the test, reset the control, open the gas valve, set the thermostat to the proper setting and ensure that the boiler operates properly.

12. CHECKING GAS PRESSURE AND COMBUSTION

ANALYSIS

The boiler is factory set and requires no additional adjustment once installed. If the installation does not include a gas meter (for example LPG) and there are no means by which to calculate the gas rate, then a combustion analysis test must be carried out in accordance with local regulations to ensure the appliance is left working safely and correctly. Additionally, if the gas valve has been adjusted, replaced, or the appliance has been converted for use with another gas type, then it becomes necessary to carry out a combustion analysis/ check to ensure that correct combustion is occurring. If there are no means to gas rate the appliance and/or carry out a combustion analysis check, then it will not be possible to complete the commissioning procedure. Details on how to carry out the combustion analysis can be found in Section 11.

NOTICE: It’s imperative that a sufficient dynamic – gas – pressure is maintained at all times. Should the dynamic gas pressure fall below an acceptable level, the appliance may malfunction or sustain damage.

13. FINAL FLUSHING OF THE HEATING SYSTEM

The system shall be flushed. Cleaners or chemicals used, must be suitable for Aluminum heat exchangers and shall be from a reputable manufacturer and shall be administered in strict accordance with the manufacturers’ instructions.

NOTICE: Chemicals used to clean the system and/or inhibit corrosion must be pH neutral, i.e. they should ensure that the level of the pH in the system water remains neutral. Premature failure of certain components can occur if the level of pH in the system water is out of normal levels.

- - F), the

9. INITIAL FLUSHING OF THE SYSTEM

The whole of the heating system must be flushed both cold and hot as detailed in Fig. 42a. Open all radiator or heating valves and the boiler flow & return service valve. Drain the boiler and system from the lowest points. Open the drain valve full bore to remove any installation debris from the boiler prior to lighting. Refill the boiler and heating system.

10. PRE-OPERATION CHECKS

Before attempting the initial lighting of the appliance, the following checks must be carried out:

- Ensure all gas service valves from the meter to the appliance are open and the supply pipe has been properly purged;

- Ensure the proper electrical checks have been carried out, particularly continuity, polarity, and resistance to ground;

14. SETTING THE BOILER OPERATING TEMPERATURE

The flow outlet temperature can be adjusted between 104-176°F (40-80°C) depending on the boiler configuration via the Heating thermostat knob (Fig. 1A). If the 3-way valve is connected, the flow outlet temperature to the tank can be adjusted between 95-140°F (35-60°C) via the DHW temperature selector (Fig. 1A).

15. REGULATING THE CENTRAL HEATING SYSTEM

Fully open all radiator and circuit valves and run the appliance for both heating and hot water until heated water is circulating. If conditions are warm remove any thermostatic heads. Adjust radiator return valves and any branch circuit return valves until the individual return temperatures are correct and are

approximately equal.

Page 42

16. FINAL CHECKS

- ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS V ALVE ARE TIGHT AND CHECKED FOR TIGHTNESS.

- ENSURE THE APPLIANCE FLUE SYSTEM IS INSTALLED CORRECTLY AND IS PROPERLY SECURED.

- ENSURE ALL PIPE WORK IS RE-CHECKED FOR SOUNDNESS.

- REATTACH APPLIANCE CASING.

- COMPLETE CHECKLIST

Complete details of the boiler, controls, installation and commissioning in the checklist at the back of this book. It is important that the checklist is correctly completed and handed to the user. Failure to install and commission the appliance to the

manufacturers instructions may invalidate the warranty

17. INSTRUCTING THE USER

Hand over all documentation supplied with this appliance – including these instructions – and explain the importance of keeping them in a safe place. Explain to the user how to isolate the appliance from the gas, water and electricity supplies, and the locations of all drain points. Show the user how to operate the appliance and any associated controls correctly. Show the user the location of any isolating valves and the location of all manual air release points. Explain to the user how to turn off the appliance for both long and short periods and advise on the necessary precautions to prevent freeze damage. Explain to the user that for continued safe and efficient operation, the appliance must be serviced annually by a qualified service person.

18. WARRANTY

To validate the appliance warranty, it’s necessary to register the

appliance details with us. The warranty can be registered in several ways, see last pages of this manual for details.

Page 43

10 - START-UP AND OPERATION

XPak wall-mounted condensing boiler is designed for the production of heating and domestic hot water if a storage tank is connected. The control panel contains the main boiler control and management functions.

1. SWITCHING ON THE APPLIANCE

Switch on the boiler as follows:

- Open the gas tap under the boiler by turning it counterclockwise (Fig. 46)

- Turn on the general switch of the system and then, after lowering the flap, turn the function selector to summer winter on the chosen operating mode.

Pump cycle mode: when power is restored to the boiler and/ or the boiler is powered for the first time, the boiler will enter a 2minute purge cycle whereby only the pump will run for 15-seconds then off for 15-seconds and will not “fire” until this period has elapsed. To interrupt the purge cycling remove the knob of the main selector switch and press the CO button (Fig. 59).

Off/reset - Select this position when the boiler needs to be reset or switched off.

Summer mode

by the water tank is activated. The display indicates the storage

tank temperature (only with the external water tank connected with a sensor).

Winter mode

and, if connected to an external water tank, it provides domestic hot w

Winter mode tank temperature

hot water for heating and, if connected to an external water tank with a sensor the storage tank temperature.

2. HOW TO READ THE DISPLAY TEMPERATURE

● (dot in the middle)= means hundred (Fig.43)

● (dot on RIGHT side)= means DHW mode (Fig. 44)

example:

Fig. 43

Fig. 44

NOTICE:

For temperature over 199°F (93°C) the display shows .

Adjusting heating water temperature

To adjust the heating water temperature turn the knob mar ked

(Fig. 50) clockwise to increase and counterclockwise to decrease. When turning the knob, the required temperature automatically appears on the digital display.

NOTICE: Depending on the type of system, it is possible to pre-select the suitable temperature range:

- standard systems 104-176°F (40-80°C)

- floor systems 68-113°F (20-45°C). For further details, consult the “Boiler configuration” (Fig. 61)

3. ADJUSTING HEATING WATER TEMPERATURE WITH

AN OUTDOOR PROBE CONNECTED

When an outdoor probe is connected, the value of the delivery temperature is automatically chosen by the system which rapidly adjusts ambient temperature to the changes in outdoor tempe-

or winter tank temperature F (Fig. 54) depending

- The domestic hot water function provided

- The boiler produces hot water for heating

ater. The display indicates the boiler flow temperature.

- The boiler produces

, it provides domestic hot water . The display indicates

Heating mode

60°F 160°F

DHW mode

40°F 140°F

rature. To increase or decrease the temperature with respect to the value automatically calculated by the PCB, turn the heating water selector (Fig. 50) clockwise to increase and counterclockwise to decrease. Adjustment settings range from comfort levels - 5 to + 5 which are indicated on the digital display when the knob is turned.

4. ADJUSTING DOMESTIC HOT WATER TEMPERATURE (IF A STORAGE TANK WITH SENSOR AND 3-WAY VALVE IS INSTALLED)

When turning the knob, the required temperature automatically appears on the digital display. The domestic hot w ater adjustment

ranges lies between 95°F (35°C) and 140°F (60°C). When choosing the temperature, both for heating and domestic hot water, the display shows the value being selected. About 4 seconds after the selection has been made, the modification is recorded and the display returns to the delivery or domestic hot water temperature read by the probe. Priority is always given to DHW production. The boiler setting depends from the jumper JP position (Fig. 63).

- CASE A (factory set) heating only + external water tank with

thermostat adjustment inapplicable - jumper in position 3

- CASE B heating only + external water tank with sensor - to

adjust the temperature of the domestic hot water in the water tank, turn the temperature selector clockwise to increase and counterclockwise to decrease - jumper in position 2.

5. WORKING THE BOILER

If a programmable timer or ambient thermostat are mounted, these must be switched on and adjusted to higher than ambient temperature in order to allow the boiler to start. The boiler remains on standby until the burner ignites as a result of a demand for heat. The g reen indicator LED (B, Fig. 52), located on the left-hand side of the panel, lights up to indicate the flame is present. The boiler continues to work until the selected temperatures have been reached. It then returns to “stand-by” while displaying delivery temperature. In the event of a starting or operating fault, the boiler performs a “SAFETY STOP”: the green indicator LED on the control panel goes out, a fault code flashes on the display (Fig. 53) and a red indicator LED (D) lights up in the event of a shutdown. To identify the fault codes and reset the boiler, consult the “Indicator LEDs and faults” section.

