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.
