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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 com
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CONTENTS WARNINGS 4 WIRING DIAGRAM 40 Pay Attention to These Terms 4 START-UP 41 BEFORE INSTALLATION 5 Pre Start-up 41 Product Receipt 5 Pre Start-up Check 41 Model Identification 5 Initial Start-up 41 Ratings and Certifications 5 Preparation 42 Installations at Elevation 5 Start-Up 42 Component Locations 6 OPERATION 44 General Information 6 Lighting Instructions 44 Time/Temperature Relationships To Turn Off Gas to Appliance 45 in Scalds 7 XFyre Error Codes 45 GENERAL SAFETY 7 Heater Errors 45 I
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WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. Indicates special ins
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Model Identification BEFORE INSTALLATION The model identification number and heater serial Raypak strongly recommends that this manual be re- number are found on the heater rating plate located on viewed thoroughly before installing your XFyre heater. the upper rear jacket panel of the heater. The model Please review the General Safety information before number will have the form H7-850 or similar depend- installing the heater. Factory warranty does not apply ing on the heater size and configura
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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 MBTUH Gas conn. Vent Size Water Model Input (NPT) (inches) conn. No. (NPT) Max. Min. N P Flue Intake 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 Table A: Basic Data 6
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Heater Water Volume Model No. (gallons) 300 2.9 500 4.2 850 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 Water temperature over 125°F can causeinstant severe burns or death main gas valve before the outlet temperature reaches from scalds. 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. Children, disabled, and elderly are When supplying
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Clearances INSTALLATION Indoor Installations Installation Codes Min. Clearances Recommended Installations must follow these codes: Heater from Combustible Service Side Surfaces Clearances • Local, state, provincial, and national codes, laws, regulations and ordinances Floor* 0” 0” • National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition (NFGC) Rear 24” 24” • National Electrical Code, ANSI/NFPA 70 - latest Right Side 0” 0” edition (NEC) • Standard for Controls and Safety Devices for Left Si
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Min. Clearances Recommended Heater from Combustible Service Side Surfaces Clearances Rear 24” 24” Right Side 0” 0” 24” Left Side 0” 0” SERVICE CLEARANCE Top Unobstructed 24” Front Open 24” Vent 12” 12” Termination Table E: Clearances — Outdoor Installations Combustion and Ventilation Air NOTE: Use of this boiler in construction areas 24” where fine particulate matter, such as concrete or SERVICE dry-wall dust, is present may result in damage to the CLEARANCE boiler that is not covered by the war
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Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 2 U.S. Installations Canadian Installations Clearance above grade, veranda, porch, A 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening; 1 foot (30 cm) B 3 ft (91 cm) opened above opening C Clearance to permanently closed window ** Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- D 5
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mechanical room. All ducting must be self-supported. Combustion Air Filter CAUTION: Use TruSeal combustion air if This heater is supplied with an integral combustion air damaging airborne contaminants are or may be filter. This filter will reduce the amount of particulates present in the boiler area. See the Appendix of this that pass through the combustion system and heat manual regarding air contamination. exchanger but will not protect against chemical inside air contamination (See Appendix).
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b. Where communicating with the outdoors and terminated 18 in. (450 mm) from the floor, but through horizontal ducts, each opening shall not near piping. This air supply opening require- 2 have a minimum free area of 1 in. per 2,000 ment shall be in addition to the air opening for 2 BTUH (1,100 mm per kW) of total input rat- ventilation air required in 1. (above). ing of all equipment in the enclosure. WARNING: Care must be taken to ensure that the 2. One permanent opening, commencing within 12
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To perform hydrostatic test: Relief Valve Installation and Piping 1. Connect fill water supply. With bleed valve open, WARNING: Pressure relief valve discharge piping fill heater with water. When water flows from bleed must be piped near the floor and close to a drain to valve, shut off water. Close bleed valve. Carefully eliminate the potential of severe burns. Do not pipe fill the rest of the system, making sure to eliminate to any area where freezing could occur. Refer to any entrapped air by
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Air-Separation/Expansion Tank Fig. 6: Air-Separation/Expansion Tank All heaters should be equipped with a properly sized *Maximum 4 times the pipe diameter or 12”, whichever is less. expansion tank and air separator fitting as shown in Fig. 8: Dual Heaters (Reverse/Return) Fig. 6 above. 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 When designing the water piping system f
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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 in
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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 DANGER: Make sure the gas on which the heater sparingly only on male pipe ends, leaving the two will operate is the same type as specified on the rat- end threads bare. ing plate. CAUTION: Support gas supply piping with Gas piping must have a sediment trap ahead of the hangers, not by the heater or its accessories. Make heater gas controls, and a
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3/4” NPT 1” NPT 1-1/4” NPT 1-1/2” NPT 2” NPT Model No. N P N P N P N P N P 300 15 30 45 100 175 400 390 500 10 15 40 65 150 150 350 850 15 25 55 55 125 175 450 3 Natural Gas – 1,000 BTU/ft , 0.60 specific gravity at 0.5 in. WC pressure drop 3 Propane Gas – 2,500 BTU/ft , 1.53 specific gravity at 0.6 in. WC pressure drop Table J: Maximum Equivalent Pipe Length may power up to two pumps directly (1 hp max boiler Electrical Power Connections pump, 3 A max DHW pump) and may control a third system pu
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contacts, optional 0–10 VDC control wiring and cas- cade 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-pow- ered control modules and the heater should be supplied from the same power source. NOTE: Field-supplied isolation relays should be Fig. 13: Multi-meter installed when field-connected controllers are mounted more than 50 equivalent feet (18 AWG) Making the Electrical Connec
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Field Wiring Connections DANGER: SHOCK HAZARD CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause im- proper and dangerous operation. Verify proper operation after servicing. Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. Fig. 16: XFyre Single Heater Control Wiring the Thermostat Fig. 14: Rear Wiring Location 1. Connect the room thermostat to the terminals marked THERMOSTAT in the
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Wiring the Outdoor Sensor Wiring the Optional 0–10 Volt Building Control Signal 1. There is no connection required if an outdoor sen- sor is not used in this installation. 1. A signal from a building management system may be connected to the XFyre boiler to enable remote 2. If using an Outdoor Sensor, connect the wires for control. This signal should be a 0–10 volt positive sensor to the terminals marked OUTDOOR SEN DC signal. When this input is enabled using the (shown in Fig. 16) in the electr
