Raypak XPAK 85 User Manual
CONTENTS  
9 - COMMISSIONING  
40  
40  
40  
40  
40  
40  
40  
41  
41  
41  
41  
41  
41  
41  
41  
41  
42  
42  
1 - WARNINGS  
4
1. Check/control water chemistry  
2. Freeze protection (when used)  
3. The heating system  
PAY ATTENTION TO THESE TERMS  
4
2 - GENERAL SAFETY  
6
6
4. Initial filling of the system  
5. Purge air from boiler manual air release  
6. System drain  
TIME/TEMPERATURE RELATIONSHIPS IN SCALDS  
7. Check thermostat circuit(s)  
8. Testing for gas leaks  
3 - BEFORE INSTALLATION  
6
7
9. Initial flushing of the system  
10. Pre-operation checks  
4 - REGULATIONS AND GUIDELINES  
11. Initial lighting  
5 - INTRODUCTION  
8
10  
12  
12  
12  
12  
12  
12  
12  
13  
14  
15  
15  
12. Checking gas pressure and combustion analysis  
13. Final flushing of the heating system  
14. Setting the boiler operating temperature  
15. Regulating the central heating system  
16.Final checks  
TECHNICAL DATA  
PRINCIPLE COMPONENTS  
MODE OF OPERATION (AT REST)  
MODE OF OPERATION  
17.Instructing the user  
18.Warranty  
SAFETY DEVICES  
42  
BANNED MATERIAL STATEMENT  
MANUAL HANDLING STATEMENT  
XPAK INTERNAL HYDRAULIC CIRCUIT  
PIPING CONNECTIONS  
10 - START-UP AND OPERATION  
43  
1. Switching on the appliance  
2. How to read the display temperature  
3. Adjusting heating water temperature with an outdoor probe connected 43  
4. Adjusting domestic hot water temperature (if a storage tank with  
sensor and 3-way valve is installed)  
5. Working the boiler  
6. Reset function  
7. Switching off  
43  
43  
DIMENSIONS AND CONNECTIONS  
PACKAGING AND TRANSPORTATION  
1. Scope of delivery  
2.Transporting the boiler  
3. Boiler box content  
43  
43  
43  
43  
15  
15  
8. Indicator LEDs and faults  
44  
6 - INSTALLATION  
16  
PREPARE XPAK LOCATION  
1. Installations must comply with  
2. Before locating the XPak boiler  
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  
16  
16  
16  
16  
16  
16  
16  
16  
11 - CHECKS, ADJUSTMENTS AND FAULT FINDING  
46  
1. Checking appliance operation  
2. Appliance modes of operation  
3. Selector switch in the off/stand by position  
4. On-board functions  
46  
46  
46  
46  
46  
46  
47  
47  
47  
47  
47  
47  
48  
48  
48  
49  
5. Heating mode  
6. DHWmode  
7. Boiler fan speeds  
PREPARE XPAK  
16  
16  
17  
17  
17  
8. Checking the CO2 and adjusting the gas valve  
9. Gas valve maximum setting  
10.Gas valve minimum setting  
11.Combustion analysis test  
12.External faults  
1. Remove XPak boiler from box  
2. Placing the wall-mounted XPak boiler  
3. XPak wall mounting instructions  
4. Installation steps  
13.Electrical checks  
XPAK PIPING  
1. Relief valve  
2. Generalpipinginformation  
3. Separate low water cutoff  
4. Backflow preventer  
5. Fitting the heating circuit supply and return pipes  
6. Expansion tank and make-up water  
7. Sizing space heat system piping  
8. Boiler with DHW tank  
9. Waterside Flow (primary circuit)  
10.Proceduresummary  
17  
14.Component values & characteristics  
15.Boiler configuration  
17  
17  
17  
17  
17  
17  
17  
18  
18  
18  
18  
16.Setting the outdoor reset curve with outdoor sensor  
17.Fault codes  
51  
12 - SERVICING INSTRUCTIONS  
52  
1. General  
52  
52  
52  
52  
2. Routine annual servicing  
3. Replacement of components  
4. Component removal procedure  
11.Fill and purge heating system  
XPAK INSTALLATION DIAGRAMS  
MAKING THE GAS CONNECTION  
BOILER TEMPLATE  
19  
22  
23  
24  
13 - LPG INSTRUCTIONS  
56  
56  
PROPANE GAS  
COMBUSTION AIR AND VENTILATION OPENINGS  
INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM 24  
14 - EXPLODED DIAGRAMS  
59  
VENT SYSTEMS  
25  
1. Flue gas system  
25  
25  
25  
26  
IMPORTANT INSTRUCTIONS FOR THE  
COMMONWEALTH OF MASSACHUSETTS  
2. Boiler supply  
64  
65  
3. Installations of supplied vent components  
4. Minimum Clearances from Vent/Air Inlet Termination  
LIMITED PARTS WARRANTY  
CONNECTING THE CONDENSATE WATER DRAIN  
1. Condensate Connection  
34  
34  
START-UP CHECKLIST FOR FAN-ASSISTED  
RAYPAK PRODUCTS  
67  
7 - ELECTRICAL CONNECTIONS  
1. External connection board connections  
2. Electrical supply  
34  
34  
34  
34  
35  
35  
35  
35  
35  
35  
35  
36  
37  
37  
37  
3. Fieldwiring  
4. Casing removal  
5. Appliance terminal block  
6. Connecting the electrical supply (120V)  
7. External wiring  
8. External wiring limitations  
9. Connecting thermostat  
10.Other devices  
11.Terminal strip details  
12.Outdoor sensor connection  
13.3-way valve wiring connection  
14.Remote control connection  
WIRING FUNCTIONAL DIAGRAM  
38  
8 - START-UP PROCEDURE  
39  
3
1 - WARNINGS-  
PAY ATTENTION TO THESE TERMS  
CAUTION: This boiler requires forced water circulation when  
the burner is operating. See minimum and maximum flow rates.  
Severe damage will occur if the boiler is operated without proper  
water flow circulation.  
DANGER:  
Indicates the presence of immediate hazards which will cau-  
se severe personal injury, death or substantial property  
damage if ignored.  
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. All high voltage wires must be the same size  
(105°C, stranded wire) as the ones on the unit or larger.  
WARNING:  
Indicates the presence of hazards or unsafe practices which  
could cause severe personal injury, death or substantial  
property damage if ignored.  
CAUTION:  
Indicates the presence of hazards or unsafe practices which  
could cause minor personal injury or product or property  
damage if ignored.  
NOTE: 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. Loosen the bleed screw until water  
is released and then close.  
IMPORTANT, THERE ARE NO OTHER MANUAL AIR  
RELEASE VALVES LOCATED ON THE APPLIANCE.  
NOTICE:  
Indicates special instructions on installation, operation, or  
maintenance which are important but not related to personal  
injury hazards.  
The following instructions must be observed  
– The boiler must only be used for its designated purpose,  
observing the Installation Instructions.  
– Only use the boiler in the combinations and with the  
accessories and spares listed.  
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.  
– Other combinations, accessories and consumables must only  
be used if they are specifically designed for the intended  
application and do not affect the system performance and the  
safety requirements.  
WARNING: Should overheating occur or the gas supply valve  
fail to shut, do not turn off or disconnect the electrical supply to  
the boiler. Instead, shut off the gas supply at a location external  
to the boiler.  
– Maintenance and repairs must only be carried out by  
authorized professionals.  
WARNING: Do not use this boiler if any part has been under  
water. Immediately call a qualified service technician to inspect  
the boiler and to replace any part of the control system and any  
gas control which has been under water.  
– You must report the installation of a condensing gas boiler to  
the relevant gas utility company and have it approved.  
– You are only allowed to operate the condensing gas boiler  
with the combustion air/flue gas system that has been  
specifically designed and approved for this type of boiler.  
– Please note that local permission for the flue system and the  
condensate water connection to the public sewer system may  
be required.  
AVERTISSEMENT: En cas de surchauffe ou de non fermeture  
de la vanne d’alimentation en gaz, n’éteignez ou ne  
débranchez pas l’alimentation électrique de la chaudière.  
Coupez plutôt l’alimentation en gaz à l’extérieur de la  
chaudière.  
You must also observe:  
– The local building regulations stipulating the installation rules.  
– The local building regulations concerning the air intake and  
outlet systems and the chimney connection.  
AVERTISSEMENT: N’utilisez pas cette chaudière si une partie  
de celle-ci s’est retrouvée sous l’eau. Appelez immédiatement  
un technicien de service qualifié pour inspecter la chaudière  
et pour remplacer toute partie du système de contrôle et toute  
commande de gaz s’étant retrouvée sous l’eau.  
– The regulations for the power supply connection.  
– The technical rules laid down by the gas utility company  
concerning the connection of the gas burner fitting to the local  
gas main.  
– The instructions and standards concerning the safety  
equipment for the water/space heating system.  
– The Installation Instructions for building heating systems.  
– The boiler must be located in an area where leakage of the  
tank or connections will not result in damage to the area  
adjacent to the boiler or to lower floors of the structure. When  
such locations cannot be avoided, it is recommended that a  
suitable drain pan, adequately drained, be installed under  
the boiler. The pan must not restrict combustion air flow.  
– The boiler must be installed such that the gas ignition system  
components are protected from water (dripping, spraying, rain  
etc.) during boiler operation and service.  
WARNING: To minimize the possibility of improper operation,  
serious personal injury, fire, or damage to the boiler:  
•
Always keep the area around the boiler free of combustible  
materials, gasoline, and other flammable liquids and vapors.  
Boiler should never be covered or have any blockage to the  
flow of fresh air to the boiler.  
•
WARNING: Risk of electrical shock. More than one disconnect  
switch may be required to de-energize the equipment before  
servicing.  
– The boiler must not be installed on carpeting.  
– The boiler must only be installed on a wall.  
– Do not restrict or seal any air intake or outlet openings.  
– If you find any defects, you must inform the owner of the system  
of the defect and the associated hazard in writing.  
WARNING - CALIFORNIA PROPOSITION  
65: This product contains chemicals known to the State of  
California to cause cancer, birth defects or other reproductive  
harm.  
4
DANGER  
if flammable gas explodes.  
Beware if you smell gas: there may be an explosion hazard!  
Warning: If the information in these instructions is not followed  
exactly, a fire or explosion may result causing property  
damage, personal injury or death.  
- Do not store or use gasoline or other flammable vapors and  
liquids in the vicinity of this or any other boiler.  
What to do if you smell gas  
- Do not try to light any boiler.  
- 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 supplier.  
Observe these instructions as general warnings:  
– Chemicals used to clean the system and/or inhibit corrosion  
must be pH neutral, i.e. they should ensure that the level of the  
pH in the system water remains neutral.  
Premature failure of certain components can occur if the pH  
level in the system water is out of normal levels.  
– Raypak recommends that an inhibitor - suitable for use with  
aluminum heat exchangers - is used to protect the boiler and  
system from the effects of corrosion and/or electrolytic action.  
The inhibitor must be administered in strict accordance with  
the manufacturers instructions.  
– A properly sized expansion tank must be installed in the boiler  
system. No valve is to be placed between the boiler and the  
expansion tank.  
– When the boiler has been filled for the first time or the system  
has been drained and refilled, it will be necessary to purge  
any air that may have become trapped within the appliance  
heat exchanger.  
NOTE: Glycol in the system must not exced 40%.  
Observe these instructions for space heating water:  
– Thoroughly flush the system prior to filling.  
Only use untreated main water to fill and top off the system.  
– Do not use water softners in the system.  
– 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.  
Unsuitable heating system water promotes the formation of  
sludge and corrosion. This may damage the heat exchanger  
or affect its operation.  
– A properly sized expansion tank must be installed in the boiler  
system.  
Tools, materials and additional equipment  
For the installation and maintenance of the boiler you will need  
the standard tools for space heating, gas and water fitting.  
In addition, a handtruck with a fastening belt is very useful.  
Disposal  
– Dispose of the boiler packaging in an environmentally sound  
manner.  
– Dispose of components of the heating system (e. g. boiler or  
control device), that must be replaced, by handing them in to  
an authorized recycling facility.  
5
T I M E / T E M P E R A T U R E  
RELATIONSHIPS IN SCALDS  
2 - GENERAL SAFETY  
To meet domestic hot water use needs, the high limit safety control  
on this boiler is adjustable up to 140°F (60°C).Water temperatures  
over 125°F (50°C) can cause instant severe burns or death from  
scalds.  
The following chart details the relationship of water temperature  
and time with regard to scald injury and may be used as a guide  
in determining the safest water temperature for your applications.  
When supplying general purpose hot water, the recommended  
initial setting for the temperature control is 125°F (50°C).  
Safety and energy conservation are factors to be considered  
when setting the water temperature on the thermostat. The most  
energy-efficient operation will result when the temperature setting  
is the lowest that satisfies the needs of the application.  
Water temperature over 125°F (50°C) can cause instant severe  
burns or death from scalds. Children, disabled and elderly are at  
highest risk of being scalded.  
Water  
Time to Produce Serious  
Burn  
Temperature  
120°F  
125°F  
130°F  
135°F  
140°F  
145°F  
150°F  
155°F  
More than 5 minutes  
1-1/2 to 2 minutes  
About 30 seconds  
About 10 seconds  
Less than 5 seconds  
Less than 3 seconds  
About 1-1/2 seconds  
About 1 second  
• Feel water before bathing or showering.  
• Temperature limiting valves are available.  
NOTE: When this boiler is supplying general purpose hot  
water for use by individuals, a thermostatically controlled  
mixing valve for reducing point of use water temperature is  
recommended to reduce the risk of scald injury. Contact a  
licensed plumber or the local plumbing authority for further  
information.  
Table courtesy of The Shriners Burn Institute  
The temperature of the water in the boiler can be regulated by  
using the Raypak Remote Control REC08. To comply with safety  
regulations, the control is set when shipped from the factory.  
Maximum water temperatures occur just after the boiler’s burner  
has shut off.To determine the water temperature being delivered,  
turn on a hot water faucet and place a thermometer in the hot  
water stream and read the thermometer.  
CAUTION: Hotter water increases the risk of scalding! There  
is a hot water scald potential if the thermostat is set too high.  
WARNING: This boiler cannot supply hot water for use by  
individuals directly. A heat exchanger must be used in  
conjunction with this boiler to meet DHW needs.  
3 - BEFORE INSTALLATION  
Raypak strongly recommends that this manual be reviewed  
thoroughly before installing your XPak boiler. Please review the  
General Safety information before installing the boiler. Factory  
warranty does not apply to boilers that have been improperly  
installed or operated. (Refer to the warranty at the back of this  
manual.) Installation and service must be performed by a qualified  
installer, service agency or gas supplier. If, after reviewing this  
manual, you still have questions which this manual does not  
answer, please contact the manufacturer or your local Raypak  
representative. Thank you for purchasing a Raypak product. We  
hope you will be satisfied with the high quality and durability of  
our equipment.  
Product Receipt  
On receipt of your boiler it is suggested that you visually check  
for external damage to the shipping package. If the package is  
damaged, make a note to that effect on the Bill of Lading when  
signing for the shipment. Remove the boiler from the shipping  
packaging. Report any damage to the carrier immediately. On  
occasion, items are shipped loose. Be sure that you receive the  
correct number of packages as indicated on the Bill of Lading.  
Claims for shortages and damages must be filed with the carrier  
by consignee. Permission to return goods must be received from  
Raypak prior to shipping. Goods returned to the factory without  
an authorized Returned Goods Receipt number will not be  
accepted. All returned goods are subject to a restocking charge.  
When ordering parts, you must specify the model and serial  
number of the boiler. When ordering under warranty conditions,  
you must also specify the date of installation. 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.  
Also the boiler serial number can be found on the back page of this  
manual and inside the front control panel flap.  
6
Ratings and Certifications  
Standards:  
• Gas fired hot water boiler for either direct vent installation or for  
installation using indoor combustion air. Design according to:  
ANSI Z21.13b 2007 – CSA 4.9b 2007 – Fired low pressure hot  
water boilers. Category IV.  
• SCAQMD Rule 1146.2  
All Raypak boilers are National Board Approved, and design-  
certified and tested by the Canadian Standards Association  
(CSA) for the U.S. and Canada. Each boiler is constructed in  
accordance with Section IV of the American Society of Mechanical  
Engineers (ASME) Boiler Pressure Vessel Code and bears the  
ASME H stamp. This boiler also complies with the latest edition  
of the ASHRAE 90.1 Standard.  
WARNING:Altering any Raypak pressure vessel by installing  
replacement heat exchangers, tube bundle headers, or any  
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.  
Installations at Elevation  
Rated inputs are suitable for up to 4,500 ft elevation (see technical  
data table). Consult the factory for installations at altitudes over  
4,500 ft above sea level. No hardware changes are required to  
the boilers for installations up to 10,000 ft (adjustments may be  
required).  
4 - REGULATIONS AND  
GUIDELINES  
The installation must be conform to the requirements of the  
authority having jurisdiction or, in the absence of such  
requirements, to the latest edition of the National Fuel Gas  
Code, ANSI Z223.1. In Canada, installation must be in  
accordance with the requirements of CAN/CSA B149.1,  
Natural Gas and Propane Installation Code.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.  
Install CO detectors per local regulations. Boiler requires  
yearly maintenance, see chapter “Checks, adjustments and  
fault finding”.  
Operating Limits of the boiler:  
Max. boiler temperature:  
Max. operating pressure:  
194°F (90 °C)  
45 psi (3.1 bar)  
The hot water distribution system must comply with all  
applicable codes and regulations.When replacing an existing  
boiler, it is important to check the condition of the entire hot  
water distribution system to ensure safe operation.  
7
5 - INTRODUCTION  
XPAK 85  
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.  
R
F
G
P
C
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.  
XPAK 120  
General layout (Fig. 1)  
1
2
3
4
5
6
7
8
9
Water pressure switch  
Pump  
Bottom auto air vent (AAV)  
Gas injector  
Condense trap  
Return sensor  
H stamp main heat exchanger  
Main heat exchanger  
Flue thermostat  
10 Flue sensor  
11 Flue gas analysis test point  
12 Flue outlet & air intake  
13 Blocked flue switch  
14 Top automatic air vent  
15 Flow sensor  
16 High limit thermostat  
17 Ignition transformer  
18 Sensing Electrode  
19 Spark Electrode  
20 Top automatic air vent drain pipe  
21 Condensate level sensor  
22 Cylindric Burner  
23 Fan assembly  
24 Mixer  
25 Gas modulator coil  
26 Gas valve  
27 Pressure relief valve  
R
F
G
P
C
Boiler IN connection  
Boiler OUT connection  
Gas connection  
Pressure relief valve drain  
Condensate drain pipe  
R
G
F
P
Fig. 1  
C
8
Fig. 1A  
B
C
E
A
D
G
F
A
B
C
D
E
F
Pressure gauge  
Green led  
2-digit LED display  
Red led  
Temperature selector space heating  
Mode selector switch  
Temperature selector Domestic Hot Water  
G
Off/reset - Select this position when the boiler needs to be  
reset or switched off.  
Summer mode - The domestic hot water function provided  
by the water tank is activated. The display indicates the  
storage tank temperature (only with the external water tank  
connected with a sensor).  
Winter mode - The boiler produces hot water for heating  
and, if connected to an external water tank, it provides  
domestic hot water.The display indicates the boiler flow tem-  
perature.  
Winter mode tank temperature - The boiler produces hot  
water for heating and, if connected to an external water tank  
with a sensor, it provides domestic hot water. The display  
indicates the storage tank temperature.  
F
Temperature selector DHW- Move the temperature selector  
clockwise to increase the hot water temperature in the water  
tank or counter-clockwise to reduce the temperature (working  
only if a tank sensor is connected).  
Temperature selector Heating - Move the temperature  
selector clockwise to increase the heating temperature or  
counterclockwise to reduce the temperature.  
2-digit LED display - Displays the temperature according  
the mode selector switch. During a fault condition, the  
appropriate code will be displayed (refer to the installation  
instructions regarding fault codes).  
