Raypak XPAK 120 Installation & Operating Instructions Manual
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Raypak XPAK 120 Installation & Operating Instructions Manual

Raypak boiler user manual
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Jorge Arturo Delgado
March 15, 2025

WE HAVE A ERROR CODE NUMBER E-42:HSI PROOF FAILURE, VERIFY HSI CURRENT. REPLACE HSI, IGN CTRL

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Summary of Contents for Raypak XPAK 120

  • Page 2 The boiler was designed for heating water for a space heating system and generating hot water e.g. for domestic purposes. The boiler can be fitted with a remote control or an On/Off room thermostat (24 V), external sensor and with a 3-way valve for DHW indirect storage tank controlled either with a tank thermostat or a tank sensor (accessories).

  • Page 3: Table Of Contents

    3. Clearances for service access 4. Residential garage installation 5. Exhaust vent and intake air vent 6. Prevent combustion air contamination 7. When removing an existing boiler from an existing common vent system PREPARE XPAK 1. Remove XPak boiler from box 2.

  • Page 4: Warnings

    DANGER: Make sure the gas on which the boiler will operate is the same type as that specified on the boiler rating plate and on the coloured sticker near the boiler gas connection. WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the boiler.
  • Page 5 – Do not use inhibitors or other additives! – The maximum permissible flow rate of the XPAK 85 this is 5.7 GPM (1,300 ltr/hr), for the XPAK 120 is 6.2 GPM (1,400 ltr/hr). – When using oxygen-permeable pipes, e.g. for floor heating systems, you must separate the system using heat exchangers.

  • Page 6: General Safety

    Purchased parts are subject to replacement only under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted and will be replaced in kind only per Raypak’s standard warranty. Model Identification The model identification number and boiler serial number are found on the boiler rating plate located on the casing right side.

  • Page 7: Regulations And Guidelines

    ASME parts not manufactured and/or approved by Raypak will instantly void the ASME and CSA ratings of the vessel and any Raypak warranty on the vessel. Altering the ASME or CSA ratings of the vessel also violates national, state, and local approval codes.

  • Page 8: Introduction

    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.
  • Page 9 Green LED lit - Boiler is working/responding to a heating/ tank request (flame ON). Red LED lit - Boiler has identified a fault and has shut down. Refer to installation instructions on how to reset. Pressure gauge - Ensure the system pressure is set correctly (minimum 7 p.s.i.

  • Page 10: Technical Data

    < 20 < 15 < 135 < 15 < 20 < 15 < 200 < 40 Tab. 1 XPak 120 27,300 - 119,500 8.0 - 35.0 27,300 - 114,300 8.0 - 33.5 26,600 - 108,300 7.8 - 31.7 92.6 6.82 1.70...
  • Page 11 Stainless Steel ASME approved extruded aluminum Groundfos UPM 15-52 Watts M350 - M2 ASME approved MVL RG 128 Honeywell VC6011 + VCZMK6000 0.20 inch (5.1 mm) 0.15 inch (3.9 mm) XPak 120 2 3/8 0.18 123.17 55.87 121.18 54.97 28.48 12.92...

  • Page 12: Principle Components

    When the appliance reaches the desired temperature the burner will shut down and the boiler will perform a three-minute post purge (timer delay). When the request for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

  • Page 13: Piping Connections

    A - boiler in connection B - boiler out connection C - gas supply connection D - pressure relief valve drain connection E - condensate connection Ø (rubber flexible) F - boiler drain valve - open-ended spanner dimension Fig. 3 4.73” 1.76” 2.55”...

  • Page 14: Dimensions And Connections

    Note: The XPak boiler has passed the zero inches vent clearance to combustibles testing requirements provided by the boiler Harmonized Standard ANSI Z21.13b 2007 – CSA 4.9b 2007 and therefore is listed for zero clearance to combustibles when vented with a single wall special venting system (AL29-4C material) or UL/ULC-listed gas vent material.

  • Page 15: Packaging And Transportation

    For other stud spacing a solid mounting surface must be provided by the installer. Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only. Mount the wall bracket using 4 5/16" lag screws. Ensure the bracket is level when mounted.

