Raypak XPAK 85 User Manual
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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 DEVICES
12
BANNED MATERIAL STATEMENT
12
MANUAL HANDLING STATEMENT
12
XPAK INTERNAL HYDRAULIC CIRCUIT
12
PIPING CONNECTIONS
13
DIMENSIONS AND CONNECTIONS
14
PACKAGING AND TRANSPORTATION
15
1. Scope of delivery
15
2. Transporting the boiler
15
3. Boiler box content
15
6 - INSTALLATION
16
PREPARE XPAK LOCATION
16
1. Installations must comply with
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2. Before locating the XPak boiler
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3. Clearances for service access
16
4. Residential garage installation
16
5. Exhaust vent and intake air vent
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6. Prevent combustion air contamination
16
7. When removing an existing boiler from an existing common
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vent system
PREPARE XPAK
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1. Remove XPak boiler from box
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2. Placing the wall-mounted XPak boiler
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3. XPak wall mounting instructions
17
4. Installation steps
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XPAK PIPING
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1. Relief valve
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2. General piping information
17
3. Separate low water cutoff
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4. Backflow preventer
17
5. Fitting the heating circuit supply and return pipes
17
6. Expansion tank and make-up water
17
7. Sizing space heat system piping
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8. Boiler with DHW tank
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9. Waterside Flow (primary circuit)
18
10.Procedure summary
18
11.Fill and purge heating system
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XPAK INSTALLATION DIAGRAMS
19
MAKING THE GAS CONNECTION
22
BOILER TEMPLATE
23
COMBUSTION AIR AND VENTILATION OPENINGS
24
INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM
24
VENT SYSTEMS
25
1. Flue gas system
25
2. Boiler supply
25
3. Installations of supplied vent components
25
4. Minimum Clearances from Vent/Air Inlet Termination
26
CONNECTING THE CONDENSATE WATER DRAIN
34
1. Condensate Connection
34
7 - ELECTRICAL CONNECTIONS
34
1. External connection board connections
34
2. Electrical supply
34
3. Field wiring
34
4. Casing removal
35
5. Appliance terminal block
35
6. Connecting the electrical 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 valve wiring connection
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14. Remote control connection
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WIRING FUNCTIONAL DIAGRAM
38
8 - START-UP PROCEDURE
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9 - COMMISSIONING
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1. Check/control water chemistry
40
2. Freeze protection (when used)
40
3. The heating system
40
4. Initial filling of the system
40
5. Purge air from boiler manual air release
40
6. System drain
40
7. Check thermostat circuit(s)
41
8. Testing for gas leaks
41
9. Initial flushing of the system
41
10. Pre-operation checks
41
11. Initial lighting
41
12. Checking gas pressure and combustion analysis
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13. Final flushing of the heating system
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14. Setting the boiler operating temperature
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15. Regulating the central heating system
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16.Final checks
42
17.Instructing the user
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18.Warranty
42
10 - START-UP AND OPERATION
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1. Switching on the appliance
43
2. How to read the display temperature
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3. Adjusting heating water temperature with an outdoor probe connected
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4. Adjusting domestic hot water temperature (if a storage tank with
sensor and 3-way valve is installed)
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5. Working the boiler
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6. Reset function
43
7. Switching off
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8. Indicator LEDs and faults
44
11 - CHECKS, ADJUSTMENTS AND FAULT FINDING
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1. Checking appliance operation
46
2. Appliance modes of operation
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3. Selector switch in the off/stand by position
46
4. On-board functions
46
5. Heating mode
46
6. DHW mode
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7. Boiler fan speeds
47
8. Checking the CO2 and adjusting the gas valve
47
9. Gas valve maximum setting
47
10. Gas valve minimum setting
47
11. Combustion analysis test
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12. External faults
47
13. Electrical checks
48
14. Component values & characteristics
48
15. Boiler configuration
48
16. Setting the outdoor reset curve with outdoor sensor
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17. Fault codes
51
12 - SERVICING INSTRUCTIONS
52
1. General
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2. Routine annual servicing
52
3. Replacement of components
52
4. Component removal procedure
52
13 - LPG INSTRUCTIONS
56
PROPANE GAS
56
14 - EXPLODED DIAGRAMS
59
IMPORTANT INSTRUCTIONS FOR THE
COMMONWEALTH OF MASSACHUSETTS
64
LIMITED PARTS WARRANTY
65
START-UP CHECKLIST FOR FAN-ASSISTED
RAYPAK PRODUCTS
67