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.
CONTENTS WARNINGS Pay Attention to These Terms BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information Time/Temperature Relationships in Scalds GENERAL SAFETY INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connection Venting Venting Installation Tips Ventin
WARNINGS Pay Attention to These Terms DANGER: WARNING: CAUTION: NOTE: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. 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.
BEFORE INSTALLATION Model Identification The model identification number and heater serial number are found on the heater rating plate located on the upper rear jacket panel of the heater. The model number will have the form H7-850 or similar depending 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).
Component Locations Model 300 shown. Component locations may vary slightly in larger models. Fig. 1: Component Locations — Sides Fig. 3: Component Locations — Rear Fig. 2: Component Locations — Top General Information Model No. 300 500 850 MBTUH Input Water conn. Max. Min. (NPT) 300 500 850 60 1-1/2” 170 2” 100 2” Gas conn.
Model No. Heater Water Volume (gallons) 500 4.2 300 850 2.9 5.8 Table B: Heater Water Volume 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.
INSTALLATION Clearances Indoor Installations Installation Codes Installations must follow these codes: • • • • • Local, state, provincial, and national codes, laws, regulations and ordinances National Fuel Gas Code, ANSI Z223.
Heater Side Min. Clearances from Combustible Surfaces Recommended Service Clearances Right Side 0” 0” Rear Left Side 24” SERVICE CLEARANCE 24” 0” 24” 0” Top Unobstructed 24” Vent Termination 12” 12” Front Open 24” Table E: Clearances — Outdoor Installations 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.
Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 1 2 t TT * 2 U.S. Installations Canadian Installations A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 ft (1.
Combustion Air Filter mechanical room. All ducting must be self-supported. CAUTION: Use TruSeal combustion air if damaging airborne contaminants are or may be present in the boiler area. See the Appendix of this manual regarding air contamination. 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).
b. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in.2 per 2,000 BTUH (1,100 mm2 per kW) of total input rating of all equipment in the enclosure. 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. 2.
Relief Valve Installation and Piping To perform hydrostatic test: 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 any entrapped air by using high-point vents. Close feed valve. Test at standard operating pressure for at least 24 hours.
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. *Maximum 4 times the pipe diameter or 12”, whichever is less. Fig. 8: Dual Heaters (Reverse/Return) with Primary/Secondary Piping Three-Way Valves Domestic Hot Water Three-way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used.
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.
Gas Supply 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 end threads bare. DANGER: Make sure the gas on which the heater will operate is the same type as specified on the rating plate. 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.
Model No. 300 500 850 3/4” NPT N 15 1” NPT P N 30 45 10 15 1-1/4” NPT 1-1/2” NPT 100 175 400 390 15 25 55 55 P 40 N 65 P 150 N P 150 350 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.
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 It is strongly recommended that all individually-powered 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. Fig.
Field Wiring Connections DANGER: SHOCK HAZARD CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components. Fig. 16: XFyre Single Heater Control Wiring the Thermostat Fig. 14: Rear Wiring Location 1.
Wiring the Outdoor Sensor Wiring the Optional 0–10 Volt Building Control Signal 1. There is no connection required if an outdoor sensor is not used in this installation. 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 DC signal. When this input is enabled using the installer menu, a building control system can be used to control either the setpoint temperature or the heat output of the XFyre boiler.
Fig. 17: XFyre Cascade System Wiring 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. 3. Create a hole to route the communication cables through where the dimples are in the side of the cabinet (see Fig.
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 marked 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.
Cascade Follower Pump and Sensor Wiring Category II – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent. 1. Connect the boiler pump to the terminals marked BOILER PUMP NEUT (#6), BOILER PUMP HOT (#5), and GROUND (#4) at the rear terminal strip. Category III – A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.
Combustion Air Supply From Inside Building (Non-Direct Venting) From Outside Building (Direct Venting) Exhaust Configuration Vertical Venting Heater Venting Category Horizontal Throughthe-Wall Venting Vertical Venting IV Horizontal Throughthe-Wall Venting Certified Vent Materials (Canada Only: ULCS636 PVC and CPVC) Stainless Steel, AL29-4C, ANSI/ASTM D1785 Sch 40 PVC, ANSI/ASTM F441 Sch 40 CPVC Table K: Venting Category Requirements WARNING: Do not use foam core or cellular core pipe for venting.
