Page 3 - CONTENTS
3 CONTENTS 1 - WARNINGS 4 PAY ATTENTION TO THESE TERMS 4 2 - GENERAL SAFETY 6 TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 6 3 - BEFORE INSTALLATION 6 4 - REGULATIONS AND GUIDELINES 7 5 - INTRODUCTION 8 TECHNICAL DATA 10 PRINCIPLE COMPONENTS 12 MODE OF OPERATION (AT REST) 12 MODE OF OPERATION 12 SAFETY ...
Page 4 - You must also observe:; PAY ATTENTION TO THESE TERMS
4 CAUTION : This boiler requires forced water circulation when the burner is operating. See minimum and maximum flow rates.Severe damage will occur if the boiler is operated without properwater flow circulation. NOTE : Minimum 18 AWG, 105°C, stranded wire must be used for all low voltage (less than ...
Page 6 - - BEFORE INSTALLATION; Product Receipt; Water
6 3 - BEFORE INSTALLATION Raypak strongly recommends that this manual be reviewedthoroughly before installing your XPak boiler. Please review theGeneral Safety information before installing the boiler. Factorywarranty does not apply to boilers that have been improperlyinstalled or operated. (Refer t...
Page 7 - Ratings and Certifications; WARNING; : Altering any Raypak pressure vessel by installing; Installations at Elevation; GUIDELINES; Operating Limits of the boiler:
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 hotwater boilers. Category IV. • SCAQMD Rule 1146.2All Raypak boilers ar...
Page 9 - Pressure gauge
9 Fig. 1A A Pressure gauge B Green led C 2-digit LED display D Red led E Temperature selector space heating F Mode selector switch G Temperature selector Domestic Hot Water F Off/reset - Select this position when the boiler needs to be reset or switched off. Summer mode - The domestic hot water func...
Page 10 - TECHNICAL DATA
10 TECHNICAL DATA Tab. 1 XPak 85 XPak 120 Input - Output Input - (0 - 2000 ft / 0 - 610 m) Btu/hr 25,600 - 87,000 27,300 - 119,500 kW 7.5 - 25.5 8.0 - 35.0 Input - (2000 - 4500 ft / 610 - 1375 m) Btu/hr 25,600 - 82,900 27,300 - 114,300 kW 7.5 - 24.3 8.0 - 33.5 Output (176°F - 86°F / 80°C - 30°C) Btu...
Page 13 - Legend; A - boiler in connection
13 PIPING CONNECTIONS (FIG. 3) Legend A - boiler in connection 3/4” NPT - male B - boiler out connection 3/4” NPT - male C - gas supply connection 3/4” NPT - female D - pressure relief valve drain connection 3/4” NPT - female E - condensate connection Ø (rubber flexible) 0.825” (21 mm) female F - bo...
Page 15 - PACKAGING AND TRANSPORTATION; TRANSPORTING THE BOILER
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 i...
Page 17 - XPAK PIPING
17 2. PLACING THE WALL-MOUNTED XPAK BOILER XPak boilers are wall mounted. Use only the XPak boiler wallmounting 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 theboiler are approximately:XPak 85 = 82...
Page 19 - XPAK INSTALLATION DIAGRAMS; The following illustrations are simplified conceptual; Key for installation sample diagrams
19 XPAK INSTALLATION DIAGRAMS NOTICE: The following illustrations are simplified conceptual illustrations only. Key for installation sample diagrams 1. XPak boiler 2. Gas shut off valve 3. Expansion vessel 4. Radiators 5. Under floor heating 6. Pressure relief valve discharge pipe 7. Indirect DHW ta...
Page 22 - MAKING THE GAS CONNECTION
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 localregulations or, if such regulations do not exist, with CAN/CSAB149...
Page 23 - Wall Mounting Information
23 BOILER TEMPLATE (Fig. 15) Wall Mounting Information XPak comes with a template,which allows you to easily markthe location of the screws for themounting bracket and the locationof the flue gas pipe on the wall(Raypak coaxial PP vent systemonly).The connection to the gas circuitsmust be made on si...