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. (0.45 bar))  
9
Tab. 1  
TECHNICAL DATA  
XPak 85  
XPak 120  
Input - Output  
Input - (0 - 2000 ft / 0 - 610 m)  
Btu/hr  
kW  
25,600 - 87,000  
7.5 - 25.5  
27,300 - 119,500  
8.0 - 35.0  
Input - (2000 - 4500 ft / 610 - 1375 m)  
Output (176°F - 86°F / 80°C - 30°C)  
Btu/hr  
kW  
25,600 - 82,900  
7.5 - 24.3  
27,300 - 114,300  
8.0 - 33.5  
Btu/hr  
kW  
25,200 - 76,600  
7.4 - 22.5  
26,600 - 108,300  
7.8 - 31.7  
Energy Guide  
AFUE  
%
91.8  
92.6  
Gas  
Gas supply pressure Natural Gas (A)  
in w.c.  
kPa  
6.82  
1.70  
3.5  
Min. gas supply pressure Natural Gas (A)  
Max. gas supply pressure Natural Gas (A)**  
Gas supply pressure LPG (E)  
Min. gas supply pressure LPG (E)  
Max. gas supply pressure LPG (E)**  
Gas Rate max natural gas (A)  
Gas Rate min natural gas (A)  
Gas Rate max LPG (E)  
in w.c.  
kPa  
0.87  
10.5  
2.62  
11  
in w.c.  
kPa  
in w.c.  
kPa  
2.75  
8
in w.c.  
kPa  
1.99  
13  
in w.c.  
kPa  
3.24  
ft3/hr  
sm3/hr  
ft3/hr  
sm3/hr  
lbs/hr  
kg/hr  
lbs/hr  
kg/hr  
87.77  
2.49  
26.14  
0.74  
4.02  
1.82  
1.20  
0.54  
121.01  
3.43  
28.01  
0.79  
5.55  
2.52  
Gas Rate min LPG (E)  
1.28  
0.58  
System Data  
Minimum relief valve capacity  
Maximum operating pressure  
lbs/hr  
p.s.i.  
bar  
87  
119.50  
45  
3.1  
6.52  
0.45  
15  
Minimum operating pressure  
Recommended system pressure  
Boiler max flow rate (ltr/hr)  
p.s.i.  
bar  
p.s.i.  
bar  
1
GPM  
ltr/hr  
in w.c.  
mbar  
CAN G  
USG  
ltr  
5.72  
1,300  
60.22  
150  
0.70  
0.85  
3.2  
6.2  
1,400  
44.11  
110  
0.84  
1.0  
3.8  
Pump residual head at max flow rate  
Primary water content  
Boiler Water Temperature  
Adjustable high limit range - high temp. (radiators heating)* °F  
°C  
104 - 176  
40 - 80  
68 - 113  
20 - 45  
95 - 140  
35 - 60  
194  
Adjustable high limit range - low temp. (space heating)*  
°F  
°C  
°F  
°C  
°F  
°C  
DHW production - set point  
Max boiler temperature  
90  
Electric Data  
Electric rate voltage  
Current less than  
V - Hz  
A
120 - 60  
1.19  
133  
1.25  
141  
Electric consumption (pump included)  
Electrical protection rating  
Fuses  
W
IP  
IPX5D  
4 - 250  
A - VAC  
Flue Gas Values  
CO2 setting natural gas (A)  
CO2 setting LPG (E)  
NOx @ max (A)  
%
%
8.5%  
10.0%  
ppm  
ppm  
ppm  
ppm  
ppm  
ppm  
ppm  
ppm  
< 20  
< 15  
< 135  
< 15  
< 20  
< 15  
< 200  
< 40  
< 20  
< 15  
< 170  
< 25  
< 20  
< 20  
< 220  
< 35  
NOx @ min (A)  
CO @ max (A) without air  
CO @ min (A) without air  
NOx @ max (E)  
NOx @ min (E)  
CO @ max (E) without air  
CO @ min (E) without air  
10  
XPak 85  
XPak 120  
Boiler flue gas connection  
in  
2 3/8  
60  
2 3/8  
60  
mm  
Combustion air connection outer dia.  
Free fan unit feed pressure  
in  
4
4
mm  
100  
100  
0.18  
45  
in w. c.  
Pa  
0.26  
65  
Flue gas mass flow rate at rated full load (A)  
Flue gas mass flow rate at rated full load (E)  
Flue gas mass flow rate at rated partial load (A)  
Flue gas mass flow rate at rated partial load (E)  
lbs/hr  
kg/hr  
lbs/hr  
kg/hr  
lbs/hr  
kg/hr  
lbs/hr  
kg/hr  
90.39  
41  
123.17  
55.87  
121.18  
54.97  
28.48  
12.92  
27.99  
12.70  
0.41  
1.56  
0.16  
0.6  
88.89  
40.32  
26.58  
12.06  
25.08  
11.88  
0.37  
1.41  
0.13  
0.48  
186.0  
86.0  
163.0  
73.0  
194.0  
90.0  
Condensate flow rate (A) at max - 122/86 °F (50/30°C)USG/hr  
ltr/hr  
Condensate flow rate (A) at min. - 122/86 °F (50/30°C) USG/hr  
ltr/hr  
Flue temperature at boiler return temp. 86°F/30°C  
at full load (A)  
°F  
°C  
°F  
°C  
°F  
°C  
170.0  
77.0  
165.0  
74.0  
186.0  
86.0  
Flue temperature at boiler return temp. 86°F/30°C  
at partial load (A)  
Flue temperature at boiler return temp. 140°F/60°C  
at full load (A)  
Max flues length de-rate less 2%  
Max length horizontal coaxial 60/100 mm  
ft  
6.5  
2
40+40  
12+12  
6.5  
2
16+16  
5+5  
m
ft  
Max total length 2 pipe 3” (80 mm) (air + flues)  
m
Max flues length de-rate less 5%  
Max length horizontal coaxial 60/100 mm  
ft  
26  
7.8  
130+130  
40+40  
26  
7.8  
115+115  
35+35  
m
ft  
Max total length 2 pipe 3” (80 mm) - (air + flues)  
m
Minimum Clearances To Combustibles  
Top - front - rear  
in  
0 - 0 - 0  
0 - 0 - 0  
0 - 0 - 0  
0 - 0 - 0  
mm  
in  
Left - right - vent pipe  
mm  
Recommended Minimum Service Clearances  
Top - front - rear  
in  
12 - 24 - 0  
300 - 600 - 0  
1 - 1  
mm  
in  
Left - right  
mm  
25 - 25  
Pipe Connections  
Gas supply connection (shut off valve)  
Boiler in connection  
in  
3/4 NPT - female  
3/4 NPT - male  
3/4 NPT - male  
3/4 NPT - female  
0.825 female  
21 female  
in  
Boiler out connection  
in  
Pressure relief valve  
in  
Condensate connection diameter (rubber flexible)  
in  
mm  
in  
Boiler drain valve - open-ended wrench dimension  
7/16  
11  
mm  
Boiler Dimensions And Weight  
Height x Width x Dept  
in  
30.7 x 15.75 x 14.1  
30.7 x 17.7 x 14.1  
mm  
lbs  
kg  
780 x 400 x 358  
780 x 450 x 358  
Weight net  
73  
33  
80  
36  
Components  
Burner  
Stainless Steel  
Main heat exchanger  
Gas valve  
ASME approved extruded aluminum  
SIT 848  
Pump  
Groundfos UPM 15-52  
Groundfos UPM 15-62  
Pressure relief valve  
Fan  
Watts M350 - M2 ASME approved  
MVL RG 128  
3-way valve for DHW tank (field supply)  
Injector Natural Gas (A) Ø  
Injector LPG (E) - black coated Ø  
Honeywell VC6011 + VCZMK6000  
0.20 inch (5.1 mm)  
0.15 inch (3.9 mm)  
0.26 inch (6.7 mm)  
0.19 inch (5.0 mm)  
notes  
*See jumpers configurations for heating temperature range setting  
**If the gas supply pressure exceeds the maximum gas supply pressure value, a separate gas pressure regulator must be installed  
upstream of the heating system.  
11  
PRINCIPLE COMPONENTS  
A fully integrated electronic control board featuring electronic  
temperature control, anti-cycle control, pump over-run, actuator  
anti-block function, self-diagnostic fault indicator, full air/gas  
modulation.  
BANNED MATERIAL STATEMENT:  
No banned materials or substances have been used in the  
manufacture or production of this appliance or its inherent  
components  
- Radial aluminum heat exchanger.  
- Electronic ignition with flame supervision  
- Integral pump  
MANUAL HANDLING STATEMENT:  
CAUTION: This appliance may require 2 or more persons  
to lift or carry it to the installation location; due to the weight  
of the appliance it may be necessary for two people to lift  
and attach the appliance to its mounting. To avoid the  
possibility of injury during the installation, servicing or  
cleaning of this appliance, care should be taken when  
handling component edges.  
- Fan  
- Water pressure switch  
- Condensate level sensor  
- Pressure gauge  
- Pressure relief valve  
- Flue thermostat  
- Flue sensor  
- Blocked flue switch  
MODE OF OPERATION (AT REST)  
When the appliance is at rest and there are no requests for heating  
or hot water, the following functions are active:  
- 2-stage freeze protection system – the freeze protection system  
protects the appliance against the risk of freeze damage. The  
first stage enables activation of the pump should the tempera-  
ture of the appliance fall to 43°F (6oC). Should the first stage  
become active, the appliance will function on minimum +25%  
power until it reaches 95°F (35oC).  
- Anti-seize function – the anti-seize function enables the pump  
to be energized for short periods, when the appliance has been  
inactive for more than 24-hours.  
XPAK INTERNAL HYDRAULIC  
CIRCUIT (FIG. 2)  
MODE OF OPERATION  
top  
autoair  
valve  
flow  
temperature  
sensor  
When there is a request for heat and/or hot water, via the  
programmer/time clock and/or any external control, the pump and  
fan are started, the fan speed will modulate until the correct signal  
voltage is received at the control PCB. At this point an ignition  
sequence is enabled.  
Ignition is sensed by the electronic circuitry to ensure flame  
stability at the burner. Once successful ignition has been  
achieved, the electronic circuitry increases the gas rate to 75% of  
the MAX Heating (set by the corresponding HTG trimmer) for a  
period of 15 minutes. Thereafter, the boiler’s output will either  
increase to maximum or modulate to suit the set requirement.  
When the appliance reaches the desired temperature the burner  
will shut down and the boiler will perform a three-minute post purge  
(timer delay).  
manualair  
release  
return  
temperature  
sensor  
mainheat  
exchanger  
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.  
pressure  
relief  
valve  
SAFETY DEVICES  
bottom  
autoair  
valve  
When the appliance is in use, safe operation is ensured by:  
- a water pressure switch that monitors system water pressure  
and will de-activate the pump (when lockout condition is  
reached), fan and burner should the system water pressure  
drop below the rated tolerance;  
pressure  
switch  
- blocked flue switch that monitors flue pressure and will de-  
activate the pump (when lockout condition is reached), fan and  
burnershouldthefluepressureincreaseovertheratedtolerance;  
- fan speed sensor to ensure safe operation of the burner;  
- a high limit thermostat that over-rides the temperature control  
circuit to prevent or interrupt the operation of the burner;  
- flame sensor that will shut down the burner when no flame signal  
is detected;  
pump  
drain  
valve  
- a sensor that interrupts the operation of the appliance if the  
condensate pipe becomes blocked;  
automatic  
bypass  
- a pressure relief valve which releases excess pressure from the  
primary circuit;  
- a flue sensor that controls the flue temperature continuously  
checking to be right according the output;  
- a flue thermostat that over-rides the temperature control circuit  
to prevent or interrupt the operation of the burner.  
pressure  
reliefvalve  
Heating  
return  
Heating  
flow  
Fig. 2  
12  
PIPING CONNECTIONS (FIG. 3)  
Legend  
A - boiler in connection  
B - boiler out connection  
3/4” NPT - male  
3/4” NPT - male  
C - gas supply connection  
3/4” NPT - female  
3/4” NPT - female  
0.825” (21 mm) female  
7/16” (11 mm)  
D - pressure relief valve drain connection  
E - condensate connection Ø (rubber flexible)  
F - boiler drain valve - open-ended spanner dimension  
F
4.73”  
120 mm  
1.76”  
45 mm  
2.55”  
65 mm  
A
C
D
E
B
Fig. 3  
13  
DIMENSIONS AND CONNECTIONS (Fig. 4)  
Recommended minimum service clearances  
5-1/2”  
(140mm)  
8-5/8”  
(219mm)  
1”(25mm)  
1” (25 mm)  
14-1/8”(359mm)  
XPak85=15-3/4”(400mm)  
XPak 120 = 17-3/4” (451 mm)  
=
=
1” (25 mm)  
1” (25 mm)  
XPak 85= 3-15/16“ (97 mm)  
XPak 120= 4-1/2“ (114 mm)  
Fig. 4  
Minimum Clearances to Combustibles  
Top=0  
Front =0 AL, CL  
Rear=0  
Left=0  
Right=0  
AL = Alcove  
CL = Closet  
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. The zero inches vent clearance to combustibles  
for the XPak boiler supercedes the clearance to combustibles listing that appears on the special venting system label.  
14  
PACKAGING AND TRANSPORTATION  
1. SCOPE OF DELIVERY  
The boiler is delivered fully assembled.  
- When receiving the delivery, check if the packaging is intact.  
- Check that all the items listed in Table 2 are included in the  
delivery.  
2
2. TRANSPORTING THE BOILER  
CAUTION: The boiler may be damaged when it is improperly  
secured.  
- Only transport the boiler using the right transportation  
equipment, such as a handtruck with a fastening belt or  
special equipment for maneuvering steps.  
- During transportation the boiler must be secured on the  
transportation equipment to prevent it from falling off.  
- Protect all parts against impacts if they are to be  
transported.  
1
- Observe the transportation markings on the packaging.  
- Packaged boilers must always be lifted and carried to  
their destination by two people, or you must use a handtruck  
or special equipment to transport them to their destination.  
- Transport the boiler to the room where it is to be installed.  
3. BOILER BOX CONTENT (Table 2)  
Wall stud  
16" C/C  
4,53" Hole for 60/100mm coaxial vent  
3" vent adaptor (supplied)  
Inlet air either right or left  
1
.
5
"
i
n
s
i
d
e
3
"
3" inlet air adapter (not supplied)  
Pos. Parts  
Quantity Packaging  
Boiler bracket  
(supplied)  
XPak  
120  
Ø1/4" holes  
for 5/16" lag  
screws (4 places)  
inside 3.15"  
1
2
3
Boiler with casing  
Wall bracket  
Technical documents  
including:  
1
1
1
1 box  
Screw (2x) (fitted)  
Exhaust vent adapter (supplied)  
Screw (2x) (supplied)  
Screw (2x) (supplied)  
Inlet air adapter (supplied)  
XPak  
85  
14.17"  
16.25"  
3
XPak 120 - 17.81"  
XPak 85 - 15.75"  
C
L
Boiler outline  
CENTER LINE  
OF BOILER  
WARNING  
This boiler is heavy and awkward to lift. It is  
recommended and safer to install the boiler with two  
people. Use caution as to not drop this boiler which  
could cause personal injury. Verify that the boiler is  
securely mounted before leaving the boiler unsupervised.  
- User’s Instructions  
- Installation Instructions  
- Wall Mounting Template  
Top manual air vent drain pipe  
Gas shut off valve  
Flue gas adaptors including:  
- vent adaptor for two pipes  
vent system  
Ensure there is adequate clearances for mounting the boiler (details given in  
installation instructions).  
The wall mount bracket is designed for  
center. For other stud spacing  
the installer.  
Do not mount the boiler to  
studs only.  
Mount the wall bracket using  
when mounted.  
a
stud spacing of 16 inches from  
solid mounting surface must be provided by  
a
a
hollow wall. Be sure to mount the boiler to the  
4
5/16" lag screws. Ensure the bracket is level  
Extreme care is needed to ensure the bolts are secured in the studs.  
Hang the boiler on the bracket and secure the bottom of the boiler with two (2)  
additional lag screws.  
5.90"  
3.14"  
XPak  
120  
XPak  
120  
3.35"  
1.38"  
4
5
6
1
1
1
XPak  
85  
XPak  
85  
IN3/4" NPT male  
OUT3/4" NPT male  
Pressure relief valve drain  
3/4" NPT female  
Condensate piping flexible (supplied)  
4/5" female  
Gas shut off valve (supplied)  
3/4" NPT female  
Ø1/4" holes for earthquake restraint (2 places)  
- intake air adaptor for two pipes  
- 3” adaptor  
- 4 screws  
LPG conversion kit  
- injector black coated  
- LPG sticker  
- LPG conversion labelling  
- Conversion instructions  
4
5
7
1
Refer to Fig. 5 for Boiler box contents.  
6
7
Fig. 5  
15  
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.  
6 - INSTALLATION  
PREPARE XPAK LOCATION  
1. INSTALLATIONS MUST COMPLY WITH:  
- Local, state, provincial, and national codes, laws, regulations  
and ordinances.  
The intake and exhaust venting methods are detailed in the  
VentingSection.DonotattempttoinstalltheXPakBoilerusingany  
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.  
- National Fuel Gas Code, ANSI Z223.1 – latest edition.  
- National Electrical Code.  
- ForCanadaonly:B149InstallationCode, CSAC22.1Canadian  
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  
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.  
2. BEFORE LOCATING THE XPAK BOILER  
1. Check for nearby connection to:  
- System water piping  
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  
airwilldamagetheboiler,resultinginpossibleseverepersonal  
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.  
- 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.  
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.  
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.  
Thiswillcausefluegasspillageorappliancemalfunction, resulting  
in possible severe personal injury, death or substantial property  
damage.  
4. If the new XPak is to replace an existing boiler, check for and  
correct any existing system problems such as:  
- System leaks.  
WARNING: Failure to follow all instructions can result in flue  
gas spillage and carbon monoxide emissions, causing severe  
personal injury or death.  
- Incorrectly-sized expansion tank.  
-Lackoffreezeprotectioninheatingwatercausingsystemand  
boiler to freeze and leak.  
- Excessive glycol which will affect the boiler system operation.  
Atthetimeofremovalofanexistingboiler, thefollowingstepsshall  
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.  
3. CLEARANCES FOR SERVICE ACCESS  
a. Seal any unused openings in the common venting system.  
b. Visuallyinspecttheventingsystemforpropersizeandhorizontal  
pitchanddeterminethereisnonblockageorrestriction,leakage,  
corrosion and other deficiencies which could cause an unsafe  
condition.  
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.  
c. Insofar as is practical, close all building doors and windows and  
all doors between the space in which the appliances remaining  
connectedtothecommonventingsystemarelocatedandother  
spacesofthebuilding.Turnonclothesdryersandanyappliance  
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  
lightinginstructions.Adjustthermostatsoappliancewilloperate  
continuously.  
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:  
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.CanadianinstallationsmustcomplywithB149Installation  
Code.  
-
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.  
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.  
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.  
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.  
16  
2. PLACING THE WALL-MOUNTED XPAK BOILER  
XPak boilers are wall mounted. Use only the XPak boiler wall  
mounting instructions included in the box.  
2. GENERAL PIPING INFORMATION  
CAUTION: Use two wrenches when tightening water piping  
at boiler, using one wrench to prevent the boiler return line or  
supply line from turning. Failure to support the boiler piping  
connectionstopreventthemfromturningcouldcausedamage  
to boiler components.  
WARNING: The wall must be capable of carrying the weight  
of the boiler and its related components. The weights of the  
boiler are approximately:  
XPak 85 = 82 lbs (37 kg).  
XPak 120 = 93 lbs (42 kg).  
NOTICE: The XPak boiler control module uses temperature  
sensors to provide both high limit protection and modulating  
temperature control. The PCB also provides low water  
protection using a water pressure switch (minimum 6.5 psi  
(0.45 bar)) and blocked flue switch. Some codes/jurisdictions  
may require additional external controls for high limit and/or  
low water cutoff protection.  
Failure to comply with above could result in severe personal  
injury, death or substantial property damage  
3. XPAK WALL MOUNTING INSTRUCTIONS  
WARNING: This boiler is heavy and awkward to lift. It is  
recommended and safer to install the boiler with two people.  
Use caution as to not drop the boiler which could cause  
personal injury. Verify that the boiler is securely mounted  
before leaving the boiler unsupervised.  
3. SEPARATE LOW WATER CUTOFF  
A low water cutoff may be required by state local code or some  
insurance companies. Check code requirements before  
installation of the XPak boiler.  
If required:  
The wall must be vertically plumb and capable of carrying the  
weight of the XPak and its related components.  
- Use a low water cutoff designed for hydronic installations  
- Follow low water cutoff manufacturer’s instructions  
The building frame (studs) must be 16" on center. If not, you must  
use 1/2" minimum plywood 24" x 48", fastened with at least (14)  
#12 x 3" (3/16" x 3") round head tapping screws to the frame of the  
buildingtoprovidepropersupportfortheboiler. Alternatemethods  
of mounting must not be used. (ex. toggle bolts, hollow wall  
anchors)oranyotherfastenerotherthan#12x3"(3/16"x3")round  
head tapping screws.  
NOTICE:  
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.  
4. BACKFLOW PREVENTER  
Use a backflow preventer specifically designed for hydronic boiler  
installations. This valve should be installed on the cold water fill  
supply line per local codes.  
CAUTION: If the XPak is not vertically plumb, improper and  
unsatisfactory operation may occur. This will cause excessive  
condensation build-up causing unnecessary maintenance  
and nuisance fault codes.  
5. FITTING THE HEATING CIRCUIT SUPPLY AND RETURN  
PIPES  
4. INSTALLATION STEPS  
NOTICE:  
Prior to lifting the XPak Boiler onto the wall, use the enclosed  
template to level and locate the wall bracket. Mount the wall  
bracket using lag screws. Ensure the bracket is level when  
mounted. Extreme care is needed to ensure the bolts are secured  
in the studs. Hang the boiler on the bracket and secure the bottom  
of the boiler with two (2) additional lag screws. This will provide  
additional strength and support to the XPak boiler.  
