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INSTALLATION & OPERATING
Models
88AR–398A
Type H
WARNING: If the information in these instructions
are not followed exactly, a fire or explosion may
result causing property damage, personal injury or
death.
FOR YOUR SAFETY: Do not store or use gaso-
line or other flammable vapors and liquids or other
combustible materials in the vicinity of this or any
other appliance. To do so may result in an explo-
sion or fire.
WHAT TO DO IF YOU SMELL GAS:
•
Do not try to light any appliance.
•
Do not touch any electrical switch; do not use
any phone in your building.
•
Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
•
If you cannot reach your gas supplier, call the
fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas suppli-
er.
Catalog No. 1000.66B
INSTRUCTIONS
Effective: 06-01-16
®
®
C
US
AVERTISSEMENT: Assurez-vous de bien suivre
les instructions données dans cette notice pour
réduire au minimum le risqué d'incendie ou
d'explosion ou pour éviter tout dommage matériel,
toute blessure ou la mort.
Ne pas entreposer ni utilizer d'essence ou ni
d'autres vapeurs ou liquids inflammables à proim-
ité de cet appareil ou de tout autre appareil.
CE FAIRE SI VOUS SENTEZ UNE ODEUR
DE GAS:
•
Ne pas tenter d'allumer d'appareil.
•
Ne touchez á aucun interrupteur; ne pas vous
server des téléphones se trouvant dans la
bâtiment.
•
Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivre les instructions
du fournisseur.
•
Si vous ne pouvez rejoinder le fournisseur,
appelez le service es incendies.
L'installation et l'entretien doivent être assurés par
un installeur qualifié ou par le fournisseur de gaz.
Replaces: 12-08-15
P/N 241556
Rev. 3
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Summary of Contents for Raypak 88AR–398A
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS ® Models 88AR–398A Type H ® AVERTISSEMENT: Assurez-vous de bien suivre les instructions données dans cette notice pour WARNING: If the information in these instructions réduire au minimum le risqué d’incendie ou are not followed exactly, a fire or explosion may d’explosion ou pour éviter tout dommage matériel, result causing property damage, personal injury or toute blessure ou la mort.
- Page 2 Rev. 3 reflects the following: Changes to: Minor changes to pages 8, 17, 22, 29, 37, 38, 39, 40, 52, 55, 58, 59, 66 and 67. Updated Wiring Diagram on page 47. Additions: Information under Condensate Management on page 37. Deletions: Information under Ignition Control Functions on page 39.
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Page 3: Table Of Contents
CONTENTS WARNINGS Outdoor Reset Concept WIRING DIAGRAM Pay Attention to These Terms BEFORE INSTALLATION Converting Natural to Propane Gas Product Receipt Gas Valve & Combustion Settings START-UP Model Identification Ratings and Certifications Pre Start-up Installations at Elevation Pre Start-up Check Component Locations Initial Start-up General Information... -
Page 4: Warnings
WARNING: This appliance produces condensate from the flue products that is acidic and highly corrosive. Raypak recommends the use of a WARNING: Vent connectors serving any other condensate neutralizer kit to avoid long-term appliances shall not be connected into any portion of... -
Page 5: Before Installation
Raypak repre- sentative or visit our website at www.raypak.com. Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment. -
Page 6: Model Identification
Fig 1: Boiler Carton Contents ASME parts not manufactured and/or approved by Raypak will instantly void the ASME and CSA ratings Items Included: of the vessel and any Raypak warranty on the 1. (1) XPak FT Boiler vessel. -
Page 7: Component Locations
Component Location Fig 2: Component Locations General Information Minimum AFUE Rating Gas conn. (NPT) Vent Size (inches) Water Model Operating Input (MBH) Conn. Input Flue Intake (NPT) (MBH) 88AR 17.0 12.0 1” ½” ½” 2”/3”** 2”/3”** 108AR 22.0 13.0 1” ½”... -
Page 8: Boiler Dimensions
Dimensions GAS SUPPLY CONNECTION 3.79 FLUE OUTLET WATER INLET AIR INLET CONDENSATE WATER OUTLET OUTLET Fig 3: Boiler Dimensions Model 88AR/ 16.4 35.8 16.5 108AR 198AR/ 18.6 36.2 19.4 10.0 11.3 12.3 278AR 398A 21.4 38.6 22.1 10.1 12.0 13.0 15.3 Table B: Basic Data... -
Page 9: Time/Temperature Relationships In Scalds
