Raypak XPAK 120 manual

[...]

2 Subject to technical changes! Slight changes may be made to the illustrations, process steps and technical data as a result of our policy of continuous improvement. About these instructions These Installation Instructions contain important information for the safe and professional installation, start-up and maintenance of the boiler with boiler c[...]

3 CONTENTS 1 - W ARNINGS 4 PA Y ATTENTION T O THESE TERMS 4 2 - GENERAL SAFETY 6 TIME/TEMPERA TURE RELA TIONSHIPS IN SCALDS 6 3 - BEFORE INST ALLA TION 6 4 - REGULA TIONS 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 MA TERIAL ST A TEMENT 12[...]

4 CAUTION : This boiler requires forced w ater 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 A WG, 105°C, stranded wire must be used for all low voltage (less than 30 volts) external connections to the unit. S[...]

5 Observe these instructions as general warnings: – Chemicals used to clean the system and/or inhibit corrosion must be pH neutral, i.e. they should ensure that the level of the pH in the system water remains neutral. Premature failure of certain components can occur if the pH level in the system water is out of normal levels. – Raypak recommen[...]

6 3 - BEFORE INST ALLA TION Raypak strongly recommends that this manual be reviewed thoroughly bef ore installing your XP ak boiler. Please revie w the General Saf ety information before installing the boiler . F actor y warranty does not apply to boilers that have been improperly installed or operated. (Refer to the warranty at the back of this ma[...]

7 Ratings and Certifications Standards: • Gas fired hot water boiler for either direct vent installation or for installation using indoor combustion air . Design according to: ANSI Z21.13b 2007 – CSA 4.9b 2007 – Fired low pressure hot water boilers. Categor y IV . • SCAQMD Rule 1146.2 All Raypak boilers are National Board Approved, and desi[...]

8 XP AK 85 Fig. 1 G F R P C 5 - INTRODUCTION The XPak boiler is a wall hung, fan assisted, direct vent, heating boiler only . These boilers – by design – incorporate electronic ignition, circulating pump, pressure relief valve, pressure gauge, and automatic bypass. As supplied, the boiler will automatically modulate to provide central heating o[...]

9 Fig. 1A A Pressure gauge B Green led C 2-digit LED display D Red led E T emperature selector space heating F Mode selector switch G T emperature selector Domestic Hot Water F Off/reset - Select this position when the boiler needs to be reset or switched off. Summer mode - The domestic hot water function provided by the water tank is activ ated. T[...]

10 TECHNICAL DA T A Tab. 1 XPak 85 XPak 120 Input - Output Input - (0 - 2000 ft / 0 - 610 m) Btu/hr 25,600 - 87,000 27,300 - 119,500 k W 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 k W 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 k W 7[...]

11 XPak 85 XPak 120 Boiler flue gas connection i n 2 3/8 2 3/8 m m 60 60 Combustion air connection outer dia. i n 4 4 m m 100 100 Free fan unit feed pressure in w . c. 0.26 0.18 Pa 65 45 Flue gas mass flow rate at rated full load (A) lbs/hr 90.39 123.17 kg/hr 4 1 55.87 Flue gas mass flow rate at rated full load (E) lbs/hr 88.89 121.18 kg/hr 40.32 5[...]

12 BANNED MA TERIAL ST A TEMENT : No banned materials or substances have been used in the manufacture or production of this appliance or its inherent components MANUAL HANDLING ST A TEMENT : 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 [...]

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 d[...]

14 Minimum Clearances to Combustibles T op=0 F ront =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 Harmonize d Standard ANSI Z21.13b 2007 – CSA 4.9b 2007 and therefore is listed for zero clearance to combustibles wh[...]

15 PACKAGING AND TRANSPORT A TION 1. SCOPE OF DELIVERY The boiler is delivered fully assembled. - When receiving the delivery , check if the pac kaging is intact. - Check that all the items listed in T able 2 are included in the deliv er y . 2. TRANSPORTING THE BOILER CAUTION: The boiler ma y be damaged when it is improper ly secured. - Only transp[...]