- To protect the entire heating system Raypak recommends  
installing a filter in the return circuit. When connecting the  
boiler to an existing heating system this filter must definitely  
be installed.  
- Install shut-off valves immediately before and after the dirt  
particle filter to enable the filter to be cleaned.  
- Install a filling and drain cock in the heating system supply  
pipe if required.  
- Also install a safety valve in the system.  
XPAK PIPING  
NOTICE: When using oxygen-permeable pipes, e. g. for floor  
heating systems, you must separate the system using heat  
exchangers.  
1. RELIEF VALVE  
The XPak has a pressure relief valve factory fitted.  
Connect discharge piping to safe disposal location, following  
guidelines in the WARNING below:  
- Thoroughly flush all pipes and radiators.  
- Refer to the installation template for the pipe connection  
dimensions.  
WARNING: To avoid water damage or scalding due to relief  
valve operation:  
- Connect the pipes so that they are free from strain.  
- Discharge line must be connected to relief valve outlet and  
run to a safe place of disposal. Terminate the discharge line  
in a manner that will prevent possibility of severe burns or  
property damage should the valve discharge.  
- Discharge line must be as short as possible and be the same  
size as the valve discharge connection throughout its entire  
length.  
6. EXPANSION TANK AND MAKE-UP WATER  
1. Ensure expansion tank size will handle boiler and system  
water volume and temperature. Allow 2 gallons for the boiler  
and its piping.  
CAUTION:Undersized expansion tanks cause system water  
to be lost from relief valve and makeup water to be added  
through fill valve. Eventual failure can result due to excessive  
make-up water addition.  
- Discharge line must pitch downward from the valve and  
terminate no more than 6” (150 mm) above the floor drain  
where any discharge will be clearly visible.  
The discharge line shall terminate plain, not threaded, with  
a material serviceable for temperatures of 375 °F (190°C) or  
greater.  
2. Expansion tank must be located near to the boiler as shown  
in Piping “XPak installation diagrams”. No valve is to be placed  
between the boiler and the expansion tank.  
- Do not pipe the discharge to any place where freezing could  
occur.  
7. SIZING SPACE HEAT SYSTEM PIPING  
- Size the piping and components in the space heating system  
using recognized design methods.  
- Do not plug or place any obstruction in the discharge line.  
- Test the operation of the valve after filling and pressurizing  
system by lifting the lever. Make sure the valve discharges  
freely. If the valve fails to operate correctly, replace it with a  
new relief valve.  
NOTICE:  
- The boiler, when used in connection with a refrigeration  
system, must be installed so the chilled medium is piped  
in parallel with the boiler and with appropriate valves to  
prevent the chilled medium from entering the boiler.  
- The boiler piping system of a hot water boiler connected to  
heating coils located in air handling units where they may  
be exposed to refrigerated air circulation must be equipped  
with flow control valves or other automatic means to prevent  
gravity circulation of the boiler water during the cooling cycle.  
- For boilers installed with only a pressure relief valve, the  
separate storage vessel must have a temperature and  
pressure relief valve installed. This relief valve shall comply  
with the standard for Relief Valves for Hot Water Supply  
Systems, ANSI Z21.22/CSA4.4.  
- Failure to comply with the above guidelines could result in  
failure of the relief valve to operate, resulting in possibility of  
severe personal injury, death or substantial property damage.  
17  
8. BOILER WITH DHW TANK  
required system volume and capacity, no valve is to be placed  
between the boiler and the expansion tank.  
6. Install an Air Elimination Device on the system supply if  
required, the boiler has two auto air vents built in.  
7. Install a drain valve at the lowest point of the system.  
Note: The XPak has a proper internal drain valve. (see Fig.  
42a)  
8. The Safety Relief Valve is installed at the factory. Pipe the  
discharge of the safety relief valve to prevent injury in the  
event of pressure relief. Pipe the discharge to a maximum of  
6” (152 mm) above the floor to a drain. Provide piping that is  
thesamesizeasthesafetyreliefvalveoutlet.Neverblockthe  
outlet of a safety relief valve.  
- Connect the external hot-water tank according to the Installation  
instructions of the hot-water tank and fittings concerned.  
Domestic Hot Water Production via DHW Storage Tank  
XPak boilers can be used in conjunction with the stand-alone  
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.  
Boiler can accept also a DHW tank controlled by a thermostat  
(see boiler configuration jumpers Fig. 61), in this case the DHW  
set point can not be adjusted on the control panel but only on the  
tank thermostat (field supplied).  
Both cases the supplied water temperature to the tank is 176°F  
(80°C) and it goes ahead with priority over heating until the tank  
request is satisfied (either the sensor or the termostat open).  
The boiler can control a 3-way valve directly from the boiler control  
panel (see 3-way installations Fig. 38).  
Refer to electrical connections for 3-way valve installation.  
Size and select the DHW storage tank based on the forecast  
DHW consumption of the building in question.  
If different method of DHW production are used, the boiler flow  
temperature is set as heating mode (see boiler configuration  
jumpers Fig. 61).  
11. FILL AND PURGE HEATING SYSTEM  
CAUTION: For installation that incorporates standing Iron  
Radiation and systems with manual vents at the high points.  
Follow above section and starting with the nearest manual air  
vent, open vent until water flows out, then close vent. Repeat  
procedure, working your way toward furthest air vent. It may  
be necessary to install a basket strainer in an older system  
where larger amounts of sediment may be present. Annual  
cleaning of the strainer may be necessary.  
WARNING: Use only inhibited propylene glycol solutions  
whicharespeciallyformulatedforhydronicsystems. Ethylene  
glycol is toxic and can attack gaskets and seals used in  
hydronic systems. Glycol mixtures should not exceed 40%.  
1.Glycolinhydronicapplicationswhichisspeciallyformulated  
for this purpose includes inhibitors that prevent the glycol  
from attacking metallic system components. Make certain  
that the system fluid is checked for the correct glycol  
concentration and inhibitor level.  
2.Theglycolsolutionshouldbetestedatleastonceayearand  
as recommended by the glycol manufacturer.  
3.Anti-freeze solutions expand more than water. Allowances  
must be made for this expansion in the system design.  
9. WATERSIDE FLOW (PRIMARY CIRCUIT)  
The boiler is designed only for closed loop, forced circulation hot  
water heating systems.  
XPak is equipped with an internal 3 speed pump.  
PUMP DUTY  
Fig. 6 below shows the flow-rate available – after allowing for  
pressure loss through the appliance – for system requirements.  
When using this graph, apply only the pressure loss of the system.  
The graph is based on a 36°F (20°C) temperature differential.  
CAUTION: It is highly recommended that you carefully follow  
the glycol manufacturer’s recommended concentrations,  
expansion requirements and maintenance recommendations  
(pH additive breakdown, inhibitor reduction, etc.). You must  
carefully calculate the additional friction loss in the system as  
well as the reduction in heat transfer co-efficients; pH must be  
maintained between 6-8.  
CAUTION: The XPak should not be operated as a potable  
Hot Water Boiler. The XPak should not be operated in a open  
system.  
10. PROCEDURE SUMMARY  
1. Connect the system return marked “In”.  
2. Connect the system supply marked “Out”.  
3. Install a Back Flow preventor on the Cold Feed Make-Up  
Water line.  
4. Install a Pressure Reducing Valve if required on the Cold  
Feed Make-Up Water line, 15 PSI (1 bar) nominal on the  
system return. Check Pressure Gauge which should read  
minimum pressure of 12 PSI (0.8 bar)  
5. Install an Expansion Tank on the system supply. Consult the  
tankmanufacturer’sinstructionforspecificinformationrelating  
to expansion tank installation. Size the expansion tank for the  
XPak 120  
XPak 85  
16  
16  
15  
14  
12  
11  
15  
14  
12  
11  
10  
9
10  
9
7
7
6
5
6
5
3
2
3
2
0.6  
0
0.6  
0
0
20  
41  
61  
81  
102  
122  
142  
163  
183  
203  
224  
244  
264  
285  
305  
0
20  
41  
61  
81  
102  
122  
142  
163  
183  
203  
224  
244  
264  
285  
305  
Flow rate (gph)  
Flow rate (gph)  
Fig. 6  
18  
XPAK INSTALLATION DIAGRAMS  
NOTICE:The following illustrations are simplified conceptual  
illustrations only.  
Key for installation sample diagrams  
1. XPak boiler  
2. Gas shut off valve  
3. Expansion vessel  
4. Radiators  
5. Under floor heating  
6. Pressure relief valve discharge pipe  
7. Indirect DHW tank  
8. 3-way valve  
9. 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. Tank thermostat  
17. Tank sensor  
18. Mixing valve anti scald  
19. Radiator valve  
20. Condense neutralizer  
21. Tank drain valve  
22. Tank pressure relief valve  
23. Pump  
24. 3-way mixing valve  
25. Pressure gauge  
26. Bypass radiator  
Fig. 7  
Fig. 8  
19  
Fig. 9  
Fig. 10  
20  
Fig. 11  
Fig. 12  
21  
MAKING THE GAS CONNECTION  
DANGER: Only carry out work on gas conduits and fittings if  
you are licensed for such work.  
- Determine proper size gas pipe for the installation using  
Table 3 and Table 4. Do not forget the pipe fitting losses  
and observe proper size of the fittings.  
- Install the furnished 3/4” female gas cock on the gas  
connection (3/4” male on the boiler) (Fig. 13).  
- Connect the gas pipe to the gas cock so that it is free from  
any strain.  
CAUTION: The boiler and its individual shutoff valve must  
be disconnected from the gas supply piping system during  
any pressure testing of that system at test pressures in excess  
of 1/2 psi (3.5 kPa).  
Fig. 13  
Open  
position  
Closed  
position  
A
B
A- Manual main gas shutoff  
C
valve (supplied)  
B- Coupling (field supplied)  
C- To gas supply  
Fig. 14  
NOTICE: When installing the gas supply connection, it must  
comply with local regulations or, if such regulations do not exist,  
with the National Fuel Gas Code, ANSI Z 223.1.  
In Canada, the gas supply connection must comply with local  
regulations or, if such regulations do not exist, with CAN/CSA  
B149, Natural Gas and Propane Installation Code. A sediment  
trap must be provided upstream of the gas controls.  
Gas Pipe Capacity for different pipe sizes  
Tab. 3  
Length of  
pipe (feet)  
Gas Volume Capacity  
(ft3/h)*  
3/4”  
278  
190  
152  
130  
115  
93  
1”  
1 1/4”  
1,060  
730  
1 1/2”  
10  
20  
30  
40  
50  
75  
100  
150  
520  
350  
285  
245  
215  
175  
160  
120  
1,600  
1,100  
890  
760  
670  
545  
480  
380  
590  
500  
440  
360  
79  
64  
305  
250  
* Maximum pipe capacity in ft3/hr, based on a specific gravity of 60 (42  
mbar) and a inlet gas pressure of 14 inches W.C. (35 mbar) or less and a  
pressure drop of 0.3 inches W.C. (20 mbar)  
Equivalent length for pipe fittings in feet  
Tab. 4  
Steel pipe  
diameter  
in inches  
Equivalent length for Pipe Fittings in feet  
Type of pipe fitting  
90° Elbow  
Tee  
(flow thru  
branch)  
Gate valve Gas cocks  
Equivalent length in feet  
3/4  
1
1 1/4  
1 1/2  
2.1  
2.6  
3.5  
4.0  
4.1  
5.2  
6.9  
8.0  
0.5  
0.6  
0.8  
0.9  
1.25  
1.60  
2.15  
2.50  
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).  
22  
BOILER TEMPLATE (Fig. 15)  
Wall Mounting Information  
XPak comes with a template,  
which allows you to easily mark  
the location of the screws for the  
mounting bracket and the location  
of the flue gas pipe on the wall  
(Raypak coaxial PP vent system  
only).  
Wall stud  
16" C/C  
4,53" Hole for 60/100mm coaxial vent  
3" vent adaptor (supplied)  
1 . 5 "  
inside 3"  
Inlet air either right or left  
3" inlet air adapter (not supplied)  
Boiler bracket  
(supplied)  
XPak  
120  
The connection to the gas circuits  
must be made on site, 3/4” gas  
cock is supplied with the boiler.  
Ø1/4" holes  
for 5/16" lag  
screws (4 places)  
inside 3.15"  
Screw (2x) (fitted)  
Exhaust vent adapter (supplied)  
Screw (2x) (supplied)  
Screw (2x) (supplied)  
Inlet air adapter (supplied)  
XPak  
85  
14.17"  
16.25"  
XPak 120 - 17.81"  
XPak 85 - 15.75"  
C
L
Boiler outline  
CENTER LINE  
OF BOILER  
WARNING  
This boiler is heavy and awkward to lift. It is  
recommended and safer to install the boiler with two  
people. Use caution as to not drop this boiler which  
could cause personal injury. Verify that the boiler is  
securely mounted before leaving the boiler unsupervised.  
Ensure there is adequate clearances for mounting the boiler (details given in  
installation instructions).  
The wall mount bracket is designed for a stud spacing of 16 inches from  
center. 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.  
Extreme care is needed to ensure the bolts are secured in the studs.  
Hang the boiler on the bracket and secure the bottom of the boiler with two (2)  
additional lag screws.  
5.90"  
3.14"  
XPak  
120  
XPak  
120  
3.35"  
1.38"  
XPak  
85  
XPak  
85  
IN3/4" NPT male  
OUT3/4" NPT male  
Pressure relief valve drain  
3/4" NPT female  
Condensate piping flexible (supplied)  
0.825” female  
Gas shut off valve (supplied)  
3/4" NPT female  
4/5" female  
Ø1/4" holes for earthquake restraint (2 places)  
Fig. 15  
23  
COMBUSTION  
VENTILATION OPENINGS  
AIR  
AND  
INSTALLATION OF THE EXHAUST  
AND AIR INTAKE SYSTEM  
Provisions for combustion and ventilation air must be made in  
accordance with section 5.3, Air for Combustion and Ventilation,  
of the National Flue Gas Code, ANSI Z223.1, or Sections 7.2, 7.3  
or 7.4 of CAN/CGA B149, Installation Codes, or applicable  
provisions of the local building codes.  
NOTICE: Consult local and state codes pertaining to special  
building code and fire department requirements. Adhere to  
national code requirements.  
NOTICE:Observethelistedmaximumlengthsofventsystem,  
which are boiler model dependent. The maximum permissible  
lengths are listed in the main specification Tab. 5.  
CAUTION: BOILER DAMAGE AND OPERATIONAL  
FAILURES !  
Due to insufficient or lacking openings for combustion air  
and/or ventilation of the boiler room. Provisions for  
combustion air and ventilation are always required,  
regardless whether the combustion air is taken from the  
outside (sealed combustion) or inside (room air for  
combustion). Insufficient ventilation of the boiler room can  
lead to high air temperatures.  
An optional concentric vent/air intake body can be used for the  
installation of a vertical venting system as well as for a horizontal  
venting system. The concentric vent/air intake body can be ordered  
through Raypak Inc.  
The boiler can also be operated with separate air intake and  
exhaust piping.  
The termination shall be at least 4 ft (1220 mm) for the U.S. and  
6ft. (1830 mm) for Canada away from a gas utility meter, service  
regulator or the like (for room air applications only).  
The termination shall terminate at least 4 ft (1220 mm) below, 4 ft  
(1220 mm) horizontally from, or 1 ft (305 mm) above any door,  
window, or gravity air inlet into any building.  
This can result in boiler damage.  
– Make sure that intake and exhaust openings are sufficiently  
sized and no reduction or closure of openings takes place.  
– When the problem is not resolved, do not operate the boiler.  
– Pleasenotetheserestrictionsanditsdangerstotheoperator  
of the boiler.  
Ventmustbeatleast12inches(305mm)abovegrade, anticipated  
snow line or roof surface (Canada 18” (457 mm) minimum).  
Vent termination must be at least 7 ft (2135 mm) above a public  
walkway (see Fig. 20).  
WARNING: BOILER DAMAGE !  
Due to contaminated air.  
– Boiler must be clear and free from combustible materials,  
gasoline and other flammable vapors and liquids, and  
corrosive liquids and vapors. Never use chlorine and  
hydrocarbon containing chemicals (such as spray  
chemicals, solution and cleaning agents, paints, glues etc)  
in the vicinity of the boiler.  
Vent must be 3 ft (915 mm)above any forced air intake within 10  
ft (3050 mm) (see Fig. 20).  
Do not extend exposed vent pipe outside the building beyond  
recommended distance. Condensate could freeze and block vent pipe.  
Vent should terminate at least 3 ft (915 mm) away from adjacent  
walls, inside corners and below roof overhang.  
– Do not store and use these chemicals in the boiler room.  
– Avoid excessive dust formation and build-up.  
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.  
NOTICE: When one expects contaminated combustion air  
(near swimming pools, chemical cleaning operations and  
hair salons), sealed combustion operation is recommended.  
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.  
Installedyoucanslidethepipeontotheadapter,properlysupported  
and the exhaust pipe must be pitched a minimum of a ¼ inch per  
foot back to the boiler. This allows the condensate to drain away.  
DANGER: FIRE DANGER !  
Due to flammable materials or liquids.  
– Do not store flammable materials and liquids in the  
immediate vicinity of the boiler.  
NOTICE:  
- Do not use cellular core pipe.  
All Air from Inside the Building (room air)  
- A minimum clearance of 4 feet horizontally from and in no case  
above and below, unless a 4-foot horizontal distance is  
maintained, from electric meters, gas  
The room shall be provided with two permanent openings  
communicating directly with an additional room(s). The total input  
of all gas utilization equipment installed in the combined space  
shall be considered in making this determination. Each opening  
shall have a minimum free area of 1 square inch per 1,000 Btu per  
hour of total input rating of all gas utilization equipment in the  
confined space, but no less than 100 square inches. One opening  
shall commence within 12 inches (305 mm) of the top, and one  
opening shall commence within 12 inches (305 mm) of the bottom  
of the enclosure. The minimum dimension of air openings shall be  
not less than 3 inches (75 mm).  
Below are approved examples of vertical and horizontal venting  
installation  
- Place pipe supports every 5 feet (1525 mm) of horizontal run,  
beginning with support near boiler.  
- Periodic cleaning of the vent terminal and air-intake screens is  
mandatory.  
- The minimum covering wall thickness is 1" (25 mm).  
- The maximum covering wall thickness is 16" (406 mm).  
- For Direct venting properly reassembele and reseal the vent  
and air-intake systems.  
All Air from Outdoor (sealed combustion)  
The room shall be provided with two permanent openings, one  
commencing within 12 inches (305 mm) from the top, and one  
commencing within 12 inches (305 mm) from the bottom of the  
enclosure. The openings shall communicate directly, or by ducts,  
withtheoutdoorsorspaces(crawlorattic)thatfreelycommunicate  
with the outdoors.  
CAUTION: Vent connectors serving appliances vented by  
natural draft shall not be connected into any portion of  
mechanical draft systems operating under positive pressure.  
The minimum dimension of air openings shall be no less than 3  
inches (75 mm).  
1. Where directly communicating with the outdoors, each open-  
ing shall have a minimum free area of 1 square inch per 4,000  
Btu/hr of total input rating of all equipment in the enclosure.  
2. Where communicating with the outdoors through vertical ducts,  
each opening shall have a minimum free area of 1 square inch  
per 4,000 Btu/hr of total input rating of all equipment in the  
enclosure.  
3. Where communicating with the outdoors through horizontal  
ducts, eachopeningshallhaveaminimumfreeareaof1square  
inch per 2,000 Btu/hr of total input rating of all equipment in the  
enclosure.  
4. Whereductsareused, theyshallbeofthesamecross-sectional  
area as the free area of the opening to which they connect.  
Fig. 15A  
24  
VENT SYSTEMS  
1
3
2
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 – CSA 4.9b 2007 standards and are certified  
together with the XPak boiler as a constructional unit.  
The XPak boiler may also be vented vertically or horizontally,  
using a metallic AL29-4C® special stainless steel - Suggested  
sources: ProTech System Inc., or room air dependent venting  
system (UL/ULC listed for category IV).  
Fig. 16  
For a more detailed description of the direct vent and single-wall  
vent system, please refer to the following installation Instructions.  
4
5
A
NOTICE:  
B
Brick or masonry surfaces directly behind the horizontal vent  
termination should be protected with a rust-resistant sheet  
metal plate.  
A
Tab. 5  
FasNseal  
stainless steel vent  
6
Country  
Diameter  
Material  
US + CANADA  
3”  
Stainless steel  
Single wall  
Maximum Equivalent Length 3” (80 mm)  
De-rate less 2%  
De-rate less 5%  
XPak 85 XPak 120 XPak 85 XPak 120  
Horizontally/  
vertically  
vented  
1 Gasket in EPDM (peroxide) -58°F (-50°C) – 302°F (150°C)  
2 Adapter in PP (polypropylene) male/female 80 mm > 3”  
16+16  
5+5  
ft  
40+40  
12+12  
130+130 115+115  
40+40 35+35  
m
(air+flues)  
Always follow XPak Installation Instructions.  
