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CONTENTS
1 - WARNINGS 4
PAY ATTENTION TO THESE TERMS 4
2 - GENERAL SAFETY 6
TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 6
3 - BEFORE INSTALLATION 6
4 - REGULATIONS AND GUIDELINES 7
5 - INTRODUCTION 8
TECHNICAL DATA 10
PRINCIPLE COMPONENTS 12
MODE OF OPERATION (AT REST) 12
MODE OF OPERATION 12
SAFETY DEVICES 12
BANNED MATERIAL STATEMENT 12
MANUAL HANDLING STATEMENT 12
XPAK INTERNAL HYDRAULIC CIRCUIT 12
PIPING CONNECTIONS 13
DIMENSIONS AND CONNECTIONS 14
PACKAGING AND TRANSPORTATION 15
1. Scope of delivery 15
2. Transporting the boiler 15
3. Boiler box content 15
6 - INSTALLATION 16
PREPARE XPAK LOCATION 16
1. Installations must comply with 16
2. Before locating the XPak boiler 16
3. Clearances for service access 16
4. Residential garage installation 16
5. Exhaust vent and intake air vent 16
6. Prevent combustion air contamination 16
7. When removing an existing boiler from an existing common 16
vent system
PREPARE XPAK 16
1. Remove XPak boiler from box 16
2. Placing the wall-mounted XPak boiler 17
3. XPak wall mounting instructions 17
4. Installation steps 17
XPAK PIPING 17
1. Relief valve 17
2. General piping information 17
3. Separate low water cutoff 17
4. Backflow preventer 17
5. Fitting the heating circuit supply and return pipes 17
6. Expansion tank and make-up water 17
7. Sizing space heat system piping 17
8. Boiler with DHW tank 18
9. Waterside Flow (primary circuit) 18
10.Procedure summary 18
11.Fill and purge heating system 18
XPAK INSTALLATION DIAGRAMS 19
MAKING THE GAS CONNECTION 22
BOILER TEMPLATE 23
COMBUSTION AIR AND VENTILATION OPENINGS 24
INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM 24
VENT SYSTEMS 25
1. Flue gas system 25
2. Boiler supply 25
3. Installations of supplied vent components 25
4. Minimum Clearances from Vent/Air Inlet Termination 26
CONNECTING THE CONDENSATE WATER DRAIN 34
1. Condensate Connection 34
7 - ELECTRICAL CONNECTIONS 34
1. External connection board connections 34
2. Electrical supply 34
3. Field wiring 34
4. Casing removal 35
5. Appliance terminal block 35
6. Connecting the electrical supply (120V) 35
7. External wiring 35
8. External wiring limitations 35
9. Connecting thermostat 35
10.Other devices 35
11.Terminal strip details 36
12.Outdoor sensor connection 37
13.3-way valve wiring connection 37
14. Remote control connection 37
WIRING FUNCTIONAL DIAGRAM 38
8 - START-UP PROCEDURE 39
9 - COMMISSIONING 40
1. Check/control water chemistry 40
2. Freeze protection (when used) 40
3. The heating system 40
4. Initial filling of the system 40
5. Purge air from boiler manual air release 40
6. System drain 40
7. Check thermostat circuit(s) 41
8. Testing for gas leaks 41
9. Initial flushing of the system 41
10. Pre-operation checks 41
11. Initial lighting 41
12. Checking gas pressure and combustion analysis 41
13. Final flushing of the heating system 41
14. Setting the boiler operating temperature 41
15. Regulating the central heating system 41
16.Final checks 42
17.Instructing the user 42
18.Warranty 42
10 - START-UP AND OPERATION 43
1. Switching on the appliance 43
2. How to read the display temperature 43
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) 43
5. Working the boiler 43
6. Reset function 43
7. Switching off 43
8. Indicator LEDs and faults 44
11 - CHECKS, ADJUSTMENTS AND FAULT FINDING 46
1. Checking appliance operation 46
2. Appliance modes of operation 46
3. Selector switch in the off/stand by position 46
4. On-board functions 46
5. Heating mode 46
6. DHW mode 46
7. Boiler fan speeds 47
8. Checking the CO2 and adjusting the gas valve 47
9. Gas valve maximum setting 47
10.Gas valve minimum setting 47
11.Combustion analysis test 47
12.External faults 47
13.Electrical checks 48
14.Component values & characteristics 48
15.Boiler configuration 48
16.Setting the outdoor reset curve with outdoor sensor 49
17.Fault codes 51
12 - SERVICING INSTRUCTIONS 52
1. General 52
2. Routine annual servicing 52
3. Replacement of components 52
4. Component removal procedure 52
13 - LPG INSTRUCTIONS 56
PROPANE GAS 56
14 - EXPLODED DIAGRAMS 59
IMPORTANT INSTRUCTIONS FOR THE
COMMONWEALTH OF MASSACHUSETTS 64
LIMITED PARTS WARRANTY 65
START-UP CHECKLIST FOR FAN-ASSISTED
RAYPAK PRODUCTS 67