6. RESET FUNCTION

T o reset the boiler , turned the function selector to move it to the required position and check that the red indicator LED has gone out. At this point, the boiler starts automatically if correct operating conditions have been restored; when the burner ignites, the green indicator led lights up and the digital display indicates the instantaneous operating temperature.

NOTICE: Simply turning the selector to boiler. If the boiler continues not to work, call your local Service Technician.

In normal operating conditions, when the function selector is turned to anti-freeze phase (AF - Fig. 56) is in progress or the combustion analysis function is activated (CO - Fig. 58).

7. SWITCHING OFF

For short absences (weekends, brief journeys, etc.) turn the function selector to As the boiler remains powered with the gas tap open, it is protected by the following systems:

- Freeze protection:

Heating

The function starts if the temperature measured by the flow sensor falls below 43°F (6°C). In this mode, a heat demand is generated and the burner ignites at minimum power. This is maintained until the temperature of the water flow reaches 95°F (35°C).

, the digital display indicates “- -” (Fig. 55) unless the

OFF/RESET.

(Fig. 54) then

does not reset the

Page 44

Domestic hot water (with connection to an external water tank with probe)

The function starts if the temperature measured by the water tank probe falls below 40°F (4°C). In this mode, a heat demand is generated and the burner ignites at minimum power. This is maintained until the temperature of the delivery water reaches 95°F (35°C).

NOTICE: During the freeze protection mode, AF flashes on the display (Fig. 56)

- circulator anti-block: if the boiler remains inactive, the circulator performs a 30-second operating cycle every 24 hours. If the boiler is planned not to be used for a long period, proceed as follows:

- move the function selector to OFF-RESET

- turn the main system switch to “off”

8. INDICATOR LEDS AND FAULTS

Green indicator LED (Fig. 52)

Off = boiler on stand-by, no flame On = burner on, the boiler works regularly.

Red indicator LED (Fig. 53)

Stop: just the fault code flashes on the digital display. Block: the red indicator LED lights up and the fault code flashes

on the digital display. The fault code is not displayed in the OFF/RESET (

display it, move the function selector to

, or F. During

) mode. To

combustion analysis and the freeze protection mode, instead, it is displayed. To reset the boiler, turn the function selector to

(OFF/ RESET) and then move it to be required position (Fig. 47) . If the boiler still doesn’t work, call in the local Service Technician.

Pressure gauge

B Green led C 2-digit LED display D Red led E Temperature selector space heating F Mode selector switch G Temperature selector Domestic Hot Water*

* The parts of the manual refering to the DHW circuit should be only considered if a indirect water tank with sensor is installed, case B (Fig. 61)

Fig. 45

Page 45

Open

position

D red indicator LED fault

Fig. 46

DHW mode

Fig. 48

Fig. 47

Heating mode

Fig. 49

B green indicator LED

boiler status

Fig. 50

Code

AL10 AL20 AL21

AL29 AL60 AL71 AL73 AL28 AL26 AL79

AL41 AL40 AL34 AL52 AL55

AL91

Description of alarm

Ignition attempts finished (no flame/condensate present) Limit thermostat fault, blocked flue switch, flue thermostat Low temperature thermostat/condensate pump safety device fault Flue sensor over temperature lock out Water tank probe fault Delivery probe fault (open/short circuit) Return probe fault (open/short circuit) Return/delivery probe differential fault Return over temperature Delivery over temperature / return-delivery probe differential fault System water pressure low System water pressure low (after 10 minutes) Fan tacho fault Generic electronic fault No boiler mode configuration fault (corresponding jumper absent) The main heat exchanger need to be cleaned – call the Raypak technical service

Fig. 51 Fig. 52

Status

Block Block Block

Block Block Stop Stop Block Block Block

Stop Block Block Block Block

Advice

For AL41 faults

If the pressure on the water gauge located on the control panel is less than 7 psi (0.5 bar), proceed as follows:

- Turn the function selector to

(Fig. 54)

- Fill the system until the pressure indicated on the water gauge lies between 14-21 psi (1-1.5 bar) (Fig. 45 pos. A)

- Move the function selector to the desired position.

In case of frequent pressure drops, call your local Service Technician.

Fig. 53 Fig. 54

Closed

Fig. 55

Fig. 56

position

Fig. 57

For alarm AL91

The boiler has an internal self diagnostic system that can advise if it is necessary to clean the main heat exchanger (alarm code AL91) after 2500 hours of working in particular conditions. After the heat exchanger cleaning (using the cleaning kit – Raypak Part No. 013142F) it is necessary to reset the hour meter with the following instructions: Switch off the electric supply to the boiler Remove the knob of the main selector Switch on the boiler while pressing the CO button for at least 4 seconds (Fig. 59). To check if the counter has been reset, switch OFF and ON the boiler main supply, after the lighting of all the segments of the display, the value of the counter will appear.

NOTICE

The reset counter procedure must be carry on after every heat exchanger deep cleaning and in any case after heat exchanger replacement.

NOTICE

To check the hours of the counter, switch off the main supply, than switch on. After the lighting of all the elements of the display, a number will appear: multiply for 100 to get the hours (18 = 1800 hours, 01 = 100 hours)

Page 46

11 - CHECKS, ADJUSTMENTS AND FAULT FINDING

1. CHECKING APPLIANCE OPERATION

When carrying out any repairs or servicing to the appliance, the relevant commissioning procedure must be undertaken to ensure the continued safe operation of the appliance. Particular attention should be made to ensure gas tightness, water tightness, and the electrical integrity of the appliance.

2. APPLIANCE MODES OF OPERATION

NOTICE

There must be sufficient system water pressure min 7 psi (0.5 bar) to ensure the water pressure switch is activated. If there is insufficient system pressure the pump and fan will be prevented from operating and the low-pressure fault code will be displayed.

The 2-digit display can show several different modes of operation.

3. SELECTOR SWITCH IN THE OFF/STAND BY POSITION

When the selector switch is in the Off/reset position, the following functions are active.

Active functions:

- Freeze protection system

- Pump anti-seize

4. ON-BOARD FUNCTIONS

- THERMOREGULATION: When an outdoor air sensor is connected to the appliance, the electronic circuitry will automatically adjust the flow outlet temperature to suit local weather conditions in order to maintain comfort and efficiency . A specific operating curve that is most suited to the system type and geographical area can also be selected (Fig. 65).

- CO FUNCTION: the CO function when activated, will allow the appliance to run at maximum and minimum output while a combustion analysis check is being carried out. While the CO function is active, all other functions are disabled (minimum power operating period, anti-cycle, set-point, etc). Once enabled, the CO function will remain active for a 15-minute period, or until the function is manually deactivated (refit and rotate in any direction the main selector switch).

- FREEZE PROTECTION: This function is only active when there are no requests for heating or DHW. If the temperature drops below 43°F (6°C), the boiler will operate on minimum power until the temperature of the primary thermistor reaches 95°F (35°C). Thereafter the pump & fan will post-purge for 30-seconds .

- ANTI-CYCLE FUNCTION: The anti-cycle function ensures the burner remains switched off for at least 3-minutes after the set-point hysteresis (set-point + 9°F (5°C)).

- PUMP ANTI-SEIZE FUNCTION: When there has been no heating or DHW request for 24-hours, the anti-seize cycle is activated. The pump will be activated f or a period of 30-seconds.

- ACTUATOR ANTI-SEIZE FUNCTION: When there has been no heating or DHW request for 24-hours, the anti-seize cycle is activated. The divertor valve actuator (3-way valve) will cycle briefly to the heating position, and then back to the DHW position.

5. HEATING MODE

With the selector switch in the ON position ( additional controls (time clock, programmer , room thermostat, etc,) calling for heat, the appliance will operate in the heating mode. The pump and fan will be activated via the flow temperature sensor. When the fan is sensed to be operating correctly (blower signal), the ignition sequence commences. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry increases the gas rate to 75% of the MAX Heating (set by the corresponding HTG trimmer) for a period of 15 minutes. The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow temperature sensor, consequently a high temperature at the flo w sensor results in a lower fan speed. As the water temperature increases, the temperature sensors – located on the flow pipe of the boiler – reduce the fan speed via the electronic circuitry. Depending on the load, either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required. When the boiler has reached the set point (+ hysteresis), the burner will switch off. The built-in anti-cycle device prevents the bur ner from re-lighting for approximately 3-minutes. When the temperature of the flow sensor falls below the set point (- hysteresis), the burner will re-light.