Select vent material based on  
- Country of the installation  
- Vent configuration  
- Preferred material  
- Necessary maximum equivalent length  
NOTICE:  
The minimum covering wall thickness is 1” (25 mm)  
The maximum covering wall thickness is 16” (406 mm)  
Fig. 17  
2. BOILER SUPPLY  
XPak boilers are supplied with the following vent components and they  
are certified together with the XPak boiler as a constructional unit.  
- 60/100 mm vent exit (Fig. 16 pos. 1)  
- Left side intake air (factory sealed with two screws) for two pipes  
solutions (Fig. 16 pos. 2)  
- Right side intake air (factory sealed with two screws) for two  
pipes solutions (Fig. 16 pos. 3)  
- Vent adaptor for two pipes vent system – 80 mm dia exit (Fig. 16  
pos. 5) (Fig. 19)  
- Intakeairadaptorfortwopipesventsystem–80mmdiaexit(Fig.  
16 pos. 6) (Fig. 18)  
- 3” adaptor (inside diameter 3”) (Fig. 16 pos 4, Fig. 17)  
- Paper template to fix the boiler and the flues (Fig. 15)  
Fig. 18  
3. INSTALLATIONS OF SUPPLIED VENT COMPONENTS  
In the case of installations using two pipes or room dependent air  
the following instructions must be observed.  
1. Install the vent adapter (Fig. 19) to the boiler vent connection  
(Fig. 16 pos. 1)  
2. Use the two supplied screws to ensure the closing between  
the adapter and boiler (Fig. 16 pos. 5)  
3. Insert the 3” adapter (Fig. 17) into the vent adapter (Fig. 19) in  
the case using 3” vents  
4. Install the air adapter (Fig. 18) to the boiler air connection (choose  
right or left installation (Fig. 16 pos. 2 - 3), using the two supplied  
screws (Fig. 16 pos. 6) in the case of two pipes, room sealed vent  
installation.  
Fig. 19  
25  
4.MINIMUMCLEARANCESFROMVENT/AIRINLETTERMINATION  
Fig. 20  
V = vent terminal X = air supply inlet  
Tab. 6  
\\\ = area where terminal is not permitted  
U.S. Installations1  
Canadian Installations2  
A
B
Clearance above grade, veranda,  
porch, deck, or balcony  
1 ft (30 cm)  
1 ft (30 cm)  
3 ft (91 cm)  
Clearance to window or door that may  
be opened  
4 ft (1.2m) below or to side of  
opening; 1 foot (30 cm) above  
opening  
C
D
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  
5 ft (1.5m)  
E
F
Clearance to unventilated soffit  
Clearance to outside corner  
Clearance to inside corner  
*
*
*
*
*
G
H
6 ft (1.83m)  
Clearance to each side of center line  
extended above meter/regulator assembly  
*
3 ft (91 cm) within a height  
15 ft above the meter/ regulator  
assembly  
I
Clearance to service regulator vent outlet  
*
6 ft (1.83m)  
3 ft (91 cm)  
J
Clearance to non-mechanical air supply inlet to  
building or the combustion air inlet to any other  
appliance  
4 ft (1.2m) below or to  
side of opening; 1 ft  
(30 cm) above opening  
K
L
Clearance to mechanical air supply inlet  
3 ft (91 cm) above if within  
10 ft (3m) horizontally  
6 ft (1.83m)  
7 ft (2.13m) t  
Clearance above paved sidewalk or paved driveway  
located on public property  
7 ft (2.13m)  
M
Clearance under veranda, porch, deck or balcony  
*
12 in. (30 cm) TT  
1 In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code  
2 In accordance with the current CAN/CGA-B149 Installation Codes  
t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves both dwellings  
TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and underside  
of veranda, porch, deck or balcony is greater than 1 ft (30cm)  
* Clearances in accordance with local installation codes and the requirements of the gas supplier  
26  
NOTICE: The following illustrations are simplified conceptual  
illustrations only.  
Legend for illustrations 23-24-25-26-27-28-29-30-31-32  
Two pipes vent adaptors (included with the boiler)  
Mounting Clip (set of 4) 3.94” (100 mm) for coaxial  
90° Elbow 3” (80 mm) single wall  
Pos. 1  
Pos. 2 (Fig. 24)  
Pos.2(Fig.25-26-27-28)  
Pos. 2(Fig. 29-30-31-32)  
Pos. 3 (Fig. 25-26-28)  
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” (80 mm) single wall  
Roof Flashing flat universal  
Pos. 4 (FIg. 25-26-28)  
Pos. 4 (Fig. 23)  
Pos. 5  
Straight Pipe 3.28 ft (1 m) 3” (80 mm) single wall  
Straight Pipe 6.56 ft (2 m) 3” (80 mm) single wall  
Roof Flashing sloping universal  
Pos. 6 (Fig. 28)  
Pos. 6 (Fig. 24)  
Pos. 7  
45° Elbow 3.94” (100 mm) coaxial  
Horizontal inlet air vent 2.82 ft (0.86 m) 3” (80 mm) single wall  
Straight Pipe 1.64 ft (0.5 m) 3.94” (100 mm) coaxial  
Adaptorforroomairdependentoperation  
Straight Pipe 3.28 ft (1 m) 3.94” (100 mm) coaxial  
90° Elbow 3.94” (100 mm) coaxial  
Pos. 8 (Fig. 25-26-27)  
Pos. 8 (Fig. 24)  
Pos. 9 (Fig. 28)  
Pos. 9 (Fig. 24)  
Pos. 10 (Fig. 24)  
Pos.10(Fig.25-26-27-28)  
Pos. 11  
Mounting Clip (set of 4)  
Vertical vent termination 3”(80 mm) single wall  
Fig. 23  
Fig. 24  
VERTICALCOAXIAL  
SEALEDCOMBUSTIONOPERATION  
VERTICALCOAXIAL  
SEALEDCOMBUSTIONOPERATION  
27  
TWO PIPES SINGLE WALL  
Fig. 25  
SEALEDCOMBUSTIONOPERATION  
a = total intake length = INTAKE  
b = total flue length = EXHAUST  
TWO PIPES SINGLE WALL  
Fig. 26  
SEALEDCOMBUSTIONOPERATION  
a = total intake length = INTAKE  
b = total flue length = EXHAUST  
28  
TWO PIPES SINGLE WALL  
Fig. 27  
SEALEDCOMBUSTIONOPERATION  
a = total intake length = INTAKE  
b = total flue length = EXHAUST  
TWO PIPES SINGLE WALL  
Fig. 28  
ROOMAIRDEPENDENTOPERATION  
a = total intake length = 0  
b = total flue length = EXHAUST  
a = 0  
29  
Stainless Steel 3” Vent System1  
US + CANADA  
Vent System - Room Air independent Operation (Sealed Combustion Operation) - Fig. 12-14-15-17  
Tab. 7  
Vent System diameter  
3”  
Vent system material  
Stainless steel  
Two pipes vent adaptors (included with the boiler)  
adaptor 80 mm > 3” (included with the boiler 1 pcs) for flue  
adaptor 80 mm > 3” for intake air  
Combustion air intake vent material  
ULC/UL listed1  
-
-
-
-
Field supplied  
Field supplied  
Order No.  
Order No.  
3
Stainless steel Vent material  
45° elbow EqL = 2 ft / 0,6m  
90° elbow EqL = 3 ft / 0,9m  
Bird Screen c/w Termination  
Venting support2 dia. 3”  
Field supplied  
Order No.  
Field supplied  
Fieldsupplied  
Order No.  
Order No.  
1stainless steel vent material must be ULC/UL listed, stainless steel AL29-4C® for category IV boilers. Sources FasNseal – Protech  
System Inc.  
2 Order Mounting Clip for each straight length of vent pipe installed, boiler can not support weight of vent system  
3
allowable material for combustion air ABS – CPVC – PVC or stainless steel  
- Do not exceed maximum equivalent vent length.  
- Always follow XPak Venting System Installation Instructions.  
Stainless Steel Vent System1  
US + CANADA  
Vent System - Room Air Dependent Operation - Fig. 13-16-18  
Tab. 8  
Vent System diameter  
3”  
Vent system material  
Adaptor for room air dependent operation  
adaptor 80 mm > 3” (included with the boiler 1 pcs)  
ULC/UL listed1  
Stainless steel  
3
013102  
-
Order No.  
-
Stainless steel Vent material  
45° elbow EqL = 2 ft / 0,6m  
90° elbow EqL = 3 ft / 0,9m  
Bird Screen c/w Termination  
Venting support2 dia. 3”  
Field supplied  
Order No.  
Field supplied  
Fieldsupplied  
Order No.  
Order No.  
1 Stainless steel vent material must be ULC/UL listed, stainless steel AL29-4C® for category IV boilers. Sources FasNseal –  
Protech System Inc.  
2 Order Mounting Clip for each straight length of vent pipe installed, boiler can not support weight of vent system  
3
Provide a proper air opening in the room (size according indication pg. 7)  
- Do not exceed maximum equivalent vent length.  
- Always follow XPak Venting System Installation Instructions.  
30  
DESCRIPTION  
DIAGRAM  
DRAWING  
P/N 013040  
Two pipes vent adaptors  
(included with the boiler)  
Fig. 29-30-31-32  
Pos. 1  
P/N 013040  
adaptor 80 mm > 3”  
(included with the boiler 1 pcs)  
Fig. 29-30-31-32  
Pos. 2  
TWO PIPES SINGLE WALL  
SEALEDCOMBUSTIONOPERATION  
Fig. 29  
a = total intake length = INTAKE  
b = total flue length = EXHAUST  
31  
Fig. 30  
TWO PIPES SINGLE WALL  
SEALEDCOMBUSTIONOPERATION  
a = total intake length = INTAKE  
b = total flue length = EXHAUST  
TWO PIPES SINGLE WALL  
Fig. 31  
SEALEDCOMBUSTIONOPERATION  
a = total intake length = INTAKE  
b = total flue length = EXHAUST  
32  
Fig. 32  
a = total intake length = 0  
TWO PIPES SINGLE WALL  
SEALEDCOMBUSTIONOPERATION  
b = total flue length = EXHAUST  
33  
7 - ELECTRICAL CONNECTIONS  
CONNECTING THE CONDENSATE  
WATER DRAIN  
Devices such as outdoor sensor, 3-way valve, tank sensor, tank  
thermostat, remote controls are all connected to the external  
connection board.  
Install the condensate drain flexible pipe (Ø 0.825” - 21mm  
female flexible rubber connection) with a suitable gradient (min.  
2.5%).  
Discharge condensate from the boiler into the drainage system,  
either directly or (if required) via a neutralization unit (not  
supplied).  
The electrical connections to the boiler must be made in  
accordance with all applicable local codes and the latest revision  
of the National Electrical Code, ANSI/NFPA-70.  
Installations should also conform with CSA C22.1 Canadian  
Electrical Code Part 1 if installed in Canada.  
1. EXTERNAL CONNECTION BOARD CONNECTIONS  
A qualified electrician should connect the electrical supply to the  
appliance. If controls – external to the appliance – are required,  
a competent person must undertake the design of any external  
electrical circuits. ANY EXTERNAL CONTROL OR WIRING MUST  
BE SERVED FROM THE SAME ISOLATOR AS THAT OF THE  
APPLIANCE. Wiring to the appliance must be rated for operation  
in contact with surfaces up to 194°F (90°C).  
1. CONDENSATE CONNECTION  
The condensate drain of the boiler is equipped with a built-in  
siphon trap in order to keep flue gases from being discharged  
via the condensate drain.  
The condensate formed both in the condensing boiler and in the  
flue gas pipe must be discharged into the public sewage system  
in accordance with all applicable local regulations.  
The condensate produced by a gas-fired heating system has a  
pH value between 3 and 4.  
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.  
With a neutralization unit installed, all condensate from the boiler  
and the flue gas pipe enters into the neutralization unit where it  
is treated and released into the public sewage system with a  
safe pH value of above 6.5.  
The use of neutralization granulate (performing the neutralizing  
process) is dependent on the operation of the heating system.  
To determine the required refill amount, check granulate level  
several times during the first year of operation. In some cases  
one granulate fill may last an entire year.  
The condensate discharge outlet to the drainage system  
connection must be clearly visible. It must be installed with a  
suitable gradient and provided with a stench trap.  
WARNING: ELECTRICAL SHOCK HAZARD — For your  
safety, turn off electrical power supply at service entrance  
panel before making any electrical connections to avoid  
possible electric shock hazard. Failure to do so can cause  
severe personal injury or death.  
AVERTISSEMENT: RISQUE DE CHOC ÉLECTRIQUE —  
Pourvotresécurité,coupezl'alimentationélectriqueauniveau  
du tableau de distribution avant d'effectuer tout raccordement  
électrique afin d'éviter un risque éventuel de choc électrique.  
La non-observation du dernier point peut provoquer de  
graves blessures ou la mort.  
NOTICE: Wiring must be N.E.C. Class 1. If original wiring as  
supplied with heater must be replaced, use only TEW 221°F  
(105 °C) wire or equivalent. Heater must be electrically  
grounded as required by National Electrical Code ANSI/  
NFPA 70 — latest edition.  
If the condensate outlet of the boiler is lower than the drain, a  
condensate pump must be used (see electrical wiring to loch out  
the boiler in the case of failure of the condensate pump - alarm 21).  
Only corrosion-resistant materials may be used for condensate  
drainage purposes (e.g. braided hose). Do not use galvanized  
materials or materials containing copper for piping, couplings etc.  
Please note that other requirements may apply depending on  
local regulations and/or project-specific details.  
It is advisable to contact your local waterworks office (authority  
responsible for waste water regulations) well before  
commencing with the installation of the neutralization unit in order  
to establish details of local regulations that apply.  
CAUTION: Label all wires prior to disconnection when  
servicing controls. Wiring errors can cause improper and  
dangerous operation.  
Verify proper operation after servicing.  
2. ELECTRICAL SUPPLY  
The boiler requires a 120V 60Hz power supply. Ensure the  
electrical supply is properly polarized.  
The boiler must be grounded.  
There must only be one common isolator, providing complete  
electrical isolation for the boiler and any external controls using  
PVC insulated cable 18 AWG x3C 105 °C /221°F.  
All wiring must be installed in accordance with requirements of  
National Electrical Code and any additional national, state, or  
local code requirements having jurisdiction. All wiring must be  
N.E.C. Class 1. The boiler must be electrically grounded in  
accordance with the National Electrical Code, ANSI/NFPA No.  
70-latest edition.  
NOTICE: Pipe ventilation must take place between the  
siphon trap and the neutralization unit (if applicable).  
In Canada, installation must conform to CSA C22.1 Canadian  
Electrical Code Part 1 and any local codes.  
3. FIELD WIRING  
Theelectricaljunctionboxhasa24voltterminalcompartmentand  
120 volt terminal compartment. Each terminal connection is  
clearly marked to ensure correct installation.  
Electrical  
Optional devices  
(24V) terminal block  
supply (120V)  
terminal block  
B
Fig. 33  
Fig. 34  
34  
7. EXTERNAL WIRING  
4. CASING REMOVAL (Fig. 33)  
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.  
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.  
8. EXTERNAL WIRING LIMITATIONS  
Any external wiring must remain within the limits as detailed in  
the table below  
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).  
CONNECTION  
MAX. LENGTH  
Outdoor air sensor  
Room thermostat  
100 ft (30 metres)  
100 ft (30 metres)  
100 ft (30 metres)  
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).  
Remote control connection  
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.  
External connection board connections  
Make all electrical connections inside the external connection  
box.  
10. OTHER DEVICES  
- Open the cover of the external connection box (Fig. 34).  
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.  
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.  
IMPORTANT  
Boiler terminal strip (Fig. 35)  
- The boiler must always be supplied with a permanent 120V  
electrical supply.  
The XPak terminal strip is divided in two separated area: low  
voltage and high voltage area.  
- Always remove the link on M4a terminal strip on the appliance  
low voltage 24V terminal strip whenever additional controls  
are connected to the appliance.  
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:  
- Do not connect any controls or auxiliary equipment to the 24V  
terminal strip, other than that approved/supplied by the  
manufacturer.  
- 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.  
35  
Tab. 9  
11. TERMINAL STRIP DETAILS  
Terminal  
strip  
Description  
Technical  
Indications  
specifications  
reference  
M3  
Main supply  
120 VAC – 60 Hz  
The main supply cable must be anchored to the  
boiler frame (Fig. 39) and pass through the  
strains relief (field supplied). Cable as specified in  
the electrical supply.  
M3a  
3-way valve:  
Connections for DHW  
external 3-way valve  
Model: Honeywell VC6011 (actuator) + VCZMK6000  
(Cartridge valve)  
The 3-way valve cable must be anchored to the boiler  
frame (Fig. 39) and pass through the strains relief (field  
supplied) (Fig. 39). Cable as specified in the electrical  
supply.  
120 VAC – 60 Hz  
12 K Ohm B3760  
M4  
M4  
Outdoor sensor  
Remote control  
Open therm plus protocol Only Raypak Part No. 013073  
M4a  
M4a  
Room thermostat  
24 VDC  
Volt free (Jumper when not used)  
Tank sensor  
for DHW  
10 K Ohm B3435  
Immersion type.  
If the boiler is installed with a tank sensor, the Jumper  
on the PCB must be in position 2 (Fig. 61)  
M2a  
M3b  
Tank thermostat  
for DHW  
On/off (NO)  
Volt free  
If the boiler is installed with a tank termostat, the  
Jumper on the PCB must be in position 3 (Fig. 61)  
Under-floor heating limit On/off (NC)  
thermostat and condensate  
Volt free.  
This is a generic input to lock out the boiler. Jumper when  
(generic available alarm) not used). If the contact will be  
open the alarm number 21  
will appear on the display and the boiler is lock out  
REMOTE CONTROL  
0T+  
EXTERNAL  
SENSOR  
UNDERFLOOR HEATING LIMIT  
THERMOSTAT OR  
HIGH VOLTAGE  
LOW VOLTAGE  
CONDENSATE PUMP ALARM  
(jumper when not used)  
120V  
-t°  
ROOM  
3W  
THERMOSTAT  
(jumper when  
not used)  
N
L
TANK  
SENSOR  
TANK  
THERMOSTAT  
M3b  
F=  
fuse 4AF  
-t°  
M3a  
M4  
M3  
V
M2  
M4a  
PCB fuse=4AT  
Fig. 35  
36  
12. OUTDOOR SENSOR CONNECTION  
The user can program the desired supply temperature based on  
the outdoor temperature. Once the outdoor sensor is connected  
to the control board, the water temperature of the boiler will adjust  
to run the boiler more efficiently and provide greater comfort to the  
living space.  
Fig. 36  
ConnectionSpecification–Wire22AWGmaximumto100ft(30m).  
Outdoor Sensor is connected in the junction box on the XPak.  
Route wires from the terminal strip to your outdoor sensor, which  
will allow the user to change the temperature going to the Central  
Heating loop automatically. Place the outdoor sensor preferably  
to the north or northwest or to the side which will be affected by  
changing weather conditions outside. NOTE: Do not locate the  
sensor in the direct sunlight.  
13. 3-WAY VALVE WIRING CONNECTION  
XPak boiler can manage an external 3-way valve (field supplied),  
the terminal strip (M3a) output is 120V – 60 Hz (see electric  
diagram).  
Fig. 37  
Logic of the boiler managing 3-way valve  
1. Boiler configuration in DHW (case A and case B), see Fig. 61  
for boiler jumper configuration.  
2. Once the jumper has set in DHW mode (tank with probe or  
tank with thermostat), when there is a heat request from the  
sensor or from the thermostat, there is power out (120V – 60  
Hz) to the boiler terminal strip M3a (Fig. 35).  
3. The output to the 3-way valve DHW pin is continuously supply  
up to the heat is satisfied.  
4. The room thermostat request is independent from the DHW  
request (Priority is always given to DHW production).  
5. The 3-way valve is always powered, even if there is no DHW  
demand.  
WARNING: The 3-way valve is continuously powered even  
if there is no heat request from the tank.  
Wiring connections 3-way valve  
Suggested source: Honeywell VC6011 (actuator) + VCZMK6000  
Wiring the valve as per diagram Fig. 38.  
Follow the installation of the piping referring to the diagram  
showing the logic of working Fig. 38.  
The connections colors and schematic refer to the Honeywell  
VC6011 (actuator) + VCZMK6000.  
Fig. 38  
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.  
All the boiler settings can be made only by Remote Control once  
it is connected.  
See Remote Control instruction for setting and use.  
Choose one of the two options for the strain relief that XPak allows  
1
2
Straight-Thru:  
Heyco HFC-Z 1/2  
Strain Relief  
Bushings:  
Main supply  
cable  
Heyco SR 7K-2  
2
1
2
3 way valve  
cable  
1
Listed under UL  
File #E-206446  
Listed under UL File  
#E-15331 CSA  
LR8919  
Fig. 39  
37  
WIRING FUNCTIONAL DIAGRAM  
Fig. 40  
38  
8 - START-UP PROCEDURE  
There are several steps involved in starting up the boiler.  
