Raypak 85, 120 manual Installation, Prepare Xpak Location

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6 - INSTALLATION

PREPARE XPAK LOCATION

1. INSTALLATIONS MUST COMPLY WITH:

-Local, state, provincial, and national codes, laws, regulations and ordinances.

-National Fuel Gas Code, ANSI Z223.1 – latest edition.

-National Electrical Code.

-For Canada only: B149 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

NOTICE: The XPak boiler gas manifold and controls meet safe lighting and other performance criteria as specified in ANSI Z21.13b 2007 – CSA 4.9b 2007

2.BEFORE LOCATING THE XPAK BOILER

1.Check for nearby connection to:

-System water piping

-Venting connections

-Gas supply piping

-Electrical power

2.Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids.

WARNING: Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

3.The XPak must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

4.If the new XPak is to replace an existing boiler, check for and correct any existing system problems such as:

-System leaks.

-Incorrectly-sized expansion tank.

-Lack of freeze protection in heating water causing system and boiler to freeze and leak.

-Excessive glycol which will affect the boiler system operation.

3. CLEARANCES FOR SERVICE ACCESS

1.See figure for recommended service clearances. If you do not provide minimum clearances shown, it might not be possible to service the boiler without removing it from the space.

WARNING: The space must be provided with combustion/ ventilation air openings correctly sized for all other appliances located in the same space as the XPak boiler. The boiler internal front cover must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room in the case of sealed combustion operation. This is particularly important if the boiler is located in the same room as other appliances. Failure to comply with the above warnings could result in severe personal injury, death or substantial property damage.

4.RESIDENTIAL GARAGE INSTALLATION Precautions

Take the following special precautions when installing the XPak in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1, paragraph 5.1.9:

- Mount the boiler with a minimum of 18 inches above the floor of the garage to the bottom of the boiler to ensure the burner and ignition devices will be no less than 18 inches above the floor.

- Locate or protect the boiler so it cannot be damaged by a moving vehicle.

5.EXHAUST VENT AND INTAKE AIR VENT

XPaks are rated ANSI Z21.13b 2007 – CSA 4.9b 2007 – Fired low pressure steam and hot water boilers. Category IV.(pressurized vent, likely to condense in the vent). Also installations with air dependent operation are allowed providing proper openings in the room are provided.

NOTICE: To prevent combustion air contamination when considering exhaust vent and intake air vent termination. Intake and exhaust may be vented vertically through the roof or out a side wall.

The intake and exhaust venting methods are detailed in the Venting Section. Do not attempt to install the XPak Boiler using any other means. Be sure to locate the boiler such that the air intake and exhaust vent piping can be routed through the building and properly terminated. The air intake and exhaust vent piping lengths, routing and termination method must all comply with the methods and limits given in the Venting section.

6. PREVENT COMBUSTION AIR CONTAMINATION Install intake air piping for the XPak as described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.

WARNING: You must pipe outside air to the boiler air intake for sealed combustion operation. Ensure that the intake air will not contain any of the contaminants below. Contaminated air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. For example, do not pipe intake air vent near a swimming pool. Also avoid areas subject to exhaust fumes from laundry facilities. These areas may contain contaminants.

7.WHEN REMOVING AN EXISTING BOILER FROM AN EXISTING COMMON VENT SYSTEM

Do not install the XPak boiler into a common vent with any other appliance.

This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.

WARNING: Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a.Seal any unused openings in the common venting system.

b.Visually inspect the venting system for proper size and horizontal pitch and determine there is non blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

c.Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d.Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

e.Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 — latest edition. Correct by resizing to approach the minimum size as determined using the appropriate tables in Table 13 of ANSI Z223.1 2006 of that code. Canadian installations must comply with B149 Installation Code.

PREPARE XPAK

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 components come to room temperature.

1.REMOVE XPAK BOILER FROM BOX

1.XPak is heavy and awkward to lift.

Care must be taken to place it in a safe location prior to installation on the wall to prevent damage to the bottom mechanical connections.