Page 24 - All Air from Inside the Building (room air)
24 C O M B U S T I O N A I R A N DVENTILATION OPENINGS Provisions for combustion and ventilation air must be made inaccordance with section 5.3, Air for Combustion and Ventilation,of the National Flue Gas Code, ANSI Z223.1, or Sections 7.2, 7.3or 7.4 of CAN/CGA B149, Installation Codes, or applicabl...
Page 25 - INSTALLATIONS OF SUPPLIED VENT COMPONENTS; VENT SYSTEMS; Country
25 2. BOILER SUPPLY XPak boilers are supplied with the following vent components and theyare 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...
Page 26 - MINIMUM CLEARANCES FROM VENT/AIR INLET TERMINATION; Canadian Installations2
26 4. MINIMUM CLEARANCES FROM VENT/AIR INLET TERMINATION U.S. Installations1 Canadian Installations2 A Clearance above grade, veranda,porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may 4 ft (1.2m) below or to side of be opened opening; 1 foot (30 cm) above 3 ft ...
Page 31 - Two pipes vent adaptors; TWO PIPES SINGLE WALL
31 Fig. 29 a = total intake length = INTAKEb = total flue length = EXHAUST DESCRIPTION DIAGRAM DRAWING P/N 013040 Two pipes vent adaptors Fig. 29-30-31-32 (included with the boiler) Pos. 1 P/N 013040 adaptor 80 mm > 3” Fig. 29-30-31-32 (included with the boiler 1 pcs) Pos. 2 TWO PIPES SINGLE WALL...
Page 34 - - ELECTRICAL CONNECTIONS; EXTERNAL CONNECTION BOARD CONNECTIONS; ELECTRICAL SHOCK HAZARD — For your; The boiler must be grounded.; Pipe ventilation must take place between the; CONDENSATE CONNECTION; RISQUE DE CHOC ÉLECTRIQUE —
34 Fig. 34 Fig. 33 B 7 - ELECTRICAL CONNECTIONS Devices such as outdoor sensor, 3-way valve, tank sensor, tankthermostat, remote controls are all connected to the externalconnection board.The electrical connections to the boiler must be made inaccordance with all applicable local codes and the lates...
Page 36 - TERMINAL STRIP DETAILS
36 REMOTE CONTROL EXTERNAL SENSOR 0T+ M4 -t° M2 TANK THERMOSTAT V ROOM THERMOSTAT (jumper when not used) TANK SENSOR -t° M4a M3b M3a M3 UNDERFLOOR HEATING LIMIT THERMOSTAT OR CONDENSATE PUMP ALARM (jumper when not used) LOW VOLTAGE HIGH VOLTAGE 120V N L F= fuse 4AF PCB fuse=4AT Cod. 20003227 3W BLUE...
Page 37 - The 3-way valve is continuously powered even
37 12. OUTDOOR SENSOR CONNECTION The user can program the desired supply temperature based onthe outdoor temperature. Once the outdoor sensor is connectedto the control board, the water temperature of the boiler will adjustto run the boiler more efficiently and provide greater comfort to theliving s...
Page 38 - WIRING FUNCTIONAL DIAGRAM
Page 39 - There are several steps involved in starting up the boiler.
39 8 - START-UP PROCEDURE There are several steps involved in starting up the boiler. FOR YOUR SAFETY READ BEFORE OPERA TING W ARNING : If y ou do not f ollo w these instr uctions e xactly , a fire or e xplosion ma y result causing proper ty damage , personal injur y, or loss of lif e. A. This appli...
Page 42 - INSTRUCTING THE USER
42 16. FINAL CHECKS - ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS VAL- VE ARE TIGHT AND CHECKED FOR TIGHTNESS. - ENSURE THE APPLIANCE FLUE SYSTEM IS INSTALLED CORRECTLY AND IS PROPERLY SECURED. - E N S U R E A L L P I P E W O R K I S R E - C H E C K E D F O R SOUNDNESS. - REATTACH APPLIANCE CASING....
