Raypak X Pak 85 Installation Manual

CONTENTS

WARNINGS

Pay Attention to These Terms 4
For your safety read before operating 5

COMPONENT LOCATION

General layout 6
Control board 7

GETTING STARTED

Before switching ON 8
Boiler controls 8
Lighting the boiler 8
Adjusting the operating temperature 8
Adjusting the hot water temperature 8
How to top-up the system pressure 9
How to reset the boiler 9

BOILER FAULT CODES

How to shut down the system for short periods 9
How to shut down the system for long periods 9
How to care for the boiler 9

WHAT IF...

What if I suspect a gas leak 10
What if I have frequently have to top-up the system 10
What if the red light is ON 10
What if the boiler is due its annual service 10
What if I need to call a service technician 10

MAINTENANCE

Suggested Minimum Maintenance Schedule 10
Preventive Maintenance Schedule 11

3

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.

NOTE:
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 colored 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 the manual valve
directly below the boiler.

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

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

• 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.

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.

AVERTISSEMENT: Une mauvaise installation, réglage,
altération, révision ou entretien peut provoquer des dommages
matériels, des blessures, l’exposition à des matières
dangereuses* ou la mort. Examinez attentivement les
informations dans cette notice. *Cette unité contient des matières
qui ont été identifiées comme étant cancérigènes, ou
éventuellement cancérigènes, chez l’homme.

WARNING: Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal injury,
exposure to hazardous materials* or loss of life. Review the
information in this manual carefully. *This unit contains materials
that have been identified as carcinogenic, or possibly
carcinogenic, to humans.

NOTE: This manual should be maintained in legible condition
and kept adjacent to the boiler or in another safe place for
future reference.

4

For your safety read before operating

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,

Pour votre sécurité lisez avant de mettre
en marche

pour

ouvrir

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

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

"Comment couper l'admission de gaz

de l'appareil" et appelez un technicien

qualifié ou le fournisseur de gaz.

vanne gaz en arret

4. Tournez le bouton de commande de gaz

Cod. 20003235

dans le sens horaire à la position "arret"

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,

car certains gaz sont plus lourds que l'air

or attempted repair may result in a fire

or explosion.

D. Do not use this appliance if any part has

et peuvent s'accumuler au niveau du sol.

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.

call the fire department.

- If you cannot reach your gas supplier,

B. AVANT DE FAIRE FONCTIONNER, reniflez

knob. Never use tools. If the handle will

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

call a qualified service technician. Force

C. Use only your hand to turn the gas control

QUE FAIRE SI VOUS SENTEZ UNE ODEUR

DE GAZ:

been under water. Immediately call a

qualified service technician to inspect the

appliance and to replace any part of the

vous servir des téléphones se trouvant

dans le bâtiment

- Ne pas tenter d'allumer l'appareil

- Ne touchez à aucun interrupteur; ne pas

- Appelez immédiatement votre fournisseur

control system and any gas control which

has been under water.

de gaz depuis un voisin. Suivez les

sécurité sur la portion supérieure de cette

1. ARRÊTEZ! Lisez les instructions de

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

in the safety information above this label.

étiquette

plus basse

2. Réglez le thermostat à la température la

3. Coupez l'alimentation électrique de

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

to open valve. Handle will be parallel to

8. Turn gas shutoff valve counterclockwise

l'appareil

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

pipe.

9. Install top cover.

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

vanne gaz en marche

pour

fermer

to OPEN

COMMENT COUPER L'ADMISSION DE GAZ L'APPAREIL

plus basse

1. Réglez le thermostat à la température la

valve. Handle will be perpendicular to pipe.

4. Turn gas shut off valve clockwise to close

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

3. Retirez le couvercle

2. Coupez l'alimentation électrique de

Do not force.

5. Install top cover.

FOR YOUR SAFETY READ BEFORE OPERATING

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.

Follow the gas supplier's instructions.

use any phone in your building.

a neighbor's phone.

- Do not touch any electric switch; do not

- Immediately call your gas supplier from

OPERATING INSTRUCTIONS

on this label.

1. STOP! Read the safety information above

2. Set the thermostat to lowest setting.

TO TURN OFF GAS TO APPLIANCE

Gas Valve OPEN

to CLOSE

ignition device which automatically lights

the burner. Do not try to light the burner

by hand.

valve. Handle will be perpendicular to

pipe. Do not force.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an

5. Remove top cover.

6. Turn gas shutoff valve clockwise to close

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.

5

COMPONENT LOCATION

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

XPak 85

R

GF

P

C

XPak 120

R

F

G

P

Fig. 1

C

6

Control board

Fig. 2

A

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.

BC

G

D

E

F

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

F

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))

7

GETTING STARTED

Before switching ON

Before switching the boiler on please familiarize yourself with:

- how to isolate the boiler from the gas, water, and electricity
supplies;

- how to check and top-up – if necessary – the system water
pressure;

- the time clock or programmer;

- any external thermostats and their functions;

- the boiler controls.

