Raypak 300, 850 User Manual

INSTALLATION & OPERATING

INSTRUCTIONS

Models 300, 500 & 850

Types H & W

WARNING: Improper installation, adjustment, alteration, service or maintenance can

cause property damage, personal injury, exposure to hazardous materials* or loss of life. Review the information in this manual carefully. *This unit contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference.

Catalog No. 1000.65 Effective: 10-16-09 Replaces: NEW P/N 241366 Rev. 1

CONTENTS

WARNINGS 4

Pay Attention to These Terms 4

BEFORE INSTALLATION 5

Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 6 Time/Temperature Relationships in Scalds 7

GENERAL SAFETY 7 INSTALLATION 8

Installation Codes 8 Equipment Base 8 Clearances 8 Combustion and Ventilation Air 9 Conventional Combustion Air Supply 11 Water Piping 12 Hydronic Heating 13 Gas Supply 16 Electrical Power Connections 17 Field Wiring Connection 19 Venting 23 Venting Installation Tips 25 Venting Configurations 25 Outdoor Installation 31 Controls 32 Operating Instructions 35

WIRING DIAGRAM 40 START-UP 41

Pre Start-up 41 Pre Start-up Check 41 Initial Start-up 41 Preparation 42 Start-Up 42

OPERATION 44

Lighting Instructions 44 To Turn Off Gas to Appliance 45 XFyre Error Codes 45 Heater Errors 45 Heater Faults 45

TROUBLESHOOTING 45

XFyre Fault Text 46 Sensor Resistance Values 48

MAINTENANCE 49

Suggested Minimum Maintenance Schedule 49 Preventive Maintenance Schedule 49

APPENDIX 52

Inside Air Contamination 52 Important Instructions for the Commonwealth of Massachusetts 53

WARRANTY 54 START-UP CHECKLIST 55

WARNINGS

Pay Attention to These Terms

ndicates the presence of immediate hazards which will cause severe

DANGER:

I personal injury, death or substantial property damage if ignored.

WARNING:

CAUTION:

NOTE:

DANGER: Make sure the gas on which the boiler

will operate is the same type as that specified on the boiler rating plate.

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.

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.

Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the

State of California to cause cancer, birth defects or other reproductive harm.

CAUTION: If this boiler is to be installed above radiation level, it must be provided with a low water cut-off device at the time of boiler installation.

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.

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.

CAUTION: If this boiler is to be installed in a negative or positive pressure equipment room, there are special installation requirements. Consult factory for details.

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.

BEFORE INSTALLATION

Model Identification

Raypak strongly recommends that this manual be reviewed thoroughly before installing your XFyre heater. Please review the General Safety information before installing the heater. Factory warranty does not apply to heaters 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 your local Raypak representative or visit our website at www.raypak.com.

Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.

Product Receipt

WARNING: Pump motors should NOT be

supported by any type of stand or support from above due to possible misalignment of pump and motor which may occur.

On receipt of your heater it is suggested that you visually check for external damage to the shipping crate. If the crate is damaged, make a note to that effect on the Bill of Lading when signing for the shipment. Next, remove the heater from the shipping packaging. Report any damage to the carrier immediately.

The model identification number and heater serial

umber are found on the heater rating plate located on

n the upper rear jacket panel of the heater. The model

umber will have the form H7-850 or similar depend-

n ing on the heater size and configuration. The letter(s) in the first group of characters identifies the application (H = Hydronic Heating, W = Hot Water). The number which follows identifies the firing mode (7 = electronic modulation). The second group of characters identifies the size of the heater (three numbers representing the approximate MBTUH input), and, where applicable, a letter, indicating the manufacturing series.

Ratings and Certifications

Standards:

• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Hot Water Boilers

• CAN 3.1 - latest edition, Industrial and Commercial Gas-Fired Package Boilers

• SCAQMD Rule 1146.2

All Raypak heaters are National Board Registered, and design-certified and tested by the Canadian Standards Association (CSA) for the U.S. and Canada. Each heater is constructed in accordance with Section IV of the American Society of Mechanical Engineers (ASME) Heater Pressure Vessel Code and bears the ASME “H” stamp. This heater also complies with the latest edition of the ASHRAE 90.1 Standard.

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 the factory 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 heater. 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. Parts will be replaced in kind only per Raypak’s standard warranties.

WARNING: Altering any Raypak pressure vessel by installing replacement heat exchangers 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 2000 ft elevation without de-rating. Consult your local representative or the factory for installations at altitudes over 2000 ft above sea level. No hardware changes are required to the heaters for installations up to 10,000 ft (adjustments may be required).

Component Locations

Model 300 shown. Component locations may vary slightly in larger models.

Fig. 1: Component Locations — Sides

Fig. 2: Component Locations — Top

General Information

Model

No.

300 300 60 1-1/2” 3/4” 3/4” 4 4

500 500 100 2” 1” 1” 4 4

850 850 170 2” 1-1/4” 1-1/4” 6 6

Fig. 3: Component Locations — Rear

MBTUH

Input

Max. Min. N P Flue Intake

Water conn. (NPT)

Table A: Basic Data

Gas conn.

(NPT)

Vent Size

(inches)

Water temperature over 125°F can cause instant severe burns or death from scalds.

Children, disabled, and elderly are at highest risk of being scalded.

See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available, see manual.

Water

Temp.

Time to Produce Serious

Burn

120°F More than 5 minutes

125°F 1-1/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 1-1/2 seconds

155°F About 1 second

Table courtesy of T he Shriners Burn Institute

Model No.

300 2.9

500 4.2

850 5.8

Table B: Heater Water Volume

Heater Water Volume

(gallons)

GENERAL SAFETY

To meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the recommended initial setting for the temperature control is 125°F.

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 can cause instant severe burns or death from scalds. Children, disabled and elderly are at highest risk of being scalded.

• Feel water before bathing or showering.

• Temperature limiting valves are available.

NOTE: When this heater 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.

Maximum water temperatures occur just after the heater’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.

Time/Temperature Relationships in 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.

Table C: Time to Produce Serious Burn

INSTALLATION

Clearances

Installation Codes

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)

• National Electrical Code, ANSI/NFPA 70 - latest edition (NEC)

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, (CSD-1) when required

• For Canada only: CAN/CSA B149 Natural Gas and Propane Installation Code and CSA C22.1 C.E.C. Part 1 (C22.1)

Equipment Base

The heater must be mounted on a level, structurally sound surface. The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment installed in enclosed parking garages must be located at least 18 in. above the floor.

CAUTION: The boiler must be level to allow condensate to drain properly from the heat exchanger.

Indoor Installations

Heater

Side

Floor* 0” 0”

Rear 24” 24”

Right Side 0” 0”

Left Side 0” 0”

Top 12” 24”

Front Open 24”

Vent 1” 1”

*DO NOT install on carpeting.

Table D: Clearances — Indoor Installations

When installed according to the listed minimum clearances from combustible construction, these heaters can be serviced without removing permanent structural construction around the heater. However, for ease of servicing, we recommend a clearance of at least 24 in. in front, at least 24 in. on the rear and 24 in. above the top of the heater. This will allow the heater to be serviced in its installed location without movement or removal of the heater.

Min. Clearances

rom Combustible

Surfaces

Recommended

ervice

Clearances

CAUTION: This boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the structure. When such locations cannot be avoided, it is recommended that a suitable catch pan, adequately drained, be installed under the appliance. The pan must not restrict air flow.

In addition, the heater shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation or service (circulator replacement, control replacement, etc.).

If the heater needs to be secured to the ground, use the holes in the anchoring legs on the heater.

Service clearances less than the minimum may require removal of the heater to service either the heat exchanger or the burner components. In either case, the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater.