  • Page 16: Installation Prepare Xpak Location

    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.

  • Page 17: Placing The Wall-Mounted Xpak Boiler

    A hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be provided with a low water cut off device either as apart of the boiler or at the time of the boiler installation.

  • Page 18: Boiler With Dhw Tank

    DHW storage tanks. The boiler can control the DHW tank temperature directly from the boiler control panel. In case a tank sensor is installed (see boiler configuration jumpers Fig. 61) adjust the tank temperature via the DHW selector. The display shows the tank temperature if main selector in proper position.

  • Page 19: Xpak Installation Diagrams

    Under floor heating Pressure relief valve discharge pipe Indirect DHW tank 3-way valve Room thermostat (24V) 10. Remote control (Raypak) 11. Condensate drain pipe 12. Valve ball 13. Hydraulic manifold box package 14. High limit thermostat floor heating 15. Outdoor sensor 16.
  • Page 20 Fig. 9 Fig. 10...
  • Page 21 Fig. 11 Fig. 12...

  • Page 22: Making The Gas Connection

    1 1/4 1 1/2 NOTICE: The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

  • Page 23: Boiler Template

    For other stud spacing a solid mounting surface must be provided by the installer. Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only. Mount the wall bracket using 4 5/16" lag screws. Ensure the bracket is level when mounted.

  • Page 24: Combustion Air And Ventilation Openings

    It is not recommended to terminate vent above any door or window, condensate can freeze causing ice formations. Do not use chimney as a raceway if another boiler or fireplace is vented into or through chimney. All vent pipes must be glued, except for the flue gas adapter which is fix into place and the first connection to the flue gas adapter.

  • Page 25: Vent Systems

    VENT SYSTEMS 1. FLUE GAS SYSTEM Raypak coaxial PP (Polypropylene/Aluminium) concentric flue gas/fresh air systems, Raypak coaxial Alu/Alu concentric flue gas/fresh air systems and two-pipe aluminum systems for room air independent operation (sealed combustion) and air dependent operation and side wall venting are tested to ANSI ANSI Z21.13b 2007 –...

  • Page 26: Minimum Clearances From Vent/Air Inlet Termination

    4. MINIMUM CLEARANCES FROM VENT/AIR INLET TERMINATION Fig. 20 V = vent terminal X = air supply inlet Tab. 6 Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the terminal...
  • Page 27 Mounting Clip (set of 4) 3.94” (100 mm) for coaxial 90° Elbow 3” (80 mm) single wall Adaptor 80 mm > 3” (included with the boiler 1 pcs) 45° Elbow 3” (80 mm) single wall Vertical vent termination 3.28 ft (1 m) 3.94” (100 mm) coaxial Pos. 3 Straight Pipe 1.64 ft (0.5 m) 3”...
  • Page 28 Fig. 25 a = total intake length = INTAKE b = total flue length = EXHAUST Fig. 26 a = total intake length = INTAKE b = total flue length = EXHAUST TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION...
  • Page 29 Fig. 27 a = total intake length = INTAKE b = total flue length = EXHAUST Fig. 28 a = total intake length = 0 b = total flue length = EXHAUST a = 0 TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION TWO PIPES SINGLE WALL ROOM AIR DEPENDENT OPERATION...
  • Page 30 ULC/UL listed, stainless steel AL29-4C System Inc. Order Mounting Clip for each straight length of vent pipe installed, boiler can not support weight of vent system allowable material for combustion air ABS – CPVC – PVC or stainless steel - Do not exceed maximum equivalent vent length.
  • Page 31 P/N 013040 Two pipes vent adaptors (included with the boiler) P/N 013040 adaptor 80 mm > 3” (included with the boiler 1 pcs) Fig. 29 a = total intake length = INTAKE b = total flue length = EXHAUST DIAGRAM Fig.
  • Page 32 Fig. 30 a = total intake length = INTAKE b = total flue length = EXHAUST Fig. 31 a = total intake length = INTAKE b = total flue length = EXHAUST TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION...
  • Page 33 Fig. 32 TWO PIPES SINGLE WALL SEALED COMBUSTION OPERATION a = total intake length = 0 b = total flue length = EXHAUST...