Boiler controls (see Fig. 2)

The boiler controls are situated on the lower front of the boiler. The
boiler controls include:

- Pressure gauge

- Green led (burner ON)

- 2-digit LED display

- Red led (fault indicator)

- Temperature selector space heating

- Mode selector switch

- Temperature selector Domestic Hot Water

The pressure gauge shows the current pressure of your heating
system, the gauge should be typically set between 15-22 psi (1-

1.5 bar). When the boiler is operating the gauge may rise or fall

slightly, this is quite normal. The minimum permissible level for the
safe and efficient operation of the boiler is 7 psi (0.45 bar). Should
the pressure fall below 7 psi (0.45 bar), the boiler may lockout.

The boiler mode selector is used to switch the boiler to the
various operating modes:

OFF/RESET

Summer mode

Winter mode

Winter mode tank temperature

F

NOTE

THE BOILER FREEZE PROTECTION IS ACTIVE IN ALL OF
THE ABOVE MODES.

The temperature selector DHW can be used to adjust the
temperature of the water in the storage tank. The temperature

range is adjustable between 95°F and 140°F (35°C and 60°C)
for the tank storage temperature.

The temperature selector CH
temperature of the radiators or floor heating. The temperature

range is adjustable between 104°F and 176°F (40°C and 80°C)
for standard heating systems.

Moreover if floor heating mode is selected (by using the relative
jumper), the temperature range for heating mode can be modified
between 68°F and 113°F (20°C and 45°C).

The 2-digit LED display normally shows the operating tempera­ture of the boiler (or storage tank temperature if fitted and the mode
selector in the proper position), however it can also display
additional characters or flashing numbers to signify specific
operating modes or fault codes.

can be used to adjust the

How to read the display temperature Fig. 3)

● (dot in the middle) = means hundred (Fig. 3)

● (dot on RIGHT side) = means DHW mode (Fig. 3a)

example:

Fig. 3

Heating mode

60°F 160°F

Fig. 3a

DHW mode

40°F 140°F

NOTICE:

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

When the status indicator (Green) is lit it indicates that the flame
is detected and the burner is fully in ON status.

When the fault indicator (Red) is lit it indicates that the boiler has
identified a possible fault and performed a safety shut-down.

.

Lighting the boiler

Ensure the gas and electrical supply to the boiler are turned on.
When power is restored to the boiler and/or the boiler is powered

for the first time, the boiler start a series of checking and on the
display appears a series of letters and numbers. If the checking
is ok, the boiler start an automatic purge cycling for 2 minutes, the
display will show as per Fig. 4.
After this cycling the boiler is ready to be used.
Turn the mode selector switch to the ON position. When there is
a request for heating or hot water, the boiler will begin an ignition
sequence. When the boiler reaches the set temperature, the
burner will go off for a minimum period of approximately 3 minutes.

WHEN THE ROOM THERMOSTAT HEATING REQUEST HAS
BEEN SATISFIED, THE BOILER WILL SWITCH OFF
AUTOMATICALLY.

Fig. 4

Adjusting the operating temperature

Rotate the temperature selector – clockwise to increase, counter­clockwise to decrease – to the desired temperature setting. The
temperature can be set between 104°F and 176°F (40°C and
80°C) standard heating systems and between 68°F and 113°F
(20°C and 45°C) under-floor heating systems.

NOTE

If the boiler fails to ignite during the ignition sequence, it will enter
a lockout condition. Should this occur, please allow a period of at
least two minutes before resetting the boiler.

Adjusting the hot water temperature

Rotate the temperature selector – clockwise to increase, counter­clockwise to decrease – to the desired temperature setting. The
storage temperature can be set from a minimum of 95°F (35°C)
to a maximum of 140°F (60°C) if the tank has a temperature
sensor; in the case of a tank with thermostat the storage tempe­rature is set directly on the tank thermostat.

8

How to top-up the system pressure (Fig. 5-6)

The system pressure must be checked periodically to ensure the
correct operation of the boiler. The needle on the gauge should
be reading between 15-22 psi (1-1.5 bar) when the boiler is in an
off position and has cooled to room temperature. If the pressure
requires ‘topping-up’ use the following instructions as a guide.

- Locate the filling valve connections (usually beneath the boiler,
see Fig. 5).

- Attach the filling loop to both connections (if available).

- Open the filling valve slowly until you hear water entering the
system.

- Close the filling valve when the pressure gauge (on the boiler)
reads between 15-22 psi (1-1.5 bar)

- Remove the filling loop from the connections.

control

Fig. 5

flow/return

pipe

valve

temporary

connection

double

check valve

control

valve

supply

pipe

BOILER FAULT CODES

CODE ACTION REQUIRED

AL10 Reset boiler. Call service technician if fault re-occurs

AL20 Reset boiler. Call service technician if fault re-occurs

AL21 Reset boiler. Call service technician if fault re-occurs

AL26 Reset boiler. Call service technician if fault re-occurs

AL28 Reset boiler. Call service technician if fault re-occurs

AL29 Reset boiler. Call service technician if fault re-occurs

AL34 Reset boiler. Call service technician if fault re-occurs

AL40 Check system pressure and refill if necessary.

Reset boiler. Call service technician if fault re-occurs

AL41 Check system pressure and refill if necessary.