Outdoor Installations

These heaters are design-certified for outdoor installation. Heaters must not be installed under an overhang unless clearances are in accordance with local installation codes and the requirements of the gas supplier. Three sides must be open in the area under the overhang. Roof water drainage must be diverted away from heaters installed under overhangs.

24”

SERVICE

CLEARANCE

24”

SERVICE

CLEARANCE

24”

SERVICE

CLEARANCE

Heater

Side

Min. Clearances

from Combustible

urfaces

Recommended

Service

learances

Rear 24” 24”

Right Side 0” 0”

Left Side 0” 0”

Top Unobstructed 24”

Front Open 24”

Vent

Termination

Table E: Clearances — Outdoor Installations

12” 12”

Combustion and Ventilation Air

NOTE: Use of this boiler in construction areas

where fine particulate matter, such as concrete or dry-wall dust, is present may result in damage to the boiler that is not covered by the warranty. If operated in a construction environment, a clean source of combustion air must be provided directly to the boiler.

Indoor Units

This heater must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation. Combustion air can be supplied via conventional means where combustion air is drawn from the area immediately surrounding the heater, or via direct vent, where combustion air is drawn directly from outside. All installations must comply with the requirements of the NFGC (U.S.) and B149 (Canada), and all local codes.

Venting not shown for clarity. Heater must be vented per

instructions in this manual

Fig. 4: Minimum Clearances from Combustible

Surfaces — Indoor and Outdoor Installations

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the boiler and void the warranty. (See the Appendix.)

NOTE: It is recommended that the intake vent be insulated in cold climates to minimize sweating.

U.S. Installations

Canadian Insta llations

Clearance above grade, veranda, porch, deck, or balcony

1 ft (30 cm) 1 ft (30 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

3 ft (91 cm)

C 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 Clearance to unventilated soffit **

F Clearance to outside corner **

G Clearance to inside corner 6 ft (1.83m) *

Clearance to each side of center line ex- tended above meter/regulator assembly

3 ft (91 cm) within a height

15 ft above the me-

ter/regulator assembly

I Clearance to service regulator vent outlet * 6 ft (1.83m)

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

3 ft (91 cm)

K Clearance to mechanical air supply inlet

3 ft (91 cm) above if within

10 ft (3m) horizontally

6 ft (1.83m)

Clearance above paved sidewalk or paved driveway located on public property

7 ft (2.13m)

7 ft (2.13m) t

Clearance under veranda, porch, deck or balcony

* 12 in. (30 cm) TT

In accordance with the current ANSI Z223.1/NFP A 5 4 National Fuel Gas Code

In accordance with the current CAN/CGA-B149 Installation Codes

t Vent terminal shall not terminat e directly above sidewalk or paved driveway located between 2 single family dwellings that serves

both dwellings

TT Permitted only if veranda, porc h, deck, or balcony is fully open on a minimu m of two sides beneath the floor and top of terminal and

underside of ver anda, porch, deck or balcony is greater than 1 ft (30c m)

* Clearances in accordance with local installation codes and the requirements of the gas supplier

Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table F: Vent/Air Inlet Termination Clearances

Combustion Air Filter

echanical room. All ducting must be self-supported.

This heater is supplied with an integral combustion air filter. This filter will reduce the amount of particulates that pass through the combustion system and heat exchanger but will not protect against chemical inside air contamination (See Appendix). The filter must be checked periodically to verify that adequate combustion air is being supplied to the heater. See the Maintenance section of this manual for information on checking the filter and establishing service intervals.

Direct Vent

If outside air is drawn through the intake pipe directly to the unit for combustion:

1. Install the combustion air ducting kit.

2. Install combustion air direct vent in accordance with Fig. 23 (horizontal) or Fig. 24 (vertical) of this manual.

3. Provide adequate ventilation of the space occupied by the heater(s) by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area shall be at least 1 in.2of free area per 20,000 BTUH (111 mm2per kW) of total input rating of all equipment in the room when the opening is communicating directly with the outdoors or through vertical duct(s). The total cross-sectional area shall be at least 1 in.2of free area per 10,000 BTUH (222 mm2per kW) of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct(s).

4. In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of a motorized sealed damper on the air intake to prevent the circulation of cold air through the heater during the non-operating hours.

TruSeal™ Combustion Air

In addition to the 4 previous steps, combustion air may be ducted directly to the heater by using PVC, CPVC or sealed single-wall galvanized ducting. The duct will attach directly to the air collar located on the rear of the heater when the combustion air ducting kit is installed, using three or four sheet metal screws (not supplied) equally positioned around the circumference of the duct. The screws and duct connection point must be sealed with RTV (not supplied). TruSeal is generally used when damaging contaminants are present in the

CAUTION: Use TruSeal combustion air if

amaging airborne contaminants are or may be

d present in the boiler area. See the Appendix of this manual regarding air contamination.

Conventional Combustion Air Supply

U.S. Installations

All Air from Inside the Building

The confined space shall be provided with TWO permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for a room large in comparison (NFGC). 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

per 1,000 BTUH (2,225 mm2per kW) of the total

1 in. input rating of all gas utilization equipment in the confined space, but not less than 100 in.2(645 cm2). One opening shall commence within 12 in. (305 mm) of the top, and one opening shall commence within 12 in. (305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 in. (76 mm) in any direction.

All Air from Outdoors

The confined space shall communicate with the outdoors in accordance with one of the methods below. The minimum dimension of air openings shall not be less than 3 in. (76 mm) in any direction. Where ducts are used, they shall be of the same cross-sectional area as the net free area of the openings to which they connect.

1. Two permanent openings, one commencing within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

a. Where directly communicating with the out-

doors or where communicating to the outdoors through vertical ducts, each open- ing shall have a minimum free area of 1 in. per 4,000 BTUH (550 mm2per kW) of total input rating of all equipment in the enclosure.

b. Where communicating with the outdoors

through horizontal ducts, each opening shall have a minimum free area of 1 in.2per 2,000

TUH (1,100 mm

er kW) of total input rat-

ing of all equipment in the enclosure.

2. One permanent opening, commencing within 12 n. (305 mm) of the top of the enclosure, shall be

i permitted where the equipment has clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (152 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors, and shall have a minimum free area of:

a. 1 in.

per 3,000 BTUH (740 mm2per kW) of the total input rating of all equipment located in the enclosure, and

b. Not less than the sum of the areas of all vent

connectors in the confined space.

WARNING: Do not use the “one permanent opening” method if the equipment room is under negative pressure conditions.

Canadian Installations

and terminated 18 in. (450 mm) from the floor, but not near piping. This air supply opening requirement shall be in addition to the air opening for ventilation air required in 1. (above).

WARNING: Care must be taken to ensure that the equipment room is not under negative pressure conditions.

3. For heaters when air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator, drafthood or similar flue gas dilution device installed in the same space, in addition to the opening for ventilation air required in 1., there shall be a permanent air supply opening(s) having a total cross-sectional area of not less than 1 in.2for each 30,000 BTUH (74 mm2per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere with the intended purpose of the opening(s) for ventilation air referred to in 1. This opening(s) can be ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down 18 in. (450 mm) from the floor, but not near piping.

4. Refer to the B149 Installation Code for additional information.

CAUTION: All combustion air must be drawn from the air outside of the building; the mechanical equipment room must communicate directly with the outdoors.

1. Ventilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area of such an opening(s) shall be at least 10% of the area required in 2. and 3. (below), but in no case shall the cross-sectional area be less than 10 in. (65 cm2).

2. For heaters using a barometric damper in the vent system, there shall be a permanent air supply opening(s) having a cross section area of not less

than 1 in. to and including 1 million BTUH, plus 1 in. 14,000 BTUH (160 mm

per 7,000 BTUH (320 mm2per kW) up

per kW) in excess of 1

per

million BTUH. This opening(s) shall be either located at or ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down

Water Piping

General

The heater should be located so that any water leaks will not cause damage to the adjacent area or structures.

