Raypak 120, 85 Appliance Terminal Block, External Wiring Limitations, Connection MAX. Length

4. CASING REMOVAL (Fig. 33)

To gain internal access to the appliance you must first remove the casing, proceed as outlined below:

-remove the 3 screws (B) located at the Left/Right/Front of the underside of the casing

-lift the casing upward to disengage it from the top locating hooks and then remove

-store the casing and screws (B) safely until required. Re-fit in the reverse order.

5. APPLIANCE TERMINAL BLOCK

The appliance terminal block is located on the rear of the control panel. Remove the casing. Gently pull the control panel forwards and down. Locate the terminal block cover (see Fig. 34).

NOTICE: The appliance comes with a factory installed jumper for room thermostat connection to allow basic operation of the boiler via the mode selector switch. If it is anticipated that external controls will be required please refer to the wiring diagrams (remove room thermostat jumper if there is the remote control installed on the low voltage terminal strip - M4 Fig. 35).

External connection board connections

Make all electrical connections inside the external connection box.

- Open the cover of the external connection box (Fig. 34).

Connecting incoming power

The boiler must be electrically grounded in accordance with local codes, or in absence of local codes, with the National Electrical Code, ANSI/INFPA 70 and/or the CSA C22.1, Electrical Code.

Boiler terminal strip (Fig. 35)

The XPak terminal strip is divided in two separated area: low voltage and high voltage area.

The high voltage area is dedicated to:

-connections incoming power: ground neutral line, a fuse (4A) is factory fit directly on the terminal strip, 3 pins - M3

-connection for 3-way DHW valve (field supplied) 3 pins - M3a The low voltage area is dedicated to:

-external sensor (2 pins - M4)

-remote control (2 pins - M4)

-DHW tank sensor (2 pins - M4a)

-DHW tank thermostat (2 pins - M2)

-Room thermostat (2 pins - M4a) factory jumper

-External alarm (3 pins - M3b) factory jumper

6.CONNECTING THE ELECTRICAL SUPPLY (120V) Unhook and remove the terminal block cover (120V). Pass the cable through the cable anchorage point on the control panel. Pass the cable through the Strain Relief Bushings (field supplied) (Fig. 39).

The boiler is equipped with 4 holes in the lower support .

- Chose the circle holes in the case of using Heyco-Flex Metallic (SR 7K-2) (Fig. 39 ref. 2).

- Chose the non-circle holes in the case of using Strain Relief Bushings (1/2” HFC-Z 1/2) (Fig. 39 ref. 1).

Connect the supply cable wires (LIVE, NEUTRAL & GROUND) to their corresponding terminals (L, N & G) on the appliance - 120V - terminal block. When connecting the GROUND wire, ensure that it’s left slightly longer (about 1 in (20 mm)) that the others, this will prevent strain on the GROUND wire should the cable become taut.

Do not remove the link wire unless additional external controls are to be fitted. The securing screw on the cable anchorage should now be tightened (Fig. 37). This must be done before the control panel is reinstalled in the upright position. The appliance casing, screws and lower cover can now be reinstalled.

NOTICE: It is the installer’s responsibility to ensure that the appliance is properly grounded.

Raypak cannot be held responsible for any damages or injuries caused as a result of incorrect ground wiring.

7. EXTERNAL WIRING

The appliance comes with a factory installed room thermostat link to allow basic operation of the boiler via the mode selector switch. If external controls are to be added to the system, they must be connected to the appliance as shown in the following diagrams. For advice on controls that are not featured in this book, please contact Raypak technical department.

8. EXTERNAL WIRING LIMITATIONS

Any external wiring must remain within the limits as detailed in the table below

CONNECTION	MAX. LENGTH
Outdoor air sensor	100 ft (30 metres)
Room thermostat	100 ft (30 metres)
Remote control connection	100 ft (30 metres)

9. CONNECTING THERMOSTAT

1.Connect room thermostat or end switch, terminal strip is 24V (Fig. 35 ref. M4a)

2.Install thermostat on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, direct sunshine or fireplaces.

10. OTHER DEVICES

Contact Raypak technical department should you require more specific information on the suitability of a particular control. Further guidance on the recommended practice for the installation of external controls, can be found.

IMPORTANT

-The boiler must always be supplied with a permanent 120V electrical supply.

-Always remove the link on M4a terminal strip on the appliance low voltage 24V terminal strip whenever additional controls are connected to the appliance.

-Do not connect any controls or auxiliary equipment to the 24V terminal strip, other than that approved/supplied by the manufacturer.

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