Call service technician if fault re-occurs

AL52 Call service technician

AL55 Call service technician

AL60 Call service technician

AL71 Call service technician if fault re-occurs

AL73 Call service technician if fault re-occurs

AL74 Reset boiler. Call service technician if fault re-occurs

AL79 Reset boiler. Call service technician if fault re-occurs

AL91 Main heat exchanger needs cleaning. Call service

technician

correct

pressure

value

Fig. 6

How to reset the boiler

When the red fault LED is illuminated, the boiler will need to be
reset manually. Before resetting the boiler, check what action is
required to be taken, using the information on the fault code table
below. Allow a period of two minutes to elapse before rotate the
status mode knob. To reset the alarm, the status mode knob must
be rotated to the OFF position.

IMPORTANT

If the boiler requires to be reset frequently, it may be indicative of
a fault, please contact your installer or Raypak Customer Services
for further advice.

How to shut down the system for short
periods

The system and boiler can be shut down for short periods by
simply turning the mode selector switch to the off position. It is also
advisable to turn off the main water supply to the house.

How to shut down the system for long
periods

If the house is to be left unoccupied for any length of time –
especially during the winter – the system should be thoroughly
drained of all water. The gas, water, and electricity supply to the
house should also be turned off. For more detailed advice contact
your installer.

How to care for the boiler

To clean the outer casing use only a clean damp cloth. Do not
use any scourers or abrasive cleaners. Damage to the cabinet
finish may occur.

9

WHAT IF...

What if I suspect a gas leak

If you suspect a gas leak, turn off the gas supply at the gas meter
and contact your installer or local gas supplier. If you require
further advice please contact your nearest Raypak office.

MAINTENANCE

Suggested Minimum Maintenance
Schedule

Regular service by a qualified service agency and maintenance
must be performed to ensure maximum operating efficiency.
Maintenance as outlined below may be performed by the owner.

What if I have frequently have to top-up
the system

If the system regularly requires topping-up, it may be indicative of
a leak. Please contact your installer and ask him to inspect the
system.

What if the red light is ON

If the Red LED light is illuminated, it indicates that the boiler has
failed to ignite or has detected a possible fault. When this happens
the boiler automatically shuts down and requires a manual reset.

What if the boiler is due its annual service

Advice for tenants only

Your landlord should arrange for servicing.

Advice for homeowners

Please contact Raypak Customer Service if you would prefer a
Raypak service engineer or agent to service your boiler.
Alternatively your local registered service agency may be able to
service the boiler for you.

What if I need to call a service technician

If you think your boiler may have developed a fault, please contact
your installer or Raypak Customer Services. Have all your details
in hand including full address, relevant contact numbers, and your
complete boiler serial number.

Daily

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

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

Monthly

1. Check for piping leaks around fittings.
If found,

leak compounds.

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

3. Visually inspect for proper operation of the condensate drains
on the boiler and in the venting. If leaks are observed repair at
once.

4. Check air vents for leakage.

Yearly (Beginning of Each Heating Season)
WARNING: Annual service should ONLY be performed by a

qualified service agency. Schedule annual service by calling a
qualified service agency.

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

2. Visually inspect all flue product carrying areas of the boiler
including the venting system and main burner for proper
function, deterioration or leakage. Ensure that condensate
drains are inspected and ensure that condensate is being
directed to appropriate condensate management system or
drain, as required by local codes.

3. Check that area is free from combustible materials, gasoline,
and other flammable vapors and liquids.

4. Check for and remove any obstruction to the flow of
combustion or ventilation air to heater.

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

6. Check operation of safety devices. Refer to manufacturers’
instructions.

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

8. Check blower and blower motor.

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

repair at once. DO NOT use petroleum-based stop-

10

Periodically

1. Check relief valve. Refer to manufacturer’s instructions on
valve.

Preventive Maintenance Schedule

WARNING: Preventative maintenance should ONLY be
performed by a qualified service agency in accordance with
the procedures listed in the heater Installation and Operating
Instruction Manual.
The following procedures are recommended and are good

practice for all XPak installations.

Daily

1. Check gauges, monitors and indicators.

2. Check instrument and equipment settings.

Monthly

1. Check flue, vent, stack, or outlet dampers.

Semi-Annually

1. Recalibrate all indicating and recording gauges.

2. Check flame failure detection system components.

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

Annually

1. Test flame failure detection system.

2. Test high limit and operating temperature.

3. Check flame sensor.

4. Conduct a combustion test at full fire. Carbon dioxide
should be 8.5% at full fire for natural gas, and 10.0% for
propane gas. Carbon monoxide should be < 130 ppm.

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

6. Perform leakage test on gas valves.

7. Test air switch in accordance with manufacturer’s
instructions. (Turn panel switch to the “On” position until
blower is proven, then turn the switch to “Off”).

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

As Required

1. Check drip leg and gas strainers.

2. Check flame failure detection system.

3. Check igniter.

4. Check flame signal strength.

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

6. Alarm 91 (AL91) the main heat exchanger need cleaning

11

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Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] Fax [phone]