CAUTION: This boiler requires forced water circulation when the burner is operating. See Table G and Table H for minimum and maximum flow rates

and water pump selection. The pump must be interlocked with the boiler to prevent heater operation without water circulation.

NOTE: Minimum pipe size for in/out connections is 1-1/2” NPT for model 300 and 2” NPT for models 500 and 850. Verify proper flow rates and ∆T as instructed in this manual.

Relief Valve Installation and Piping

To perform hydrostatic test:

WARNING: Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur. Refer to

ocal codes.

The heater is supplied with a Section IV “HV” stamped relief valve sized for the full input of the unit. The relief valve assembly is shipped loose and must be mounted directly to the heater outlet. No valve shall be installed between the heater and the relief valve. The relief valve shall be mounted with its spindle vertical (see Fig. 1, 2 and 3 on page 6). Relief valve discharge piping shall provide no less than the cross sectional area of the relief valve outlet and must be routed to a safe point of discharge. Installation must comply with all national, state and local codes.

WARNING: The pressure relief valve must be installed at the outlet of the boiler. No valve is permitted to be installed between the boiler and the relief valve.

1. Connect fill water supply. With bleed valve open, fill heater with water. When water flows from bleed valve, shut off water. Close bleed valve. Carefully fill the rest of the system, making sure to eliminate

ny entrapped air by using high-point vents. Close

a feed valve. Test at standard operating pressure for at least 24 hours.

2. Make sure constant gauge pressure has been maintained throughout test.

3. Check for leaks. Repair if found.

Hydronic Heating

Pump Selection

In order to ensure proper performance of your heater system, you must install a correctly-sized pump. Raypak recommends designing for a ∆T within the range of 20°F to 40°F (5°C to 20°C). See Table G for acceptable flow rates for each model (∆T is the temperature difference between the inlet and outlet water when the heater is firing at full rate).

Temperature & Pressure Gauge

The temperature and pressure gauge is shipped loose for field installation and must be installed within 12 inches of the boiler outlet (if possible) in an easily readable location. Installation must comply with ASME Section IV as well as all applicable national, state and local codes.

Hydrostatic Test

Unlike many types of heaters, this heater does not require hydrostatic testing prior to being placed in operation. The heat exchanger has already been factory-tested and is rated for 160 psi operating pressure. However, Raypak does recommend hydrostatic testing of the piping connections to the heater and the rest of the system prior to operation. This is particularly true for hydronic systems using expensive glycolbased anti-freeze. Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply.

Leaks must be repaired at once to prevent damage to the heater. NEVER use petroleum-based stop-leak compounds.

Feedwater Regulator

Raypak recommends that a feedwater regulator be installed and set at 12 psi minimum pressure at the highest point of the system. Install a check valve or back flow device upstream of the regulator, with a manual shut-off valve as required by local codes.

Piping

All high points should be vented. A heater installed above radiation level must be provided with a low water cut-off device (sales order option F-10). This heater, when used in connection with a refrigeration system, must be installed so that the chilled medium is piped in parallel with the heater with appropriate valves to prevent the chilled medium from entering the heater.

The piping system of a hot water heater connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air, must be equipped with flow control valves or other automatic means to prevent gravity circulation of the heater water during the cooling cycle. It is highly recommended that the piping be insulated.

Air-Separation/Expansion Tank

Fig. 6: Air-Separation/Expansion Tank

All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig. 6 above.

Three-Way Valves

Three-way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used. Raypak heaters are high-recovery, low-mass heaters which are not subject to thermal shock.

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Fig. 8: Dual Heaters (Reverse/Return)

with Primary/Secondary Piping

Domestic Hot Water

When designing the water piping system for domestic hot water applications, water hardness should be considered. Table H indicates the suggested flow rates for soft and medium water. Hard water must be softened for direct heating with the XFyre. Water hardness is expressed in grains per gallon.

*Maximum 4 times the pipe diameter or 12”, whichever is less.

Fig. 7: Single Heater — Low-Temperature (Heat Pump)

Application with Primary/Secondary Piping

Model

No.

20°F ∆T 30°F ∆T 40°F ∆T Min. Flow Max. Flow

gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) ∆T gpm ∆P (ft) ∆T

300 28 17 19 8 14 5 14 5 40 36 27 17

500 47 16 31 7 24 4 24 4 40 56 24 18

850 80 40 53 17 40 10 40 10 40 80 40 20

Notes: Basis for minimum flow is ∆T . Basis for maximum flow is gpm.

Table G: Heater Rates of Flow and Pressure Drops

Fig. 9: Single Domestic Hot Water Heater and Storage

Tank

NOTE: If local codes require a vacuum relief valve, acquire one locally and install per valve manufacturer’s instructions.

Potable Water and Space Heating

CAUTION: When this heater is used for both

potable water and space heating, observe the following to ensure proper operation.

1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water.

2. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space heating.

3. If the heater will be used to supply potable water, it shall not be connected to any heating system or components previously used with a non-potable water heating appliance.

4. When the system requires water for space heating at temperatures higher than 140°F (60°C), a means such as a mixing valve shall be installed to temper the water in order to reduce scald hazard potential.

Fig. 10: Multiple Boilers — Reverse Return,

Primary/Secondary Piping with Indirect DHW

Model

No.

Soft (0–4 grains per gallon) Medium (5–15 grains per gallon)

∆T gpm ∆P MTS SHL ∆T gpm ∆P MTS SHL

300 30 19 8 1.5 10 20 28 17 1.5 20

500 30 31 7 2 8 20 47 16 2 18

850 30 53 17 2 20 20 80 40 2 46

∆T = Temperature rise, °F. ∆P = Pressure drop through heat exchanger, ft. SHL = System head loss, ft (based on heater and tank placed no more than 5 ft apart and equivalent length of 25 ft of tubing). gpm = Gallons per minute, flow rate. MTS = Minimum tubing size. CAUTION: For scale free operation with Medium water (5–15 grains per gallon of total hardness), the operating control must NOT be set higher than 130°F. For higher than 130°F operation, or Hard water (>16 grains per gallon of total hardness), a water softener/treatment system must be utilized.

Table H: Domestic Water Heater Flow Rate Requirements

Gas Supply

DANGER: Make sure the gas on which the heater

will operate is the same type as specified on the rating plate.

CAUTION: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two

nd threads bare.

Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. It is recommended that a union be installed in the gas supply piping adjacent to the heater for servicing. The gas supply pressure to the heater must not exceed 10.5 in. WC for natural gas or 13.0 in. WC for propane gas. A poundsto-inches regulator must be installed to reduce the gas supply pressure if it is higher than noted above. This regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the heater gas controls. Refer to Table J for maximum pipe lengths.

Gas Supply Connection

CAUTION: The heater must be disconnected from

the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa).

The heater must be isolated from the gas supply piping system by closing the upstream manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa). Relieve test pressure in the gas supply line prior to re-connecting the heater and its manual shut-off valve to the gas supply line. FAILURE

TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. Over-pressurized gas valves are

not covered by warranty. The heater and its gas connections shall be leak-tested before placing the appliance in operation. Use soapy water for leak test. DO NOT use an open flame.

CAUTION: Support gas supply piping with hangers, not by the heater or its accessories. Make sure the gas piping is protected from physical damage and freezing, where required.

Gas Supply Pressure

A minimum of 4.0 in. WC and a maximum of 10.5 in. WC upstream gas pressure is required under load and no-load conditions for natural gas. A minimum of 4.0 in. WC and a maximum of 13.0 in. WC is required for propane gas. The gas pressure regulator(s) supplied on the heater is for low-pressure service. If upstream pressure exceeds these values, an intermediate gas pressure regulator, of the lockup type, must be installed.