Fig. 41  
39  
9 - COMMISSIONING  
1. CHECK/CONTROL WATER CHEMISTRY  
system the pressure gauge will begin to rise. Once the gauge  
has reached 15 p.s.i. (1 bar) close both valves and begin venting  
all manual air release valves, starting at the lowest first. It may be  
necessary to go back and top-up the pressure until the entire  
system has been filled. Inspect the system for water tightness,  
fixing any leaks.  
WARNING: Do not use petroleum-based cleaning or sealing  
compounds in heater system. Damage to elastomer seals  
and gaskets in system could occur, resulting in substantial  
property damage.  
Water pH between 6.0 and 8.0  
1. Maintain heater water pH between 6.0 and 8.0. Check with  
litmus paper or have chemically analyzed by water treatment  
company.  
WARNING:Eliminateallsystemleaks.Continualfreshmake-  
up water will reduce boiler life. Minerals can build up in the  
heat exchanger, reducing heat transfer, overheating heat  
exchanger, and causing heat exchanger failure.  
2. If pH differs from above, consult local water treatment company  
for treatment needed.  
Hardness less than 7 grains.  
5. The system may have residual substances that could affect  
water chemistry. After the system has been filled and leak  
tested, verify water pH and chlorine concentrations are  
acceptable.  
1. Consult local water treatment companies for unusually hard  
water areas (above 7 grains hardness).  
Chlorine concentration less than 200 ppm  
1. Filling with chlorinated fresh water should be acceptable since  
drinking water chlorine levels are typically less than 5 ppm.  
2. Do not use the heater to directly heat swimming pool or spa  
water.  
3. Do not fill heater or operate with water containing chlorine in  
excess of 200 ppm.  
CAUTION: It is important that you purge the system of air to  
avoid damage to the heater.  
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. Slacken the bleed screw using a 7/16” (11mm) open-  
ended spanner until water is released and then close.  
IMPORTANT, THERE ARE NO OTHER MANUAL AIR RELEASE  
VALVES LOCATED ON THE APPLIANCE.  
Clean system to remove sediment  
1. You must thoroughly flush the system (without heater  
connected) to remove sediment. The high-efficiency heat  
exchanger can be damaged by buildup or corrosion due to  
sediment.  
2. Flush system until water runs clean and you are sure piping is  
free of sediment.  
WARNING: Never open the Manual Air Vent while the boiler  
is hot. Allow boiler to cool to room temperature to avoid  
scalding while purging.  
Test/replace freeze protection fluid  
1. For systems using freeze protection fluids, follow fluid  
manufacturer’s instructions to verify inhibitor level and that  
other fluid characteristics are satisfactory.  
Fill the system and watch that system pressure rises to correct  
cold-fill pressure.  
After the system has operated for a while, eliminate any residual air.  
2. Freeze protection fluid must be replaced periodically due to  
degradation of inhibitors over time. Follow all fluid  
manufacturer’s instructions.  
6. SYSTEM DRAIN (Fig. 42a)  
Use a open-ended wrench (dimensions 7/16” (11 mm)) to drain  
2. FREEZE PROTECTION (WHEN USED)  
the water inside the boiler:  
- attach the rubber pipe supplied to the drain valve (A)  
- locate the wrench hole under the boiler  
- fit the wrench to the valve  
WARNING: NEVER use automotive or standard glycol  
antifreeze, even ethylene glycol made for hydronic systems.  
Use only freeze-prevention fluids certified by fluid  
manufacturer as suitable for use with aluminum heaters,  
verified in fluid manufacturer’s literature.  
Throroughly clean and flush any system that has used glycol  
before installing the new XPak Boiler. Provide XPak boiler owner  
with a material safety data sheet (MSDS) on the fluid used (if  
requested).  
- gently rotate the wrench counterclockwise  
- drain the boiler  
- close the valve rotating the wrench clockwise  
- remove the rubber pipe from the valve once the valve as been  
closed  
DANGER: The system water temperature could be very hot,  
be sure when the valve is opening that the rubber pipe is  
well attached.  
Frontal water flushing can occur and cause instant severe  
burns or death from scalds.  
1. Determine freeze protection fluid quantity using total system  
water content, following fluid manufacturer’s instructions.  
Remember to include expansion tank water content.  
2. Local codes may require back flow preventer or actual  
disconnect from city water supply.  
3. When using freeze protection fluid with automatic fill, install a  
water meter to monitor water makeup. Freeze protection fluid  
mayleakbeforethewaterbeginstoleak,causingconcentration  
to drop, reducing the freeze protection level.  
3. THE HEATING SYSTEM  
The appliance contains components that may become damaged  
or rendered inoperable by oils and/or debris that are residual  
from the installation of the system, consequently it is essential  
that the system be flushed in accordance with the following  
instructions.  
4. INITIAL FILLING OF THE SYSTEM  
Ensure both flow and return service valves are open, remove  
appliance casing as described, identify the automatic air release  
valves (AAV) and loosen the dust cap/s by turning the cap  
counterclockwise one full turn. Ensure all manual air release  
valves located on the heating system are closed. Fill the system  
via proper filling method (field supplied). As water enters the  
Fig. 42  
40  
- Ensure the 4 AMP fuses are installed;  
- Ensure the system has been filled, vented, and the pressure  
set to 15 p.s.i. (1 bar);  
- Ensure the flue system has been installed properly and in  
accordance with the instructions;  
- Ensure all appliance service valves are open.  
11. INITIAL LIGHTING AND IGNITION SAFETY SHUTOFF  
DEVICE TEST  
Ensure the electrical supply to the appliance is switched on. Ensure  
any external controls are switched to an ‘ON’ position and are  
calling for heat.  
A
Fig. 42a  
Move the selector switch to the ON position (  
appliance will now operate.  
-
-
F ), the  
7. CHECK THERMOSTAT CIRCUIT(S)  
1. Disconnect the two external wires connected to the boiler  
thermostat terminals (low voltage terminal strip M4a).  
2. Connect a voltmeter across these two incoming wires. Close  
each thermostat, zone valve and relay in the external circuit one  
at a time and check the voltmeter reading across the incoming  
wires.  
3. There should NEVER be a voltage reading.  
4. If a voltage does occur under any condition, check and correct  
the external wiring.  
NOTICE:  
After installation, the boiler must be turned ON and the  
thermostat set for CFH and operated with the manual gas  
shut-off valve below the unit closed. Allow the boiler to go  
through its 5 ignition tries and then lock out.The display should  
indicates the alarm code 10. After the test, reset the control,  
open the gas valve, set the thermostat to the proper setting  
and ensure that the boiler operates properly.  
5. Once the external thermostat circuit wiring is checked and  
correctedifnecessary, reconnecttheexternalthermostatcircuit  
wires to boiler low voltage terminal strip. Allow the boiler to  
cycle.  
12. CHECKING GAS PRESSURE AND COMBUSTION  
ANALYSIS  
The boiler is factory set and requires no additional adjustment  
once installed.  
If the installation does not include a gas meter (for example LPG)  
and there are no means by which to calculate the gas rate, then a  
combustion analysis test must be carried out in accordance with  
local regulations to ensure the appliance is left working safely  
and correctly.  
Additionally, if the gas valve has been adjusted, replaced, or the  
appliance has been converted for use with another gas type,  
then it becomes necessary to carry out a combustion analysis/  
check to ensure that correct combustion is occurring.  
If there are no means to gas rate the appliance and/or carry out a  
combustion analysis check, then it will not be possible to comple-  
te the commissioning procedure.  
Details on how to carry out the combustion analysis can be found  
in Section 11.  
NOTICE: It’s imperative that a sufficient dynamic – gas –  
pressure is maintained at all times. Should the dynamic gas  
pressure fall below an acceptable level, the appliance may  
malfunction or sustain damage.  
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.  
WARNING: Before starting the XPak, and during initial  
operation, smell near the floor and around the heater for gas  
odorant or any unusual odor. Remove heater front door and  
smell interior of heater enclosure. Do not proceed with startup  
if there is any indication of a gas leak. Repair any leak at once.  
WARNING: LPG boiler only — Your propane supplier mixes  
an odorant with the LPG to make its presence detectable. In  
some instances, the odorant can fade, and the gas may no  
longer have an odor. Before startup (and periodically  
thereafter), have the LPG supplier verify the correct odorant  
level in the gas.  
WARNING:  
- Cover endangered positions before leak testing.  
- Do not spray the leak testing agent onto cables, plugs or  
electrical connection lines.  
13. FINAL FLUSHING OF THE HEATING SYSTEM  
The system shall be flushed. Cleaners or chemicals used, must  
be suitable for Aluminum heat exchangers and shall be from a  
reputable manufacturer and shall be administered in strict  
accordance with the manufacturers’ instructions.  
- Do not allow it to drip onto them either.  
DANGER: Leaks may be caused to pipes and screw  
connections during commissioning and maintenance  
activities.  
- Carry out a proper leak test.  
NOTICE: Chemicals used to clean the system and/or inhibit  
corrosion must be pH neutral, i.e. they should ensure that the  
level of the pH in the system water remains neutral.  
Premature failure of certain components can occur if the level  
of pH in the system water is out of normal levels.  
- Only use approved leak detection agents for leak detection.  
- Disconnect the heating system from the power supply.  
- Check the exterior tightness of new pipe sections up to  
and including the direct sealing point on the gas burner  
fitting.  
9. INITIAL FLUSHING OF THE SYSTEM  
14. SETTING THE BOILER OPERATING TEMPERATURE  
The flow outlet temperature can be adjusted between 104-176°F  
(40-80°C) depending on the boiler configuration via the Heating  
thermostat knob (Fig. 1A).  
If the 3-way valve is connected, the flow outlet temperature to the  
tank can be adjusted between 95-140°F (35-60°C) via the DHW  
temperature selector (Fig. 1A).  
The whole of the heating system must be flushed both cold and  
hot as detailed in Fig. 42a. Open all radiator or heating valves  
and the boiler flow & return service valve. Drain the boiler and  
system from the lowest points. Open the drain valve full bore to  
remove any installation debris from the boiler prior to lighting.  
Refill the boiler and heating system.  
10. PRE-OPERATION CHECKS  
Before attempting the initial lighting of the appliance, the following  
checks must be carried out:  
- Ensure all gas service valves from the meter to the appliance  
are open and the supply pipe has been properly purged;  
- Ensure the proper electrical checks have been carried out,  
particularly continuity, polarity, and resistance to ground;  
15. REGULATING THE CENTRAL HEATING SYSTEM  
Fully open all radiator and circuit valves and run the appliance for  
both heating and hot water until heated water is circulating. If  
conditions are warm remove any thermostatic heads. Adjust  
radiator return valves and any branch circuit return valves until  
the individual return temperatures are correct and are  
approximately equal.  
41  
16. FINAL CHECKS  
- ENSURE ALLTEST NIPPLES ONTHE APPLIANCE GASVAL-  
VE ARE TIGHT AND CHECKED FOR TIGHTNESS.  
- ENSURE THE APPLIANCE FLUE SYSTEM IS INSTALLED  
CORRECTLY AND IS PROPERLY SECURED.  
- ENSURE ALL PIPE WORK IS RE-CHECKED FOR  
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. INSTRUCTING THE USER  
Hand over all documentation supplied with this appliance –  
including these instructions – and explain the importance of  
keeping them in a safe place.  
Explain to the user how to isolate the appliance from the gas,  
water and electricity supplies, and the locations of all drain points.  
Show the user how to operate the appliance and any associated  
controls correctly.  
Show the user the location of any isolating valves and the location  
of all manual air release points.  
Explain to the user how to turn off the appliance for both long and  
short periods and advise on the necessary precautions to prevent  
freeze damage.  
Explain to the user that for continued safe and efficient operation,  
the appliance must be serviced annually by a qualified service  
person.  
18. WARRANTY  
To validate the appliance warranty, it’s necessary to register the  
appliance details with us. The warranty can be registered in  
several ways, see last pages of this manual for details.  
42  
10 - START-UP AND OPERATION  
XPak wall-mounted condensing boiler is designed for the  
production of heating and domestic hot water if a storage tank is  
connected.  
rature. To increase or decrease the temperature with respect to  
the value automatically calculated by the PCB, turn the heating  
water selector (Fig. 50) clockwise to increase and  
counterclockwise to decrease.  
The control panel contains the main boiler control and manage-  
ment functions.  
Adjustment settings range from comfort levels - 5 to + 5 which are  
indicated on the digital display when the knob is turned.  
1. SWITCHING ON THE APPLIANCE  
4. ADJUSTING DOMESTIC HOT WATER TEMPERATURE  
(IF A STORAGE TANK WITH SENSOR AND 3-WAY  
VALVE IS INSTALLED)  
Switch on the boiler as follows:  
- Open the gas tap under the boiler by turning it  
counterclockwise (Fig. 46)  
When turning the knob, the required temperature automatically  
appears on the digital display.The domestic hot water adjustment  
ranges lies between 95°F (35°C) and 140°F (60°C). When  
choosing the temperature, both for heating and domestic hot  
water, the display shows the value being selected. About 4  
seconds after the selection has been made, the modification is  
recorded and the display returns to the delivery or domestic hot  
water temperature read by the probe. Priority is always given to  
DHW production.  
The boiler setting depends from the jumper JP position (Fig. 63).  
- CASE A (factory set) heating only + external water tank with  
thermostat adjustment inapplicable - jumper in position 3  
- CASE B heating only + external water tank with sensor - to  
adjust the temperature of the domestic hot water in the water  
tank, turn the temperature selector clockwise to increase and  
counterclockwise to decrease - jumper in position 2.  
- Turn on the general switch of the system and then, after  
lowering the flap, turn the function selector to summer  
,
winter  
or winter tank temperature  
(Fig. 54) depending  
F
on the chosen operating mode.  
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” until this period has  
elapsed. To interrupt the purge cycling remove the knob of the  
main selector switch and press the CO button (Fig. 59).  
Off/reset - Select this position when the boiler needs to be  
reset or switched off.  
Summer mode  
- The domestic hot water function provided  
by the water tank is activated. The display indicates the storage  
tank temperature (only with the external water tank connected  
with a sensor).  
5. WORKING THE BOILER  
Winter mode  
- The boiler produces hot water for heating  
and, if connected to an external water tank, it provides domestic  
hot water. The display indicates the boiler flow temperature.  
If a programmable timer or ambient thermostat are mounted,  
these must be switched on and adjusted to higher than ambient  
temperature in order to allow the boiler to start.  
The boiler remains on standby until the burner ignites as a result  
of a demand for heat.The green indicator LED (B, Fig. 52), located  
on the left-hand side of the panel, lights up to indicate the flame  
is present. The boiler continues to work until the selected  
temperatures have been reached. It then returns to “stand-by”  
while displaying delivery temperature.  
In the event of a starting or operating fault, the boiler performs a  
“SAFETY STOP”: the green indicator LED on the control panel  
goes out, a fault code flashes on the display (Fig. 53) and a red  
indicator LED (D) lights up in the event of a shutdown.To identify  
the fault codes and reset the boiler, consult the “Indicator LEDs  
and faults” section.  
Winter mode tank temperature  
- The boiler produces  
F
hot water for heating and, if connected to an external water tank  
with a sensor, it provides domestic hot water.The display indicates  
the storage tank temperature.  
2. HOW TO READ THE DISPLAY TEMPERATURE  
● (dot in the middle)= means hundred (Fig.43)  
● (dot on RIGHT side)= means DHW mode (Fig. 44)  
example:  
Fig. 43  
Heating mode  
6. RESET FUNCTION  
To reset the boiler, turned the function selector to (Fig.54) then  
move it to the required position and check that the red indicator  
LED has gone out.  
At this point, the boiler starts automatically if correct operating  
conditions have been restored; when the burner ignites, the green  
indicator led lights up and the digital display indicates the  
instantaneous operating temperature.  
60°F  
40°F  
160°F  
140°F  
DHW mode  
Fig. 44  
NOTICE: Simply turning the selector to does not reset the  
boiler.  
If the boiler continues not to work, call your local Service  
Technician.  
NOTICE:  
For temperature over 199°F (93°C) the display shows  
.
In normal operating conditions, when the function selector is  
turned to , the digital display indicates “- -” (Fig. 55) unless the  
anti-freeze phase (AF - Fig. 56) is in progress or the combustion  
analysis function is activated (CO - Fig. 58).  
Adjusting heating water temperature  
To adjust the heating water temperature turn the knob marked  
(Fig. 50) clockwise to increase and counterclockwise to  
decrease.  
When turning the knob, the required temperature automatically  
appears on the digital display.  
7. SWITCHING OFF  
For short absences (weekends, brief journeys, etc.) turn the  
function selector to  
OFF/RESET.  
As the boiler remains powered with the gas tap open, it is  
protected by the following systems:  
NOTICE: Depending on the type of system, it is possible to  
pre-select the suitable temperature range:  
- Freeze protection:  
- standard systems 104-176°F (40-80°C)  
Heating  
- floor systems 68-113°F (20-45°C).  
The function starts if the temperature measured by the flow  
sensor falls below 43°F (6°C). In this mode, a heat demand is  
generated and the burner ignites at minimum power. This is  
maintained until the temperature of the water flow reaches  
95°F (35°C).  
For further details, consult the “Boiler configuration” (Fig. 61)  
3. ADJUSTING HEATING WATER TEMPERATURE WITH  
AN OUTDOOR PROBE CONNECTED  
When an outdoor probe is connected, the value of the delivery  
temperature is automatically chosen by the system which rapidly  
adjusts ambient temperature to the changes in outdoor tempe-  
43  
Domestic hot water (with connection to an external water tank  
with probe)  
The function starts if the temperature measured by the water tank  
probe falls below 40°F (4°C). In this mode, a heat demand is  
generated and the burner ignites at minimum power. This is  
maintained until the temperature of the delivery water reaches  
95°F (35°C).  
NOTICE: During the freeze protection mode, AF flashes on  
the display (Fig. 56)  
- 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”  
8. INDICATOR LEDS AND FAULTS  
Green indicator LED (Fig. 52)  
Off = boiler on stand-by, no flame  
On = burner on, the boiler works regularly.  
Red indicator LED (Fig. 53)  
Stop: just the fault code flashes on the digital display.  
Block: the red indicator LED lights up and the fault code flashes  
on the digital display.  
The fault code is not displayed in the OFF/RESET ( ) mode. To  
display it, move the function selector to  
,
or F . During  
combustion analysis and the freeze protection mode, instead, it is  
displayed.To reset the boiler, turn the function selector to (OFF/  
RESET) and then move it to be required position (Fig. 47). If the  
boiler still doesn’t work, call in the local Service Technician.  
B
C
E
A
D
G
F
A
B
C
D
E
Pressure gauge  
Green led  
2-digit LED display  
Red led  
Temperature selector space heating  
F
G
Mode selector switch  
Temperature selector Domestic Hot Water*  
* The parts of the manual refering to the DHW circuit should be only considered if a indirect water tank with sensor is installed, case B (Fig. 61)  
Fig. 45  
44  
Open  
position  
D red indicator LED fault  
Fig. 46  
Fig. 48  
Fig. 47  
DHW mode  
Heating mode  
Fig. 53  
Fig. 55  
Fig. 56  
Fig. 54  
Fig. 49  
B green indicator LED  
boiler status  
Closed  
position  
Fig. 51  
Fig. 52  
Fig. 57  
Fig. 50  
Status  
Code Description of alarm  
Block  
Block  
Block  
AL10 Ignition attempts finished (no flame/condensate present)  
AL20 Limit thermostat fault, blocked flue switch, flue thermostat  
AL21 Low temperature thermostat/condensate pump safety  
device fault  
Block  
Block  
Stop  
AL29 Flue sensor over temperature lock out  
AL60 Water tank probe fault  
AL71 Delivery probe fault (open/short circuit)  
AL73 Return probe fault (open/short circuit)  
AL28 Return/delivery probe differential fault  
AL26 Return over temperature  
Stop  
Block  
Block  
Block  
AL79 Delivery over temperature / return-delivery probe  
differential fault  
Stop  
AL41 System water pressure low  
Block  
Block  
Block  
Block  
AL40 System water pressure low (after 10 minutes)  
AL34 Fan tacho fault  
AL52 Generic electronic fault  
AL55 No boiler mode configuration fault (corresponding jumper  
absent)  
Advice  
AL91 The main heat exchanger need to be cleaned –  
call the Raypak technical service  
For AL41 faults  
If the pressure on the water gauge located on the control panel is  
less than 7 psi (0.5 bar), proceed as follows:  
- Turn the function selector to  
(Fig. 54)  
- Fill the system until the pressure indicated on the water gauge  
lies between 14-21 psi (1-1.5 bar) (Fig. 45 pos. A)  
- Move the function selector to the desired position.  
In case of frequent pressure drops, call your local Service  
Technician.  