  • Page 34: Connecting The Condensate Water Drain

    Some local codes may require the use of a separate neutralization unit to treat the aggressive and corrosive condensate. Raypak offers a Condensate Neutralizer Kit (Z-12 option) for use when managing the condensate is desired or required. Order part number 013141.

  • Page 35: Casing Removal

    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...

  • Page 36: Terminal Strip Details

    (Fig. 39) and pass through the strains relief (field supplied) (Fig. 39). Cable as specified in the electrical supply. 12 K Ohm B3760 Open therm plus protocol Only Raypak Part No. 013073 24 VDC Volt free (Jumper when not used) 10 K Ohm B3435 Immersion type.

  • Page 37: Outdoor Sensor Connection

    14. REMOTE CONTROL CONNECTION The boiler can be fully remoted using an open therm plus remote control (use only Raypak REC 08 Part No 013073). When the control is installed with the boiler display shows as per Fig. 36. No operation can be made on the boiler control panel once the remote control is installed.

  • Page 38: Wiring Functional Diagram

    WIRING FUNCTIONAL DIAGRAM Fig. 40...

  • Page 39: Start-Up Procedure

    8 - START-UP PROCEDURE There are several steps involved in starting up the boiler. Fig. 41...

  • Page 40: Commissioning

    5. PURGE AIR FROM BOILER MANUAL AIR RELEASE (Fig. 42) When the boiler has been filled for the first time or the system has been drained and refilled, it will be necessary to release any air that may have become trapped within the appliance heat exchanger.

  • Page 41: Check Thermostat Circuit(S)

    Allow the boiler to cycle. 8. TESTING FOR GAS LEAKS Prior to start-up of the boiler you must check the external tightness of the gas supply valve and confirm this in the start-up report. Inspect the entire installation including the gas meter.

  • Page 42: Final Checks

    SOUNDNESS. - REATTACH APPLIANCE CASING. - COMPLETE CHECKLIST Complete details of the boiler, controls, installation and commissioning in the checklist at the back of this book. It is important that the checklist is correctly completed and handed to the user. Failure to install and commission the appliance to the manufacturers instructions may invalidate the warranty 17.

  • Page 43: Start-Up And Operation

    Pump cycle mode: when power is restored to the boiler and/ or the boiler is powered for the first time, the boiler will enter a 2- minute purge cycle whereby only the pump will run for 15-seconds then off for 15-seconds and will not “fire”...

  • Page 44: Indicator Leds And Faults

    - circulator anti-block: if the boiler remains inactive, the circulator performs a 30-second operating cycle every 24 hours. If the boiler is planned not to be used for a long period, proceed as follows: - move the function selector to OFF-RESET - turn the main system switch to “off”...
  • Page 45 (alarm code AL91) after 2500 hours of working in particular conditions. After the heat exchanger cleaning (using the cleaning kit – Raypak Part No. 013142F) it is necessary to reset the hour meter with the...

  • Page 46: Checks, Adjustments And Fault Finding

    75% of the MAX Heating (set by the corresponding HTG trimmer) for a period of 15 minutes. The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow temperature sensor, consequently a high temperature at the flow sensor results in a lower fan speed.

  • Page 47: Gas Valve Minimum Setting

    ATTENTION Gas type and appliance fan speed (output) must be set according to the specific appliance specification. Raypak accepts no responsibility if the gas type and/or fan speed is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge.

  • Page 48: Electrical Checks

    120VAC. If so proceed to next stage. - Connect test leads between the Neutral & Ground connections at the boiler terminal strip (Fig. 35). The meter should read less than 1 VAC. If so polarity is correct. REVERSED POLARITY OR SUPPLY FAULT...