When connecting additional gas utilization equipment to the gas piping system, the existing piping must be checked to determine if it has adequate capacity for the combined load. The gas valve pressure regulator on the heater is nominally preset as noted in Table I.

During normal operation, carbon dioxide should be 8.5 to 9.0% at full fire for natural gas and between 9.0 and

9.5% for propane gas. Carbon monoxide should be ‹150 ppm.

Manifold Pressure (in. WC)

Model

No.

Natural Gas Propane Gas

High Low High Low

Fig. 10: Gas Supply Connection

300 -0.2 -0.1 -0.2 -0.1

500 -0.3 -0.1 -0.3 -0.1

850 -3.2 -0.2 -2.7 -0.1

NOTE: Manifold pressures should be ±0.3 in. WC.

Table I: Manifold Gas Pressure Settings

Model

3/4” NPT 1” NPT 1-1/4” NPT 1-1/2” NPT 2” NPT

N P N P N P N P N P

500 10 15 40 65 150 150 350

850 15 25 55 55 125 175 450

Natural Gas – 1,000 BTU/ft3, 0.60 specific gravity at 0.5 in. WC pressure drop Propane Gas – 2,500 BTU/ft3, 1.53 specific gravity at 0.6 in. WC pressure drop

Table J: Maximum Equivalent Pipe Length

Electrical Power Connections

Installations must follow these codes:

• National Electrical Code and any other national, state, provincial or local codes or regulations having jurisdiction.

• Safety wiring must be NEC Class 1.

• Heater must be electrically grounded as required by the NEC.

• In Canada, CSA C22. 1 C.E.C. Part 1.

The XFyre 300–850 heaters are wired for 120 V single-phase 60 Hz power. Consult the wiring diagram shipped with the heater. Before starting the heater, check to ensure proper voltage to the heater and pump(s). A larger circuit breaker may be needed for pumps larger than 1/4 hp.

Boiler pumps up to 1 hp and DHW pumps up to 1/4 hp get their power supply directly from the heater power supply (connections in rear wiring box). XFyre heaters

may power up to two pumps directly (1 hp max boiler pump, 3 A max DHW pump) and may control a third system pump, depending on the configuration of the controller and the installation requirements. Install a circuit breaker sized sufficiently for both the heater and the pump(s). DHW pumps larger than 1/4 hp or 3 A must use a separate power supply and run the power through an external field supplied pump contactor. Use appropriately-sized wire as defined by NEC, CSA and/or local codes. All primary wiring should be 125% of minimum rating.

If any of the original wire as supplied with the heater must be replaced, it must be replaced with 105°C wire or its equivalent.

All 120 VAC field wiring connections to the XFyre heater are made inside the rear wiring box as shown in Fig. 11a. Power to the XFyre heater should be connected to terminals 1, 2, and 3 as shown in Fig. 11a. Low voltage wiring is connected to the field wiring board at the front of the unit. Sensors, Thermostat (TT)

Fig. 11a: Wiring Electrical Connections

Fig. 11b: Wiring Electrical Connections

Cascade Master

contacts, optional 0–10 VDC control wiring and cascade connections are wired into the front mounted field wiring board as shown in Fig. 15–19.

Field-Connected Controllers

t is strongly recommended that all individually-pow-

I ered control modules and the heater should be supplied from the same power source.

NOTE: Field-supplied isolation relays should be installed when field-connected controllers are mounted more than 50 equivalent feet (18 AWG) from heater.

Check the Power Source

NOTE: Minimum 18 AWG, 105°C, stranded wire

must be used for all low voltage (less than 30 volts) external connections to the unit. Solid conductors should not be used because they can cause excessive tension on contact points. Install conduit as appropriate. All high voltage wires must be the same size (105°C, stranded wire) as the ones on the unit or larger.

Fig. 13: Multi-meter

Making the Electrical Connections

Refer to Fig. 11a–19.

1. Verify that circuit breaker is properly sized by referring to heater rating plate. A dedicated circuit breaker should be provided and sized for the heater and all pumps powered through the heater.

NOTE: Current draw noted on rating plate does not include pump current.

2. Turn off all power to the heater. Verify that power has been turned off by testing with a multi-meter prior to working with any electrical connections or components.

3. Observe proper wire colors while making electrical connections. Many electronic controls are polarity sensitive. Components damaged by improper electrical installation are not covered by warranty.

Fig. 12: Wiring Connections

WARNING: Using a multi-meter, check the following voltages at the circuit breaker panel prior to connecting any equipment. Make sure proper polarity is followed and house ground is proven. (See Fig. 13.)

Check the power source:

AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum

4. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code.

5. Install heater controls, thermostats, or building management systems in accordance with the applicable manufacturers’ instructions.

6. Conduit should not be used as the earth ground.

NOTE: A grounding electrode conductor shall be used to connect the equipment grounding conductors, the equipment enclosures, and the grounded service conductor to the grounding electrode.

Field Wiring Connections

DIMPLES FOR ALTERNATE LOW VOLTAGE WIRE ROUTING

FIELD WIRING BOARD

DANGER: SHOCK HAZARD

CAUTION: Label all wires prior to disconnection

when servicing controls. Wiring errors can cause im-

roper and dangerous operation. Verify proper

p operation after servicing.

Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components.

Fig. 14: Rear Wiring Location

Fig. 15: Front Wiring Location

Fig. 16: XFyre Single Heater Control

Wiring the Thermostat

1. Connect the room thermostat to the terminals marked THERMOSTAT in the electrical junction box (shown in Fig. 16). Alternately, any dry contact closure across these terminals will enable the XFyre unit to run. Caution should be used to ensure neither of the terminals becomes connected to ground.

2. Mount the thermostat on an inside wall as central as possible to the area being heated, but away from drafts or heat producing devices, such as television sets, that could effect the ability of the thermostat to measure the room temperature accurately.

3. If the thermostat is equipped with an anticipator, and it is connected directly to the XFyre boiler, the anticipator should be set at .1 amps. If the thermostat is connected to other devices, the anticipator should be set to match the power requirements of the device it is connected to. See the instruction manual for the connected devices for further information.

Wiring the Outdoor Sensor

1. There is no connection required if an outdoor sensor is not used in this installation.

. If using an Outdoor Sensor, connect the wires for

sensor to the terminals marked OUTDOOR SEN (shown in Fig. 16) in the electrical junction box. Caution should be used to ensure neither of these terminals becomes connected to ground.

3. Use a minimum 22 AWG wire for runs of 100 feet or less, and minimum 18 AWG wire for runs of up to 150 feet.

4. Mount the outdoor sensor on an exterior surface of the building, preferably on the north side in an area that will not be affected by direct sunlight and that will be exposed to varying weather conditions.

Wiring the Indirect Sensor

1. There is no indirect sensor connection required if an indirect water heater is not used in the installation.

2. The XFyre boiler will operate an indirect fired water heater with either a thermostat type aquastat installed in the indirect tank or a Raypak tank sensor. When a tank sensor is used, the XFyre control will automatically detect its presence and a demand for heat from the indirect water heater will be generated when the tank temperature falls below the user settable setpoint by more than the user selectable offset. The demand will continue until the sensor measures that the indirect water heater temperature is above the setpoint.

Wiring the Optional 0–10 Volt Building Control Signal

1. A signal from a building management system may be connected to the XFyre boiler to enable remote control. This signal should be a 0–10 volt positive

C signal. When this input is enabled using the

D installer menu, a building control system can be used to control either the setpoint temperature or the heat output of the XFyre boiler. The control interprets the 0–10 volt signal as follows. When the signal is between 0 and 1 volt, the XFyre boiler will be in stand by mode, not firing. When the signal rises above 1 volt, the XFyre boiler will ignite. As the signal continues to rise towards its maximum of 10 volts, the XFyre boiler will increase either in setpoint temperature or firing rate, depending on the setting of screen 17 in the installer menu. See the Installer Menu section for details on the setting of screens 16 and 17 for this option.