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Contents Page About these instructions About the XPakContents Following instructions must be observed PAY Attention to These TermsYou must also observe What to do if you smell gas Observe these instructions as general warningsObserve these instructions for space heating water Tools, materials and additional equipmentGeneral Safety Before InstallationM E / T E M P E R a T U R E Relationships in Scalds Water Time to Produce SeriousRegulations and Guidelines Operating Limits of the boilerIntroduction General layout FigAB C DE Technical Data Recommended Minimum Service Clearances Boiler Dimensions And WeightXPak Max flues length de-rate less 2%Manual Handling Statement Mode of Operation AT Rest Xpak Internal Hydraulic Circuit FIG Mode of OperationSafety Devices Principle ComponentsPiping Connections FIG Dimensions and Connections Fig Boiler BOX Content Table Pos Parts Quantity Packaging Packaging and TransportationScope of Delivery Transporting the BoilerPrepare Xpak Location InstallationPrepare Xpak Xpak Piping Procedure Summary Boiler with DHW TankWaterside Flow Primary Circuit Pump DutyXpak Installation Diagrams Key for installation sample diagramsPage Page Length Gas Volume Capacity Pipe feet Ft 3/h Making the GAS ConnectionGas Pipe Capacity for different pipe sizes Equivalent length for pipe fittings in feetBoiler Template Fig All Air from Inside the Building room air All Air from Outdoor sealed combustionFlue GAS System Vent SystemsBoiler Supply Installations1 Canadian Installations2 Minimum Clearances from VENT/AIR Inlet TerminationVertical Coaxial Sealed Combustion Operation TWO Pipes Single Wall Room AIR Dependent Operation Field supplied Stainless steel013102 Description Diagram Drawing TWO Pipes Single Wall = total intake length = Connecting the Condensate Water Drain Electrical ConnectionsExternal Wiring External Wiring LimitationsConnecting Thermostat Appliance Terminal BlockHigh Terminal Strip DetailsLow Remote Control Connection WAY Valve Wiring ConnectionOutdoor Sensor Connection Wiring Functional Diagram START-UP Procedure Are several steps involved in starting up the boilerFreeze Protection When Used CommissioningCHECK/CONTROL Water Chemistry Heating SystemTesting for GAS Leaks Initial Lighting and Ignition Safety Shutoff Device TestCheck Thermostat Circuits Initial Flushing of the SystemFinal Checks WarrantyInstructing the User Switching on the Appliance Reset FunctionSwitching OFF START-UP and OperationGreen indicator LED Fig Indicator Leds and FaultsRed indicator LED Fig For AL41 faults For alarm AL91CHECKS, Adjustments and Fault Finding CHECKING/ADJUSTING the Boiler FAN Speeds GAS Valve Minimum Pressure SettingExternal Faults Installation FaultsFault Finding Reversed Polarity or Supply FaultBoiler Configuration Electrical ChecksSetting the Outdoor Reset Curve with Outdoor Sensor Programmable Timer DAY+NIGHTSelecting the offset heating curve Fig Type of Heat Request Standard212 194 176 158 140 122 104 Fault Codes Code Cause Alarm Type ActionReplacement of Components Component Removal ProcedureServicing Instructions GeneralWater Pressure Switch Fig Flow Sensor Primary Thermistor FigReturn Sensor Return Thermistor Fig Printed Circuit Board FigBlocked Flue Pressure SWITCH/IGNITION Transformer Fig Flue FAN & Mixer FigBurner Fig Main Heat Exchanger FigCondensate Trap Removal Fig Flue Collector and Flue Thermostat Removal FigGAS Supply Installation LPG InstructionsPropane GAS GAS SupplyTechnical Data LPG Sequence of the Ignition System Exploded Diagrams 56a Xpak Drawing Call OUT Description Important Instructions for the Commonwealth of Massachusetts Limited Warranty Applicable Warranty PeriodsHOW to Make Warranty Claim START-UP Checklist for FAN-ASSISTED Raypak Products Your XPak serial number For future reference

120, 85 specifications

The Raypak 120,85 is a prominent model in the realm of pool and spa heating solutions, designed to deliver unmatched efficiency and performance. Renowned for its robust features and innovative technologies, the Raypak 120,85 stands out as a reliable choice for homeowners seeking to maintain the perfect water temperature in their pools and spas.

One of the primary characteristics of the Raypak 120,85 is its impressive heating capacity. With a total output of 120,000 BTUs, this heater quickly and efficiently warms up water, ensuring that users can enjoy comfortable swimming conditions regardless of the outdoor temperature. The 85 indicates its ability to deliver consistent performance even in cooler climates, making it an adaptable option for various geographical locations.

The Raypak 120,85 is equipped with a state-of-the-art, copper fin tube heat exchanger, which provides superior heat transfer efficiency. This technology enhances the heater's ability to warm water rapidly while maintaining energy efficiency. Additionally, the copper material is known for its durability and resistance to corrosion, ensuring a long lifespan for the heat exchanger.

Another key feature of the Raypak 120,85 is its electronic ignition system. This innovation eliminates the need for a standing pilot light, which not only saves energy but also enhances safety by reducing the risk of gas leaks associated with traditional ignition systems. The electronic ignition provides precise control, ensuring a reliable start each time.

The Raypak 120,85 also boasts a digital display control panel, allowing users to easily monitor and adjust the water temperature settings. This intuitive interface provides accurate readings and simplifies the operation, making it accessible for all users, regardless of their technical expertise.

Furthermore, this heater is designed with a compact footprint, making it suitable for a variety of installation spaces, whether it’s in a pool equipment area or near a spa. Its robust build quality and weather-resistant design ensure that it can withstand the elements, making it a durable and long-lasting investment.

In summary, the Raypak 120,85 combines advanced heating technology, robust construction, and user-friendly features. With its high BTU output, efficient heat exchanger, electronic ignition, and digital controls, it represents a top-tier option for anyone seeking reliable and effective heating solutions for pools and spas. Whether for leisure or relaxation, the Raypak 120,85 promises to deliver an optimal swimming experience, season after season.
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