U.S. Installations 2. Less than 7 ft (2.13 m) above a paved sidewalk or paved driveway located on public property. Refer to the latest edition of the National Fuel Gas Code. Vent termination requirements are as follows: 3. Within 6 ft (1.8 m) of a mechanical air supply inlet to any building. 2. The vent must not be less than 7 ft above grade when located adjacent to public walkways. 5. Within 6 ft (1.8 m) of any gas service regulator vent outlet. 4.
Model No. 300 500 850 Certified Vent Material (Canada Only: ULC-S636 PVC and CPVC) Stainless Steel, AL29-4C, ANSI/ASTM D1785 Sch 40 PVC, ANSI/ASTM F441 Sch 40 CPVC Vent and Intake Air Vent Size (in.) Vertical Vent Height1 (ft) Min. 4 0 6 Max. 100 Combustion Air Intake Pipe Material Vertical Air Inlet Max. Length* (ft) Galvanized Steel, PVC, ABS, CPVC 100 1 Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details.
mon venting system are located and other spaces 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 hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. NOTE: When using PVC vent termination, insert the round stainless mesh screens provided with the unit into the tee and terminals.
Note: Heaters rotated to show venting connections. Fig. 21: Typical Common Venting Horizontal Through-the-Wall Direct Venting (Category IV) 12” MIN ABOVE SNOWLINE Refer to Table F and local codes. Refer to Table F and local codes. Fig. 23: Horizontal Through-the-Wall Direct Venting Fig.
NOTE: While a drain connection is required in the vent of all XFyre installations, the drain can be accomplished 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 collector for condensing stacks or an inline vertical or horizontal collector available from several of the listed vent manufacturers. equivalent ft, an appropriately sized variable-speed extractor must be used.
Model No. Certified Vent Material (Canada Only: ULC-S636 PVC and CPVC) Stainless Steel, AL29-4C, ANSI/ASTM D1785 Sch 40 PVC, ANSI/ASTM F441 Sch 40 CPVC 300 500 850 Vent and Intake Air Vent Size (in.) Horizontal Vent Height (ft) Min. 4 0 Max. 100 6 Combustion Air Intake Pipe Material Air Inlet Max. Length (ft)* Galvanized Steel, PVC, ABS, CPVC 100 * Subtract 10 ft per elbow. Max. 4 elbows.
This type of installation can cause non-warrantable problems with components and poor operation of the boiler due to the recirculation of flue products. Multiple 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. 6. Vent terminal must be at least 3 ft above any forced air inlet located within 10 ft. Adjacent brick or masonry surfaces must be protected with a rust-resistant sheet metal plate.
Controls High Limit — Manual Reset This boiler is equipped with a fixed-setting manual reset high limit temperature device as standard or it may have an optional adjustable setting manual reset high temperature device. 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.
Flow Switch The optional high gas pressure switch connection 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 pressure switch), as necessary. If the gas pressure regulator in the valve fails, the high gas pressure switch automatically shuts down the burner.
Blocked Condensate Drain Sensor 5. If the appliance fails to start, refer to the Troubleshooting section in the back of this manual. 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.
User Menu Items Screen No.
Status Menu 1 Items Screen No.
Status Menu 2 Items Screen No. 1 Default Information Displayed Range Description Analog DHW Temp (if active) Temp/Fan Analog 0-10V input setpoint or fan modulation control Analog sig 0-10.0V Analog 0-10V signal XX.X V Status Menu 3 Items (Cascade Mode only) Screen No.
Installer Menu Items (continued) Screen No.
Installer Menu The installer menu consists of several items that can be adjusted. To access the installer menu, press and hold the ENTER/MENU key for 5 seconds. Using the UP and DOWN, and LEFT and RIGHT arrow keys, enter 925, 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.
WIRING DIAGRAM 40
NOTE: The wiring diagrams in this manual show all standard options. Refer to the large wiring diagram provided with your boiler for options installed on your specific unit(s). BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell near the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS: START-UP • • Pre Start-up • Filling System (Heating Boilers) • Fill system with water. Purge all air from the system.