2. Connect a building management system or other auxiliary control signal to the terminals marked +0–10 V and -0–10 V in the electrical junction box (shown in Fig. 16) Caution should be used to ensure that the +0–10 V connection does not become connected to ground.

Wiring the Cascade System Communication Bus

1. Use standard CAT3 or CAT5 computer network

patch cables to connect the communication bus between each of the boilers. These cables are readily available at any office supply, computer, electronic, department or discount home supply store in varying lengths.

3. Connect the indirect tank sensor to the terminals marked DHW SENSOR (shown in Fig. 16) in the electrical junction box. Caution should be used to ensure neither of these terminals becomes connected to ground.

2. It is recommended that the shortest length cable possible be used to reach between the boilers and create a neat installation. Do not run unprotected cables across the floor or where they will become wet or damaged. Avoid running communication cables parallel with, or close to or against, high voltage (120 volt or greater) wiring. Raypak recommends that the total maximum length of communication bus cables not exceed 200 feet.

Fig. 17: XFyre Cascade System Wiring

3. Create a hole to route the communication cables through where the dimples are in the side of the cabinet (see Fig. 15), or route the wires to the rear junction box and out of the cabinet.

4. Connect the boilers in a daisy chain configuration as shown in Fig. 17 above. It is best to wire the boilers using the shortest wire runs rather than trying to wire them in the order that they are

addressed. The communication bus jacks on the customer connection panel are interchangeable so you can use either one or both in any order to connect the cable to. If you have connected the boilers to each other properly, two of the boilers will have one open connection port on them.

* - May be configured as DHW SENSOR for single boiler Cascade with Indirect

5. Connect the boiler pump to the terminals marked BOILER PUMP NEUT (#6), BOILER PUMP HOT (#5), and GROUND (#4).

6. Connect the system pipe sensor to the terminals

arked SYS SENSOR, as shown in Fig. 18.

7. Connect the outdoor sensor (if used) to the terminals marked OUTDOOR SEN.

8. Connect the signal to start the system to the terminals marked THERMOSTAT.

NOTE: This signal can come from a room thermostat or a dry contact closure. No power of any voltage should be fed into either of these terminals.

Fig. 18: XFyre Cascade Master

Cascade Master Pump and Sensor Wiring

1. On the boiler designated as the Cascade Master, apply the System Sensor and DHW Sensor decals (included) to the field wiring board as shown in Fig.

18. Apply the SYSTEM PUMP and EXT HEATER labels to the wiring electrical connections terminal strip as shown in Fig. 11b on page 17.

2. Connect the system pump hot wire to terminal #11, marked SYSTEM PUMP (see Fig 11b).

3. Connect the system pump neutral to terminal #6, marked BOILER PUMP NEUT, and the pump ground wire to terminal #3, marked GROUND, at the rear terminal strip.

4. Connect a jumper wire from terminal #1, marked 120 V BLACK (HOT), terminal #11, marked SYSTEM PUMP POWER, at the rear terminal strip.

Fig. 19: XFyre Cascade Follower

Cascade Follower Pump and Sensor Wiring

. Connect the boiler pump to the terminals marked

BOILER PUMP NEUT (#6), BOILER PUMP HOT

#5), and GROUND (#4) at the rear terminal strip.

(

2. If you are using an indirect fired water tank connected directly to the follower boiler, connect the pump for it to the terminals marked DHW PUMP NEUT (#8), DHW PUMP HOT (#7), and GROUND (#3) at the rear terminal strip.

If you desire, an alarm bell or light can be connected to the alarm contacts of the follower boiler. Optionally, the normally-closed alarm contact may be used to turn a device off if the boiler goes into lockout mode. The alarm contacts are rated 5 amps at 120 VAC.

To connect an alarm device, connect the power for the device to the ALARM COM terminal. Connect the alarm device hot wire to the ALARM NO terminal. Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device.

To connect a device that should be powered off during a boiler lockout condition, follow the same instructions as above except use the ALARM NC terminal rather than the ALARM NO terminal.

Note that in a cascade system the alarm output of the boiler addressed as #1 will also be active if the master boiler has a lockout condition. The alarm output of boilers addressed as 2–7 will only sound if a lockout condition occurs on that specific boiler.

CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the boiler.

Venting

General

Appliance Categories

Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent.

Category I – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category II – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate

roduction in the vent.

ategory III – A heater which operates with a positive

vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category IV – A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

See Table K for appliance category requirements.

NOTE: For additional information on appliance categorization, see the ANSI Z21.13 Standard and the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes.

CAUTION: Condensate drains for the vent piping are required for installations of the XFyre. Follow vent manufacturer instructions for installation and location of condensate drains in the vent. Condensate drain traps must be primed with water to prevent gas flue leak and must be routed to an appropriate container for neutralization before disposal, as required by local codes.

WARNING: Contact the manufacturer of the vent material if there is any question about the appliance categorization and suitability of a vent material for application on a Category IV vent system. Using improper venting materials can result in personal injury, death or property damage.

CAUTION: Raypak recommends the use of a condensate neutralizer, sales order option Z-12.

Use only approved PVC or CPVC vent materials (in Canada, ULC-S636 approved plastic materials must be used) or special gas vent pipes listed for use with Category IV gas burning heaters, such as the AL29-4C stainless steel vents offered by Heat Fab Inc. (800772-0739), Protech System, Inc. (800-766-3473), Z-Flex (800-654-5600) or American Metal Products (800-423-4270). Pipe joints must be positively sealed. Follow the vent manufacturer’s installation instructions carefully. Vent installations shall be in accordance with Part 7, Venting of Equipment, of the NFGC, ANSI Z223.1/NFPA 54, Section 7, Venting Systems and Air Supply for Appliances, of the B149 Code, or applicable provisions of the local building codes.

Combustion

Air Supply

Exhaust

Configuration

Heater Venting

Category

Certified Vent

Materials

Combustion Air

Inlet Material

From Inside Building (Non-Direct Venting)

From Outside Building

(Direct Venting)

WARNING: Do not use foam core or cellular core pipe for venting.

Vertical Venting

orizontal Through-

the-Wall Venting

Vertical Venting

Horizontal Through-

the-Wall Venting

Table K: Venting Category Requirements

Support of Vent Stack

The weight of the vent stack or chimney must not rest on the heater vent connection. Support must be provided in compliance with applicable codes. The vent should also be installed to maintain proper clearances from combustible materials. Use insulated vent pipe spacers where the vent passes through combustible roofs and walls.

When using PVC or CPVC venting on models 300 and 500, insert the vent pipe 3-5 inches into the unit and provide rigid support to the vent, so that it will not shift laterally.

Vent Terminal Location

(Canada Only: ULC-

636 PVC and CPVC)

Stainless Steel,

WARNING: DO NOT insulate PVC or CPVC vent pipe.

5. The bottom of the vent terminal and the air intake

6. Single-wall Category IV metal vent pipe shall not

7. Through-the-wall vents for Category IV appli-

8. Locate and guard vent termination to prevent acci-

AL29-4C, ANSI/ASTM

D1785 Sch 40 PVC,

ANSI/ASTM F441 Sch

40 CPVC

shall be located at least 12 in. above grade, including normal snow line.

be used outdoors in cold climates for venting gasfired equipment without insulation.

ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

dental contact by people or pets.

Galvanized Steel,

PVC, ABS,

CPVC

1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.

