Raypak 85, 120 manual Introduction, General layout Fig

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5 - INTRODUCTION

The XPak boiler is a wall hung, fan assisted, direct vent, heating boiler only. These boilers – by design – incorporate electronic ignition, circulating pump, pressure relief valve, pressure gauge, and automatic bypass.

As supplied, the boiler will automatically modulate to provide central heating outputs between 25,600 - 87,000 Btu/hr (7.5-25.5 kW) - XPak 85 and 27,300 - 119,500 Btu/hr (8-35 kW) XPak 120.

IMPORTANT

It is the law that all gas appliances are installed by a competent person.

It is in your own interest and that of safety to ensure that the law is complied with.

•The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

•The installation should conform with CGA B149 INSTALLATION CODE and/or local installation Code, plumbing or waste water codes and other codes as applicable.

•Clearances from combustible material must be strictly adhered to.

•Manufacturers instructions must NOT be interpreted in anyway as overriding statutory obligations.

The XPak family comprises a range of high-efficiency hot water boilers with outputs ranging from 87,000 Btu/hr (25.5 kW) to 119,500 Btu/hr (35 kW). Each appliance is provided with a fan powered flue outlet with an annular co-axial combustion air intake that can be rotated – horizontally – through 360 degrees for various horizontal or vertical applications. The XPak can also be used with two pipe flue vent system. These appliances are designed for use with a sealed system only; consequently they are not intended for use on open vented systems.

This booklet is an integral part of the appliance. It is therefore necessary to ensure that the booklet is handed to the person responsible for the property in which the appliance is located/ installed. A replacement copy can be obtained from Raypak customer services.

General layout (Fig. 1)

1Water pressure switch

2Pump

3Bottom auto air vent (AAV)

4Gas injector

5Condense trap

6Return sensor

7H stamp main heat exchanger

8Main heat exchanger

9Flue thermostat

10Flue sensor

11Flue gas analysis test point

12Flue outlet & air intake

13Blocked flue switch

14Top automatic air vent

15Flow sensor

16High limit thermostat

17Ignition transformer

18Sensing Electrode

19Spark Electrode

20Top automatic air vent drain pipe

21Condensate level sensor

22Cylindric Burner

23Fan assembly

24Mixer

25Gas modulator coil

26Gas valve

27Pressure relief valve

RBoiler IN connection F Boiler OUT connection G Gas connection

P Pressure relief valve drain C Condensate drain pipe

8

 

 

XPAK 85

R

F

G

P

 

 

 

 

 

 

C

 

XPAK 120

R

F

G

P

Fig. 1

 

 

C

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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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