NOTICE: If the spark/sensing electrode does not sense ignition the appliance will re-attempt ignition a further 4-times then go to lockout. When the set-point has been reached (the position of the heating temperature selector) as measured at the primary thermistor, the appliance will begin the modulation phase whereby the fan and gas valve will continuously modulate to maintain the set-point. If the temperature continues to rise and exceeds the setpoint by 9°F (5°C) (hysteresis), the burner will shut down. A new ignition sequence will be enabled when the 3- minute anti-cycle has been performed and the temperature at the primary thermistor has dropped 9°F (5°C) (hysteresis) below the set-point.

NOTICE: When the request for heating and/or hot water has been satisfied, the appliance pump and fan may continue to circulate to dissipate any residual heat within the appliance.

6. DHW MODE

With the selector switch in either the hot water only or heating & hot water position, the appliance will operate in the hot water mode whenever a tank sensor/thermostat is in request. If there is a request the pump and fan will be activated via the flow temperature sensor. When the fan is sensed to be operating correctly (blower signal), the ignition sequence commences. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuit allows the gas rate to achieve the modulation value.

- - F) and any

OFF/reset position

Normal heating request (example 140°F (60

Fig. 58

Freeze protection mode active

C)).

Purge cycle mode active

Combustion analysis mode active

Normal DHW request (example 140°F (60oC))

Page 47

NOTICE: When the request for heating and/or hot water has been satisfied, the boiler pump and fan may continue to circulate to dissipate any residual heat within the boiler.

7. BOILER FAN SPEEDS

The boiler fan speeds require to be checked and/or adjusted prior to making any adjustments to the gas valve or if the main PCB has been replaced.

ATTENTION

Gas type and appliance fan speed (output) must be set according to the specific appliance specification. Raypak accepts no responsibility if the gas type and/or fan speed is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge.

CHECKING/ADJUSTING THE BOILER FAN SPEEDS

Move the selector switch to the OFF position and remove the 3selector knobs.

ABSOLUTE MAX FAN SPEED

Locate the MAX trim pot (Fig. 59) and gently adjust clockwise or counterclockwise to achieve the correct fan speed (see Table 10 below).

NOTICE: The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

ABSOLUTE MIN FAN SPEED

Locate the MIN trim pot (Fig. 59) and gently adjust clockwise or counterclockwise to achiev e the correct fan speed (see T able 10 below).

NOTICE: The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

IGNITION FAN SPEED

NOTICE: Do this operation only after the adjusting of

absolute max and min fan speed.

Locate the IGN trim pot (Fig. 59) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see Table 10 below).

NOTICE: The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

HEATING FAN SPEED

Locate the HTG trim pot (Fig. 59) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see Table 10 below).

NOTICE: The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

FAN SPEED TABLE

Use the following table to set the corresponding fan speeds that are relative to the boiler you are working on.

FAN SPEED (rpm) TABLE Tab. 10

MODEL MAX MIN HTG IGN 85 5,800 2,000 5,800 3,700 120 5,600 1,500 5,600 3,700

8. CHECKING THE CO2 AND ADJUSTING THE GAS VALVE

THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYZER. Isolate the boiler from the electrical supply and remove the casing as described in Fig. 33. Set the flue gas analyzer to read CO2 and insert the probe into the flue analysis test point (Pos. B in Fig. 59a). Restore the electrical supply to the boiler and switch the boiler to the OFF mode. To adjust the gas valve you must first ensure that the fan speed potentiometers (trim pot) have been set correctly (Tab. 10). Remove the 3-selector knobs, locate and press the CO button (Fig. 59). The appliance will now operate in CO mode for approximately 15-minutes.

9. GAS VALVE MAXIMUM PRESSURE SETTING (Fig. 61)

Locate and gently turn the HTG trim pot until the maximum value (max fan speed) is obtained and check that it corresponds with the appropriate CO2 value (Maximum) for the respective boiler (see the data table for values). If the CO2 reading is correct, proceed to gas valve minimum setting. Howe ver , if the CO2 reading is incorrect, the maximum gas pressure must be adjusted as follows:

- Using a suitable screwdriver, very slowly turn the maximum pressure adjustment screw (Fig. 60)– clockwise to decrease, counter clockwise to increase – until the correct value is displayed on the CO2 analyzer (allow time for the analyzer to stabilize).

10. GAS VALVE MINIMUM PRESSURE SETTING

Locate and gently turn the HTG trim pot until the minimum value (min fan speed) is obtained and check that it corresponds with the appropriate CO2 value (Minimum) for the respective appliance. If the CO2 reading is correct, rotate the HTG trim pot until the correct value is obtained for the respectiv e appliance (see fan speed Tab. 10). However, if the CO2 reading is incorrect, the minimum gas pressure must be adjusted as follows:

- Remove the sealing screw

- Using a suitable screwdriver, very slowly turn the minimum pressure adjustment screw (Fig. 60) – clockwise to increase, counter clockwise to decrease - until the correct value is displayed on the CO2 analyzer (allow time for the analyzer to stabilize).

COMPLETION

On completion of the combustion analysis check and/or any gas valve adjustment, set the HTG trim pot to the corresponding value as detailed in the fan speed table. Reattach the 3-selector knobs. Remove the test probe from the test point and reattach the sealing screws and/or cap.

DANGER: A GAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HA VE BEEN REMOVED, REPLACED, OR DISTURBED.

11. COMBUSTION ANALYSIS TEST

A combustion analysis check can easily be carried out on the boiler via the test points located on the top of the appliance.

- Insert the flue gas analyzer probe into the flue gas test point (Pos. B in Fig. 59a).

- Operate the boiler in CO mode and compare the values with those shown in T ab . 1 (Nat. Gas) or Section 13 (LPG). If diff erent adjust the gas valve accordingly.

Fig. 59

Fig. 59a

HTG

TMR

12. EXTERNAL FAULTS

Before carrying out any troubleshooting or component replacement, ensure the fault is not attributable to any aspect of the installation.

MIN

IGN

MAX

INSTALLATION FAULTS

Symptom Possible cause

No display/ignition Check wiring/check

electrical supply

No hot water Check external controls No heating Check external controls

Fault code Possible cause 10 Check gas supply, check

flue system, check polarity, check condensate

Page 48

Maximum

pressure

adjustment

Compensation

pipe connection

Fig. 60

NOTE: The gas valve sticker “WARNING: VALVE IS NOT FIELD SERVICEABLE” means the v alve can be adjusted but not disassembled.

screw

Minimum pressure

adjustment

screw

13. ELECTRICAL CHECKS

Any electrical checks must be carried out by a ServiceTechnician Qualified.

GROUND CONTINUITY TEST

Isolate the boiler from the electrical supply, and using a suitable multi-meter carry out a resistance test. Connect test leads between an appliance ground point and the ground wire of the appliance supply cable. The resistance should be less than 1 OHM. If the resistance is greater than 1 OHM check all ground wires and connectors for continuity and integrity.

SHORT CIRCUIT CHECK

Isolate the boiler from the electrical supply, and using a suitable multi-meter, carry out a short circuit test between the Live & Neutral connections at the appliance terminal strip (Fig. 35). Repeat above test on the Live & Ground connections at the appliance terminal strip.

NOTICE: Should it be found that the fuse has failed but no fault is indicated, a detailed continuity check will be required to trace the fault. A visual inspection of components may also assist in locating the fault.

POLARITY CHECK

With the boiler connected to the electrical supply and using a suitable multimeter, carry out the following voltage tests:

- Connect test leads between the Live & Neutral connections at the boiler terminal strip (Fig. 35). The meter should read approximately 120VAC. If so proceed to next stage.

- Connect test leads between the Live & Ground connections at the boiler terminal strip (Fig. 35). The meter should read approximately 120VAC. If so proceed to next stage.

- Connect test leads between the Neutral & Ground connections at the boiler terminal strip (Fig. 35). The meter should read less than 1 VAC. If so polarity is correct.

REVERSED POLARITY OR SUPPLY FAULT

Repeat the above tests at the appliance isolator , if testing re v eals correct polarity and/or supply at the isolator, re-check wiring and connections between the isolator and the boiler. If tests on the isolator also reveal reversed polarity or a supply fault, consult the local electricity supplier for advice.

RESISTANCE TO GROUND CHECK

Isolate the boiler from the electrical supply, and using a suitable multi-meter carry out a resistance test. Connect test leads between the Live & Ground connections at the appliance terminal strip (Fig. 35). If the meter reads other than infinity there is a fault that must be isolated, carry out a detailed continuity check to identify the location of the fault. These series of checks must be carried out before attempting any troubleshooting procedures on the appliance. On completion of any task that required the disconnection and re-connection of any electrical wiring or component, these checks must be repeated.