For alarm AL91  
The boiler has an internal self diagnostic system that can advise  
if it is necessary to clean the main heat exchanger (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  
following instructions:  
Switch off the electric supply to the boiler  
Remove the knob of the main selector  
Switch on the boiler while pressing the CO button for at least 4  
seconds (Fig. 59). To check if the counter has been reset, switch  
OFF and ON the boiler main supply, after the lighting of all the  
segments of the display, the value of the counter will appear.  
NOTICE  
The reset counter procedure must be carry on after every heat  
exchanger deep cleaning and in any case after heat exchanger  
replacement.  
NOTICE  
To check the hours of the counter, switch off the main supply, than  
switch on. After the lighting of all the elements of the display, a  
number will appear: multiply for 100 to get the hours (18 = 1800  
hours, 01 = 100 hours)  
45  
11 - CHECKS, ADJUSTMENTS AND FAULT FINDING  
5. HEATING MODE  
1. CHECKING APPLIANCE OPERATION  
With the selector switch in the ON position (  
-
-
F ) and any  
When carrying out any repairs or servicing to the appliance, the  
relevant commissioning procedure must be undertaken to  
ensure the continued safe operation of the appliance. Particular  
attention should be made to ensure gas tightness, water  
tightness, and the electrical integrity of the appliance.  
additional controls (time clock, programmer, room thermostat, etc,)  
calling for heat, the appliance will operate in the heating mode.The  
pump and fan will be activated via the flow temperature sensor.  
When the fan is sensed to be operating correctly (blower signal),  
the ignition sequence commences. Ignition is sensed by the  
electronic circuitry to ensure flame stability at the burner. Once  
successful ignition has been achieved, the electronic circuitry  
increases the gas rate to 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. As the water temperature increases, the  
temperature sensors – located on the flow pipe of the boiler –  
reduce the fan speed via the electronic circuitry. Depending on  
the load, either the water temperature will continue to rise until  
the set point is achieved or the water temperature will fall whereby  
fan speed will increase relative to the output required. When the  
boiler has reached the set point (+ hysteresis), the burner will  
switch off. The built-in anti-cycle device prevents the burner from  
re-lighting for approximately 3-minutes. When the temperature  
of the flow sensor falls below the set point (- hysteresis), the  
burner will re-light.  
2. APPLIANCE MODES OF OPERATION  
NOTICE  
There must be sufficient system water pressure min 7 psi (0.5 bar)  
to ensure the water pressure switch is activated. If there is  
insufficient system pressure the pump and fan will be prevented  
from operating and the low-pressure fault code will be displayed.  
The 2-digit display can show several different modes of  
operation.  
3. SELECTOR SWITCH IN THE OFF/STAND BY POSITION  
When the selector switch is in the Off/reset position, the following  
functions are active.  
Active functions:  
- Freeze protection system  
- Pump anti-seize  
4. ON-BOARD FUNCTIONS  
- THERMOREGULATION: When an outdoor air sensor is  
connected to the appliance, the electronic circuitry will  
automatically adjust the flow outlet temperature to suit local  
weather conditions in order to maintain comfort and efficiency. A  
specific operating curve that is most suited to the system type  
and geographical area can also be selected (Fig. 65).  
NOTICE: If the spark/sensing electrode does not sense  
ignition the appliance will re-attempt ignition a further 4-times  
then go to lockout. When the set-point has been reached  
(the position of the heating temperature selector) as  
measured at the primary thermistor, the appliance will begin  
the modulation phase whereby the fan and gas valve will  
continuously modulate to maintain the set-point.  
If the temperature continues to rise and exceeds the set-  
point by 9°F (5°C) (hysteresis), the burner will shut down. A  
new ignition sequence will be enabled when the 3- minute  
anti-cycle has been performed and the temperature at the  
primary thermistor has dropped 9°F (5°C) (hysteresis) below  
the set-point.  
- CO FUNCTION: the CO function when activated, will allow  
the appliance to run at maximum and minimum output while a  
combustion analysis check is being carried out. While the CO  
function is active, all other functions are disabled (minimum  
power operating period, anti-cycle, set-point, etc). Once  
enabled, the CO function will remain active for a 15-minute  
period, or until the function is manually deactivated (refit and  
rotate in any direction the main selector switch).  
- FREEZE PROTECTION:This function is only active when there  
are no requests for heating or DHW. If the temperature drops  
below 43°F (6°C), the boiler will operate on minimum power  
until the temperature of the primary thermistor reaches 95°F  
(35°C).Thereafter the pump & fan will post-purge for 30-seconds.  
- ANTI-CYCLE FUNCTION: The anti-cycle function ensures  
the burner remains switched off for at least 3-minutes after the  
set-point hysteresis (set-point + 9°F (5°C)).  
- PUMP ANTI-SEIZE FUNCTION: When there has been no  
heating or DHW request for 24-hours, the anti-seize cycle is  
activated.The pump will be activated for a period of 30-seconds.  
- ACTUATOR ANTI-SEIZE FUNCTION: When there has been  
no heating or DHW request for 24-hours, the anti-seize cycle is  
activated. The divertor valve actuator (3-way valve) will cycle  
briefly to the heating position, and then back to the DHW position.  
NOTICE: When the request for heating and/or hot water has  
been satisfied, the appliance pump and fan may continue to  
circulate to dissipate any residual heat within the appliance.  
6. DHW MODE  
With the selector switch in either the hot water only or heating &  
hot water position, the appliance will operate in the hot water  
mode whenever a tank sensor/thermostat is in request. If there is  
a request the pump and fan will be activated via the flow tempe-  
rature sensor. When the fan is sensed to be operating correctly  
(blower signal), the ignition sequence commences. Ignition is  
sensed by the electronic circuitry to ensure flame stability at the  
burner. Once successful ignition has been achieved, the  
electronic circuit allows the gas rate to achieve the modulation  
value.  
OFF/reset position  
Freeze protection mode active  
Combustion analysis mode active  
Normal heating request (example 140°F (60oC)).  
Normal DHW request (example 140°F (60oC))  
Purge cycle mode active  
Fig. 58  
46  
8. CHECKING THE CO2 AND ADJUSTING THE GAS VALVE  
THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE  
AID OF A PROPERLY CALIBRATED FLUE GAS ANALYZER.  
Isolate the boiler from the electrical supply and remove the casing  
as described in Fig. 33. Set the flue gas analyzer to read CO2 and  
insert the probe into the flue analysis test point (Pos.B in Fig. 59a).  
Restore the electrical supply to the boiler and switch the boiler to  
the OFF mode. To adjust the gas valve you must first ensure that  
the fan speed potentiometers (trim pot) have been set correctly  
(Tab. 10).  
NOTICE: When the request for heating and/or hot water has  
been satisfied, the boiler pump and fan may continue to  
circulate to dissipate any residual heat within the boiler.  
7. BOILER FAN SPEEDS  
The boiler fan speeds require to be checked and/or adjusted  
prior to making any adjustments to the gas valve or if the main  
PCB has been replaced.  
ATTENTION  
Remove the 3-selector knobs, locate and press the CO button  
(Fig. 59). The appliance will now operate in CO mode for  
approximately 15-minutes.  
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.  
9. GAS VALVE MAXIMUM PRESSURE SETTING (Fig. 61)  
Locate and gently turn the HTG trim pot until the maximum value  
(max fan speed) is obtained and check that it corresponds with  
the appropriate CO2 value (Maximum) for the respective boiler  
(see the data table for values). If the CO2 reading is correct,  
proceed to gas valve minimum setting.However, if the CO2 reading  
is incorrect, the maximum gas pressure must be adjusted as  
follows:  
- Using a suitable screwdriver, very slowly turn the maximum  
pressure adjustment screw (Fig. 60)– clockwise to decrease,  
counter clockwise to increase – until the correct value is  
displayed on the CO2 analyzer (allow time for the analyzer to  
stabilize).  
CHECKING/ADJUSTING THE BOILER FAN SPEEDS  
Move the selector switch to the OFF position and remove the 3-  
selector knobs.  
ABSOLUTE MAX FAN SPEED  
Locate the MAX trim pot (Fig. 59) and gently adjust clockwise or  
counterclockwise to achieve the correct fan speed (see Table 10 below).  
NOTICE: The display shows the fan RPM in multiples of 1000,  
i.e. 2.5 = 2500RPM.  
ABSOLUTE MIN FAN SPEED  
Locate the MIN trim pot (Fig. 59) and gently adjust clockwise or  
counterclockwise to achieve the correct fan speed (seeTable 10 below).  
10. GAS VALVE MINIMUM PRESSURE SETTING  
Locate and gently turn the HTG trim pot until the minimum value  
(min fan speed) is obtained and check that it corresponds with the  
appropriate CO2 value (Minimum) for the respective appliance. If  
the CO2 reading is correct, rotate the HTG trim pot until the correct  
value is obtained for the respective appliance (see fan speed Tab. 10).  
However, if the CO2 reading is incorrect, the minimum gas  
pressure must be adjusted as follows:  
NOTICE: The display shows the fan RPM in multiples of 1000,  
i.e. 2.5 = 2500RPM.  
IGNITION FAN SPEED  
NOTICE: Do this operation only after the adjusting of  
absolute max and min fan speed.  
LocatetheIGNtrimpot(Fig. 59) andgentlyadjustclockwiseorcounter  
clockwise to achieve the correct fan speed (see Table 10 below).  
- Remove the sealing screw  
- Using a suitable screwdriver, very slowly turn the minimum  
pressure adjustment screw (Fig. 60) – clockwise to increase,  
counter clockwise to decrease - until the correct value is  
displayed on the CO2 analyzer (allow time for the analyzer to  
stabilize).  
NOTICE: The display shows the fan RPM in multiples of  
1000, i.e. 2.5 = 2500RPM.  
HEATING FAN SPEED  
COMPLETION  
Locate the HTG trim pot (Fig. 59) and gently adjust clockwise or  
counter clockwise to achieve the correct fan speed (see Table 10  
below).  
On completion of the combustion analysis check and/or any gas  
valve adjustment, set the HTG trim pot to the corresponding value  
as detailed in the fan speed table. Reattach the 3-selector knobs.  
Remove the test probe from the test point and reattach the sealing  
screws and/or cap.  
NOTICE: The display shows the fan RPM in multiples of  
1000, i.e. 2.5 = 2500RPM.  
DANGER:A GASTIGHTNESS CHECK MUST BE CARRIED  
OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN  
REMOVED, REPLACED, OR DISTURBED.  
FAN SPEED TABLE  
Use the following table to set the corresponding fan speeds that  
are relative to the boiler you are working on.  
11. COMBUSTION ANALYSIS TEST  
FAN SPEED (rpm) TABLE  
MODEL MAX MIN  
Tab. 10  
A combustion analysis check can easily be carried out on the  
boiler via the test points located on the top of the appliance.  
- Insert the flue gas analyzer probe into the flue gas test point  
(Pos. B in Fig. 59a).  
HTG  
IGN  
85  
120  
5,800  
5,600  
2,000  
1,500  
5,800  
5,600  
3,700  
3,700  
- Operate the boiler in CO mode and compare the values with  
those shown inTab.1 (Nat.Gas) or Section 13 (LPG).If different  
adjust the gas valve accordingly.  
12. EXTERNAL FAULTS  
Before carrying out any troubleshooting or component  
replacement, ensure the fault is not attributable to any aspect of  
the installation.  
HTG  
IGN  
CO  
MAX  
MIN  
TMR  
INSTALLATION FAULTS  
Symptom  
No display/ignition  
Possible cause  
Fig. 59  
Check wiring/check  
electrical supply  
No hot water  
No heating  
Check external controls  
Check external controls  
A
B
Fault code  
10  
Possible cause  
Check gas supply, check  
flue system, check polarity,  
check condensate  
Fig. 59a  
47  
Maximum  
pressure  
adjustment  
screw  
FAULT FINDING  
Before attempting any faultfinding, the electrical checks must be  
carried out. Isolate the appliance from the electrical supply.  
Disconnect any external controls from terminal plug (Fig. 35),  
and insert a jumper between the two wires at the room thermostat  
connections (Fig. 35 ref. M4a).  
Compensation  
pipe connection  
NOTICE: Restore the electrical supply to the boiler and turn the  
main selector switch to the heating request position .The boiler  
should now function. Should the boiler fail to respond, the internal  
fuses and connectors should be checked to ensure integrity  
and continuity.  
Minimum  
pressure  
adjustment  
screw  
14. COMPONENT VALUES & CHARACTERISTICS  
Fig. 60  
COMPONENT  
VALUE  
120VAC  
120VAC  
120VAC  
120VAC  
120VAC  
24 Vdc  
Fan  
NOTE: The gas valve sticker “WARNING: VALVE IS NOT FIELD  
SERVICEABLE”means the valve can be adjusted but not disassembled.  
Pump  
3-way valve (field supplied)  
Ignition transformer  
Gas valve  
Room thermostat connection  
NTC sensor (dry contact)  
NTC sensor (wet contact)  
13. ELECTRICAL CHECKS  
10Kohm  
10Kohm  
Any electrical checks must be carried out by a ServiceTechnician  
Qualified.  
GROUND CONTINUITY TEST  
FUNCTION  
VALUE  
Isolate the boiler from the electrical supply, and using a suitable  
multi-meter carry out a resistance test. Connect test leads between  
an appliance ground point and the ground wire of the appliance  
supply cable. The resistance should be less than 1 OHM. If the  
resistance is greater than 1 OHM check all ground wires and  
connectors for continuity and integrity.  
Standard Heating Range °F (°C)  
Floor Heating Range °F (°C)  
CH limited power at 75%  
Heating OFF hysteresis °F (°C)  
Heating ON hysteresis °F (°C)  
Anti-cycle delay  
104-176 (40-80)  
68-113 (20-45)  
15 Min  
SP+8 (+5)  
SP-8 (-5)  
3-min  
30-sec  
Min+25  
203 (95)  
167 (75)  
15-min  
203 (95)  
221 (105)  
95 (35)  
SHORT CIRCUIT CHECK  
Pump over-run  
Isolate the boiler from the electrical supply, and using a suitable  
multi-meter, carry out a short circuit test between the Live & Neutral  
connections at the appliance terminal strip (Fig. 35). Repeat above  
test on the Live & Ground connections at the appliance terminal  
strip.  
Low output (min. output + %)  
CO function max temp. °F (°C)  
CO re-light temp. °F (°C)  
CO function time  
Flow NTC max temp. °F (°C)  
High limit thermostat °F (°C)  
Maximum differential °F (°C)  
NOTICE: Should it be found that the fuse has failed but no fault  
is indicated, a detailed continuity check will be required to trace  
the fault. A visual inspection of components may also assist in  
locating the fault.  
IGNITION CONTROL  
VALUE  
5
Ignition attempts before L/O (lockout).  
Re-ignition attempts after loss of flame  
signal  
POLARITY CHECK  
With the boiler connected to the electrical supply and using a  
suitable multimeter, carry out the following voltage tests:  
- Connect test leads between the Live & Neutral connections at  
the boiler terminal strip (Fig. 35). The meter should read  
approximately 120VAC. If so proceed to next stage.  
- Connect test leads between the Live & Ground connections at  
the boiler terminal strip (Fig. 35). The meter should read  
approximately 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.  
5
15. BOILER CONFIGURATION  
The electronic board contains a series of jumpers that can be  
used to configure the boiler; access these by loosening the  
fasteners B and removing the control panel cover A after turning  
off the main switch (Fig. 62).  
Locate the JP positioning (Fig. 63).  
JUMPER IN POSITION 1 (Fig. 61):  
The position nr. 1 of the jumper indicates the boiler heating tem-  
perature; pre-selection of the most suitable heating temperatu-  
re adjustment field according to the type of system.  
Jumper not inserted (factory set) - case 1  
Standard system (radiators) 104-176°F (40-80°C)  
Jumper inserted - case 2  
REVERSED POLARITY OR SUPPLY FAULT  
Repeat the above tests at the appliance isolator, if testing reveals  
correct polarity and/or supply at the isolator, re-check wiring and  
connections between the isolator and the boiler. If tests on the  
isolator also reveal reversed polarity or a supply fault, consult the  
local electricity supplier for advice.  
Floor system (radiant heating) 68-113°F (20-45°C).  
NOTICE:The boiler has been factory-configured for standard  
RESISTANCE TO GROUND CHECK  
systems.  
Isolate the boiler from the electrical supply, and using a suitable  
multi-meter carry out a resistance test. Connect test leads between  
the Live & Ground connections at the appliance terminal strip  
(Fig. 35). If the meter reads other than infinity there is a fault that  
must be isolated, carry out a detailed continuity check to identify  
the location of the fault.  
These series of checks must be carried out before attempting  
any troubleshooting procedures on the appliance. On completion  
of any task that required the disconnection and re-connection of  
any electrical wiring or component, these checks must be  
repeated.  
JUMPER IN POSITION 2:  
Jumper inserted:  
heating + indirect water tank with sensor  
JUMPER IN POSITION 3:  
Jumper inserted:  
heating + indirect water tank with thermostat - factory set  
JUMPER IN POSITION 4:  
unused  
48  
JUMPER IN POSITION 5:  
Select KT by turning the trimmer located under the domestic hot  
water temperature knob (A).  
unused  
The settable values of KT are:  
JUMPER IN POSITION 6:  
- standard system: 1,0-1,5-2,0-2,5-3,0  
- floor system: 0,2-0,4-0,6-0,8  
unused  
The boiler is supplied standard with the jumper in position 3  
(standard heating + indirect water tank with thermostat); if  
you wish to use an external water tank with sensor, move this  
jumper from position 3 to position 2 (case B, Fig 61); if you  
wish to have low temperature for floor space heating move  
the not inserted jumper in position 1 (Fig 61).  
TYPE OF HEAT REQUEST  
STANDARD  
If a room thermostat is connected to the boiler: room  
thermostat  
The room thermostat makes a heat request when its contact  
closes, while it stops it when its contact opens. Though delivery  
temperature is automatically calculated by the boiler, the user  
may manually override it. By modifying HEATING on the user  
interface (C), the HEATING SET POINT will no longer be available  
but just a value that can be set from +5 to -5 as required. Please  
note that the number displayed is a comfort level: +5 means feel  
hotter, -5 means feel colder. Modifications to this value do not  
directly change flow temperature but affect the calculation made  
to automatically determine its value by modifying the reference  
temperature of the system (0 = 68°F (20°C)).  
CASE B  
6
CASE A  
radiators  
(factory set)  
radiators  
floor heating  
floor heating  
6
1
6
6
1
1
1
PROGRAMMABLE TIMER (DAY+NIGHT)  
If a programmable timer (day+night selector) is connected to  
the boiler, set parameter 51 = 1 (this parameter can only be  
modified from the remote control unit) (Fig. 67) available only  
from Raypak technical service.  
Indirect water tank with  
thermostat to control  
DHW temperature  
Indirect water tank with  
sensor to control DHW  
temperature  
When the contact is closed, the heat request is made by the delivery  
probe on the basis of the external temperature in order to maintain  
the rated ambient temperature at the DAY level 68°F (20 °C).When  
the contact opens, it does not stop the heat request but reduces  
(parallel shift) the temperature curve to the NIGHT level 61°F (16  
°C).  
Fig. 61  
A
JP  
This activates the night mode.  
Though flow temperature is automatically calculated by the boiler,  
the user may manually override it.  
By modifying HEATING on the user interface (C, Fig. 13.2), the  
HEATING SET POINT will no longer be available but just a value  
that can be set from +5 to -5 as required. Please note that the  
number displayed is a comfort level: +5 means feel hotter, -5  
means feel colder.  
Modifications to this value do not directly change flow tempera-  
ture but affect the calculation made to automatically determine  
its value by modifying the reference temperature of the system  
(0 = 68°F (20°C) for DAY level; 61°F (16°C) for NIGHT level).  
B
Fig. 63  
Fig. 62  
16. SETTING THE OUTDOOR RESET CURVE WITH  
OUTDOOR SENSOR  
Outdoor temperature reset only works with the outdoor air sensor  
connected, therefore, after installation, connect the outdoor air  
sensor to the relative connections on the boiler terminal board  
(Fig. 35).  
If a remote control (Raypak REC 08) is installed refer to  
instructions for setting the outdoor sensor using.  
This enables the outdoor temperature reset function.  
The user can program the desired supply temperature based on  
the heat transmitter that will be used in the installation. Once the  
outdoor sensor is connected to the control board, the water  
temperatureoftheboilerwilladjusttoruntheboilermoreefficiently  
and provide greater comfort to the living space.  
NOTICE: The DHW temperature is independent from the  
outdoor air sensor.  
Selecting the offset heating curve (Fig. 65)  
The offset heating curve maintains a theoretical ambient tempe-  
rature of 68°F (20°C) at outdoor temperatures ranging from 68°F  
to -4°F (+20°C to -20°C).The choice of the curve depends on the  
rated minimum outdoor temperature (of the geographical area)  
and the rated delivery temperature (on the type of system) and  
must be carefully calculated by the installer using the following  
formula using the correct values in °F or °C:  
Nominal flow Temp. - Tshift  
68°F (20°C) - min. external design Temp.  
