Raypak XPAK 120 Installation & Operating Instructions Manual Download Page 1

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Summary of Contents for XPAK 120

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Page 2: ...ce 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 fitte...

Page 3: ...lectrical 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 37 13 3 way valv...

Page 4: ...alled 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 durin...

Page 5: ...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 Thi...

Page 6: ...E R A T U R E 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...

Page 7: ...d 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 boi...

Page 8: ...ge 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 combu...

Page 9: ...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 th...

Page 10: ...System Data Minimum relief valve capacity lbs hr 87 119 50 Maximum operating pressure p s i 45 bar 3 1 Minimum operating pressure p s i 6 52 bar 0 45 Recommended system pressure p s i 15 bar 1 Boiler...

Page 11: ...Max total length 2 pipe 3 80 mm air flues ft 130 130 115 115 m 40 40 35 35 Minimum Clearances To Combustibles Top front rear in 0 0 0 mm 0 0 0 Left right vent pipe in 0 0 0 mm 0 0 0 Recommended Minim...

Page 12: ...inactive for more than 24 hours 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 spee...

Page 13: ...nection 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 rubber flexible 0 825 21 mm female F boiler drain valve open...

Page 14: ...r UL ULC listed gas vent material The zero inches vent clearance to combustibles for the XPak boiler supercedes the clearance to combustibles listing that appears on the special venting system label D...

Page 15: ...35 1 38 XPak 120 17 81 XPak 85 15 75 14 17 16 25 C C 16 1 5 3 5 4 inside 3 inside 3 15 4 53 Hole for 60 100mm coaxial vent 30 71 Boiler height 3 14 XPak 120 XPak 85 XPak 85 XPak 120 1 4 holes for ear...

Page 16: ...PREPARE XPAK CAUTION CAUTION CAUTION CAUTION CAUTION Cold weather handling If boiler has been stored in a very cold location below 0 F 18 C before installation handle with care until the plastic compo...

Page 17: ...SA4 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 GENER...

Page 18: ...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 senso...

Page 19: ...discharge pipe 7 Indirect DHW tank 8 3 way valve 9 Room thermostat 24V 10 Remote control Raypak 11 Condensate drain pipe 12 Valve ball 13 Hydraulic manifold box package 14 High limit thermostat floor...

Page 20: ...20 Fig 10 Fig 9...

Page 21: ...21 Fig 11 Fig 12...

Page 22: ...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 Equivalent length for pipe fittings in feet Fig 13 Fig 14 Open position MAKING THE GAS CONNECTION DANGER Only carry out w...

Page 23: ...plied Exhaust vent adapter supplied Screw 2x supplied Screw 2x supplied Screw 2x fitted Inlet air adapter supplied Wall stud CENTER LINE OF BOILER L C Ensure there is adequate clearances for mounting...

Page 24: ...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 th...

Page 25: ...ntric 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 opera...

Page 26: ...m 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...

Page 27: ...ingle 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 slo...

Page 28: ...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 SEALEDCOMBUSTIONOPERATION TWO PIPES SINGLE WALL SEALEDCOMBUS...

Page 29: ...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 SEALEDCOMBUSTIONOPERATION TWO PIPES SINGLE WALL ROOMAIRDEPEND...

Page 30: ...able material for combustion air ABS CPVC PVC or stainless steel Do not exceed maximum equivalent vent length Always follow XPak Venting System Installation Instructions Tab 7 Stainless Steel Vent Sys...

Page 31: ...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 P...

Page 32: ...30 a total intake length INTAKE b total flue length EXHAUST TWO PIPES SINGLE WALL SEALEDCOMBUSTIONOPERATION TWO PIPES SINGLE WALL SEALEDCOMBUSTIONOPERATION a total intake length INTAKE b total flue l...

Page 33: ...33 Fig 32 TWO PIPES SINGLE WALL SEALEDCOMBUSTIONOPERATION a total intake length 0 b total flue length EXHAUST...

Page 34: ...ATER 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 condens...

Page 35: ...llic 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 te...

Page 36: ...e The 3 way valve cable must be anchored to the boiler frame Fig 39 and pass through the strains relief field supplied Fig 39 Cable as specified in the electrical supply M4 Outdoor sensor 12 K Ohm B37...

Page 37: ...Y 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 Boil...

Page 38: ...38 WIRING FUNCTIONAL DIAGRAM Fig 40...

Page 39: ...timent Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les POUR VOTRE S CURIT LISEZ AVANT DE METTRE EN MARCHE instructions du fornisseur Si vous ne pouvez rejoindre le fourniss...

Page 40: ...l water treatment company for treatment needed Hardness less than 7 grains 1 Consult local water treatment companies for unusually hard water areas above 7 grains hardness Chlorine concentration less...

Page 41: ...ly 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 swi...

Page 42: ...ing 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...

Page 43: ...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 dome...

Page 44: ...irculator 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...

Page 45: ...iler 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...

Page 46: ...uitry 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 1 CHECKING APPLIANCE OPERATION When...

Page 47: ...ained 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 Ho...

Page 48: ...ons 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...

Page 49: ...1 5 TMR Nominal flow Temp Tshift 68 F 20 C min external design Temp Select KT by turning the trimmer located under the domestic hot water temperature knob A The settable values of KT are standard sys...

Page 50: ...E FLOW TEMPERATURE 86 77 68 59 50 41 32 23 14 5 4 194 176 158 140 122 104 86 68 50 10 20 30 40 50 60 70 80 90 20 15 10 5 0 5 10 15 20 Curva climatica GIORNO Curva climatica NOTTE Outdoor reset DAY Out...

Page 51: ...or 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 refi...

Page 52: ...lowing 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 ROU...

Page 53: ...unctioning of the PCB is set for the correct boiler type application GAS VALVE Fig 72 The gas valve must be changed as complete unit Disconnect the electrical plug and leads from the gas valve slacken...

Page 54: ...ir 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 l...

Page 55: ...he reverse order FLUE COLLECTOR AND FLUETHERMOSTAT REMOVAL 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 poi...

Page 56: ...pplied 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...

Page 57: ...0 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...

Page 58: ...r 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 s...

Page 59: ...59 14 EXPLODED DIAGRAMS Drawing 1 5 7 9 3 12a 4 6 8 12a 1 10 2 11...

Page 60: ...60 Drawing 2 17 18 56a 56a 14 15 56b 13 16 12b 19...

Page 61: ...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 62: ...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...

Page 63: ...ctor 013026F 013026F Burner Components Air Box See Drawing 4 29 Air Chamber Access Panel 013037F 013038F 30 Air Chamber Side 013027F 013027F 31 Intake Air Flue Adapters 013040F 013040F 32 Combustion A...

Page 64: ...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 pr...

Page 65: ...K Commercial Extruded Aluminum Heat Exchanger The Applicable Warranty Period for the aluminum heat exchanger of the Boiler in a commercial installation as defined in Additional Warranty Exclusions and...

Page 66: ...nstaller 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 authoriza...

Page 67: ...______ Vent Material __________________ Impeller trim____________ Pump Model________ Vent Termination Type __________________ Louvers __________________ Screens____________ Combustion Air Openings Low...

Page 68: ...Your XPak serial number for future reference www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468...

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