Preparation Check Gas Supply Pressure 1. Slowly turn on main gas shut-off valve. WARNING: Do not turn on gas at this time. 2. Read the gas supply pressure from the manometer; minimum supply pressure for natural gas is 4.0 in. WC, recommended supply is 7.0 in. WC, minimum supply pressure for propane gas is 4.0 in. WC, recommended supply is 11.0 in. WC (dynamic readings, full fire input). Check Power Supply With multi-meter at incoming power, check voltage between: Hot - Common (≈120 VAC) 3.
Finishing –0.5 in. WC from the reading recorded on the start-up checklist. 1. Record all data on the “Start-up Checklist” located at the back of this manual. 3. The desired combustion CO2 is between 8.5% and 9.0% for natural gas and 9.0% and 9.5% for propane with CO less than 150 ppm. Combustion should be checked at high and low fire (Max. and Min. fan speed) by using the service mode. Enter the service mode by pressing the UP arrow key and ENTER/MENU key simultaneously for 1 second.
OPERATION Post Start-Up Check Check off steps as completed: 1. 2. 3. 4. 5. 6. 7. 8. 9. Lighting Instructions Verify that the boiler and heat distribution units or storage tank are filled with water. 1. Before lighting, make sure you have read all of the safety information in this manual. Confirm that the automatic air vent (if used) was opened two full turns during the venting procedure. 2. Set the thermostat to the lowest setting. 3. Turn off all electrical power to the appliance.
TROUBLESHOOTING To Turn Off Gas To Appliance XFyre Error Codes 1. Shut off manual gas valve field installed near gas inlet connection on back of boiler. If any of the sensors detect an abnormal condition or an internal component fails during the operation of the XFyre, the display may show an error code.
WARNING: When servicing or replacing any components of this unit be certain that: • The gas is off. • All electrical power is disconnected. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. WARNING: Do not use this appliance if any part has been under water. Improper or dangerous operation may result.
Error Text FLUE / GAS PRESS F01 Remedy 1. If the boiler is equipped with High and/or Low gas pressure switches, examine the switch(es) to see if the yellow LED is illuminated on the switch. If so, correct the gas supply problem associated with the switch and reset the switch by pressing on the cover of the switch over the red button to reset the switch. Pressing the button requires a firm push. Push the Reset button on the front panel of the boiler to reset the boiler control. 2.
Sensor Resistance Values Outdoor Sensor Temperature Sensors Water Temperature (°F) Resistance (ohms) Water Temperature (°F) Resistance (ohms) 41 25340 –13 129800 32 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203 212 –22 32550 –4 19870 98930 5 15700 12490 14 8059 32 76020 58880 23 10000 45950 36130 41 6535 28600 50 5330 22800 59 4372 18300 68 3605 14770 77 2989 12000 86 2490 9804 95 2084 8054 104 1753 6652 113 1481 1256 1070 171800 5522
MAINTENANCE condensate is being directed to appropriate condensate management system or drain, as required by local codes. Suggested Minimum Maintenance Schedule 3. Check that area is free from combustible materials, gasoline, and other flammable vapors and liquids. Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. 4. Check for and remove any obstruction to the flow of combustion or ventilation air to boiler.
3. Check burner flame. (Should see light blue flame at full input rate). Reset to original setting after each device is tested. Weekly 6. Perform leakage test on gas valves. 7. Test air switch in accordance with manufacturer’s instructions. (Turn panel switch to the “On” position until blower is proven, then turn the switch to “Off.” For low-pressure boilers, test low-water cut-off device. (With boiler in pre-purge, depress the low water cut-off test button.
Combustion Chamber Coil Cleaning Instructions WARNING: The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded that “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group1).
APPENDIX Inside Air Contamination Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high efficiency systems. The boiler can be supplied with corrosion-resistant, non-metallic intake air vent material. You may, however, choose to use outside combustion air for one or more of these reasons: Areas where contaminated combustion air commonly exists: 1.
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: (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1.
LIMITED PARTS WARRANTY XFYRE – TYPE H and W MODELS 300-850 SCOPE Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
START-UP CHECKLIST FOR THE XFYRE This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct. Additionally this form will be used to record all equipment operation functions and required settings.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