TMR =  
Tshift =86°F (30°C) standard systems (radiators)  
77°F (25°C) underfloor systems  
If the calculation generates an intermediate value between two  
curves, choose the nearest offset heating curve to that value.  
E.g.: if the value obtained by the calculation is 1.3, it lies between  
curve 1 and curve 1.5. In this case, select the nearest curve, i.e.: 1.5.  
49  
OUTDOORTEMPERATURE RESET CURVES  
(°C)  
(°F)  
212  
194  
176  
158  
140  
122  
104  
86  
68  
(°C)  
(°F)  
68  
59  
50  
41  
32  
23  
14  
5
-4  
OUTDOOR TEMPERATURE  
Fig. 65  
(°C)  
(°F)  
OUTDOOR RESET CORRECTION  
90  
80  
70  
60  
50  
40  
30  
20  
10  
194  
176  
158  
140  
122  
104  
86  
+ 5 
0 C  
68  
- 5 
50  
(°C)  
(°F)  
30  
25  
20  
15  
10  
5
0
-5  
-10  
-15  
-20  
86  
77  
68  
59  
50  
41  
32  
23  
14  
5
-4  
OUTDOOR TEMPERATURE  
Fig. 66  
NIGHT SETBACK  
(°C)  
90  
(°F)  
194  
80  
70  
60  
50  
40  
30  
20  
10  
176  
158  
140  
122  
104  
86  
Outdoor reset - DAY  
Outdoor reset - NIGHT  
68  
50  
20  
15  
10  
5
0
-5  
-10  
-15  
-20  
(°C)  
(°F)  
68  
59  
50  
41  
32  
23  
14  
5
-4  
OUTDOOR TEMPERATURE  
Fig. 67  
50  
17. FAULT CODES  
When the boiler detects a temporary fault condition, the  
appropriate code is shown flashing on the display. If/when the  
fault code is final, the pump will perform a 60-second post  
circulation and the red LED will be illuminated.  
CODE CAUSE  
ALARM TYPE  
ACTION  
AL10  
Ignition failure/not flame sensed,  
condense sensor activated  
Final  
Reset, check appliance operation  
AL20  
Limit thermostat fault, blocked flue switch,  
flue thermostat  
Final  
Final  
Final  
Reset, check appliance operation  
Reset, check appliance  
AL21  
AL26  
External device fault (UHT/CPA)  
Return temperature too high  
Reset, check pump, ensure there is sufficient  
flow sensor temperature). Circulation around  
heating circuit/s  
AL28  
Temperature differential inverted  
(return sensor temperature higher than  
flowsensor temperature)  
Final  
Reset, check pump, ensure there is sufficient  
circulation around heating circuit/s thermistors  
AL29  
AL34  
AL40  
Flue sensor over temperature lock out  
Fan blower signal fault  
Final  
Final  
Reset check appliance operation  
Reset check appliance operation, check fan  
Check/refill system pressure, reset, check  
Insufficient system water pressure  
Final  
appliance operation  
AL41  
Insufficient system water pressure  
Temporary  
Check/refill system pressure, check appliance  
operation  
AL52  
AL55  
AL60  
AL71  
AL73  
AL74  
Internal fault  
Final  
Reset, check boiler operation  
Jumper tag fault  
Final  
Check jumper tag configuration  
Check jumper tag configuration  
Check primary thermistor, check wiring  
Check return thermistor, check /wiring  
Jumper tag fault  
Temporary  
Temporary  
Temporary  
Final  
Primary (flow) sensor fault  
Return sensor fault  
Variation on temperature of primary  
Reset, check boiler operation, check  
and/or return too high pump, ensure there is  
sufficient circulation around heating circuit/s  
AL79  
AL91  
Flow temperature too high, or  
temperature differential between  
primary and return too high  
Final  
Reset, check appliance operation, check  
thermistors  
The main heat exchanger need to be  
cleaned  
Advice  
Call the Raypak technical service  
51  
12- SERVICINGINSTRUCTIONS  
1. GENERAL  
PUMP ASSEMBLY (Fig. 69)  
To ensure the continued safe and efficient operation of the boiler,  
it is recommended that it is checked and serviced at regular  
intervals. It is essential that any worn or failed component be  
replaced only with a genuine XPak spare parts. It should be  
remembered that although certain generic components may look  
similar, they will be specific to an individual appliance or product  
range. Use of non-genuine XPak spare parts could invalidate your  
warranty and may pose a potential safety hazard.The frequency of  
servicing will depend upon the particular installation conditions,  
but in general, once per year should be sufficient. It is the law that  
any servicing work is carried out by competent person such as a  
Raypak Technician, an approved service agent, or other suitably  
qualified personnel. The following instructions apply to the  
appliance and its controls, but it should be remembered that the  
central heating and the domestic hot water systems would also  
require attention from time to time.  
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.  
Disconnect and remove the pump outlet pipe (C) from the pump  
assembly/combustion chamber connection. Locate and remove  
the pressure gauge securing pin (D) and disconnect the  
pressure gauge from the pump assembly.  
Disconnect the electrical wiring from the pump’s electrical  
connection point (E). Remove locking pin (F) from pump base  
and lift pump assembly clear of the hydraulic manifold. The  
pump assembly can now be removed from the appliance.  
Replace carefully in the reverse order.  
PRESSURE RELIEF VALVE (Fig. 69)  
Disconnect the outlet pipe (L) and the flow pipe (M) from the  
safety valve, remove pressure release valve. Replace in the  
reverse order.  
2. ROUTINE ANNUAL SERVICING  
- Check the operation of the boiler and ensure it functions as  
described in Section “11. Checks, adjustments and fault  
finding”.  
LOWER AUTOMATIC AIR RELEASE VALVE (Fig. 69)  
Locate and remove the AAV locking pin (G) from the pump  
assembly and remove the AAV assembly (H). Replace in the  
reverse order.  
- Thoroughly inspect the boiler for signs of damage or  
deterioration especially the flue system and the electrical  
apparatus.  
- Check and adjust – if necessary – the system design pressure  
(see pg. 63 ref. 10).  
TOP AUTOMATIC AIR RELEASE VALVE (Fig. 70)  
Remove the drain pipe (A). Unscrew the top AAV (B). Replace  
in the reverse order. Loctite or similar should be used as a thread  
sealant for the AAV.  
- Carry out an analysis of the flue gases (pg. 73), and visually  
check the condition of the entire flue assembly.  
- Check that the burner and main heat exchanger are clean and  
free from any debris or obstruction.  
- Check and clean – if necessary – the condense trap to ensure  
correct operation.  
- Compare the performance of the appliance with its design  
specification. The cause of any noticeable deterioration should  
be identified and fixed without delay.  
XPak 85  
- The combustion blower motor does not require lubrication for  
proper operation. DO NOT attempt to oil the motor or damage  
may occur.  
H
3. REPLACEMENT OF COMPONENTS  
G
L
Although it is anticipated that this appliance will give years of  
reliable, trouble free service, the life span of components will be  
determined by factors such as operating conditions and usage.  
Should the appliance develop a fault, the troubleshooting section  
will assist in determining which component is malfunctioning.  
A
C
D
E
4. COMPONENT REMOVAL PROCEDURE  
M
To remove a component, access to the interior of the boiler is  
essential. Isolate the appliance from the electrical supply. And  
when necessary, close all service valves on the boiler, remove  
the casing and drain the water content from the boiler via the  
drain valve. Ensure some water absorbent cloths are available  
to catch any residual water that may drip from the boiler or  
removed component. Undertake a complete commissioning  
check, after replacing any component.  
F
I
XPak 120  
ALWAYSTEST FOR GASTIGHTNESS IF ANY GAS CARRYING  
COMPONENTS HAVE BEEN REMOVED OR DISTURBED.  
AIR BOX FRONT COVER REMOVAL (Fig. 68)  
Locate the two clips and remove air box front cover.If it’s necessary  
to remove the air box side cover, locate and remove the 4 securing  
screws.  
H
G
C
A
L
D
E
B
F
clips  
I
Fig. 69  
Fig. 68  
52  
XPak 85  
E
B
A
C
D
Fig. 70  
WATER PRESSURE SWITCH (Fig. 69)  
Locate and remove the screw (I) from the water pressure switch.  
Remove the wiring. Carefully remove the switch. Replace in the  
reverse order.  
E
XPak 120  
E
FLOW SENSOR (PRIMARYTHERMISTOR) (Fig. 1)  
Unclip and remove the air chamber front cover. Unclip the primary  
thermistor from the flow outlet pipe. Disconnect thermistor electrical  
plug. Replace in the reverse order.  
RETURN SENSOR (RETURN THERMISTOR) (Fig. 1)  
Unclip and remove the air chamber front cover. Unclip the return  
sensor from the return inlet pipe. Disconnect sensor electrical  
plug. Replace in the reverse order.  
PRINTED CIRCUIT BOARD (Fig. 71)  
C
Pull the control slightly forward and lower it. Push the clips (A)  
and remove cover, after carefully taking note of all wiring  
connections and jumper tag configurations; unhook and remove  
connection block (B). Disconnect all wiring from the PCB, locate  
and remove the PCB securing screws, remove the required PCB.  
Replace in the reverse order ensuring that the position of the 3  
control knobs are correctly aligned with the respective  
potentiometers on the PCB.  
D
Fig. 72  
E
INJECTOR (Fig. 72)  
Slacken and unscrew upper gas valve pipe; locate and remove  
only two screws (D). Locate and remove the injector (F) inside  
the pipe. Replace in the reverse order. Check and adjust burner  
pressure settings.  
WARNING, A GAS TIGHTNESS CHECK MUST BE CARRIED  
OUT.  
Ensure that the correct jumper configuration has been made. It  
will be necessary to check the functioning of the PCB is set for  
the correct boiler type/application.  
GAS VALVE (Fig. 72)  
The gas valve must be changed as complete unit. Disconnect  
the electrical plug and leads from the gas valve, slacken and  
unscrew upper gas valve pipe, please note that the gas injector  
is located in this upper part. Disconnect the compensation pipe  
(C). Locate and remove the two retaining screws (D); locate and  
remove the four gas valve retaining screws (E). Replace in the  
reverse order. Check and adjust burner pressure settings.  
WARNING, A GAS TIGHTNESS CHECK MUST BE CARRIED  
OUT.  
ELECTRODES & CONDENSATE SENSOR (Fig. 73)  
Unclip and remove the air chamber front and right hand side  
covers. 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.  
F
NOTICE: The gas valve sticker “WARNING: VALVE IS NOT FIELD  
SERVICEABLE” means the valve can be adjusted but not disassembled.  
B
I
G
H
A
A
D
C
Fig. 73  
Fig. 71  
53  
FLUE FAN & MIXER (Fig. 74)  
Unclip and remove the air chamber front and the right hand side  
covers. Slacken the gas pipe (A) at the air box connection and  
swing/rotate away from the fan assembly. To remove the mixer  
(B) locate and remove the three screws (C). To remove the fan  
(D), disconnect the electrical connections attached to the fan,  
locate and remove the four screws (E). Gently ease the fan from  
its location.  
A
Replace in the reverse order. Ensure all seals are in good  
condition, taking care to ensure they are replaced correctly.  
B
BURNER (Fig. 75)  
Unclip and remove the air chamber front and the right hand side  
covers. Slacken the gas pipe (A) at the air box connection and  
swing/rotate of the fan assembly.Locate and remove the 3 internal  
nuts (B) which secure the fan assembly in position (C) to the heat  
exchanger (D). Disconnect the electrode leads and ancillary  
wiring from their respective connectors. Remove the retaining  
screws (A fig. 73) for sensing electrode and remove. Remove the  
retaining nut (C fig. 73) for condensation sensor (D fig. 73) and  
remove. Gently ease the fan assembly out of its location. Once  
the assembly has been removed, the burner (E) can be withdrawn  
from the heat engine. Ensure the seal (F) is in good condition,  
taking care to ensure it is replaced correctly.Replace in the reverse  
order.  
D
C
Fig. 74  
Fig. 75  
E
D
E
F
BLOCKED  
FLUE  
PRESSURE  
SWITCH/IGNITION  
TRANSFORMER (Fig. 73)  
Disconnect the compensation pipe (G).  
Disconnect the electric wiring from the pressure switch/ignition  
transformer.  
B
A
Remove the two screw (F) on the upper part of the combustion  
chamber.  
C
Remove the screw (I).  
Remove the pressure switch. Replace in reverse order.  
Remove the two screw (H), remove the ignition transformer.  
Replace in reverse order.  
Fig. 76  
MAIN HEAT EXCHANGER (Fig. 76-77)  
Unclip and remove the three air chamber covers (front, left hand,  
right hand sides). Disconnect all the wiring connections.  
Fig. 76: slacken the gas pipe (A) at the air box connection and  
swing/rotate of the fan assembly. Disconnect the flow (B), return  
(C) and condensation connections on the heat exchanger. Locate  
and remove the 4-screws that secure the heat exchanger to the  
combustion chamber (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). Replace in the reverse order. Ensure all  
seals are in good condition, taking care to ensure they are  
replaced correctly.  
B
C
AUTOMATIC BYPASS (Fig. 78)  
A
Disconnect and remove the flow pipe (1), at the connection to the  
pressure relief valve, at heating manifold and at the connection  
to the air chamber. Using a hooked piece of wire, carefully  
withdraw the bypass cartridge (2).  
E
D
Ensure all seals are in good condition, taking care to ensure they  
are replaced correctly. Replace in the reverse order ensuring the  
cartridge is facing the correct way.  
A
2
1
B
Fig. 78‘  
Fig. 77  
54  
CONDENSATETRAP 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.  
A
FLUE COLLECTOR AND FLUETHERMOSTAT REMOVAL (Fig.  
80)  
Unclip and remove the air chamber front and left side covers.  
Locate and remove the screw (A) that secures the flue gas  
analysis test point cover (B). Disconnect the silicon pipe (right  
hand) of the blocked flue switch. Remove the clip (C) and the flue  
thermostat (D). Gently pull down and to the left and ease the flue  
collector from its location. Replace in the reverse order.  
B
C
A
B
C
Fig. 79  
B
A
C
D
Fig. 80  
55  
13 - LPG INSTRUCTIONS  
TheXPakboilerisfactorysuppliedtousenaturalgas. Theboilercan  
Thisinstructionmustberetainedadjacent use also LPG gas by installing a kit (supplied with every unit). The  
conversion to LPG is possible by:  
to the boiler as they contain important  
details about the conversion made.  
1. Install the new gas injector  
2. Modify the fan speed according the data in the table.  
The kit is composed by:  
1. Injector black coating (to be recognized from the natural gas  
that is not black coated)  
WARNING:Thisconversionkitshall  
be installed by a qualified service  
agency in accordance with the  
manufacturer’s instructions and all  
applicable codes and requirements  
of the authority having jurisdiction.  
If the information in this instructions  
is not followed exactly, a fire, an  
explosion or production of carbon  
monoxide may result causing  
property damage, personal injury  
or loss of life. The qualified service  
agency is responsible for the proper  
installationofthiskit.Theinstallation  
is not proper and complete until the  
operationoftheconvertedappliance  
is checked as specified in the  
2. Relative gas sticker (red color) to be attached under the boiler  
instead of the natural gas sticker (yellow color factory installed)  
3. Instruction of the kit  
4. LPG label to be affixed on the boiler casing and completed in  
by the organization making this conversion.  
Operations for conversion  
1. Switch off the boiler  
2. Change the gas injector  
3. Apply the red sticker  
4. Switch on the boiler  
5. Set the new fan speed  
6. Fill the final part of this instruction  
GAS SUPPLY  
The gas supply must be connected to the boiler by a competent LPG  
installer and must be of sufficient size to supply the boiler at its  
maximum output. An existing supply must be checked to ensure that  
it is of adequate size to deal with the maximum rated input of this and  
any other appliances that it serves.  
GAS SUPPLY INSTALLATION  
The entire installation including the meter must be purged and  
checked for gas tightness.  
CONVERTINGTHE BOILER GASTYPE  
To convert the boiler to another gas type it is necessary to change  
the gas injector, adjust the fan speed and the gas valve.  
NOTICE: The gas valve sticker “WARNING: VALVE IS NOT FIELD  
SERVICEABLE”means the valve can be adjusted but not disassembled.  
manufacturer’s  
instructions  
supplied with the kit.  
CHANGE THE GAS INJECTOR  
Slacken and unscrew upper gas  
valve pipe; locate and remove the  
LPG INSTRUCTIONS  
PROPANE GAS:  
CAUTION: The gas supply shall be shut off prior to  
disconnecting the electrical power, before proceding with the  
conversion.  
two screws shown as (A). Locate  
and remove the natural gas injector  
(B) inside the pipe, insert the LPG  
injector (black coating). Replace in  
the reverse order. Check and  
adjust burner pressure settings.  
WARNING:  
B
A gas tightness check must be  
carried out if any gas carryng  
components have been removed,  
replaced or disturbed.  
InstallationCodes  
A
Installations must follow these codes:  
• Local, state, provincial, and national codes, laws, regulations  
and ordinances  
• National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition  
(NFGC)  
Fig. 1  
• For Canada only: CAN/CSA B149 Natural Gas and Propane  
Installation Code and CSA C22.1 C.E.C. Part 1 (C22.1)  
CHECKING  
THE  
RELATIONSHIP OF THE  
IGNITER TO MAIN BURNER  
Remove the burner assembly as  
indicated in the boiler manual  
“Servicing instructions”.  
WARNING:XPak boilers are shipped ready to fire natural gas  
ONLY. You must install the propane orifice and regulate the  
gas valve if the boiler will be connected to propane. Failure to  
comply could result in severe personal injury, death or  
substantial property damage.  
Check the distance between the  
burner and the two electrodes  
according  
the  
distances  
Pipe sizing for natural gas  
indicated in Fig. 1A. Replace in  
the reverse order.  
Contact gas supplier to size pipes, tanks and 100% lockup gas  
pressure regulator.  
Propane supply pressure requirements  
1. Adjust propane supply regulator provided by gas supplier for  
13" w.c. maximum pressure.  
2. Pressure required at gas valve inlet pressure port: Maximum:  
13" w.c. with no flow (lockup) or 8" w.c. minimum with boiler  
operating  
Fig.1A  
56  
TECHNICALDATA-LPG  
Gas pressure  
Input - (0 - 2000 ft / 0 - 610 m)  
XPak 85  
25,600 - 87,000  
7.5 - 25.5  
25,600 - 82,900  
7.5 - 24.3  
11  
XPak 120  
27,300 - 119,500  
8.0 - 35.0  
27,300 - 114,300  
8.0 - 33.5  
11  
Btu/hr  
kW  
Btu/hr  
kW  
in w. c.  
kPa  
HTG  
IGN  
CO  
MAX  
Input - (2000 - 4500 ft / 610 - 1375 m)  
Gas supply pressure LPG  
MIN  
TMR  
2.75  
2.75  
Min. gas supply pressure LPG in w. c.  
8
8
kPa  
Max. gas supply pressure LPG in w. c.  
kPa  
1.99  
13  
3.24  
1.99  
13  
3.24  
Fig. 2  
Burner pressure (max-min)  
in w. c.  
kPa  
1.92-0.24  
0.48-0.06  
2.00-0.16  
0.50-0.04  
Fig. 3  
B (flue)  
Rate  
Gas Rate max LPG  
lbs/hr  
kg/hr  
lbs/hr  
kg/hr  
4.02  
1.82  
1.20  
0.54  
5.55  
2.52  
1.28  
0.58  
A (air)  
Gas Rate min LPG  
Emissions  
CO2 setting  
NOx @ max  
NOx @ min  
CO @ max without air  
CO @ min without air  
Injector size  
%
10.0%  
< 20  
< 15  
< 200  
< 40  
10.0%  
< 20  
< 20  
< 200  
< 35  
ppm  
ppm  
ppm  
ppm  
Injector LPG (E) - black coated  
Ø
0.15 inch (3.9 mm) 0.19 inch (5.0 mm)  
ADJUSTING THE GAS VALVE  
THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE  
AID OF A PROPERLY CALIBRATED FLUE GAS ANALYZER.  
BOILER FAN SPEEDS  
The boiler fan speeds require to be checked and/or adjusted  
prior to making any adjustments to the gas valve or if the main  
PCB has been replaced.  
CHECKING THE CO2 AND ADJUSTING THE GAS VALVE  
THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE  
AID OF A PROPERLY CALIBRATED FLUE GAS ANALYZER.  
Isolate the boiler from the electrical supply and remove the  
appliance casing. Set the flue gas analyzer to read CO2 and insert  
the probe into the flue analysis test point (A-air, B-flue Fig. 3).  
Restore the electrical supply to the boiler and switch the boiler to  
the OFF mode. To adjust the gas valve you must first ensure that  
the fan speed potentiometers (trim pots) have been set correctly.  
Remove the 3-selector knobs, locate and press the CO button).  
The appliance will now operate in CO mode for approximately 15-  
minutes.  
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.  
ADJUSTING GAS PRESSURE  
The gas pressure can not be adjusted as the boiler is equipped  
with a pneumatic gas valve.  
