Raypak XPAK 85 User Manual

10TECHNICAL DATATab. 1XPak 85 XPak 120Input - OutputInput - (0 - 2000 ft / 0 - 610 m) Btu/hr 25,600 - 87,000 27,300 - 119,500kW 7.5 - 25.5 8.0 - 35.0I

11XPak 85 XPak 120Boiler flue gas connection in 2 3/8 2 3/8mm 60 60Combustion air connection outer dia. in 4 4m

12BANNED MATERIAL STATEMENT:No banned materials or substances have been used in themanufacture or production of this appliance or its inherentcomponen

13PIPING CONNECTIONS (FIG. 3)LegendA - boiler in connection 3/4” NPT - maleB - boiler out connection 3/4” NPT - maleC - gas supply connection 3/4” NPT

14Minimum Clearances to CombustiblesTop=0Front =0 AL, CLRear=0Left=0Right=0AL = AlcoveCL = ClosetNote:The XPak boiler has passed the zero inches vent

15PACKAGING AND TRANSPORTATION1. SCOPE OF DELIVERYThe boiler is delivered fully assembled.- When receiving the delivery, check if the packaging is int

16NOTICE: To prevent combustion air contamination whenconsidering exhaust vent and intake air vent termination.Intake and exhaust may be vented vertic

172. PLACING THE WALL-MOUNTED XPAK BOILERXPak boilers are wall mounted. Use only the XPak boiler wallmounting instructions included in the box.WARNING

18required system volume and capacity, no valve is to be placedbetween the boiler and the expansion tank.6. Install an Air Elimination Device on the s

19XPAK INSTALLATION DIAGRAMSNOTICE:The following illustrations are simplified conceptualillustrations only.Key for installation sample diagrams1. XPak

2Subject to technical changes!Slight changes may be made to the illustrations, process stepsand technical data as a result of our policy of continuous

20Fig. 10Fig. 9

21Fig. 11Fig. 12

22NOTICE: When installing the gas supply connection, it mustcomply with local regulations or, if such regulations do not exist,with the National Fuel

23BOILER TEMPLATE (Fig. 15)Wall Mounting InformationXPak comes with a template,which allows you to easily markthe location of the screws for themounti

24COMBUSTION AIR ANDVENTILATION OPENINGSProvisions for combustion and ventilation air must be made inaccordance with section 5.3, Air for Combustion a

252. BOILER SUPPLYXPak boilers are supplied with the following vent components and theyare certified together with the XPak boiler as a constructional

264. MINIMUM CLEARANCES FROM VENT/AIR INLET TERMINATIONU.S. Installations1 Canadian Installations2A Clearance above grade, veranda,porch, deck, or bal

27Fig. 24Fig. 23NOTICE: The following illustrations are simplified conceptualillustrations only.Legend for illustrations 23-24-25-26-27-28-29-30-31-32

28Fig. 25Fig. 26a = total intake length = INTAKEb = total flue length = EXHAUSTa = total intake length = INTAKEb = total flue length = EXHAUSTTWO PIPE

29Fig. 28Fig. 27a = total intake length = 0b = total flue length = EXHAUSTa = total intake length = INTAKEb = total flue length = EXHAUSTa = 0TWO PIP

3CONTENTS1 - WARNINGS 4PAY ATTENTION TO THESE TERMS 42 - GENERAL SAFETY 6TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 63 - BEFORE INSTALLATION 64 - REGUL

30Stainless Steel 3” Vent System1US + CANADAVent System - Room Air independent Operation (Sealed Combustion Operation) - Fig. 12-14-15-17Vent System d

31Fig. 29a = total intake length = INTAKEb = total flue length = EXHAUSTDESCRIPTION DIAGRAM DRAWINGP/N 013040Two pipes vent adaptors Fig. 29-30-31-32(

32Fig. 31Fig. 30a = total intake length = INTAKEb = total flue length = EXHAUSTTWO PIPES SINGLE WALLSEALED COMBUSTION OPERATIONTWO PIPES SINGLE WALLSE

33Fig. 32TWO PIPES SINGLE WALLSEALED COMBUSTION OPERATIONa = total intake length = 0b = total flue length = EXHAUST

34Fig. 34Fig. 33B7 - ELECTRICAL CONNECTIONSDevices such as outdoor sensor, 3-way valve, tank sensor, tankthermostat, remote controls are all connected

354. CASING REMOVAL (Fig. 33)To gain internal access to the appliance you must first remove thecasing, proceed as outlined below:- remove the 3 screws

36REMOTE CONTROLEXTERNALSENSOR0T+M4-t°M2TANKTHERMOSTATVROOMTHERMOSTAT(jumper whennot used)TANKSENSOR-t°M4aM3bM3aM3UNDERFLOOR HEATING LIMITTHERMOSTAT O

3712. OUTDOOR SENSOR CONNECTIONThe user can program the desired supply temperature based onthe outdoor temperature. Once the outdoor sensor is connec

38WIRING FUNCTIONAL DIAGRAMFig. 40

398 - START-UP PROCEDUREThere are several steps involved in starting up the boiler.FOR YOUR SAFETY READ BEFORE OPERATINGWARNING: If you do not follow

4CAUTION: This boiler requires forced water circulation whenthe burner is operating. See minimum and maximum flow rates.Severe damage will occur if th

