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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 capacities 87,000 and 120,000 btu/hr. These Installation Instructions are intended for qualified installers, who have the necessary training and experien
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CONTENTS 9 - COMMISSIONING 40 1 - WARNINGS 4 1. Check/control water chemistry 40 PAY ATTENTION TO THESE TERMS 4 2. Freeze protection (when used) 40 3. The heating system 40 2 - GENERAL SAFETY 6 4. Initial filling of the system 40 5. Purge air from boiler manual air release 40 TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 6 6. System drain 40 7. Check thermostat circuit(s) 41 3 - BEFORE INSTALLATION 6 8. Testing for gas leaks 41 9. Initial flushing of the system 41 4 - REGULATIONS AND GUIDELINES 7 10.
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1 - WARNINGS - PAY ATTENTION TO THESE TERMS CAUTION: This boiler requires forced water circulation when DANGER: the burner is operating. See minimum and maximum flow rates. Indicates the presence of immediate hazards which will cau- Severe damage will occur if the boiler is operated without proper se severe personal injury, death or substantial property water flow circulation. damage if ignored. NOTE: Minimum 18 AWG, 105°C, stranded wire must be used WARNING: for all low voltage (less than 30 vo
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DANGER if flammable gas explodes. Beware if you smell gas: there may be an explosion hazard! Warning: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other boiler. What to do if you smell gas - Do not try to light any boiler. - Do not touch any electrical switch; do not use any phone in your buildin
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TIME/TEMPERA TURE 2 - GENERAL SAFETY To meet domestic hot water use needs, the high limit safety control RELATIONSHIPS IN SCALDS on this boiler is adjustable up to 140°F (60°C).Water temperatures The following chart details the relationship of water temperature over 125°F (50°C) can cause instant severe burns or death from and time with regard to scald injury and may be used as a guide scalds. in determining the safest water temperature for your applications. When supplying general purpose hot w
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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. Category IV. � SCAQMD Rule 1146.2 All Raypak boilers are National Board Approved, and design- certified and tested by the Canadian Standards Association (CSA) for the U.S. and Canada. Each boiler is constructed in accordance with Section IV of the Ameri
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5 - INTRODUCTION XPAK 85 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 outputs between 25,600 - 87,000 Btu/hr (7.5-25.5 kW) - XPak 85 and 27,300 - 119,500 Btu/hr (8-35 kW) XPak 120. IMPORTANT It is the law that all gas appliances are installed b
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Fig. 1A BC E A D G F 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. 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
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Tab. 1 TECHNICAL DATA 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/hr 25,200 - 76,600 26,600 - 108,300 kW 7.4 - 22.5 7.8 - 31.7 Energy Guide AFUE % 91.8 92.6 Gas Gas supply pressure Natural Gas (A) in w. c. 6.82 kPa 1.70 Min. gas supply pressure Natural Gas (A) in w.
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XPak 85 XPak 120 Boiler flue gas connection in 2 3/8 2 3/8 mm 60 60 Combustion air connection outer dia. in 4 4 mm 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 41 55.87 Flue gas mass flow rate at rated full load (E) lbs/hr 88.89 121.18 kg/hr 40.32 54.97 Flue gas mass flow rate at rated partial load (A) lbs/hr 26.58 28.48 kg/hr 12.06 12.92 Flue gas mass flow rate at r
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PRINCIPLE COMPONENTS BANNED MATERIAL STATEMENT: A fully integrated electronic control board featuring electronic No banned materials or substances have been used in the temperature control, anti-cycle control, pump over-run, actuator manufacture or production of this appliance or its inherent anti-block function, self-diagnostic fault indicator, full air/gas components modulation. - Radial aluminum heat exchanger. MANUAL HANDLING STATEMENT: - Electronic ignition with flame supervision - Integra
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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 dimension 7/16” (11 mm) F 4.73” 1.76” 2.55” 65 mm 120 mm 45 mm A B CD E Fig. 3 13
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DIMENSIONS AND CONNECTIONS (Fig. 4) Recommended minimum service clearances 5-1/2” 8-5/8” (140 mm) (219 mm) 1” (25 mm) 1” (25 mm) 14-1/8” (359 mm) XPak 85 = 15-3/4” (400 mm) XPak 120 = 17-3/4” (451 mm) == 1” (25 mm) 1” (25 mm) XPak 85= 3-15/16“ (97 mm) XPak 120= 4-1/2“ (114 mm) Fig. 4 Minimum Clearances to Combustibles Top=0 Front =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
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PACKAGING AND TRANSPORTATION 1. SCOPE OF DELIVERY The boiler is delivered fully assembled. 2 - 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 it is improperly secured. - Only transport the boiler using the right transportation equipment, such as a handtruck with a fastening belt or special equipment for maneuvering steps. - During transport
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NOTICE: To prevent combustion air contamination when 6 - INSTALLATION considering exhaust vent and intake air vent termination. Intake and exhaust may be vented vertically through the roof or out a side wall. PREPARE XPAK LOCATION 1. INSTALLATIONS MUST COMPLY WITH: The intake and exhaust venting methods are detailed in the - Local, state, provincial, and national codes, laws, regulations Venting Section. Do not attempt to install the XPak Boiler using any and ordinances. other means. Be sure to
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2. PLACING THE WALL-MOUNTED XPAK BOILER 2. GENERAL PIPING INFORMATION XPak boilers are wall mounted. Use only the XPak boiler wall CAUTION: Use two wrenches when tightening water piping mounting instructions included in the box. at boiler, using one wrench to prevent the boiler return line or supply line from turning. Failure to support the boiler piping WARNING: The wall must be capable of carrying the weight connections to prevent them from turning could cause damage of the boiler and its rela
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2nd speed 2nd speed 1st speed 1st speed 3rd speed 3rd speed 8. BOILER WITH DHW TANK required system volume and capacity, no valve is to be placed - Connect the external hot-water tank according to the Installation between the boiler and the expansion tank. instructions of the hot-water tank and fittings concerned. 6. Install an Air Elimination Device on the system supply if required, the boiler has two auto air vents built in. Domestic Hot Water Production via DHW Storage Tank 7. Install a drain
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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 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 heating 15. Outdoor sens
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Fig. 9 Fig. 10 20
