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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

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PREPARE XPAK LOCATION

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1. Installations must comply with

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2. Before locating the XPak boiler

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3. Clearances for service access

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4. Residential garage installation

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5. Exhaust vent and intake air vent

16

6. Prevent combustion air contamination

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7. When removing an existing boiler from an existing common

16

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

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4. Installation steps

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XPAK PIPING

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1. Relief valve

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2. General piping information

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3. Separate low water cutoff

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4. Backflow preventer

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5. Fitting the heating circuit supply and return pipes

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6. Expansion tank and make-up water

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7. Sizing space heat system piping

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8. Boiler with DHW tank

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9. Waterside Flow (primary circuit)

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10.Procedure summary

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11.Fill and purge heating system

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XPAK INSTALLATION DIAGRAMS

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MAKING THE GAS CONNECTION

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BOILER TEMPLATE

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COMBUSTION AIR AND VENTILATION OPENINGS

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INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM

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VENT SYSTEMS

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1. Flue gas system

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2. Boiler supply

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3. Installations of supplied vent components

25

4. Minimum Clearances from Vent/Air Inlet Termination

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CONNECTING THE CONDENSATE WATER DRAIN

34

1. Condensate Connection

34

7 - ELECTRICAL CONNECTIONS

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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

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9. Connecting thermostat

35

10.Other devices

35

11. Terminal strip details

36

12.Outdoor sensor connection

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13.3-way valve wiring connection

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14. Remote control connection

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WIRING FUNCTIONAL DIAGRAM

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8 - START-UP PROCEDURE

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9 - COMMISSIONING

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1. Check/control water chemistry

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2. Freeze protection (when used)

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3. The heating system

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4. Initial filling of the system

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5. Purge air from boiler manual air release

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6. System drain

40

7. Check thermostat circuit(s)

41

8. Testing for gas leaks

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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

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10 - START-UP AND OPERATION

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1. Switching on the appliance

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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

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7. Switching off

43

8. Indicator LEDs and faults

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11 - CHECKS, ADJUSTMENTS AND FAULT FINDING

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1. Checking appliance operation

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2. Appliance modes of operation

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3. Selector switch in the off/stand by position

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4. On-board functions

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5. Heating mode

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6. DHW mode

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7. Boiler fan speeds

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8. Checking the CO2 and adjusting the gas valve

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9. Gas valve maximum setting

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10. Gas valve minimum setting

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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

49

17. Fault codes

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12 - SERVICING INSTRUCTIONS

52

1. General

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2. Routine annual servicing

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3. Replacement of components

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4. Component removal procedure

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13 - LPG INSTRUCTIONS

56

PROPANE GAS

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14 - EXPLODED DIAGRAMS

59

IMPORTANT INSTRUCTIONS FOR THE
COMMONWEALTH OF MASSACHUSETTS

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LIMITED PARTS WARRANTY

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START-UP CHECKLIST FOR FAN-ASSISTED
RAYPAK PRODUCTS

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