NOTE: During winter months check the vent cap and make sure no blockage occurs from build-up of snow or ice.

2. Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury.

3. Gases may form a white vapor plume in winter. The plume could obstruct a window view if the termination is installed near windows.

4. Prevailing winds, in combination with below-freezing temperatures, can cause freezing of condensate and water/ice build-up on buildings, plants or roofs.

9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area.

10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations.

11. Locate or guard vent to prevent condensate from damaging exterior finishes. Use a rust-resistant sheet metal backing plate against brick or masonry surfaces.

12. DO NOT extend exposed vent pipe outside of building beyond the minimum distance required for the vent termination. Condensate could freeze and block vent pipe.

NOTE: When using PVC vent termination, insert the two round stainless mesh screens provided with the unit into the tee.

U.S. Installations

Refer to the latest edition of the National Fuel Gas Code.

ent termination requirements are as follows:

1. Vent must terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, window or gravity air inlet to the building.

2. Less than 7 ft (2.13 m) above a paved sidewalk or paved driveway located on public property.

3. Within 6 ft (1.8 m) of a mechanical air supply inlet to any building.

. Above a meter/regulator assembly within 3 ft (915

mm) horizontally of the vertical centerline of the regulator.

2. The vent must not be less than 7 ft above grade when located adjacent to public walkways.

3. Terminate vent at least 3 ft above any forced air inlet located within 10 ft.

4. Vent must terminate at least 4 ft horizontally, and in no case above or below unless 4 ft horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment.

5. Terminate vent at least 6 ft away from adjacent walls.

6. DO NOT terminate vent closer than 5 ft below roof overhang.

7. The vent terminal requires a 12 in. vent terminal clearance from the wall.

8. Terminate vent at least 1 ft above grade, including normal snow line.

9. Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane.

WARNING: The Commonwealth of Massachusetts requires that sidewall vented heaters, installed in every dwelling, building or structure used in whole or in part for residential purposes, be installed using special provisions as outlined on page 53 of this manual.

Installations in Canada

5. Within 6 ft (1.8 m) of any gas service regulator vent outlet.

6. Less than 1 ft (305 mm) above grade level.

7. Within 3 ft (915 mm) of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building or the combustion air inlet of any other appliance.

8. Underneath a verandah, porch or deck, unless the verandah, porch or deck is fully open on a minimum of two sides beneath the floor, and the distance between the top of the vent termination and the underside of the verandah, porch or deck is greater than 1 ft (305 mm).

Venting Installation Tips

Support piping:

• horizontal runs—at least every 5 ft (1.5m)

• vertical runs—use braces

• under or near elbows

WARNING: Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness, corrosion or deterioration.

Venting Configurations

For heaters connected to gas vents or chimneys, vent installations shall be in accordance with the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes.

Refer to latest edition of the B149 Installation Code.

A vent shall not terminate:

1. Directly above a paved sidewalk or driveway which is located between two single-family dwellings and serves both dwellings.

Vertical Venting (Category IV)

CAUTION: This venting system requires the

installation of a condensate drain in the vent piping per the vent manufacturer’s instructions. Failure to install a condensate drain in the venting system will void all warranties on this boiler.

odel No.

Certified Vent

Material

ent and

V Intake Air Vent Size

(in.)

Vertical Vent Height1(ft)

Min. Max.

ombustion

Air Intake

Pipe

Material

Vertical Air

nlet Max.

Length* (ft)

300

(Canada Only:

ULC-S636 PVC

and CPVC)

Stainless Steel,

AL29-4C,

0 100

ANSI/ASTM D1785

Sch 40 PVC,

ANSI/ASTM F441

850 6

Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details.

* Subtract 10 ft per elbow. Max. 4 elbows.

Installation

Sch 40 CPVC

Table L: Category IV Vertical Vent & Vertical Direct Vent

The distance of the vent terminal from adjacent public walkways, adjacent buildings, open windows and

The maximum and minimum venting length for this Category IV appliance shall be determined per the NFGC (U.S.) or B149 (Canada).

building openings must be consistent with the NFGC (U.S.) or B149 (Canada). Vents supported only by flashing and extending above the roof more than 5 ft should be securely guyed or braced to withstand snow

The diameter of vent flue pipe should be sized accord-

and wind loads.

ing to the NFGC (U.S.) and Appendix B of B149 (Canada). The minimum flue pipe diameter for conventional venting is: 4 in. (102mm) for Models 300 and 500, and 6 in. (152mm) for Model 850.

Galvanized

Steel,

PVC, ABS,

CPVC

100500

The connection from the appliance vent to the stack must be as direct as possible and shall be the same diameter as the vent outlet. The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot from the heater to the vent terminal. The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physical damage or separation of joints.

NOTE: A vent adapter (field-supplied) may be required to connect the Category IV vent to the boiler.

Termination

The vent terminal should be vertical and should terminate outside the building at least 2 ft above the highest point of the roof that is within 10 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft horizontal distance is maintained) electric meters, gas meters, regulators and relief equipment.

Fig. 20: Vertical Venting

NOTE: When using PVC vent termination, insert the round stainless mesh screens provided with the unit into the tee and terminals.

CAUTION: A listed vent cap terminal suitable for

onnection to the Cat IV vent materials, adequately

c sized, must be used to evacuate the flue products from the boilers.

Common Venting

on venting system are located and other spaces

m of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range

oods and bathroom exhausts, so they will oper-

h ate at maximum speed. Do not operate a summer

xhaust fan. Close fireplace dampers.

(d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters. This is covered in the NFGC under “Engineered Vent Systems”. Table M provides volumes of flue products at full fire for the calculation of appropriate vent and extractor sizing for common venting.

WARNING: Vent connectors serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure. If an XFyre boiler is installed to replace an existing boiler, the vent system MUST be verified to be of the correct size and of Category IV AL29-4C vent material or approved PVC/CPVC construction (in Canada, ULC-S636 approved plastic materials must be used). If it is NOT, it MUST be replaced.

NOTE: For extractor sizing, typical CO2levels are

8.5% for natural gas and 9.5% for propane gas and flue temperatures of approximately 150°F.

At the time of removal of an existing boiler, the following steps shall 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:

(a) Seal any unused openings in the common venting

system.

(b) Visually inspect the venting system for proper size

and horizontal pitch and make sure there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

(e) After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use.

(f) Any improper operation of the common venting

system should be corrected so that the installation conforms with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CSA B149. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CSA B149.

Volume of

Flue Products

(CFM)

Model No.

300

Vent Size

(inches)

500 130

850 6 220

NOTE: Data for 100% firing rate.

Table M: Volume of Flue Products Data

NOTE: Vent and intake piping must be supported so that the weight of the venting is not transfered to the unit. Horizontal runs of vent and intake piping must be supported to prevent sagging.

windows and all doors between the space in which the appliances remaining connected to the com-

Note: Heaters rotated to show venting connections.

12” MIN ABOVE SNOWLINE

Fig. 21: Typical Common Venting

Horizontal Through-the-Wall Direct Venting (Category IV)

Refer to Table F and local codes.

Fig. 22: Horizontal Through-the-Wall Venting

Refer to Table F and local codes.

Fig. 23: Horizontal Through-the-Wall Direct Venting

NOTE: While a drain connection is required in the

ent of all XFyre installations, the drain can be ac-

v complished in several different ways. The figures in this manual show the drain in a vent tee, however, this can also be accomplished using an inline collec-

or for condensing stacks or an inline vertical or

t horizontal collector available from several of the

isted vent manufacturers.

equivalent ft, an appropriately sized variable-speed extractor must be used. Each elbow used is equal to 10 ft of straight pipe with a maximum of 4 elbows each on the air intake and vent.

The vent and air intake runs should be balanced to provide approximately the same equivalent length.