Page 43 - tes the storage; Winter mode; - The boiler produces hot water for heating; Winter mode tank temperature; - The boiler produces; Adjusting heating water temperature; DHW mode
43 10 - START-UP AND OPERATION XPak wall-mounted condensing boiler is designed for theproduction of heating and domestic hot water if a storage tank isconnected.The control panel contains the main boiler control and manage-ment functions. 1. SWITCHING ON THE APPLIANCE Switch on the boiler as follows...
Page 44 - INDICATOR LEDS AND FAULTS
44 Fig. 45 A Pressure gauge B Green led C 2-digit LED display D Red led E Temperature selector space heating F Mode selector switch G Temperature selector Domestic Hot Water* * The parts of the manual refering to the DHW circuit should be only considered if a indirect water tank with sensor is insta...
Page 45 - For AL41 faults; - Fill the system until the pressure indicated on the water gauge; For alarm AL91
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 isless ...
Page 46 - NOTICE; 1 - CHECKS, ADJUSTMENTS AND FAULT FINDING
46 5. HEATING MODE With the selector switch in the ON position ( - - F ) and any additional controls (time clock, programmer, room thermostat, etc,)calling for heat, the appliance will operate in the heating mode. Thepump and fan will be activated via the flow temperature sensor.When the fan is sens...
Page 49 - JUMPER IN POSITION 5:; JUMPER IN POSITION 6:; unused; JP; TYPE OF HEAT REQUEST; (this parameter can only be
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); ifyou wish to use an external water tank with sensor, move thisjumper from position 3 to position 2 (case B, Fig 61); if...
Page 52 - 2 - SERVICING INSTRUCTIONS; genuine XPak spare parts
52 PUMP ASSEMBLY (Fig. 69) Locate and remove the 2 securing screws (A) at the rear of the pump assembly. Disconnect the flow pipe (B, only for XPak 120) from the combustion chamber connection, slacken the pipe at thehydraulic assembly and swing/rotate clear of the pump assembly.Disconnect and remove...
Page 56 - This conversion kit shall; CHANGE THE GAS INJECTOR
56 13 - LPG INSTRUCTIONS LPG INSTRUCTIONS PROPANE GAS: CAUTION: The gas supply shall be shut off prior to disconnecting the electrical power, before proceding with theconversion. Installation Codes Installations must follow these codes:• Local, state, provincial, and national codes, laws, regulation...
Page 57 - Gas pressure; MAX
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 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 k...
Page 59 - 4 - EXPLODED DIAGRAMS; Drawing 1
59 14 - EXPLODED DIAGRAMS Drawing 1 5 7 9 3 12a 4 6 8 12a 1 10 2 11
Page 60 - Drawing 2
Page 61 - Drawing 3
61 Drawing 3 12d 12d 23 24c 24e 24d 24b 22 28 26 21d 56a 21c 56a 56c 21a 28 21b 24a 20 27 12c 25 23 24b 24c 24e 24d 24a 22 21d 26 28 56a 21c 12d XPAK 120 XPAK 85 25
Page 65 - LIMITED WARRANTY; MODULATING - CONDENSING BOILER; APPLICABLE WARRANTY PERIODS
65 LIMITED WARRANTY MODULATING - CONDENSING BOILER XPAK TM HEATING BOILERS MODELS 85 & 120 SCOPE OF WARRANTY: Raypak, Inc. (“Raypak”) warrants to the first retail purchaser of the XPAKHeating Boiler that was delivered with this limited warranty certificate (the“Boiler”) that the Boiler will be f...
Page 67 - RAYPAK PRODUCTS
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. Allinformation may be used for warranty purposes and to ensure that the installation is correct. Additionally this...