16 NOTICE: To prevent combustion air contamination when considering exhaust vent and intake air vent termination. Intake and exhaust may be vented vertically through the roof or out a side wall. The intake and exhaust venting methods are detailed in the Venting Section. Do not attempt to install the XPak Boiler using any other means. Be sure to loc[...]

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). Failur[...]

18 required system volume and capacity, no valve is to be placed between the boiler and the expansion tank. 6. Install an Air Elimination Device on the system supply if required, the boiler has two auto air vents built in. 7. Install a drain valve at the lowest point of the system. Note: The XPak has a proper internal drain valve. (see Fig. 42a) 8.[...]

19 XPAK INST ALLA TION DIAGRAMS NOTICE: The f ollowing illustrations are simplified conceptual illustrations only . Key for installation sample diagrams 1. XPak boiler 2. Gas shut off valve 3. Expansion vessel 4. Radiators 5. Under floor heating 6. Pressure relief valve discharge pipe 7. Indirect DHW tank 8. 3-way valve 9. Room thermostat (24V) 10.[...]

20 Fig. 10 Fig. 9[...]

21 Fig. 11 Fig. 12[...]

22 NOTICE: When installing the gas supply connection, it must comply with local regulations or , if such regulations do not exist, with the National Fuel Gas Code, ANSI Z 223.1. In Canada, the gas supply connection must comply with local regulations or , if such regulations do not exist, with CAN/CSA B149, Natural Gas and Propane Installation Code.[...]

23 BOILER TEMPLA TE (Fig. 15) W all Mounting Information XP ak 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 th[...]

24 COMBUSTION AIR AND VENTILA TION 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 [...]

25 2. BOILER SUPPLY XPak boilers are supplied with the following vent components and they are certified together with the XPak boiler as a constructional unit. - 60/100 mm vent exit ( Fig. 16 pos. 1) - Left side intake air (factory sealed with two screws) for two pipes solutions (Fig. 16 pos. 2) - Right side intake air (factory sealed with two scre[...]

26 4. MINIMUM CLEARANCES FROM VENT/AIR INLET TERMINATION U.S. Installations1 Canadian Installations2 A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may 4 ft (1.2m) below or to side of be opened opening; 1 foot (30 cm) above 3 ft (91 cm) opening C Clearance to permanently closed[...]

27 Fig. 24 Fig. 23 NOTICE: The following illustrations are simplified conceptual illustrations only . Legend for illustrations 23-24-25-26-27-28-29-30-31-32 Two pipes vent adaptors (included with the boiler) Pos. 1 Mounting Clip (set of 4) 3.94” (100 mm) for coaxial Pos. 2 (Fig. 24) 90° Elbow 3” (80 mm) single wall Pos. 2 (Fig. 25-26-27-28) Ad[...]

28 Fig. 25 Fig. 26 a = total intake length = INTAKE b = total flue length = EXHAUST a = total intake length = INTAKE b = total flue length = EXHAUST TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION[...]

29 Fig. 28 Fig. 27 a = total intake length = 0 b = total flue length = EXHAUST a = total intake length = INTAKE b = total flue length = EXHAUST a = 0 TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION TWO PIPES SINGLE WALL ROOM AIR DEPENDENT OPERATION[...]

30 Stainless Steel 3” Vent System 1 US + CANAD A Vent System - Room Air independent Operation (Sealed Combustion Operation) - Fig. 12-14-15-17 Vent System diameter 3” V ent system material Stainless steel T wo pipes v ent adaptors (included with the boiler) - - adaptor 80 mm > 3” (included with the boiler 1 pcs) for flue - - adaptor 80 mm [...]

31 Fig. 29 a = total intake length = INTAKE b = total flue length = EXHAUST DESCRIPTION DIA GRAM DRA WING P/N 013040 T wo pipes v ent adaptors Fig. 29-30-31-32 (included with the boiler) P os. 1 P/N 013040 adaptor 80 mm > 3” Fig. 29-30-31-32 (included with the boiler 1 pcs) P os. 2 TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION[...]