The vent cap and air intake elbow are not considered in the overall length of the venting system.

CAUTION: This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer’s instructions. Failure to install a condensate drain in the venting system will void all warranties on this boiler.

Installation

These installations utilize the heater-mounted blower to draw combustion air and to vent the combustion products to the outdoors. The combustion air intake and the vent are installed horizontally through the wall to the outdoors. Adequate ventilation air must be supplied to the equipment room in accordance with the NFGC (U.S.) or B149 (Canada).

The total length of the horizontal through-the-wall direct vent system should not exceed 200 equivalent ft in length. If combined vent/intake run exceeds 200

The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to ensure that all joints are sealed properly and are airtight. The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that:

1. The vent must be installed with condensate drains as directed by the vent manufacturer.

2. The vent must be installed with a slight upward slope of not less than 1/4 inch per foot of horizontal run to the vent terminal.

Termination

The vent cap MUST be mounted on the exterior of the building. The vent cap cannot be installed in a well or below grade. The vent cap must be installed at least 1 ft above ground level and above normal snow levels. Only Raypak-approved vent caps may be used. The vent terminal must be located NO CLOSER than 12” off the wall.

Model No.

300

500

Size (in.)

Approved Intakes

PVC 90° Elbow,

Galvanized 90° Elbow SS 90°

850 6

*Must be ULC-S636 materials in Canada.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

Approved Plastic

Terminals

4" PVC Tee, Sch

Sch 40

40*

6" PVC Tee, Sch

Elbow

Table N: Horizontal Vent and Air Intake Terminals

40*

FasNSeal FSTT4, Z-Vent 2SVSTTF04

FasNSeal FSTT6, Heat Fab 9690TEE

Approved SS Terminals

ertified Vent

Model No.

300

Material

Canada Only:

(

ULC-S636 PVC

and CPVC)

Stainless Steel,

500

AL29-4C,

ANSI/ASTM D1785

Sch 40 PVC,

850 6

ANSI/ASTM F441

Sch 40 CPVC

* Subtract 10 ft per elbow. Max. 4 elbows.

Table O: Category IV Horizontal Vent & Horizontal Direct Vent

Vent and

ntake Air

I Vent Size

(in.)

orizontal Vent Height

(ft)

Min. Max.

0 100

Combustion

ir Intake

Pipe

Material

Galvanized

Steel,

PVC, ABS,

CPVC

Air Inlet

Max.

Length (ft)*

100

Direct Vent—Vertical

Fig. 24: Direct Vent - Vertical

The total length of air supply pipe cannot exceed the distances listed in Table L. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in any arrangement that does not exceed the lengths shown in Table L.

The vent cap is not considered in the overall length of the venting system.

Care must be taken during assembly that all joints are sealed properly and are airtight.

The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that:

1. The vent must be installed with a condensate drain as directed by the vent manufacturer.

2. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of horizontal run to the vent terminal.

Termination

Installation

These installations utilize the heater-mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors.

The vent cap MUST NOT be installed with any combustion air inlet directly above a vent cap. This vertical spacing would allow the flue products from the vent cap to be pulled into the combustion air intake installed above.

This type of installation can cause non-warrantable problems with components and poor operation of the

oiler due to the recirculation of flue products. Multi-

b ple vent caps installed in the same horizontal plane must have a 4 ft clearance from the side of one vent cap to the side of the adjacent vent cap(s).

5. Vent terminal must be at least 3 ft above any orced air inlet located within 10 ft.

6. Adjacent brick or masonry surfaces must be pro-

tected with a rust-resistant sheet metal plate.

Combustion air supplied from outdoors must be free of particulate and chemical contaminants. To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.

WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

The stainless steel flue direct vent cap must be furnished by the boiler manufacturer in accordance with its listing (sales order option D-15).

Outdoor Installation

Outdoor models must be vented with listed vent material per the following instructions and installed with the optional factory-supplied outdoor vent kit. A special vent terminal is provided in accordance with CSA requirements. These must be installed as illustrated in Fig. 25.

Freeze Protection

NOTE: The vent cap must be furnished by the boiler

manufacturer in accordance with its listing (sales order option D-11).

NOTE: Condensate can freeze on the vent terminal. Frozen condensate on the vent terminal can result in a blocked flue condition.

Care must be taken when locating the unit outdoors, because the flue gases discharged from the vent cap can condense as they leave the cap. Improper location can result in damage to adjacent structures or building finish. For maximum efficiency and safety, the following precautions must be observed:

1. Outdoor models must be installed outdoors and must use the outdoor vent cap available from the manufacturer (sales order option D-11).

2. Periodically check venting system. The unit’s venting areas must never be obstructed in any way and minimum clearances must be observed to prevent restriction of combustion and ventilation air. Keep area clear and free of combustible and flammable materials.

3. Do not locate adjacent to any window, door, walkway, or gravity air intake. The vent must be located a minimum of 4 ft horizontally from such areas.

4. Install above grade level and above normal snow levels.

Fig. 25: Outdoor Venting

Model

No.

300

500

850 6

*Must be ULC-S636 materials in Canada.

The Raypak electronic temperature control includes a freeze protection feature. In the event the temperature drops below 40°F at any of the temperature sensors, the pump is turned on and will remain on until the temperatures at all sensors rise to 45°F.

Approved

Size

(in.)

Table P: Outdoor Vent Terminals

Plastic

Terminals

PVC Tee,

Sch 40*

PVC Tee,

Sch 40*

Approved SS

Terminals

FasNSeal FSTT4,

Z-Vent 2SVSTTF04

FasNSeal FSTT6, Heat

Fab 9690TEE

Controls

High Limit — Manual Reset

WARNING: Installation, adjustment and service of

controls, including timing of various operating functions, must be performed by a qualified installer, service agency or the gas supplier. Failure to do so may result in control damage, malfunction, property damage, personal injury, or death.

WARNING: Turn off the power to the boiler before installation, adjustment or service of any controls. Failure to do so may result in board damage, malfunction, property damage, personal injury, or death.

CAUTION: This appliance has provisions to be connected to more than one supply source. To reduce the risk of electric shock, disconnect all such connections before servicing.

CAUTION: Risk of electric shock: More than one disconnect switch may be required to de-energize the equipment before servicing.

This boiler is equipped with a fixed-setting manual re-

et high limit temperature device as standard or it may

s have an optional adjustable setting manual reset high temperature device.

he fixed-setting manual-reset high limit is located on

T the outlet pipe of the heat exchanger on the left side of the boiler (accessible through the front door for reset as necessary).

Fig. 26: High Limit (Manual Reset)

High Limit — Auto Reset (Optional)

Ignition Control Functions

When there is a call for heat, the combustion air blower starts to purge air from the combustion chamber. After the pre-purge, the igniter is energized. The standard ignition module will lock out after failing to light four times or after losing flame three times during a single heat demand. To reset it, press and release the ESC/RESET button located on the user interface. The control will automatically reset after 1 hour. When in lock out, the control will run the blower for a 1 minute purge cycle. Turning off the power to the heater

WILL NOT reset the ignition module.

The optional single-try ignition module will attempt to light only one time before locking out. To reset it, press the ESC/RESET button on the user interface.

NOTE: Each ignition module is specific to a single model size. Care should be taken not to use a module intended for a different model size.

This heater is equipped with a fixed auto-reset high limit temperature device.

The optional auto reset high limit is located on the heat exchanger header, near the outlet.

Fig. 27: High Limit (Auto Reset)

Flow Switch

This standard, dual-purpose control, mounted and wired in series with the main gas valve, shuts off the boiler in case of pump failure or low water flow.