40system the pressure gauge will begin to rise. Once the gaugehas reached 15 p.s.i. (1 bar) close both valves and begin ventingall manual air release

417. CHECK THERMOSTAT CIRCUIT(S)1. Disconnect the two external wires connected to the boilerthermostat terminals (low voltage terminal strip M4a).2. C

4216. FINAL CHECKS- ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS VAL-VE ARE TIGHT AND CHECKED FOR TIGHTNESS.- ENSURE THE APPLIANCE FLUE SYSTEM IS INST

4310 - START-UP AND OPERATIONXPak wall-mounted condensing boiler is designed for theproduction of heating and domestic hot water if a storage tank isc

44Fig. 45APressure gaugeB Green ledC 2-digit LED displayD Red ledE Temperature selector space heatingF Mode selector switchG Temperature selector Dome

45Fig. 46Fig. 47DHW modeHeating modeFig. 48Fig. 49Fig. 50Fig. 51 Fig. 52Fig. 53 Fig. 54Fig. 55Fig. 56Fig. 57ClosedpositionB green indicator LEDboiler

465. HEATING MODEWith the selector switch in the ON position ( - - F) and anyadditional controls (time clock, programmer, room thermostat, etc,)call

47NOTICE: When the request for heating and/or hot water hasbeen satisfied, the boiler pump and fan may continue tocirculate to dissipate any residual

48COMPONENT VALUEFan 120VACPump 120VAC3-way valve (field supplied) 120VACIgnition transformer 120VACGas valve 120VACRoom thermostat connection 24 Vdc

49JUMPER IN POSITION 5:unusedJUMPER IN POSITION 6:unusedThe boiler is supplied standard with the jumper in position 3(standard heating + indirect wate

5Observe these instructions as general warnings:– Chemicals used to clean the system and/or inhibit corrosionmust be pH neutral, i.e. they should ensu

50OUTDOOR TEMPERATURE RESET CURVESOUTDOOR RESET CORRECTION NIGHT SETBACKOUTDOOR TEMPERATUREFLOW TEMPERATUREFig. 65Fig. 66Fig. 6768 59

5117. FAULT CODESWhen the boiler detects a temporary fault condition, theappropriate code is shown flashing on the display. If/when thefault code is

52PUMP ASSEMBLY (Fig. 69)Locate and remove the 2 securing screws (A) at the rear of thepump assembly. Disconnect the flow pipe (B, only for XPak 120)f

53WATER PRESSURE SWITCH (Fig. 69)Locate and remove the screw (I) from the water pressure switch.Remove the wiring. Carefully remove the switch. Repla

54MAIN HEAT EXCHANGER (Fig. 76-77)Unclip and remove the three air chamber covers (front, left hand,right hand sides). Disconnect all the wiring conne

55CONDENSATE TRAP REMOVAL (Fig. 79)Disconnect the 2 upper rubber condensate pipes (A). Removethe pin (B) that secures the trap to the air box plate. D

5613 - LPG INSTRUCTIONSLPG INSTRUCTIONSPROPANE GAS:CAUTION: The gas supply shall be shut off prior todisconnecting the electrical power, before proced

57TECHNICAL DATA - LPGGas pressure XPak 85 XPak 120Input - (0 - 2000 ft / 0 - 610 m) Btu/hr 25,600 - 87,000 27,300 - 119,500kW 7.5 - 25.5 8.0 -

58IMPORTANTA GAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANYGAS CARRYING COMPONENTS HAVE BEEN REMOVED,REPLACED, OR DISTURBED.XPAK LPG LABEL1. Fill in t

5914 - EXPLODED DIAGRAMSDrawing 1579312a46812a110211

63 - BEFORE INSTALLATIONRaypak strongly recommends that this manual be reviewedthoroughly before installing your XPak boiler. Please review theGeneral

60Drawing 2171856a56a141556b131612b19

61Drawing 312d12d2324c24e24d24b22282621d56a21c56a56c21a2821b24a202712c252324b24c24e24d24a2221d262856a21c12dXPAK 120XPAK 8525

62Drawing 5Drawing 4303029393837364356a4742313334403541324457b454652 Drawing 55753 Drawing 557b584955515352504854

63CALLOUT DESCRIPTION XPak85 XPak120 Electric/Case Components See

64Important Instructions for the Commonwealth ofMassachusettsThe Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.

65LIMITED WARRANTYMODULATING - CONDENSING BOILERXPAKTMHEATING BOILERS MODELS 85 & 120SCOPE OF WARRANTY:Raypak, Inc. (“Raypak”) warrants to the fir

663. to damage, malfunctions or failures resulting from misuse, neglect, alteration, accident, fire, flood and the like;4. to damage, malfunctions or

67START-UP CHECKLIST FOR FAN-ASSISTEDRAYPAK PRODUCTSThis start-up checklist is to be completely filled out by the service technician starting up the R

Your XPak serial numberfor future referencewww.raypak.comRaypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468

7Ratings and CertificationsStandards:• Gas fired hot water boiler for either direct vent installation or forinstallation using indoor combustion air.

8XPAK 85Fig. 1GFRPC5 - INTRODUCTIONThe XPak boiler is a wall hung, fan assisted, direct vent, heatingboiler only. These boilers – by design – incorpor

9Fig. 1AA Pressure gaugeB Green ledC 2-digit LED displayD Red ledE Temperature selector space heatingF Mode selector switchG Temperature selector Dome