32 Fig. 31 Fig. 30 a = total intake length = INTAKE b = total flue length = EXHA UST TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION a = total intake length = INTAKE b = total flue length = EXHA UST[...]

33 Fig. 32 TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION a = total intake length = 0 b = total flue length = EXHA UST[...]

34 Fig. 34 Fig. 33 B 7 - ELECTRICAL CONNECTIONS De vices such as outdoor sensor, 3-w ay v alve , 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 Cod[...]

35 4. CASING REMOV AL (Fig. 33) T o gain inter nal access to the appliance you m ust first remove the casing, proceed as outlined below: - remov e the 3 screws (B) located at the Left/Right/F ront 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) saf[...]

36 REMOTE CONTR OL EXTERNAL SENSOR 0T+ M4 -t° M2 T ANK THERMOST A T V ROOM THERMOST A T (jumper when not used) T ANK SENSOR -t° M4a M3b M3a M3 UNDERFLOOR HEA TING LIMIT THERMOST A T OR CONDENSA TE PUMP ALARM (jumper when not used) LO W V OL T A GE HIGH V OL T AGE 120V N L F= fuse 4AF PCB fuse=4A T Cod. 20003227 3W BLUE (COMMON) BROWN (CLOSED) BLA[...]

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[...]

38 WIRING FUNCTIONAL DIAGRAM Fig. 40[...]

39 8 - ST ART -UP PROCEDURE There are sev eral steps in volv ed in star ting up the boiler . FOR Y OUR SAFETY READ BEFORE OPERA TING W ARNING : If you do not f ollow these instructions exactly , a fire or explosion may result causing proper ty damage, personal injur y , or loss of lif e. A. This appliance does not hav e a pilot. It is equipped with[...]

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

41 7. CHECK THERMOSTAT CIRCUIT(S) 1. Disconnect the two external wires connected to the boiler thermostat terminals (low voltage terminal strip M4a). 2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires. 3. [...]

42 16. FINAL CHECKS - ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS V AL- VE ARE TIGHT AND CHECKED FOR TIGHTNESS. - ENSURE THE APPLIANCE FLUE SYSTEM IS INST ALLED CORRECTL Y AND IS PROPERL Y SECURED . - ENSURE ALL PIPE WORK IS RE-CHECKED FOR SOUNDNESS. - REA TT ACH APPLIANCE CASING. - COMPLETE CHECKLIST Complete details of the boiler , controls, ins[...]

43 10 - ST ART -UP AND OPERA TION XPak wall-mounted condensing boiler is designed for the production of heating and domestic hot water if a storage tank is connected. The control panel contains the main boiler control and manage- ment functions. 1. SWITCHING ON THE APPLIANCE Switch on the boiler as follows: - Open the gas tap under the boiler by tu[...]

44 Fig. 45 A Pressure gauge B Green led C 2-digit LED display D Red led E T emperature selector space heating F Mode selector switch G T emperature selector Domestic Hot W ater* * The par ts of the manual ref er ing to the DHW circuit should be only considered if a indirect water tank with sensor is instal led, case B (Fig. 61) A BC D E F G Domesti[...]

45 Fig. 46 Fig. 47 DHW mode Heating mode Fig. 48 Fig. 49 Fig. 50 Fig. 51 Fig. 52 Fig. 53 Fig. 54 Fig. 55 Fig. 56 Fig. 57 Closed position B green indicator LED boiler status Open position D red indicator LED fault For AL41 faults If the pressure on the water gauge located on the control panel is less than 7 psi (0.5 bar), proceed as follows: - T ur [...]

46 5. HEA TING MODE With the selector switch in the ON position ( - - F ) and any additional controls (time clock, progr ammer , room ther mostat, etc,) calling for heat, the appliance will oper ate in the heating mode. The pump and fan will be activ ated via the flow temperature sensor . When the fan is sensed to be operating correctly (blower sig[...]

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 F AN 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. A T[...]