FAULT FINDING

Before attempting any faultfinding, the electrical checks must be carried out. Isolate the appliance from the electrical supply. Disconnect any external controls from terminal plug (Fig. 35), and insert a jumper between the two wires at the room thermostat connections (Fig. 35 ref. M4a).

NOTICE: Restore the electrical supply to the boiler and turn the main selector switch to the heating request position

. The boiler should now function. Should the boiler fail to respond, the internal fuses and connectors should be checked to ensure integrity and continuity.

14. COMPONENT VALUES & CHARACTERISTICS

COMPONENT VALUE

Fan 120VAC Pump 120VAC 3-way valve (field supplied) 120VAC Ignition transformer 120VAC Gas valve 120VAC Room thermostat connection 24 Vdc NTC sensor (dry contact) 10Kohm NTC sensor (wet contact) 10Kohm

FUNCTION VALUE

Standard Heating Range °F (°C) 104-176 (40-80) Floor Heating Range °F (°C) 68-113 (20-45) CH limited power at 75% 15 Min Heating OFF hysteresis °F (°C) SP+8 (+5) Heating ON hysteresis °F (°C) SP-8 (-5) Anti-cycle delay 3-min Pump over-run 30-sec Low output (min. output + %) Min+25 CO function max temp. °F (°C) 203 (95) CO re-light temp. °F (°C) 167 (75) CO function time 15-min Flow NTC max temp. °F (°C) 203 (95) High limit thermostat °F (°C) 221 (105) Maximum differential °F (°C) 95 (35)

IGNITION CONTROL VALUE

Ignition attempts before L/O (lockout). 5 Re-ignition attempts after loss of flame signal 5

15. BOILER CONFIGURATION

The electronic board contains a series of jumpers that can be used to configure the boiler; access these by loosening the fasteners B and removing the control panel cover A after turning off the main switch (Fig. 62). Locate the JP positioning (Fig. 63).

JUMPER IN POSITION 1 (Fig. 61):

The position nr. 1 of the jumper indicates the boiler heating temperature; pre-selection of the most suitable heating temperature adjustment field according to the type of system.

Jumper not inserted (factory set) - case 1

Standard system (radiators) 104-176°F (40-80°C)

Jumper inserted - case 2

Floor system (radiant heating) 68-113°F (20-45°C).

NOTICE: The boiler has been factory-configured for standard systems.

JUMPER IN POSITION 2: Jumper inserted:

heating + indirect water tank with sensor

JUMPER IN POSITION 3: Jumper inserted:

heating + indirect water tank with thermostat - factory set

JUMPER IN POSITION 4:

unused

Page 49

JUMPER IN POSITION 5:

unused

JUMPER IN POSITION 6:

unused

Select KT by turning the trimmer located under the domestic hot water temperature knob (A). The settable values of KT are:

- standard system: 1,0-1,5-2,0-2,5-3,0

- floor system: 0,2-0,4-0,6-0,8

The boiler is supplied standard with the jumper in position 3 (standard heating + indirect water tank with thermostat); if you wish to use an external water tank with sensor , move this jumper from position 3 to position 2 (case B, Fig 61); if you wish to have low temperature for floor space heating move the not inserted jumper in position 1 (Fig 61).

CASE A

radiators

(factory set)

Indirect water tank with

thermostat to control

DHW temperature

floor heating

CASE B

radiators

Indirect water tank with sensor to control DHW

temperature

floor heating

Fig. 61

Fig. 62

16. SETTING THE OUTDOOR RESET CURVE WITH OUTDOOR SENSOR

Outdoor temperature reset only works with the outdoor air sensor connected, therefore, after installation, connect the outdoor air sensor to the relative connections on the boiler terminal board (Fig. 35). This enables the outdoor temperature reset function. The user can program the desired supply temperature based on the heat transmitter that will be used in the installation. Once the outdoor sensor is connected to the control board, the water temperature of the boiler will adjust to run the boiler more efficiently and provide greater comfort to the living space.

NOTICE: The DHW temperature is independent from the outdoor air sensor.

Selecting the offset heating curve (Fig. 65)

The offset heating curve maintains a theoretical ambient temperature of 68°F (20°C) at outdoor temperatures ranging from 68°F to -4°F (+20°C to -20°C). The choice of the curve depends on the rated minimum outdoor temperature (of the geographical area) and the rated delivery temperature (on the type of system) and must be carefully calculated by the installer using the following formula using the correct values in °F or °C:

TMR =

Nominal flow Temp. - Tshift

68°F (20°C) - min. external design Temp.

Fig. 63

TYPE OF HEAT REQUEST

STANDARD If a room thermostat is connected to the boiler: room thermostat

The room thermostat makes a heat request when its contact closes, while it stops it when its contact opens. Though delivery temperature is automatically calculated by the boiler, the user may manually override it. By modifying HEATING on the user interface (C), the HEATING SET POINT will no longer be availab le but just a value that can be set from +5 to -5 as required. Please note that the number displayed is a comfort level: +5 means feel hotter, -5 means feel colder. Modifications to this value do not directly change flow temperature but affect the calculation made to automatically determine its value by modifying the reference temperature of the system (0 = 68°F (20°C)).

PROGRAMMABLE TIMER (DA Y+NIGHT) If a programmable timer (day+night selector) is connected to the boiler, set parameter 51 = 1 (this parameter can only be

modified from the remote control unit) (Fig. 67) available only from Raypak technical service.

When the contact is closed, the heat request is made by the delivery probe on the basis of the external temperature in order to maintain the rated ambient temperature at the DAY level 68°F (20 °C). When the contact opens, it does not stop the heat request but reduces (parallel shift) the temperature curve to the NIGHT level 61°F (16 °C). This activates the night mode. Though flow temperature is automatically calculated by the boiler , the user may manually override it. By modifying HEATING on the user interface (C, Fig. 13.2), the HEATING SET POINT will no longer be available but just a value that can be set from +5 to -5 as required. Please note that the number displayed is a comfort level: +5 means feel hotter, -5 means feel colder. Modifications to this value do not directly change flow temperature but affect the calculation made to automatically determine its value by modifying the reference temperature of the system (0 = 68°F (20°C) for DAY level; 61°F (16°C) for NIGHT level).

If a remote control (Raypak REC 08) is installed refer to instructions for setting the outdoor sensor using.

Tshift =86°F (30°C) standard systems (radiators)

77°F (25°C) underfloor systems If the calculation generates an intermediate value between two curves, choose the nearest offset heating curve to that value. E.g.: if the value obtained by the calculation is 1.3, it lies between curve 1 and curve 1.5. In this case, select the nearest curve, i.e.: 1.5.

Page 50

(°F)

(°C)

OUTDOOR TEMPERATURE RESET CUR VES

212 194 176 158

140 122

Fig. 65

Fig. 66

FLOW TEMPERA TURE

104 86 68

(°F)

194 176

158 140

122 104 86 68 50

68 59 50 41 32 23 14 5 -4

OUTDOOR TEMPERA TURE

(°C)

+ 5 C

OUTDOOR RESET CORRECTION

0 C

- 5 C

86 77 68 59 50 41 32 23 14 5 -4

OUTDOOR TEMPERA TURE

(°C)

(°F)

-20-15-10-5051015202530

(°C)

(°F)

Fig. 67

FLOW TEMPERA TURE

(°F)

194 176 158 140 122 104 86 68 50

(°C)

Curva climatica GIORNO

Outdoor reset - DAY

NIGHT SETBACK

Curva climatica NOTTE

Outdoor reset - NIGHT

-15-10-505101520

68 59 50 41 32 23 14 5 -4

OUTDOOR TEMPERA TURE

-2

(°C)

(°F)

Page 51

17. FAULT CODES

When the boiler detects a temporary fault condition, the appropriate code is shown flashing on the display. If/when the fault code is final, the pump will perform a 60-second post circulation and the red LED will be illuminated.

