Raypak 85, 120 manual LPG Instructions, Propane GAS, GAS Supply Installation

Page 56

13 - LPG INSTRUCTIONS

This instruction must be retained adjacent to the boiler as they contain important details about the conversion made.

WARNING: This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in this instructions is not followed exactly, a fire, an explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life. The qualified service agency is responsible for the proper installation of this kit.The installation is not proper and complete until the operation of the converted appliance is checked as specified in the

manufacturer’s instructions supplied with the kit.

The XPak boiler is factory supplied to use natural gas. The boiler can use also LPG gas by installing a kit (supplied with every unit). The conversion to LPG is possible by:

1.Install the new gas injector

2.Modify the fan speed according the data in the table.

The kit is composed by:

1.Injector black coating (to be recognized from the natural gas that is not black coated)

2.Relative gas sticker (red color) to be attached under the boiler instead of the natural gas sticker (yellow color factory installed)

3.Instruction of the kit

4.LPG label to be affixed on the boiler casing and completed in by the organization making this conversion.

Operations for conversion

1.Switch off the boiler

2.Change the gas injector

3.Apply the red sticker

4.Switch on the boiler

5.Set the new fan speed

6.Fill the final part of this instruction

GAS SUPPLY

The gas supply must be connected to the boiler by a competent LPG installer and must be of sufficient size to supply the boiler at its maximum output. An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and any other appliances that it serves.

GAS SUPPLY INSTALLATION

The entire installation including the meter must be purged and checked for gas tightness.

CONVERTING THE BOILER GAS TYPE

To convert the boiler to another gas type it is necessary to change the gas injector, adjust the fan speed and the gas valve.

NOTICE: The gas valve sticker “WARNING: VALVE IS NOT FIELD SERVICEABLE” means the valve can be adjusted but not disassembled.

LPG INSTRUCTIONS

PROPANE GAS:

CAUTION: The gas supply shall be shut off prior to disconnecting the electrical power, before proceding with the conversion.

Installation Codes

Installations must follow these codes:

•Local, state, provincial, and national codes, laws, regulations and ordinances

•National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition (NFGC)

•For Canada only: CAN/CSA B149 Natural Gas and Propane Installation Code and CSA C22.1 C.E.C. Part 1 (C22.1)

WARNING: XPak boilers are shipped ready to fire natural gas ONLY. You must install the propane orifice and regulate the gas valve if the boiler will be connected to propane. Failure to comply could result in severe personal injury, death or substantial property damage.

Pipe sizing for natural gas

Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

Propane supply pressure requirements

1.Adjust propane supply regulator provided by gas supplier for 13" w.c. maximum pressure.

2.Pressure required at gas valve inlet pressure port: Maximum: 13" w.c. with no flow (lockup) or 8" w.c. minimum with boiler operating

CHANGE THE GAS INJECTOR Slacken and unscrew upper gas valve pipe; locate and remove the two screws shown as (A). Locate and remove the natural gas injector

(B)inside the pipe, insert the LPG injector (black coating). Replace in the reverse order. Check and adjust burner pressure settings.

WARNING:

A gas tightness check must be carried out if any gas carryng components have been removed, replaced or disturbed.

Fig. 1

CHECKINGTHE RELATIONSHIP OF THE IGNITER TO MAIN BURNER

Remove the burner assembly as indicated in the boiler manual “Servicing instructions”.

Check the distance between the burner and the two electrodes according the distances indicated in Fig. 1A. Replace in the reverse order.

Fig. 1A

B

A

0

 

 

 

.

 

 

 

(8

 

 

 

 

.

 

 

 

 

35”±0

 

 

9

 

 

 

 

mm

.

 

 

 

 

 

 

 

039”

 

±

 

 

1)

 

 

 

 

.039”

1)

.41”±0

±

 

 

 

 

mm

 

 

3

 

 

0 .

 

 

 

(10

 

 

 

 

56

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Contents Page About these instructions About the XPakContents You must also observe PAY Attention to These TermsFollowing instructions must be observed 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 InstallationPrepare Xpak Location 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 combustionBoiler Supply Vent SystemsFlue GAS System Installations1 Canadian Installations2 Minimum Clearances from VENT/AIR Inlet TerminationVertical Coaxial Sealed Combustion Operation TWO Pipes Single Wall Room AIR Dependent Operation 013102 Stainless steelField supplied Description Diagram Drawing TWO Pipes Single Wall = total intake length = Connecting the Condensate Water Drain Electrical ConnectionsExternal Wiring External Wiring LimitationsConnecting Thermostat Appliance Terminal BlockLow Terminal Strip DetailsHigh Outdoor Sensor Connection WAY Valve Wiring ConnectionRemote Control 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 SystemInstructing the User WarrantyFinal Checks Switching on the Appliance Reset FunctionSwitching OFF START-UP and OperationRed indicator LED Fig Indicator Leds and FaultsGreen 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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