Fig. 27: Flow Switch

Low Water Cut-Off (Optional)

The optional low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets.

he optional high gas pressure switch connection

T mounts down-stream of the gas valve. Special ports are located on the backside of the gas valve and accessible from the front of the boiler (to reset the gas

ressure switch), as necessary. If the gas pressure

p regulator in the valve fails, the high gas pressure

witch automatically shuts down the burner.

Operation of either the High or Low Gas Pressure Switch will turn on an LED inside the switch housing. Push the top of the plastic switch housing as shown in Fig. 29 to reset a tripped pressure switch. The LED will go out when the switch is reset.

Fig. 28: Low Water Cut-Off

High & Low Gas Pressure Switches

(Optional)

The optional low gas pressure switch connection mounts upstream of the gas valve (on the inlet flange to the gas valve) and is accessible through the removable access panels on the rear of the boiler to reset the gas pressure switch, as necessary. It is used to ensure that sufficient gas pressure is present for proper valve/regulator performance. The low gas pressure switch automatically shuts down the boiler if the gas supply drops below the factory setting of 3.0 in. WC for natural gas or propane gas.

Fig. 29: High/Low Gas Pressure Switch

Blocked Vent Switch

This heater is equipped with a blocked vent pressure switch to prevent the operation of the boiler when too much of the vent is blocked. This switch is located on the left side of the heater near the left rear corner.

Fig. 30: Blocked Vent Switch

Blocked Condensate Drain Sensor

UP arrow key

DOWN

arrow key

ESC/RESET

key

LEFT arrow key

RIGHT

arrow key

ENTER/MENU

key

This boiler is equipped with a condensate sensor to prevent operation when the condensate water level is too high. The boiler shutting down from the condensate sensor is indicative of a blocked drain or problem with the condensate management system. The condensate sensor is located inside the condensate reservoir at the rear of the boiler.

Fig. 31: Condensate Drain Sensor

Operating Instructions

Remove the front door. If you smell gas, STOP. Follow listed safety instructions. If you do not smell gas, follow the next steps.

. If the appliance fails to start, refer to the

Troubleshooting section in the back of this manual.

NOTE: Before you can change the temperature

rom the factory setting of 160 degrees, you must

f make sure none of the thermostats are calling for

eat. The controller will not memorize a program

h setting while in a heating cycle.

User Menu

The user menu consists of several items that can be adjusted. To access the user menu, press and hold the

ENTER/MENU key for 5 seconds. Using the UP and DOWN, and LEFT and RIGHT arrow keys, enter 600,

then press ENTER/MENU. Scroll through the list of adjustable items by pressing the LEFT or RIGHT arrow keys. Once the desired item is displayed, press the ENTER/MENU key to select it. The screen will begin to flash. Press the DOWN arrow key to decrease the values, and the UP arrow key to increase them. To store the changes, press the ENTER/MENU key. The display returns to normal mode after one minute. Pressing the ESC/RESET key before storing changes will restore the original value. Refer to Fig. 32 for display and key locations.

Adjusting the XFyre Setpoint

1. Turn on all electric power to appliance.

2. Adjust the temperature setpoint of the XFyre as desired. The factory default setting is 160°. If changes are necessary follow “Adjusting The XFyre Setpoint” in this section.

3. On the initial start-up of units with gas pressure switches, the control user interface will display flue/gas press. This is a low gas pressure switch lock-out from the factory-installed low gas pressure switch. You will also see a yellow LED illuminated under the cover of the low gas pressure switch. Once the gas is turned on, reset the gas pressure switch by FIRMLY pressing on top of the plastic cover over the red reset button. The yellow LED will go out after the switch has been reset. Press and hold the ESC/RESET key on the control panel for about 4 seconds to begin normal operation.

4. Set the thermostat to the desired setting.

To adjust the temperature on the XFyre:

– Press the ENTER/MENU key for 5 seconds to

bring up the code menu. Enter 600 to access the user menu.

– Press the DOWN arrow key to decrease the tem-

perature (minimum setpoint is 50°F).

Fig. 32: Display Interface

ser Menu Items

Screen No. Default Information Displayed Range Description

nioptespooltaehroedacsaCpooLtaeH

º091-05Fº951

aitnereffidpooltaehroedacsaCffiDpooLtaeH

Fº54-2Fº03

tniopteSWHDteSWHD

Fº581-59Fº041

laitnereffiDWHDffiDWHD

º81-1Fº5

erusaemfotinuerutarepmeTtinUerutarepmeT

/CºFº

ruoh42ro21edomkcolCedoMkcolC

MM/DD/YYYY Day 12:00:00 12/24 h

ruohkcolcteSruoHkcolC

MM/DD/YYYY Day 12:00:00

tunimkcolcteSetuniMkcolC

MM/DD/YYYY Day 12:00:00

keewfoyadteSyadkeeWkcolC

MM/DD/YYYY Day 12:00:00

tamrofetadteSedoMkcolC

MM/DD/YYYY Day 12:00:00

raeyetadteSraeYkcolC

MM/DD/YYYY Day 12:00:00

htnometadteShtnomkcolC

MM/DD/YYYY Day 12:00:00

yadetadteSetadkcolC

MM/DD/YYYY Day 12:00:00

– Press the UP arrow key to increase the tempera-

ture (maximum setpoint is 200°F, but should not exceed 180°F for “H” units or 160°F for “W” units).

Status Menu

Installers are also able to check the current status of the XFyre unit parameters by pressing either the LEFT or RIGHT arrow keys during normal operation.

The status menu can have three states depending on the enabling of 0–10 VDC input and cascade master control. Each state can be selected using the LEFT or RIGHT arrow key when it is enabled.

Service Mode

This function is intended to simplify the gas valve adjustment if needed. Manifold gas pressure settings

are listed in Table I on page 16. Automatic modulation does not take place when the controller is in Test Mode, only temperature limitation based on the XFyre Central Heating set point occurs. The user will be allowed to increase or decrease the fan speed by pressing either the UP or DOWN arrow keys.

To activate the service mode, press the UP arrow and ENTER/MENU keys together for 1 second. Once activated, you will see in the display Service and the actual fan speed. The measurement of the combustion levels should always be taken at the highest and lowest fan speed. After 10 minutes, the service mode stops automatically. To exit the service mode, press the UP and DOWN arrow keys together for 1 second.

tatus Menu 1 Items

creen No. Default Information Displayed Range Description

upply XXX ºF -13-248 ºF Heater outlet water temperature

Return XXX ºF -13-248 ºF Heater inlet water temperature

H Set 160 ºF 50-190 ºF Heater outlet water setpoint for hydronic heating

Supply XXX ºF -13-248 ºF Heater outlet water temperature

retsaMfitnioptes)rosnesmetsyS(edacsaCFº091-05Fº061teSsaC

tneserpdnaretsaMfierutarepmetrosnesmetsySFº842-31-FºXXXmetsyS

nioptesknaTWHDFº081-59Fº041teSWHD

DHW XXX ºF -13-248 ºF DHW tank temperature (if sensor is present)

Outdoor XXX ºF -40-248 ºF Outdoor air temperature (if sensor is present, otherwise off)

langisnoitazinoiemalFAu0.0emalF

PRnaFMPR0deepSnaF

langisnoitaludomrotnioptesetomeRV0.01V01-0

noitcennoconronoitcennocsubedacsaCnnoCoN/nnoCnnoCoNmmoCsuB

derewopneebsahretaehehtsruoHh0nOrewoP

taehrofllacahtiwsruoHh0nOHC

dnamedWHDahtiwsruoHh0nOWHD

snoitingilufsseccusforebmuNx0noitingidooG

edocyalpsidtluaftsaL)rorretsal(epyttluaF/1yrotsiHtluaF

tluaftsalfoemiT00:00:21yaDYYYY/DD/MM

edocyalpidtluaFepyttluaF/2yrotsiHtluaF