CODE CAUSE ALARM TYPE ACTION

AL10 Ignition failure/not flame sensed, Final Reset, check appliance operation

condense sensor activated

AL20 Limit thermostat fault, blocked flue switch,

flue thermostat Final Reset, check appliance operation AL21 External device fault (UHT/CPA) Final Reset, check appliance AL26 Return temperature too high Final Reset, check pump, ensure there is sufficient

flow sensor temperature). Circulation around heating circuit/s

AL28 Temperature differential inverted Final Reset, check pump, ensure there is sufficient

(return sensor temperature higher than circulation around heating circuit/s thermistors

flowsensor temperature) AL29 Flue sensor over temperature lock out Final Reset check appliance operation AL34 Fan blower signal fault Final Reset check appliance operation, check fan AL40 Insufficient system water pressure Final Check/refill system pressure, reset, check

appliance operation

AL41 Insufficient system water pressure Temporary Check/refill system pressure, check appliance

operation

AL52 Internal fault Final Reset, check boiler operation

AL5 5 Jumper tag fault Final Check jumper tag configuration

AL60 Jumper tag fault Temporary Check jumper tag configuration AL71 Primary (flow) sensor fault Temporary Check primary thermistor, check wiring AL73 Return sensor fault Temporary Check return ther mistor, check /wiring AL74 Variation on temperature of primar y Final Reset, check boiler operation, check

and/or return too high pump, ensure there is sufficient circulation around heating circuit/s

AL79 Flow temperature too high, or Final Reset, check appliance operation, check

temperature differential between thermistors

primary and return too high AL91 The main heat exchanger need to be Advice Call the Raypak technical service

cleaned

Page 52

12 - SERVICING INSTRUCTIONS

1. GENERAL

To ensure the continued safe and efficient operation of the boiler, it is recommended that it is checked and serviced at regular intervals. It is essential that any worn or failed component be replaced only with a genuine XPak spare parts. It should be remembered that although certain generic components may look similar, they will be specific to an individual appliance or product range. Use of non-genuine XPak spare parts could invalidate your warranty and may pose a potential saf ety hazard. The frequency of servicing will depend upon the particular installation conditions, but in general, once per year should be sufficient. It is the law that any servicing work is carried out by competent person such as a Raypak Technician, an approved service agent, or other suitably qualified personnel. The following instructions apply to the appliance and its controls, but it should be remembered that the central heating and the domestic hot water systems would also require attention from time to time.

2. ROUTINE ANNUAL SERVICING

- Check the operation of the boiler and ensure it functions as described in Section “11. Checks, adjustments and fault finding”.

- Thoroughly inspect the boiler for signs of damage or deterioration especially the flue system and the electrical apparatus.

- Check and adjust – if necessary – the system design pressure (see pg. 63 ref. 10).

- Carry out an analysis of the flue gases (pg. 73), and visually check the condition of the entire flue assembly.

- Check that the burner and main heat exchanger are clean and free from any debris or obstruction.

- Check and clean – if necessary – the condense trap to ensure correct operation.

- Compare the performance of the appliance with its design specification. The cause of any noticeable deterioration should be identified and fixed without delay.

- The combustion blower motor does not require lubrication for proper operation. DO NOT attempt to oil the motor or damage may occur.

3. REPLACEMENT OF COMPONENTS

Although it is anticipated that this appliance will give years of reliable, trouble free service, the life span of components will be determined by factors such as operating conditions and usage. Should the appliance develop a fault, the troubleshooting section will assist in determining which component is malfunctioning.

4. COMPONENT REMOVAL PROCEDURE

To remove a component, access to the interior of the boiler is essential. Isolate the appliance from the electrical supply. And when necessary, close all service valves on the boiler, remove the casing and drain the water content from the boiler via the drain valve. Ensure some water absorbent cloths are available to catch any residual water that may drip from the boiler or removed component. Undertake a complete commissioning check, after replacing any component.

AL WAYS TEST FOR GAS TIGHTNESS IF ANY GAS CARR YING COMPONENTS HAVE BEEN REMOVED OR DISTURBED.

AIR BOX FR ONT CO VER REMO VAL (Fig. 68)

Locate the two clips and remove air bo x front cover . If it’s necessary to remove the air box side co ver , locate and remove the 4 securing screws.

PUMP ASSEMBLY (Fig. 69)

Locate and remove the 2 securing screws (A) at the rear of the pump assembly. Disconnect the flow pipe (B, only for XPak 120) from the combustion chamber connection, slacken the pipe at the hydraulic assembly and swing/rotate clear of the pump assembly. Disconnect and remove the pump outlet pipe (C) from the pump assembly/combustion chamber connection. Locate and remove the pressure gauge securing pin (D) and disconnect the pressure gauge from the pump assembly.

Disconnect the electrical wiring from the pump’s electrical connection point (E). Remove locking pin (F) from pump base and lift pump assembly clear of the hydraulic manifold. The pump assembly can now be removed from the appliance. Replace carefully in the reverse order.

PRESSURE RELIEF VAL VE (Fig. 69)

Disconnect the outlet pipe (L) and the flow pipe (M) from the safety valve, remove pressure release valve. Replace in the reverse order.

LOWER AUTOMATIC AIR RELEASE VALVE (Fig. 69)

Locate and remove the AAV locking pin (G) from the pump assembly and remove the AAV assembly (H). Replace in the reverse order.

TOP A UT OMATIC AIR RELEASE VAL VE (Fig. 70)

Remove the drain pipe (A). Unscrew the top AAV (B). Replace in the reverse order . Loctite or similar should be used as a thread sealant for the AA V.

XPak 85

XPak 120

Fig. 68

clips

Fig. 69

Page 53

XPak 85

Fig. 70

WATER PRESSURE SWITCH (Fig. 69)

Locate and remove the screw (I) from the water pressure switch. Remove the wiring. Carefully remove the switch. Replace in the reverse order.

FLOW SENSOR (PRIMAR Y THERMISTOR) (Fig. 1) Unclip and remove the air chamber front cov er. Unclip the primary thermistor from the flow outlet pipe. Disconnect thermistor electrical plug. Replace in the reverse order.

RETURN SENSOR (RETURN THERMISTOR) (Fig. 1) Unclip and remove the air chamber front cover. Unclip the retur n sensor from the return inlet pipe. Disconnect sensor electrical plug. Replace in the reverse order.

PRINTED CIRCUIT BOARD (Fig. 71)

Pull the control slightly forward and lower it. Push the clips (A) and remove cover, after carefully taking note of all wiring connections and jumper tag configurations; unhook and remove connection block (B). Disconnect all wiring from the PCB, locate and remove the PCB securing screws, remove the required PCB. Replace in the reverse order ensuring that the position of the 3 control knobs are correctly aligned with the respective potentiometers on the PCB. Ensure that the correct jumper configuration has been made. It will be necessary to check the functioning of the PCB is set for the correct boiler type/application.

GAS V AL VE (Fig. 72)

The gas valve must be changed as complete unit. Disconnect the electrical plug and leads from the gas valve, slacken and unscrew upper gas valve pipe, please note that the gas injector is located in this upper part. Disconnect the compensation pipe (C). Locate and remove the two retaining screws (D); locate and remove the four gas valve retaining screws (E). Replace in the reverse order. Check and adjust burner pressure settings.

WARNING, A GAS TIGHTNESS CHECK MUST BE CARRIED OUT.

XPak 120

Fig. 72

INJECTOR (Fig. 72)

Slacken and unscrew upper gas valve pipe; locate and remove only two screws (D). Locate and remove the injector (F) inside the pipe. Replace in the reverse order. Check and adjust burner pressure settings.

WARNING, A GAS TIGHTNESS CHECK MUST BE CARRIED OUT.

ELECTRODES & CONDENSATE SENSOR (Fig. 73)

Unclip and remove the air chamber front and right hand side covers. Disconnect the electrode leads and ancillary wiring from their respective connectors. Remove the retaining screws (A) for spark and sensing electrodes and remove. Remove the retaining nut (C) for condensate sensor (D) and remove.

NOTICE: The gas valve sticker “WARNING: VALVE IS NOT FIELD SERVICEABLE” means the v alve can be adjusted but not disassembled.

Fig. 71

Fig. 73

Page 54

FLUE FAN & MIXER (Fig. 74)

Unclip and remove the air chamber front and the right hand side covers. Slacken the gas pipe (A) at the air box connection and swing/rotate away from the fan assembly. To remove the mixer

(B) locate and remove the three screws (C). To remove the fan (D), disconnect the electrical connections attached to the fan,

locate and remove the four screws (E). Gently ease the fan from its location. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

BURNER (Fig. 75)

Unclip and remove the air chamber front and the right hand side covers. Slacken the gas pipe (A) at the air box connection and swing/rotate of the fan assembly. Locate and remove the 3 internal nuts (B) which secure the fan assembly in position (C) to the heat exchanger (D). Disconnect the electrode leads and ancillary wiring from their respective connectors. Remove the retaining screws (A fig. 73) for sensing electrode and remove. Remove the retaining nut (C fig. 73) for condensation sensor (D fig. 73) and remove. Gently ease the fan assembly out of its location. Once the assembly has been removed, the burner (E) can be withdrawn from the heat engine. Ensure the seal (F) is in good condition, taking care to ensure it is replaced correctly . Replace in the reverse order.