48 COMPONENT V ALUE F a n 120V AC Pump 120V AC 3-way valve (field supplied) 120V AC Ignition transformer 120V AC Gas valve 120V AC Room thermostat connection 24 Vdc NTC sensor (dry contact) 10Kohm NTC sensor (wet contact) 10Kohm FUNCTION V ALUE Standard Heating Range °F (°C) 104-176 (40-80) Floor Heating Range °F (°C) 68-113 (20-45) CH limited [...]

49 JUMPER IN POSITION 5: unused JUMPER IN POSITION 6: unused The boiler is supplied standard with the jumper in position 3 (standard heating + indirect water tank with thermostat); if you wish to use an e xternal 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 s[...]

50 OUTDOOR TEMPERA TURE RESET CURVES OUTDOOR RESET CORRECTION NIGHT SETBACK OUTDOOR TEMPERA TURE FLOW TEMPERA TURE Fig. 65 Fig. 66 Fig. 67 68 5 9 5 0 41 3 2 2 3 14 5 -4 212 194 176 158 140 122 104 86 68 OUTDOOR TEMPERA TURE FLOW TEMPERA TURE 86 7 7 6 8 5 9 50 4 1 3 2 2 3 14 5 -4 194 176 158 140 122 104 86 68 50 10 20 30 40 50 60 70 80 90 -2 0 -15 -[...]

51 17. F AUL T 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 CA USE ALARM TYPE ACTION AL10 Ignition failure/not flame sensed, Final Reset, check appliance [...]

52 PUMP ASSEMBL Y (Fig. 69) Locate and remove the 2 securing screws (A) at the rear of the pump assemb ly . Disconnect the flow pipe (B, only for XP ak 120) from the combustion chamber connection, slacken the pipe at the h ydraulic assembly and s wing/rotate clear of the pump assembly . Disconnect and remove the pump outlet pipe (C) from the pump a[...]

53 W A TER 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 rev erse order. FLO W SENSOR (PRIMAR Y THERMIST OR) (Fig. 1) Unclip and remove the air chamber front co v er. Unclip the primar y thermistor from the flow outlet pipe. Disconnect thermis[...]

54 MAIN HEA T 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 s wing/rotate of the fan assembly . Disconnect the flow (B) , return (C) and condensation connections on the heat exchanger .[...]

55 CONDENSA TE TRAP REMO V 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 COLLECT OR AND FLUE THERMOST A T REM O V AL (F[...]

56 13 - LPG INSTRUCTIONS LPG INSTRUCTIONS PROP ANE 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, [...]

57 TECHNICAL DATA - LPG Gas pressu re XPak 85 XPak 120 Input - (0 - 2000 ft / 0 - 610 m) Btu/hr 25,600 - 87,000 27,300 - 119,500 k W 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 k W 7.5 - 24.3 8.0 - 33.5 Gas supply pressure LPG in w . c. 11 11 kP a 2.75 2.75 Min. gas supply pressure LPG in w [...]

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 lab[...]

59 14 - EXPLODED DIAGRAMS Drawing 1 5 7 9 3 12a 4 6 8 12a 1 10 2 11[...]

60 Drawing 2 17 18 56a 56a 14 15 56b 13 16 12b 19[...]

61 Drawing 3 12d 12d 23 24c 24e 24d 24b 22 28 26 21d 56a 21c 56a 56c 21a 28 21b 24a 20 27 12c 25 23 24b 24c 24e 24d 24a 22 21d 26 28 56a 21c 12d XP AK 120 XP AK 85 25[...]

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

63 CALL OU T DESCRIPTION XPak85 XPak120 Electric/Case Components See Drawing #1 1 Jack et 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 0[...]

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 u[...]

65 LIMITED W ARRANTY MODULA TING - CONDENSING BOILER XP AK TM HEA TING BOILERS MODELS 85 & 120 SCOPE OF W ARRANTY : Raypak, Inc. (“Raypak”) warr ants to the first retail purchaser of the XP AKHeating Boiler that was deliv ered with this limited w arranty cer tificate (the “Boiler”) that the Boiler will be free from defects in materials [...]

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

67 ST ART -UP CHECKLIST FOR F AN-ASSISTED RA YP AK 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 o[...]

Y our XP ak ser ial number f or future ref erence www .ra ypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468[...]