Raypak 120, 85 manual Contents

CONTENTS

1 - WARNINGS

PAY ATTENTION TO THESE TERMS

2 - GENERAL SAFETY

TIME/TEMPERATURE RELATIONSHIPS IN SCALDS

3 - BEFORE INSTALLATION

4 - REGULATIONS AND GUIDELINES

5 - INTRODUCTION TECHNICAL DATA PRINCIPLE COMPONENTS MODE OF OPERATION (AT REST) MODE OF OPERATION SAFETY DEVICES

BANNED MATERIAL STATEMENT MANUAL HANDLING STATEMENT XPAK INTERNAL HYDRAULIC CIRCUIT PIPING CONNECTIONS DIMENSIONS AND CONNECTIONS PACKAGING AND TRANSPORTATION

1.Scope of delivery

2.Transporting the boiler

3.Boiler box content

6 - INSTALLATION PREPARE XPAK LOCATION

1.Installations must comply with

2.Before locating the XPak boiler

3.Clearances for service access

4.Residential garage installation

5.Exhaust vent and intake air vent

6.Prevent combustion air contamination

7.When removing an existing boiler from an existing common vent system

PREPARE XPAK

1.Remove XPak boiler from box

2.Placing the wall-mounted XPak boiler

3.XPak wall mounting instructions

4.Installation steps

XPAK PIPING

1.Relief valve

2.General piping information

3.Separate low water cutoff

4.Backflow preventer

5.Fitting the heating circuit supply and return pipes

6.Expansion tank and make-up water

7.Sizing space heat system piping

8.Boiler with DHW tank

9.Waterside Flow (primary circuit) 10.Procedure summary

11.Fill and purge heating system

XPAK INSTALLATION DIAGRAMS MAKING THE GAS CONNECTION BOILER TEMPLATE

COMBUSTION AIR AND VENTILATION OPENINGS INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM VENT SYSTEMS

1.Flue gas system

2.Boiler supply

3.Installations of supplied vent components

4.Minimum Clearances from Vent/Air Inlet Termination

CONNECTING THE CONDENSATE WATER DRAIN

4	9 - COMMISSIONING		40
	1.	Check/control water chemistry	40
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	2.	Freeze protection (when used)	40
6	3.	The heating system	40
	4.	Initial filling of the system	40
6	5.	Purge air from boiler manual air release	40
	6.	System drain	40
6	7.	Check thermostat circuit(s)	41
	8.	Testing for gas leaks	41
7	9.	Initial flushing of the system	41
	10. Pre-operation checks		41
8	11. Initial lighting		41
	12. Checking gas pressure and combustion analysis		41
10	13. Final flushing of the heating system		41
12	14. Setting the boiler operating temperature		41
12	15. Regulating the central heating system		41
12	16.Final checks		42
	17.Instructing the user		42
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	18.Warranty		42
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12	10 - START-UP AND OPERATION		43
12	1.	Switching on the appliance	43
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	2.	How to read the display temperature	43
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	3. Adjusting heating water temperature with an outdoor probe connected		43
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	4. Adjusting domestic hot water temperature (if a storage tank with
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		sensor and 3-way valve is installed)	43
15	5.	Working the boiler	43
15	6.	Reset function	43
	7.	Switching off	43
16	8.	Indicator LEDs and faults	44
16	11 - CHECKS, ADJUSTMENTS AND FAULT FINDING		46
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16	1.	Checking appliance operation	46
16	2.	Appliance modes of operation	46
16	3.	Selector switch in the off/stand by position	46
16	4.	On-board functions	46
16	5.	Heating mode	46
16	6.	DHW mode	46
16	7.	Boiler fan speeds	47
	8. Checking the CO2 and adjusting the gas valve		47
16	9.	Gas valve maximum setting	47
17	10. Gas valve minimum setting		47
17	11. Combustion analysis test		47
17	12. External faults		47
17	13. Electrical checks		48
17	14. Component values & characteristics		48
	15. Boiler configuration		48
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	16. Setting the outdoor reset curve with outdoor sensor		49
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	17. Fault codes		51
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17	12 - SERVICING INSTRUCTIONS		52
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18	1.	General	52
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	2.	Routine annual servicing	52
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	3.	Replacement of components	52
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	4.	Component removal procedure	52
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22	13 - LPG INSTRUCTIONS		56
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	PROPANE GAS		56
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24	14 - EXPLODED DIAGRAMS		59
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25	IMPORTANT INSTRUCTIONS FOR THE
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	COMMONWEALTH OF MASSACHUSETTS		64
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26	LIMITED PARTS WARRANTY		65
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1.	Condensate Connection	34	START-UP CHECKLIST FOR FAN-ASSISTED
7 - ELECTRICAL CONNECTIONS		34	RAYPAK PRODUCTS	67
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		37
14. Remote control connection		37
WIRING FUNCTIONAL DIAGRAM		38
8 - START-UP PROCEDURE		39

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