BLOCKED FLUE PRESSURE SWITCH/IGNITION TRANSFORMER (Fig. 73)

Disconnect the compensation pipe (G). Disconnect the electric wiring from the pressure switch/ignition transformer. Remove the two screw (F) on the upper part of the combustion chamber. Remove the screw (I). Remove the pressure switch. Replace in reverse order. Remove the two screw (H), remove the ignition transformer. Replace in reverse order.

Fig. 74

Fig. 75

MAIN HEAT EXCHANGER (Fig. 76-77)

Unclip and remove the three air chamber covers (front, left hand, right hand sides). Disconnect all the wiring connections. Fig. 76: slacken the gas pipe (A) at the air box connection and swing/rotate of the fan assembly. Disconnect the flow (B), return (C) and condensation connections on the heat exchanger. Locate and remove the 4-screws that secure the heat exchanger to the combustion chamber (D). Move the heat exchanger to the right and disconnect it from the flue collector (E). The heat exchanger can now be lifted up and removed from the boiler. Fig. 77: to remove the fan burner assembly (A) locate and remove the 3 external nuts (B). Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

AUTOMATIC BYPASS (Fig. 78)

Disconnect and remove the flow pipe (1), at the connection to the pressure relief valve, at heating manifold and at the connection to the air chamber. Using a hooked piece of wire, carefully withdraw the bypass cartridge (2). Ensure all seals are in good condition, taking care to ensure they are replaced correctly. Replace in the reverse order ensuring the cartridge is facing the correct way.

Fig. 76

Fig. 77

Fig. 78‘

Page 55

CONDENSA TE TRAP REMOV AL (Fig. 79)

Disconnect the 2 upper rubber condensate pipes (A). Remove the pin (B) that secures the trap to the air box plate. Disconnect the lower rubber condensate pipe (C) from the condensate trap. Carefully remove the condensate trap. Replace in the reverse order.

FLUE COLLECTOR AND FLUE THERMOSTA T REMOV AL (Fig.

80)

Unclip and remove the air chamber front and left side covers. Locate and remove the screw (A) that secures the flue gas analysis test point cover (B). Disconnect the silicon pipe (right hand) of the blocked flue switch. Remove the clip (C) and the flue thermostat (D). Gently pull down and to the left and ease the flue collector from its location. Replace in the reverse order.

Fig. 79

Fig. 80

Page 56

13 - LPG INSTRUCTIONS

This instruction must be retained adjacent to the boiler as they contain important details about the conversion made.

WARNING: This conversion kit shall

be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in this instructions is not followed exactly, a fire, an explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life. The qualified ser vice agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer’s instructions supplied with the kit.

LPG INSTRUCTIONS

PROPANE GAS:

CAUTION: The gas supply shall be shut off prior to

disconnecting the electrical power, before proceding with the conversion.

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 – latest edition (NFGC)

• For Canada only: CAN/CSA B149 Natural Gas and Propane Installation Code and CSA C22.1 C.E.C. Part 1 (C22.1)

WARNING: XPak boilers are shipped ready to fire natural gas ONLY. You must install the propane orifice and regulate the gas valve if the boiler will be connected to propane. Failure to comply could result in severe personal injury, death or substantial property damage.

Pipe sizing for natural gas

Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

The XPak boiler is factory supplied to use natural gas. The boiler can use also LPG gas by installing a kit (supplied with every unit). The conversion to LPG is possible by:

1. Install the new gas injector

2. Modify the fan speed according the data in the table.

The kit is composed by:

1. Injector black coating (to be recognized from the natural gas that is not black coated)

2. Relative gas sticker (red color) to be attached under the boiler instead of the natural gas sticker (yellow color factory installed)

3. Instruction of the kit

4. LPG label to be affixed on the boiler casing and completed in by the organization making this conversion.

Operations for conversion

1. Switch off the boiler

2. Change the gas injector

3. Apply the red sticker

4. Switch on the boiler

5. Set the new fan speed

6. Fill the final part of this instruction

GAS SUPPLY

The gas supply must be connected to the boiler by a competent LPG installer and must be of sufficient size to supply the boiler at its maximum output. An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and any other appliances that it serves.

GAS SUPPLY INSTALLATION

The entire installation including the meter must be purged and checked for gas tightness.

CONVERTING THE BOILER GAS TYPE

To convert the boiler to another gas type it is necessary to change the gas injector, adjust the fan speed and the gas valve.

NOTICE: The gas valve sticker “WARNING: VALVE IS NOT FIELD SERVICEABLE” means the v alve can be adjusted but not disassembled.

CHANGE THE GAS INJECTOR

Slacken and unscrew upper gas valve pipe; locate and remove the two screws shown as (A). Locate and remove the natural gas injector (B) inside the pipe, insert the LPG injector (black coating). Replace in the reverse order. Check and adjust burner pressure settings.

WARNING:

A gas tightness check must be carried out if any gas carryng components have been removed, replaced or disturbed.

Fig. 1

CHECKING THE RELATIONSHIP OF THE IGNITER TO MAIN BURNER

Remove the burner assembly as indicated in the boiler manual “Servicing instructions”. Check the distance between the burner and the two electrodes according the distances indicated in Fig. 1A. Replace in the reverse order.

0.35”±0.039”

(8.9 mm ± 1)

0.41”±0.039” (10.3 mm ± 1)

Propane supply pressure requirements

1. Adjust propane supply regulator provided by gas supplier for 13" w.c. maximum pressure.

2. Pressure required at gas valve inlet pressure port: Maximum: 13" w.c. with no flow (lockup) or 8" w.c. minimum with boiler operating

Fig. 1A

Page 57

TECHNICAL DATA - LPG

Gas pressure XPak 85 XPak 120

Input - (0 - 2000 ft / 0 - 610 m) Btu/hr 25,600 - 87,000 27,300 - 119,500 Input - (2000 - 4500 ft / 610 - 1375 m) Gas supply pressure LPG in w. c. 11 11 Min. gas supply pressure LPG in w. c. 8 8 Max. gas supply pressure LPG in w. c. 13 13 Burner pressure (max-min) in w. c. 1.92-0.24 2.00-0.16

Rate

Gas Rate max LPG lbs/hr 4.02 5.55 Gas Rate min LPG lbs/hr 1.20 1.28

Emissions

CO2 setting % 10.0% 10.0% NOx @ max ppm < 20 < 20 NOx @ min ppm < 15 < 20 CO @ max without air ppm < 200 < 200 CO @ min without air ppm < 40 < 35

Injector size

Injector LPG (E) - black coated Ø 0.15 inch (3.9 mm) 0.19 inch (5.0 mm)

kW 7.5 - 25.5 8.0 - 35.0 Btu/hr 25,600 - 82,900 27,300 - 114,300 kW 7.5 - 24.3 8.0 - 33.5

kPa 2.75 2.75 kPa 1.99 1.99 kPa 3.24 3.24 kPa 0.48-0.06 0.50-0.04

kg/hr 1.82 2.52 kg/hr 0.54 0.58

Fig. 2

Fig. 3

HTG

TMR

A (air)

MIN

MAX

IGN

B (flue)

BOILER FAN SPEEDS

The boiler fan speeds require to be checked and/or adjusted prior to making any adjustments to the gas valve or if the main PCB has been replaced.

ATTENTION

Gas type and boiler fan speed (output) must be set according to the specific appliance specification. Raypak accepts no responsibility if the gas type and/or fan speed is not correctly adjusted according to the respective specification as detailed on the boiler data badge.

ADJUSTING GAS PRESSURE

The gas pressure can not be adjusted as the boiler is equipped with a pneumatic gas valve.

CHECKING/ADJUSTING THE APPLIANCE FAN SPEEDS

Move the selector switch to the OFF position and remove the 3-selector knobs.

ABSOLUTE MAX FAN SPEED

Locate the MAX trim pot (Fig. 2) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table below).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

ABSOLUTE MIN FAN SPEED

Locate the MIN trim pot (Fig. 2) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table below).

NOTE

The display shows the fan RPM in multiples of 1000, i.e.

2.5 = 2500RPM.

IGNITION FAN SPEED ATTENTION Do this operation only after the adjusting of absolute max and min fan speed.

Locate the IGN trim pot (Fig. 2) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table below).

NOTE

The display shows the fan RPM in multiples of 1000, i.e.

2.5 = 2500RPM.

HEATING FAN SPEED

Locate the HTG trim pot (Fig. 2) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table below).

NOTE

The display shows the fan RPM in multiples of 1000, i.e.

2.5 = 2500RPM.