CHECKING/ADJUSTING THE APPLIANCE FAN SPEEDS  
Move the selector switch to the OFF position and remove the  
3-selector knobs.  
GAS VALVE MAXIMUM SETTING  
Locate and gently turn the HTG trim pots until the maximum value  
(max fan speed) is obtained and check that it corresponds with  
the appropriate CO2 value (Maximum) for the respective boiler. If  
the CO2 reading is correct, proceed to gas valve minimum setting.  
However, If the CO2 reading is incorrect, the maximum gas  
pressure must be adjusted as follows:  
ABSOLUTE MAX FAN SPEED  
Locate the MAX trim pot (Fig. 2) and gently adjust clockwise or counter  
clockwise to achieve the correct fan speed (see table below).  
NOTE  
ThedisplayshowsthefanRPMinmultiplesof1000,i.e. 2.5=2500RPM.  
- Using a suitable screwdriver, very slowly turn the maximum  
adjustment screw (Fig. 4) – clockwise to decrease, counter  
clockwise to increase – until the correct value is displayed on  
the CO2 analyzer (allow time for the analyzer to stabilize).  
ABSOLUTE MIN FAN SPEED  
Locate the MIN trim pot (Fig. 2) and gently adjust clockwise or  
counter clockwise to achieve the correct fan speed (see table below).  
NOTE  
GAS VALVE MINIMUM SETTING  
The display shows the fan RPM in multiples of 1000, i.e.  
2.5 = 2500RPM.  
Locate and gently turn the HTG trim pot until the minimum value  
(min fan speed) is obtained and check that it corresponds with  
the appropriate CO2 value (Minimum) for the respective  
appliance. If the CO2 reading is correct, rotate the HTG trim pot  
until the correct value is obtained for the respective appliance  
(see fan speed table) and proceed.  
IGNITION FAN SPEED  
ATTENTION  
Do this operation only after the adjusting of absolute max and  
min fan speed.  
However, If the CO2 reading is incorrect, the minimum gas  
pressure must be adjusted as follows:  
Locate the IGN trim pot (Fig. 2) and gently adjust clockwise or  
counter clockwise to achieve the correct fan speed (see table below).  
- Using a suitable screwdriver, very slowly turn the minimum  
adjustment screw (Fig. 4) – clockwise to increase, counter  
clockwise to decrease - until the correct value is displayed on  
the CO2 analyzer (allow time for the analyzer to stabilize).  
NOTE  
The display shows the fan RPM in multiples of 1000, i.e.  
2.5 = 2500RPM.  
HEATING FAN SPEED  
INSTALLATIONS AT ELEVATION  
Locate the HTG trim pot (Fig. 2) and gently adjust clockwise or  
counter clockwise to achieve the correct fan speed (see table  
below).  
Rated inputs are suitable for up to 4,500 ft elevation (see technical  
data table). Consult the factory for installations at altitudes over  
4,500 ft above sea level. No hardware changes are required to the  
boilers for installations up to 10,000 ft (adjustments may be required).  
NOTE  
The display shows the fan RPM in multiples of 1000, i.e.  
2.5 = 2500RPM.  
COMPLETION  
On completion of the combustion analysis check and/or any gas valve  
adjustment, settheHTGtrimpottothecorrespondingvalueasdetailed  
in the fan speed table. Reattach the 3-selector knobs. Remove the test  
probe from the test point and reattach the sealing screws and/or cap.  
FAN SPEED (rpm)TABLE  
MODEL MAX  
XPak85 5,700  
XPak120 5,400  
MIN  
1,900  
1,400  
HTG  
5,700  
5,400  
IGN  
3,700  
3,700  
57  
IMPORTANT  
A GAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY  
GAS CARRYING COMPONENTS HAVE BEEN REMOVED,  
REPLACED, OR DISTURBED.  
Maximum screw  
XPAK LPG LABEL  
1. Fill in the enclosed LPG label with all the information required  
and affix the label as close as possible to existing rating plate  
2. Affix the enclosed RED color label over the existing YELLOW  
color label under the boiler near to the boiler gas connection.  
Compensation  
pipe connection  
SEQUENCE OF THE IGNITION SYSTEM  
Switch on the boiler as follows:  
- Open the gas tap under the boiler by turning it  
counterclockwise  
Minimum screw  
- Turn on the general switch of the system and then, after lowering  
the flap, turn the function selector to summer  
, winter  
or  
winter tank temperature  
depending on the chosen operating  
F
mode.  
Fig. 4  
The boiler start to run according the automatic sequence: heat  
request, fan start-up, tachometer check, ignition trials, gas  
opening and ignition start-up.  
58  
14 - EXPLODED DIAGRAMS  
Drawing 1  
2
1
12a  
6
3
8
4
11  
9
10  
7
12a  
5
59  
Drawing 2  
19  
17  
18  
56a  
12b  
56b  
56a  
14  
15  
13  
16  
60  
Drawing 3  
XPAK 85  
XPAK 120  
25  
25  
22  
28  
22  
26  
28  
21d  
12d  
26  
12d  
21d  
56a  
21c  
12d  
21b  
28  
24b  
24c  
21c  
23  
56a  
24b  
24c  
56c  
56a  
24d  
23  
27  
24e  
21a  
12c  
20  
24d  
24e  
24a  
24a  
61  
Drawing 4  
30  
29  
31  
47  
45  
34  
40  
33  
56a  
43  
35  
41  
57b  
36  
30  
37  
44  
46  
38  
39  
32  
57  
42  
58  
57b  
53 Drawing 5  
52 Drawing 5  
Drawing 5  
50  
49  
51  
48  
55  
53  
54  
52  
62  
CALL  
OUT DESCRIPTION  
XPak85  
XPak120  
Electric/Case Components  
See Drawing #1  
1
Jacket Front  
012831F  
013004F  
012829F  
012827F  
012833F  
012828F  
012830F  
012834F  
012826F  
012836F  
013003F  
013011F  
012832F  
013004F  
012829F  
012827F  
012833F  
012828F  
012830F  
012834F  
012826F  
012999F  
013003F  
013011F  
2
Boiler Mounting Bracket  
Control Panel  
3
4
Control Panel Cover  
Control Panel Door  
PC Board  
5
6
7
Control Knob  
8
Control Panel Hinge  
Pressure Gauge  
9
10  
11  
12  
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})  
Hydraulic Components - 1  
See Drawing #2  
13  
14  
15  
16  
17  
18  
19  
Water Pressure Switch  
Bypass Valve  
013005F  
013006F  
013008F  
013009F  
013012F  
013013F  
013010F  
013005F  
013007F  
013008F  
013009F  
013012F  
013013F  
013010F  
Distribution Header  
Vent Plug  
PRV - 45#  
PRV Adapter  
PRV Discharge Plumbing Kit  
Hydraulic Components - 2  
See Drawing #3  
20  
21  
22  
23  
24  
25  
26  
27  
28  
Pump  
013014F  
013016F  
013018F  
013019F  
013020F  
013022F  
013024F  
013025F  
013026F  
013015F  
013017F  
013018F  
013019F  
013021F  
013023F  
013024F  
013025F  
013026F  
Plumbing Kit - (Includes 21a, 21b, 21c and 21d)  
Air Vent  
Condensate Reservoir  
Condensate Plumbing Kit - (Includes 24a, 24b, 24c, 24d and 24e)  
Air Venting Plug Kit  
High Limit  
Pump Plug  
Water Detector  
Burner Components - Air Box  
Air Chamber Access Panel  
Air Chamber Side  
See Drawing #4  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
43  
44  
45  
46  
47  
013037F  
013027F  
013040F  
013028F  
013029F  
013030F  
013031F  
013032F  
013034F  
013035F  
013036F  
013039F  
013041F  
013042F  
013043F  
013045F  
013047F  
013049F  
013050F  
013051F  
013038F  
013027F  
013040F  
013028F  
013029F  
013030F  
013031F  
013033F  
013034F  
013035F  
013036F  
013039F  
013041F  
013064F  
013044F  
013046F  
013048F  
013049F  
013050F  
013051F  
Intake Air/Flue Adapters  
Combustion Air Blower  
Burner Assembly  
Igniter  
Condensate Electrode Kit  
Outlet Gas Manifold  
Gas Valve Kit  
Inlet Gas Manifold  
Gas Shut-Off Valve  
Burner Observation Port Kit  
Air/Gas Manifold  
Manifold Gas/Blower Inlet  
Gas Orifice - Nat  
Gas Orifice - Pro  
Combustion Air Mixer  
Flame Sensor  
Blower Heat Shield  
Ignition Transformer  
Combustion Chamber Components - Flue Drain  
Heat Exchanger Assembly  
See Drawing #5  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
013054F  
013056F  
013058F  
013059F  
013060F  
013061F  
013062F  
013063F  
013000F  
013001F  
013052F  
013055F  
013057F  
013058F  
013059F  
013060F  
013061F  
013062F  
013063F  
013000F  
013001F  
013053F  
Flue Exhaust Condensate Collector  
Flue Exhaust Condensate Collector Adapter  
Air Pressure Switch  
Outlet Heat Exchanger Seal Gasket  
Inlet Heat Exchanger Seal Gasket  
High Limit  
Flue Sensor  
Water Gasket Kit - (Includes 56a, 56b and 56c - 10pcs ea.)  
Flue Exhaust/Gas Gasket Kit - (Includes 57a and 57b)  
Nat to Pro Gas Conversion Kit  
For gas conversions, consult the factory for information.  
63  
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:  
1. INSTALLATION OF CARBON MONOXIDE DETECTORS.  
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall  
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where  
the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or  
hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure  
served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure  
the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors  
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard  
wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.  
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner  
shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30)  
day period, a battery operated carbon monoxide detector with an alarm shall be installed.  
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the  
above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.  
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a  
minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas  
fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT  
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.  
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve  
the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance  
with the provisions of 248 CMR 5.08(2)(a)1 through 4.  
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:  
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA  
54 as adopted by the Board; and  
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the  
dwelling, building or structure used in whole or in part for residential purposes.  
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of  
Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components  
with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system  
shall include:  
1. Detailed instructions for the installation of the venting system design or the venting system components; and  
2. A complete parts list for the venting system design or venting system.  
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer  
of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue  
gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:  
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation  
instructions; and  
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include  
a parts list and detailed installation instructions.  
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all  
venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the  
appliance or equipment at the completion of the installation.  
64  
LIMITED WARRANTY  
MODULATING - CONDENSING BOILER  
TM  
XPAK HEATING BOILERS MODELS 85 & 120  
SCOPE OFWARRANTY:  
Raypak, Inc. (“Raypak”) warrants to the first retail purchaser of the XPAKHeating Boiler that was delivered with this limited warranty certificate (the  
“Boiler”) that the Boiler will be free from defects in materials and workmanship under normal use and service for the Applicable Warranty Periods  
specified below. Under this Limited Warranty, Raypak will, at its option, repair or replace any defective part of the Boiler in accordance with the terms  
of this Limited Warranty. The Limited Warranty does not include labor or transportation costs, which are borne by the warranty claimant. The repair  
or replacement Boiler or part will be warranted for only the unexpired portion of the original Applicable Warranty Period. This Limited Warranty applies  
only to a Boiler that has NOT been moved from its original installation site. In the event that replacement or repair parts are no longer available, or  
significant design changes have occurred, Raypak reserves the right to replace, at its option, the Boiler or part with a current equivalent part. Please  
read this entire Limited Warranty to fully understand all of its terms and conditions.  
APPLICABLE WARRANTY PERIODS  
XPAKTM Residential Extruded Aluminum Heat Exchanger:  
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). For years 11-20 of the Applicable Warranty Period for  
the residential Boiler’s aluminum heat exchanger, Raypak will provide a replacement part for a defective part, provided that the warranty claimant  
pays the following percentages of the cost of the replacement part:  
RESIDENTIAL WARRANTY  
The table below lists the portion of the replacement part’s cost that the original homeowner  
will be responsible to pay  
Years into Warranty  
% of List Price  
First 10  
0%  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
20%  
30%  
40%  
50%  
55%  
60%  
65%  
70%  
75%  
80%  
XPAK Commercial Extruded Aluminum Heat Exchanger:  
The Applicable Warranty Period for the aluminum heat exchanger of the Boiler in a commercial installation (as defined in “Additional Warranty  
Exclusions and Terms”, below) is five (5) years after the original installation date of the Boiler. During the first three (3) years of the Applicable  
Warranty Period, Rheem will pay for 100% of the cost of the replacement part or repair (excluding labor and transportation costs). For years 4 and  
5 of the Applicable Warranty Period for the commercial Boiler’s aluminum heat exchanger, Raypak will provide a replacement part for a defective part,  
provided that the warranty claimant pays the following percentages of the cost of the replacement part:  
COMMERCIAL WARRANTY  
The table below lists the portion of the replacement part’s cost that the original owner  
will be responsible to pay  
Years into Warranty  
% of List Price  
First 3  
0%  
4
5
20%  
30%  
RESIDENTIAL BOILDER FAN:  
The Applicable Warranty Period for the fan of a Boiler in a residential installation (as defined in “Additional Warranty Exclusions and Terms”, below) is  
three (3) years from the date of original installation, or thirty-seven months (37) months from the date that the residential Boiler was shipped from  
Raypak’s factory based on Raypak’s records, whichever comes first. This Applicable Warranty Period does not apply to Boiler fans in commercial  
installations (as defined in “Additional Warranty Exclusions and Terms”, below).  
ALL OTHER COMPONENTS OF THE BOILER:  
Except as otherwise specified above for the heat exchangers and residential Boiler fan, the Applicable Warranty Period for all components in the Boiler  
is one (1) year from date of the Boiler’s original installation, or thteen (13) months from date that the Boiler was shipped from Raypak’s factory based  
on Raypak’s records, whichever comes first.  
SATISFACTORY PROOF OF ORIGINAL INSTALLATION DATE, SUCH AS INSTALLER’S INVOICE, IS REQUIRED. THIS WARRANTY WILL BE  
VOID IF THE BOILER RATING PLATE IS ALTERED OR REMOVED.  
ADDITIONAL WARRANTY EXCLUSIONS AND TERMS:  
This Limited Warranty does NOT apply:  
1. if the Boiler has been moved from its original place of installation, or if the original purchaser no longer owns the property where the original  
installation was made;  
2. to damage, malfunctions or failures resulting from improper installation, operation, or maintenance of the Boiler in accordance with the manufacturer’s  
instructions;  
65  
3. to damage, malfunctions or failures resulting from misuse, neglect, alteration, accident, fire, flood and the like;  
4. to damage, malfunctions or failures resulting from sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;  
5. to damage, malfunctions or failures resulting from high velocity flow exceeding boiler design rates;  
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;  
8. to damage, malfunctions or failures resulting from failure to eliminate air from, or replenish water in, the connected water system;  
9. to damage, malfunctions or failures resulting from chemical contamination of combustion air or use of chemically contaminated combustion air,  
including, but not limited to contaminants such as chlorine gas, halogenated hydrocarbons, and Freon.  
10. to damage, malfunctions or failures resulting from ingestion by the Boiler of drywall, sheetrock or plasterboard dust and particles, lint or dirt.  
11. to Boilers that have been installed by anyone other than a heating professional whose principal occupation is the sale and installation of heating,  
plumbing and/or air conditioning equipment.  
For purposes of this Limited Warranty, a residential installation is defined as the installation of a Boiler in any of the following residential spaces:  
a) Single-family detached dwelling;  
b) Two-family attached dwelling; or  
c) Dwelling unit of a residential building in which each dwelling unit has an individual Boiler.  
For purposes of this Limited Warranty, a commercial installation is defined as the installation of a Boiler in any site other than:  
a) Single family detached dwelling;  
b) Two family attached dwelling; or  
c) Dwelling unit of a residential building in which each dwelling unit has an individual Boiler.  
HOW TO MAKE WARRANTY CLAIM:  
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the problem. The  
installer must then notify a Raypak distributor for instructions regarding the claim. If neither the installer nor the distributor is available, immediately  
notify Raypak at 800-278-5300, supplying model number, serial number, date of original installation and a description of the problem. Proper  
authorization MUST be obtained PRIOR to any repairs for the Limited Warranty to apply. This Limited Warranty is VOID if the Boiler is  
repaired or altered in any way by ANY persons or agencies other than those authorized by Raypak. Raypak reserves the right at all times  
to inspect, or require the return of, the defective Boiler or component part and to verify warranty coverage at its factory. The failed part must first  
be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions satisfied. The replacement part will  
be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts manufactured by others, but  
Raypak will apply any such warranty as may be provided by the parts manufacturer.  
EXCLUSIVE WARRANTY-LIMITATION OF LIABILITY  
The Limited Warranty is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. ANY IMPLIED  
WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE  
APPLICABLE WARRANTY PERIOD SPECIFIED ABOVE. RAYPAK’S SOLE LIABILITY WITH RESPECT TO ANY DEFECT, SHALL BE AS SET  
FORTH INTHIS LIMITED WARRANTY.IT IS AGREEDTHAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDERTHIS LIMITED WARRANTY  
OR IN CONTRACT, TORT OR NEGLIGENCE OR OTHERWISE FOR CLAIMS FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES  
(INCLUDING NO LIABILITY FOR DAMAGE FROM WATER LEAKAGE), ALL OF WHICH ARE EXPRESSLY EXCLUDED. Some states do not  
allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages, so the above limitation or  
exclusion may not apply to you. THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER  
RIGHTS WHICH VARY FROM STATE TO STATE. We suggest you immediately record the model and serial number and date of original installation  
and retain this Limited Warranty Certificate in the event warranty service is needed.  
DO NOT RETURN THIS DOCUMENT TO RAYPAK. KEEP IT WITH YOUR BOILER OR BUSINESS RECORDS.  
Name of Owner  
Owners Address  
Name of Installer  
Installers Address  
Date of Boiler Installation  
Model Number of Your Boiler  
Telephone Number of Installer  
Serial Number of Your Boiler  
66  
START-UP CHECKLIST FOR FAN-ASSISTED  
RAYPAK PRODUCTS  
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.  
GASSUPPLYDATA  
Regulator Model & Size  
Gas Line Size (in room)  
Length of Gas Line  
Gas Shut-Off Valve Type  
( Ball, Lube cock)  
Sediment Trap  
CLEARANCES  
_________ /  
CFH  
Front Clearance  
_______________In.  
_______________In.  
_______________In.  
_______________In.  
_______________In.  
____________ In. NPT  
____________ Eq Ft  
____________  
Right Side Clearance  
Left Side Clearance  
Rear Clearance  
Overhead Clearance  
____________ Y/N  
_______Std__ Full  
Port  
ELECTRICAL  
Voltage Supply (VAC)  
Voltage -24 VAC  
No Load______ Load_____  
_____________VAC  
Voltage Com to Ground _____________VAC  
Operating Control Setting _____________deg F  
VISUAL INSPECTION OF COMPONENTS  
Verify inspection was done and condition of components are in  
good working order with a “yes”  
Wiring Harness  
Burner/s (flame)  
Remote flame sense  
_____________ Y/N  
_____________ Y/N  
_____________ Y/N  
Sketch plumbing on reverse side  
WATER SUPPLY  
Flow Rate in GPM or Delta T __________ If Avail  
Measure flow rate at full fire  
VENTING  
Number of Tanks and Size Qty____ ____ Gallons  
Vent Size:___________  
Category: _________  
Vent Material:  
Stack Height:_____  
Plumbing Size  
_______________  
sketch vent on reverse side ***  
__________________  
__________________  
Low __________in2  
Pump Size: _________ (boiler)  
Impeller trim____________  
Louvers __________________  
Pump HP: ________  
Pump Model________  
Screens____________  
Vent Termination Type:  
Combustion Air Openings:  
Ventilation air  
High _________ in2  
EMISSIONSSETTINGSANDTESTINFORMATION(ATFULLFIRE)  
NominalFactoryRecommendedSettings  
See manual or card tag  
Blower Pressure Setting  
Supply Gas Pressure  
______________ In. WC  
______________ In. WC  
See manual or card tag  
Verify stable pressure static & dynamic condition  
Manifold Gas Pressure  
_____________ In. WC  
See manual or card tag  
Tracking Pressure (clean filter) ______________In. WC  
The following measurements must be obtained with a Combustion Analyzer.  
NOX  
_____________ PPM  
_____________ %  
_____________ PPM  
_____________ %  
Less than 20 PPM (If required by Certifying Agency)  
FreeOxygen  
CO  
See manual  
Less than 170 PPM  
See manual  
CO2  
Model Number: ______________________________  
*** Note: draw venting with details, such as extractors,  
barometric dampers, blast dampers or draft inducers  
Serial Number: _______________________________  
Site Altitude Above Sea Level __________________Ft.  
Job Name _______________________________________________________________________________________  
Address _________________________________________________________________________________________  
Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; Roof______; Below Grade______  
Mechanical Contractor / Installer _______________________________________________________________________  
Date and Time of Start-up _____________Print Name and Signature of Start-up Technician_________________________  
Information must be faxed to: (805) 278-5471 in order to ensure warranty consideration Attn: Service Manager  
67  
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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