INSTALLATION Boiler Water Volume Model No. Installation Codes (gallons) Installations must follow these codes: • Local, state, provincial, and national codes, laws, 88AR regulations and ordinances 108AR • National Fuel Gas Code, ANSI Z223.1/NFPA 54 – 198AR latest edition (NFGC) •... -
Page 10: Equipment Room
Fig 4: Wall Mount Installation Clearances Equipment Room Indoor Installations Install CO detectors per local regulations. Boiler When installed according to the listed minimum clear- requires yearly maintenance, see chapter “Checks, ances from combustible construction, these boilers adjustments and fault finding”. can be serviced without removing permanent structur- al construction around the unit. - Page 12 Fig 7: Two Vertical Air Ducts - Floor Fig 8: Single Air Duct Fig 10: Two Horizontal Air Ducts Fig 9: Two Vertical air Ducts - Ceiling...
- Page 13 Fig. 11: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2 m) below or to side Clearance to window or door that may be of opening;...
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Page 14: Direct Vent
4. In cold climates, and to mitigate potential freeze- ing of all equipment in the enclosure. up, Raypak highly recommends the installation of a motorized sealed damper on the air intake to 2. One permanent opening, commencing within 12 prevent the circulation of cold air through the boiler in. -
Page 15: Water Piping
The heat exchanger is ASME certified for 80 PSI The duct can also “goose neck” through the roof. maximum working pressure. However, Raypak does The duct is preferred to be straight down 18 in. recommend hydrostatic testing of the piping connec- (450 mm) from the floor, but not near piping. -
Page 16: Hydronic Heating
System Sensor Installation Leaks must be repaired at once to prevent damage to the heater. NEVER use petroleum-based stop-leak compounds. The System Sensor (S3) is required for all selectable modes unless the unit’s firing rate will be controlled by To perform hydrostatic test: an external source such as our Temp Tracker MOD+ Hybrid sequencer. -
Page 17: Applications And Modes
Applications & Modes Pump (P1) and System Pump (P2) delay “off” as user- defined in the ADJUST menu. The System Pump (P2) The VERSA IC Control system is designed for a wide runs whenever the system is enabled for heating and range of applications. -
Page 18: Mode 1 Water Plumbing
Fig 13: MODE 1 - Single Boiler - Primary/Secondary Piping... -
Page 19: Mode 2 Water Plumbing
Fig 14: MODE 2 - Single Boiler - Primary/Secondary Piping with Indirect DHW on System Loop... -
Page 20: Mode 3 Water Plumbing
Fig 15: MODE 3 - Single Boiler - Primary/Secondary Piping with Indirect DHW on Boiler Loop... -
Page 21: Gas Supply
Gas Supply DANGER: Make sure the gas on which the unit will operate is the same type as specified on the rating plate. Gas piping must have a sediment trap ahead of the boiler gas controls, and a manual shut-off valve lo- cated outside the boiler jacket. -
Page 22: Gas Supply Pressure
Electrical Power Connections Gas Supply Pressure A minimum of 4.5 in. WC upstream gas pressure Installations must follow these codes: under full load and a maximum gas supply pressure setpoint of 10.5 in. WC under load and no-load condi- • National Electrical Code and any other national, tions for natural gas. -
Page 23: Making The Electrical Connections
Check the Power Source NOTE: Minimum 18 AWG, 105°C, stranded wire must be used for all low voltage (less than 30 volts) external connections to the unit. Solid conductors should not be used because they can cause excessive tension on contact points. Install conduit as appropriate. -
Page 24: Field Wiring Connections
Field Wiring Connections DANGER: SHOCK HAZARD Make sure electrical power to the boiler is disconnect- ed to avoid potential serious injury or damage to components. CAUTION: Wiring errors can cause improper and dangerous operation. See the wiring diagram in this manual. -
Page 25: Heating System Sensor Installation
Heating Sensor Installation 3. Use a minimum 18 AWG wire for runs of up to 150 feet. 1. Only use the System sensor provided with the unit. 4. Mount the outdoor sensor on an exterior surface of the building, preferably on the north side in an 2. - Page 26 Drive (UP) input and a Target Temperature or against, high voltage (120 volt or greater) (DOWN) setpoint. wiring. Raypak recommends that the total maxi- mum length of each set of communication bus 3. For a 4-20 mA application, refer to the VERSA IC cables not exceed 200 feet.
- Page 27 Cascade Follower Pump and Sensor Wiring 1. Once the primary boiler has been identified, addi- tional boilers will be designated as follower boilers. Ensure DIP switch 2 on each follower VERSA is set to the OFF/Down position (See Fig. 25) 2.
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Page 28: Venting
Alarm Connection WARNING: Contact the manufacturer of the vent material if there is any question about the appliance The Alarm Contacts are 3A rated dry contacts on a categorization and suitability of a vent material for normally-open relay that close during fault or lockout application on a Category IV vent system. - Page 29 Heater Combustion Combustion Exhaust Certified Vent Venting Air Inlet Air Supply Configuration Materials Category Material Vertical Venting From Inside Building (Canada Only: ULC- Horizontal Through- (Non-Direct Venting) S636 PVC and CPVC) the-Wall Venting Stainless Steel, AL29-4C, Vertical Venting Galvanized Steel, Sch 40 PVC or CPVC From Outside Building PVC, ABS,...
- Page 30 8. Terminate vent at least 1 ft above grade, including 11. DO NOT extend exposed vent pipe outside of normal snow line. building beyond the minimum distance required for the vent termination. Condensate could freeze 9. Multiple direct vent installations require a 4 ft and block vent pipe.
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Page 31: Venting Installation Tips
Vent and (ft) Combustion Vertical Vent Height Vertical Air Model Certified Vent Intake Air Air Intake Inlet Max. Material Vent Size Pipe Min. Max. Length* (ft) (in.) Material (Canada Only: 88AR ULC-S636 PVC and CPVC) 108AR Stainless Steel, Galvanized AL29-4C, Steel, 198AR ANSI/ASTM D1785... -
Page 32: Common Venting
The minimum flue pipe diameter for conventional vent- WARNING: Vent connectors serving any other ing is: 3 in. (76 mm) for Models 88AR (2” optional), appliances shall not be connected into any portion of 108AR, 198AR and 278AR, and 4 in. (102 mm) for mechanical draft systems operating under a positive Models 398A (3”... - Page 33 The drain line must Only Raypak-approved vent caps may be used. The not be allowed to freeze. Take appropriate vent terminal must be located NO CLOSER than 12”...
- Page 34 Horizontal Through-the-Wall Direct Venting (Category IV) Fig. 27: Horizontal Through-the-Wall Venting Fig. 28: Horizontal Through-the-Wall Direct Venting Fig. 29: Horizontal Through-the-Wall Venting w/ Single Termination...
- Page 35 Fig. 31: Vertical Venting w/ Stainless Fig. 30: Direct Vent - Vertical Termination Cap Fig. 32: Direct Venting w/ Elbow Terminations Fig. 33: Vertical Concentric Venting...
- Page 36 Fig. 34: Vertical - Elbow Vent Termination Fig. 35: Vertical - Stainless Termination Cap Fig. 36: Vertical - Concentric Vent Termination Fig. 37: Vertical - Stainless Tee Termination...
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Page 37: Condensate Management
10 ft of straight pipe. This will allow installation in from the boiler is acidic. Its pH is between 3.2 and 4.5. any arrangement that does not exceed the lengths Raypak recommends treating the condensate with a shown in Table M. Condensate Treatment kit (Z-12). The treatment kit is... -
Page 38: Freeze Protection
Freeze Protection CAUTION: In general, the condensate piping from To enable freeze protection, DIP switch position 7 (on the appliance must have a downward slope of ¼” per the PIM) must be turned on (UP position). This is the horizontal foot. Condensate drain traps must be default position. -
Page 39: Controls
Controls High Limit — Manual Reset Ignition Control Functions The heater is equipped with a fixed-setting manual- reset high limit temperature device as standard, set at When there is a call for heat, and all safeties are 200ºF, and it may have an additional optional closed, then the combustion air blower starts to purge adjustable manual reset high temperature device. -
Page 40: Blocked Vent Switch
Test/Reset pressure drops below the factory setting of 3.0 in. WC Low Water Cut-Off (Model 398A for natural gas or propane gas. Only) The high gas pressure switch connection mounts The standard low water cut-off automatically shuts downstream of the gas valve. Special ports are locat- down the burner whenever water level drops below the ed on the backside of the gas valve and are accessible level of the sensing probe. -
Page 41: User Interface
User Interface View Menu The user interface consists of several Menu options. Press the MENU button to scroll through the different The VIEW menu is the default menu. See Table P. It menus in the interface. Press the ITEM button to scroll displays sensor temperatures, the modulation rate of through available items within a selected menu. - Page 42 This adjustment is for various types and MIX TRIM -5 to 5 sizes of units as well as various actuator motor speeds and types supplied by Raypak MIX SPEED FAST <> MED <> SLOW This setting defines speed of response.
- Page 43 Thermal mass recovery, see Versa IC manual, catalog 5000.72. IDENTITY Identifies the unit as boiler, water heater or pool heater IGN TYPE PIM Board type ID CARD Identifies Raypak Identity Card SW ID PIM Software identification number ERROR CODE Current Error Code Table R: Boiler View Menu...
- Page 44 Monitor Menu The Monitor Menu records and displays critical Boiler information, such as, Cycle times, Run times, and Maximum/Minimum temperature readings depending on the setup. Item Application Description RUN TIME Burner 1 Burner run time (hours). Press UP/DOWN for 1 sec to clear. Cycles Burner Number of burner cycles.
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Page 45: Outdoor Reset Concept
MAX HEAT be set to OFF again by the user. (See VERSA IC Applications Guide for details.) P/N 104901 Software number of the Raypak VERSA Resets to factory settings. Press UP and DOWN for 1 second to show CLR and load DEFAULTS factory defaults to all settings. -
Page 46: Reset Ratio
RESET RATIO The control uses the four following settings to determine the reset ratio: Boiler Start (Boil START) The Boil START temperature is the theoretical boiler supply water temperature that the heating system requires when the outdoor air temperature equals the OUT START temperature setting. The Boil START is typically set to the desired building temperature. Outdoor Start (OUT START) The OUT START temperature is the outdoor air temperature at which the control provides the Boil START water temperature to the system. -
Page 47: Wiring Diagram
WIRING DIAGRAM Fig. 46: Wiring Diagram... -
Page 48: Converting Natural To Propane Gas
CONVERTING NATURAL TO PROPANE GAS ASSEMBLED ASSEMBLED ASSEMBLED ASSEMBLED ASSEMBLED ASSEMBLED ASSEMBLED ASSEMBLED ASSEMBLED These instructions are intended for boilers manufac- RUBBER R R UBBER RUBBER RUBBER RUBBER RUBBER RUBBER RUBBER ORIFICE IN ORIFICE IN ORIFICE IN ORIFICE IN ORIFICE IN ORIFICE IN ORIFICE IN ORIFICE IN... -
Page 49: Gas Valve & Combustion Settings
9. Replace the Natural Gas Venturi with the Propane Venturi (see Fig 52). HI FIRE THROTTLE HI FIRE TH HI FIRE THRO HI FIRE THROT HI FIRE THROTT HI FIRE THROTTL HI FIRE THROTTLE HI FIRE THROTTLE HI FIRE THROTTLE HI FIRE THROTTLE HI FIRE THROTTLE HI FIRE THROTTLE... -
Page 50: Start-Up
• If you cannot reach your gas supplier, call the fire NOTE: The wiring diagrams in this manual show all department. standard options. Refer to the large wiring diagram • Use only your hand to close the gas supply shutoff provided with your boiler for options installed on your valve inside the boiler. -
Page 51: Preparation
Preparation Attach Manometers to Measure Pressures 1. Turn off main gas shutoff valve. 2. Attach a 24” scale manometer to the supply pres- WARNING: Do not turn on gas at this time. sure test port on the gas valve to the heater (see Fig. -
Page 52: Start-Up
Start-Up User Test • Set DIP #1 on the VERSA IC control to “ON”. Set 1. Turn power on. USER TEST = ON in the 'ToolBox' Menu to start the user test function. 2. Turn on the boiler, approximately 45 seconds after the blower starts, the igniter should start to spark. - Page 53 Post Start-Up Check Safety Inspection 1. Verify that the boiler and heat distribution units or 1. Check all thermostats and high limit settings. storage tank are filled with water. 2. During the following safety checks leave manome- 2. Confirm that the manual air vent was opened duing ters hooked up, check and record.
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Page 54: Lighting Instructions
Fig. 55: Boiler Lighting Shut Off Instructions... -
Page 55: Troubleshooting
TROUBLESHOOTING WARNING: When servicing or replacing any XPak FT Error Codes components of this unit be certain that: • The gas is off. If any of the sensors detect an abnormal condition or • All electrical power is disconnected. an internal component fails during the operation of the Sensor Resistance Values XPak FT, the display may show an error code. -
Page 56: Xpak Ft Fault Text
WARNING: Do not use this appliance if any part 3/16” has been under water. Improper or dangerous operation may result. Contact a qualified service technician to inspect the boiler and to repair or replace any part of the boiler that has been under water prior to placing the boiler back in operation. - Page 57 LED Error Code Listing Active errors detected are indicated by LED lights on the PIM. LED Code Error Mode Recommended Troubleshooting Normal Operation Red LED steady ON, Check that the proper ID card is securely connected. Perform a ID Card Fault Green Power power and system restart.
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Page 58: Maintenance
MAINTENANCE 3. Check that area is free from combustible materi- als, gasoline, and other flammable vapors and liq- uids. Suggested Minimum Maintenance Schedule 4. Check for and remove any obstruction to the flow of combustion or ventilation air to boiler. Regular service by a qualified service agency and maintenance must be performed to ensure maximum 5. - Page 59 Monthly 2. Check drip leg and gas strainers. 1. Check flue, vent, stack, or dampers. Check flame failure detection system. (See “Post 2. Test high and low gas pressure interlocks (if Start-Up Check”.) Verify high and low fire flame equipped). (See “Safety Inspection”.) signal, compare to start-up data.
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Page 60: Combustion Chamber Cleaning Instructions
Combustion Chamber Cleaning WARNING: Instructions The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can Before beginning this procedure, you must have on hand the following items: be converted to cristobalite in very high temperature applications. The International Agency for Research –... -
Page 61: Appendix
2. You want to reduce infiltration into your building through openings around windows and doors. BLOWER/ B B LO BLOW BLOWE BLOWER BLOWER/ BLOWER/ VENTURI VENTURI You are using AL29-4C stainless steel vent pipe, which is more corrosion-resistant than standard BLOWER B B LO BLOW... -
Page 62: Important Instructions For The Commonwealth Of Massachusetts
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance (b) EXEMPTIONS: The following equipment is exempt from with regulation 248 CMR 4.00 and 5.00 for installation of 248 CMR 5.08(2)(a)1 through 4: through – the – wall vented gas appliances as follows: 1. -
Page 63: Warranty
The replacement part will be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer. -
Page 64: Start-Up Checklist
® This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. -
Page 65: Illustrated Parts List
ILLUSTRATED PARTS LIST... - Page 68 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
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