F AN SPEED (rpm) T ABLE MODEL MAX MIN HTG IGN XPak85 5,700 1,900 5,700 3,700 XPak120 5,400 1,400 5,400 3,700

ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYZER.

CHECKING THE CO2 AND ADJUSTING THE GAS VALVE

THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANAL YZER. Isolate the boiler from the electrical supply and remove the appliance casing. Set the flue gas analyzer to read CO2 and insert the probe into the flue analysis test point (A-air, B-flue Fig. 3). Restore the electrical supply to the boiler and switch the boiler to the OFF mode. To adjust the gas valve you must first ensure that the fan speed potentiometers (trim pots) have been set correctly. Remove the 3-selector knobs, locate and press the CO button). The appliance will now operate in CO mode for approximately 15minutes.

GAS VALVE MAXIMUM SETTING

Locate and gently turn the HTG trim pots until the maximum value (max fan speed) is obtained and check that it corresponds with the appropriate CO2 value (Maximum) for the respective boiler. If the CO2 reading is correct, proceed to gas valve minimum setting. However, If the CO2 reading is incorrect, the maximum gas pressure must be adjusted as follows:

- Using a suitable screwdriver, very slowly turn the maximum adjustment screw (Fig. 4) – clockwise to decrease, counter clockwise to increase – until the correct value is displayed on the CO2 analyzer (allow time for the analyzer to stabilize).

GAS VALVE MINIMUM SETTING

However, If the CO2 reading is incorrect, the minimum gas pressure must be adjusted as follows:

- Using a suitable screwdriver, very slowly turn the minimum adjustment screw (Fig. 4) – clockwise to increase, counter clockwise to decrease - until the correct value is displayed on the CO2 analyzer (allow time for the analyzer to stabilize).

INST ALLA TIONS A T ELEV ATION

COMPLETION

Page 58

IMPORTANT A GAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED, REPLACED, OR DISTURBED.

XPAK LPG LABEL

1. Fill in the enclosed LPG label with all the information required and affix the label as close as possible to existing rating plate

2. Affix the enclosed RED color label over the existing YELLOW color label under the boiler near to the boiler gas connection.

SEQUENCE OF THE IGNITION SYSTEM

Switch on the boiler as follows:

- Open the gas tap under the boiler by turning it

counterclockwise

- Turn on the general switch of the system and then, after lowering

the flap, turn the function selector to summer winter tank temperature mode.

depending on the chosen operating

, winter or

The boiler start to run according the automatic sequence: heat request, fan start-up, tachometer check, ignition trials, gas opening and ignition start-up.

Maximum screw

Compensation

pipe connection

Minimum screw

Fig. 4

Page 59

14 - EXPLODED DIAGRAMS

Drawing 1

12a

Page 60

Drawing 2

56a

56b

12b

56a

Page 61

Drawing 3

XPAK 120XPAK 85

21a

21b

56c

56a

12d

21d

12d

24c

21c

56a

12c

24b

24d

24e

24a

24c

21c

12d

24e

21d

56a

24b

24d

24a

Page 62

Drawing 4

Drawing 5

56a

52 Drawing 5

57b

53 Drawing 5

41 57b

Page 63

CALL OUT DESCRIPTION XPak85 XPak120

Electric/Case Components See Drawing #1

1 Jacket Front 012831F 012832F 2 Boiler Mounting Bracket 013004F 013004F 3 Control Panel 012829F 012829F 4 Control Panel Cover 012827F 012827F 5 Control Panel Door 012833F 012833F 6 PC Board 012828F 012828F 7 Control Knob 012830F 012830F 8 Control Panel Hinge 012834F 012834F 9 Pressure Gauge 012826F 012826F 10 Wire Harness Kit - (Includes Complete Set of Boiler Harnesses) 012836F 012999F 11 Control Panel Fuse Kit - (Includes Complete Set of Fuses) 013003F 013003F 12 Retainer Clip Kit - (Includes 12a {20pcs}, 12b {1 pc}, 12c {10 pcs} and 12d {10 pcs}) 013011F 013011F

13 Water Pressure Switch 013005F 013005F 14 Bypass Valve 013006F 013007F 15 Distribution Header 013008F 013008F 16 Vent Plug 013009F 013009F 17 PRV - 45# 013012F 013012F 18 PRV Adapter 013013F 013013F 19 PRV Discharge Plumbing Kit 013010F 013010F

20 Pump 013014F 013015F 21 Plumbing Kit - (Includes 21a, 21b, 21c and 21d) 013016F 013017F 22 Air Vent 013018F 013018F 23 Condensate Reservoir 013019F 013019F 24 Condensate Plumbing Kit - (Includes 24a, 24b, 24c, 24d and 24e) 013020F 013021F 25 Air Venting Plug Kit 013022F 013023F 26 High Limit 013024F 013024F 27 Pump Plug 013025F 013025F 28 Water Detector 013026F 013026F

29 Air Chamber Access Panel 013037F 013038F 30 Air Chamber Side 013027F 013027F 31 Intake Air/Flue Adapters 013040F 013040F 32 Combustion Air Blower 013028F 013028F 33 Burner Assembly 013029F 013029F 34 Igniter 013030F 013030F 35 Condensate Electrode Kit 013031F 013031F 36 Outlet Gas Manifold 013032F 013033F 37 Gas Valv e Kit 013034F 013034F 38 Inlet Gas Manifold 013035F 013035F 39 Gas Shut-Off Valve 013036F 013036F 40 Burner Observation Port Kit 013039F 013039F 41 Air/Gas Manifold 013041F 013041F 42 Manifold Gas/Blower Inlet 013042F 013064F 43 Gas Orifice - Nat 013043F 013044F 43 Gas Orifice - Pro 013045F 013046F 44 Combustion Air Mixer 013047F 013048F 45 Flame Sensor 013049F 013049F 46 Blower Heat Shield 013050F 013050F 47 Ignition Transformer

4 49 Flue Exhaust Condensate Collector 013056F 013057F 50 Flue Exhaust Condensate Collector Adapter 013058F 013058F 51 Air Pressure Switch 013059F 013059F 52 Outlet Heat Exchanger Seal Gasket 013060F 013060F 53 Inlet Heat Exchanger Seal Gasket 013061F 013061F 54 High Limit 013062F 013062F 55 Flue Sensor 013063F 013063F 56 Water Gasket Kit - (Includes 56a, 56b and 56c - 10pcs ea.) 013000F 013000F 57 Flue Exhaust/Gas Gasket Kit - (Includes 57a and 57b) 013001F 013001F 58 Nat to Pro Gas Conversion Kit 013052F 013053F

Hydraulic Components - 1 See Drawing #2

Hydraulic Components - 2 See Drawing #3

Burner Components - Air Box See Drawing #4

013051F 013051F

Combustion Chamber Components - Flue Drain

8 Heat Exchanger Assembly 013054F 013055F

See Drawing #5

For gas conversions, consult the factory for information.

Page 64

Important Instructions for the Commonwealth of Massachusetts

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment 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 cer tified.

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”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally v ented gas equipment provides a venting system design or v enting 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.

Page 65

LIMITED WARRANTY

MODULATING - CONDENSING BOILER

XPAK

SCOPE OF WARRANTY:

Raypak, Inc. (“Raypak”) warrants to the first retail purchaser of the XPAK Heating Boiler that was delivered with this limited warranty certificate (the “Boiler”) that the Boiler will be free from defects in materials and workmanship under normal use and service for the Applicable Warranty Periods specified below. Under this Limited Warranty, Raypak will, at its option, repair or replace any defective part of the Boiler in accordance with the terms of this Limited Warranty. The Limited Warranty does not include labor or transportation costs, which are borne by the warranty claimant. The repair or replacement Boiler or part will be warranted for only the unexpired portion of the original Applicable Warranty Period. This Limited Warranty applies only to a Boiler that has NOT been moved from its original installation site. In the event that replacement or repair parts are no longer available, or significant read this entire Limited Warranty to fully understand all of its terms and conditions.