  • Page 49: Setting The Outdoor Reset Curve With Outdoor Sensor

    (0 = 68°F (20°C) for DAY level; 61°F (16°C) for NIGHT level). If a remote control (Raypak REC 08) is installed refer to instructions for setting the outdoor sensor using.
  • Page 50 (°C) (°F) Fig. 65 (°C) (°F) Fig. 66 (°F) (°C) Fig. 67 OUTDOOR TEMPERATURE RESET CURVES OUTDOOR TEMPERATURE OUTDOOR RESET CORRECTION + 5 C - 5 C OUTDOOR TEMPERATURE NIGHT SETBACK Curva climatica GIORNO Outdoor reset - DAY Curva climatica NOTTE Outdoor reset - NIGHT OUTDOOR TEMPERATURE (°C)

  • Page 51: Fault Codes

    Check primary thermistor, check wiring Temporary Check return thermistor, check /wiring Final Reset, check boiler operation, check and/or return too high pump, ensure there is sufficient circulation around heating circuit/s Final Reset, check appliance operation, check thermistors Advice Call the Raypak technical service...

  • Page 52: Servicing Instructions

    PUMP ASSEMBLY (Fig. 69) Locate and remove the 2 securing screws (A) at the rear of the pump assembly. Disconnect the flow pipe (B, only for XPak 120) from the combustion chamber connection, slacken the pipe at the hydraulic assembly and swing/rotate clear of the pump assembly.
  • Page 53 Disconnect the electrode leads and ancillary wiring from their respective connectors. Remove the retaining screws (A) for spark and sensing electrodes and remove. Remove the retaining nut (C) for condensate sensor (D) and remove. Fig. 73 XPak 85 XPak 120...
  • Page 54 (D). Move the heat exchanger to the right and disconnect it from the flue collector (E). The heat exchanger can now be lifted up and removed from the boiler. Fig. 77: to remove the fan burner assembly (A) locate and remove the 3 external nuts (B).
  • Page 55 CONDENSATE TRAP REMOVAL (Fig. 79) Disconnect the 2 upper rubber condensate pipes (A). Remove the pin (B) that secures the trap to the air box plate. Disconnect the lower rubber condensate pipe (C) from the condensate trap. Carefully remove the condensate trap. Replace in the reverse order.

  • Page 56: Lpg Instructions Propane Gas

    13" w.c. with no flow (lockup) or 8" w.c. minimum with boiler operating 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.
  • Page 57 PCB has been replaced. ATTENTION Gas type and boiler fan speed (output) must be set according to the specific appliance specification. Raypak accepts no responsibility if the gas type and/or fan speed is not correctly adjusted according to the respective specification as detailed on the boiler data badge.
  • Page 58 2. Affix the enclosed RED color label over the existing YELLOW color label under the boiler near to the boiler gas connection. SEQUENCE OF THE IGNITION SYSTEM Switch on the boiler as follows:...

  • Page 59: Exploded Diagrams

    14 - EXPLODED DIAGRAMS Drawing 1...
  • Page 60 Drawing 2...
  • Page 61 Drawing 3 XPAK 85 XPAK 120...
  • Page 62 Drawing 4 Drawing 5 53 Drawing 5 52 Drawing 5...
  • Page 63 Control Panel Hinge Pressure Gauge Wire Harness Kit - (Includes Complete Set of Boiler Harnesses) Control Panel Fuse Kit - (Includes Complete Set of Fuses) Retainer Clip Kit - (Includes 12a {20pcs}, 12b {1 pc}, 12c {10 pcs} and 12d {10 pcs})

  • Page 64: Important Instructions For The Commonwealth Of Massachusetts

    Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...

  • Page 65: Limited Warranty

    The Applicable Warranty Period for the aluminum heat exchanger of the Boiler in a residential installation (as defined in “Additional Warranty Exclusions and Terms”, below) is twenty (20) years after the original installation date of the Boiler. During the first ten (10) years, Raypak will pay for 100% of the cost of the replacement part or repair (excluding labor and transportation costs).
  • Page 66 6. to damage, malfunctions or failures resulting from connected systems devices, such as pump or controller; 7. to damage, malfunctions or failures resulting from use of accessories or other components that are not authorized in writing by Raypak for use in conjunction with the Boiler system;...

  • Page 67: Start-Up Checklist For Fan-Assisted Raypak Products

    START-UP CHECKLIST FOR FAN-ASSISTED This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. Additionally this form will be used to record all equipment operation functions and required settings.
  • Page 68 Your XPak serial number for future reference www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468...

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Xpak 85

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