APPLICABLE WARRANTY PERIODS

XPAKTMResidential Extruded Aluminum Heat Exchanger: The Applicable Warranty Period for the aluminum heat exchanger of the Boiler in a residential installation (as defined in “Additional Warranty Exclusions and Terms”, below) is five (5) years after the original installation date of the Boiler. During the first three (3) years, Raypak will pay for 100% of the cost of the replacement part or repair (excluding labor and transportation costs). For years 4-5 of the Applicable Warranty Period for the residential Boiler’s aluminum heat exchanger, Raypak will provide a replacement part for a defective part, pays the following percentages of the cost of the replacement part:

design changes have occurred, Raypak reserves the right to replace, at its option, the Boiler or part with a current equivalent part. Please

HEATING BOILERS MODELS 85 & 120

provided that the warranty claimant

The table below lists the portion of the replacement part’s cost that the original homeowner

Years into Warranty % of List Price

First 3 0%

4 20% 5 40%

XPAK Commercial Extruded Aluminum Heat Exchanger: The Applicable Warranty Period for the aluminum heat exchanger of the Boiler in a commercial installation (as defined in “Addit ional Warranty Exclusions and Terms”, below) is three (3) years after the original installation date of the Boiler. During the first year of the Applicable Warranty Period, Raypak will pay for 100% of the cost of the replacement part or repair (excluding labor and transportation costs). For years 2 and 3 of the Applicable Warranty Period for the commercial Boiler’s aluminum heat exchanger, Raypak will provide a replacement part for a defective part, provided that the warranty claimant pays the following percentages of the cost of the replacement part:

The table below lists the por tion of the replacement part’s cost that the original owner

Years into Warranty % of List Price

1 0% 2 20% 3 40%

RESIDENTIAL BOILER F AN: The Applicable Warranty Period for the fan of a Boiler in a residential installation (as defined in “Additional Warranty Exclusions and Terms”, below) is three (3) years from the date of original installation, or thirty-seven months (37) months from the date that the residential Boiler was shipped from Raypak’s factory based on Raypak’s records, whichever comes first. This Applicable Warranty Period does not apply to Boiler fans in commercial installations (as defined in “Additional Warranty Exclusions and Terms”, below).

RESIDENTIAL WARRANTY

will be responsible to pay

COMMERCIAL WARRANTY

will be responsible to pay

ALL OTHER COMPONENTS OF THE BOILER: Except as otherwise specified above for the heat exchangers and residential Boiler fan, the Applicable Warranty Period for all components in the Boiler is one (1) year from date of the Boiler’s original installation, or thirteen (13) months from date that the Boiler was shipped from Raypak’s factory based on Raypak’s records, whichever comes first.

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

ADDITIONAL WARRANTY EXCLUSIONS AND TERMS:

This Limited Warranty does NOT apply:

1. if the Boiler has been moved from its original place of installation, or if the original purchaser no longer owns the property where the original installation was made;

2. to damage, malfunctions or failures resulting from improper installation, operation, or maintenance of the Boiler in accordance with the manufacturer’s instructions;

3. to damage, malfunctions or failures resulting from misuse, neglect, alteration, accident, fire, flood and the like;

4. to damage, malfunctions or failures resulting from sediment or lime buildup, freezing, or other conditions causing inadequate water circulation; . to damage, malfunctions or failures resulting from high velocity flow exceeding boiler design rates;

6. to damage, malfunctions or failures resulting from connected systems devices, such as pump or controller;

7. to damage, malfunctions or failures resulting from use of accessories or other components that are not authorized in writing by Raypak for use

in conjunction with the Boiler system;

8. to damage, malfunctions or failures resulting from failure to eliminate air from, or replenish water in, the connected water system;

9. to damage, malfunctions or failures resulting from chemical contamination of combustion air or use of chemically contaminated combustion air,

including, but not limited to contaminants such as chlorine gas, halogenated hydrocarbons, and Freon.

Page 66

10. to damage, malfunctions or failures resulting from ingestion by the Boiler of drywall, sheetrock or plasterboard dust and particles, lint or dirt.

11. to Boilers that have been installed by anyone other than a heating professional whose principal occupation is the sale and installation of heating, plumbing and/or air conditioning equipment.

For purposes of this Limited Warranty, a residential installation is defined as the installation of a Boiler in any of the following residential spaces:

a) Single-family detached dwelling; b) Two-family attached dwelling; or c) Dwelling unit of a residential building in which each dwelling unit has an individual Boiler.

For purposes of this Limited Warranty, a commercial installation is defined as the installation of a Boiler in any site other than:

a) Single family detached dwelling; b) Two family attached dwelling; or c) Dwelling unit of a residential building in which each dwelling unit has an individual Boiler.

HOW TO MAKE WARRANTY CLAIM:

Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the problem. The installer must then notify a Raypak distributor for instructions regarding the claim. If neither the installer nor the distributor is available, immediately notify Raypak at 800-278-5300, supplying model number, serial number, date of original installation and a description of the problem. Proper

authorization MUST be obtained PRIOR to any repairs for the Limited Warranty to apply. This Limited Warranty is VOID if the Boiler is repaired or altered in any way by ANY persons or agencies other than those authorized by Raypak. Raypak reserves the right at all times

to inspect, or require the return of, the defective Boiler or component part and to verify warranty coverage at its factory. The failed part must first

returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions satisfied. The replacement part will

be be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts manufactured by others, but Raypak will apply any such warranty as may be provided by the parts manufacturer.

EXCLUSIVE WARRANTY-LIMITATION OF LIABILITY

The Limited Warranty is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. ANY IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIOD SPECIFIED ABOVE. RAYPAK’S SOLE LIABILITY WITH RESPECT TO ANY DEFECT, SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS LIMITED WARRANTY OR IN CONTRACT, TORT OR NEGLIGENCE OR OTHERWISE FOR CLAIMS FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING NO LIABILITY FOR DAMAGE FROM WATER LEAKAGE), ALL OF WHICH ARE EXPRESSLY EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages, so the above limitation or exclusion may not apply to you. THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO RIGHTS WHICH VARY FROM STATE TO STATE. We suggest you immediately record the model and serial number and date of original installation and retain this Limited Warranty Certificate in the event warranty service is needed.

HAVE OTHER

DO NOT RETURN THIS DOCUMENT TO RAYPAK. KEEP IT WITH YOUR BOILER OR BUSINESS RECORDS.

rellatsnI fo emaNrenwO fo emaN

Owners Address Installers Address

rellatsnI fo rebmuN enohpeleTnoitallatsnI relioB fo etaD

relioB ruoY fo rebmuN laireSrelioB ruoY fo rebmuN ledoM

Page 67

START-UP CHECKLIST FOR FAN-ASSISTED

RAYPAK PRODUCTS

This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. Additionally 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. Gas Line Size (in room) ____________ In. NPT Right Side Clearance _______________In. Length of Gas Line ____________ Eq F t Left Side Clearance _______________In. Gas Shut-Off Valve Type ____________ Rear Clearance _______________In. ( Ball, Lube cock) Overhead Clearance _______________In. Sediment Trap ____________ Y/N Port _______Std__ Full ELECTRICAL

Voltage Supply (VAC) N o Load______ Load_____ Voltage -24 VAC _____________VAC

Voltage Com to Ground _____________VAC VISUAL INSPECTION OF COMPONENTS Operating Control Setting _____________deg F Verify inspection was done and condition of components are in good working order with a “yes” Wiring Harness _____________ Y/N Burner/s (flame) _____________ Y/N Remote flame sense _____________ Y/N Sketch plumbing on reverse side

WATER SUPPLY

Flow Rate in GPM or Delta T __________ If Avail

Measure flow rate at full fire

VENTING Number of Tanks and Size Qty____ ____ Gallons Vent Size:___________ Stack Height:_____ Plumbing Size _______________ Category: _________ sketch vent on reverse side *** Pump Size: _________ (boiler) Pump HP: ________ Vent Material: __________________ Impeller trim____________ Pump Model________ Vent Termination Type: __________________ Louvers __________________ Screens____________ Combustion Air Openings: Low __________in2 Ventilation air High _________ in2

EMISSIONS SETTINGS AND TEST INFORMATION (AT FULL FIRE) Nominal Factory Recommended Settings

Blower Pressure Setting ______________ In. WC See manual or card tag Supply Gas Pressure ______________ In. WC See manual or card tag Verify stable pressure static & dynamic condition Manifold Gas Pressure _____________ In. WC See manual or card tag Tracking Pressure (clean filter) ______________In. WC

The following measurements must be obtained with a Combustion Analyzer. NOX _____________ PPM Less than 20 PPM (If required by Certifying Agency) Free Oxygen _____________ % See manual CO _____________ PPM Less than 170 PPM CO2 _____________ % See manual

Model Number: ______________________________ Serial Number: _______________________________ *** Note: draw venting with details, such as extractors, Site Altitude Above Sea Level __________________Ft. barometric dampers, blast dampers or draft inducers

Job Name _______________________________________________________________________________________ Address _________________________________________________________________________________________ Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; 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) 278-5471 in order to ensure warranty consideration Attn: Service Manager

Page 68

Your XPak serial number

for future reference

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

Raypak XPAK120 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual