Raypak 300 manual

INST ALLA TION & OPERA TING INSTR UCTIONS Catalog No. 1000.65 Effective: 10-16-09 Replaces: NEW P/N 241366 Rev . 1 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 u[...]

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WARNINGS 4 Pay Attention to These T erms 4 BEFORE INST ALLA TION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 6 T ime/T emperature Relationships in Scalds 7 GENERAL SAFETY 7 INST ALLA TION 8 Installation Codes 8 Equipment Base 8 Clearances 8 Combustion[...]

4 D ANGER: I ndicates the presence of immediate hazards which will cause severe personal injury , death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury , death or substantial property damage if ignored. CA UTION: Indicates the presence of hazards or u[...]

5 BEFORE INST ALLA TION Raypak strongly recommends that this manual be re- viewed 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 oper- ated. (Refer to the warranty at the back of this manual[...]

General Infor ma tion T able A: Basic Data 6 Component Locations Fig. 1: Component Locations — Sides Fig. 2: Component Locations — T op Fig. 3: Component Locations — Rear Model No. MBTUH Input W ater conn. (NPT) Gas conn. (NPT) V ent Size (inches) 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 8[...]

7 GENERAL SAFETY T o 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 rec- ommended initia[...]

Clearances Indoor Installations When installed according to the listed minimum clear- ances from combustible construction, these heaters can be serviced without removing permanent structur- al 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[...]

9 Fig. 4: Minimum Clearances from Combustible Surfaces — Indoor and Outdoor Installations T able E: Clearances — Outdoor Installations 24” SERVICE CLEARANCE 24” SERVICE CLEARANCE 24” SERVICE CLEARANCE Combustion and V entilation Air Indoor Units This heater must be supplied with sufficient quantities of non-contaminated air to support pro[...]

10 U. S. Ins tallations 1 Canad ia n Insta llati ons 2 A Clear ance above gr ade, veranda, p orc h, deck, or balcony 1 f t (30 c m) 1 ft (30 c m) B Clear ance to window or do or that may b e o pened 4 ft (1.2 m) below or to side of openin g; 1 foot (30 c m) a bove op ening 3 ft (91 cm) C Clearance to perma nently closed window ** D V ertical cleara[...]

11 Combustion Air Filter 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 combus-[...]

b. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in. 2 per 2,000 B TUH (1,100 mm 2 p er kW) of total input rat- ing of all equipment in the enclosure. 2. One permanent opening , commencing within 12 i n. (305 mm) of the top of the enclosure, shall be permitted where the equipment ha[...]

R elief V alve Installa tion and Piping 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 mount- ed directly to the heater outlet. No valve shall be installed between the heater and the relief valve. The relief valve shall be mounted wi[...]

Air-Separation/Expansion T ank All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig. 6 above. T hree-Way V alves 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[...]

15 P ota ble Wa ter and Space Heating 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. T oxic 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 su[...]

Gas Supply Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve lo- cated outside the heater jacket. It is recommended that a union be installed in the gas supply piping adja- cent 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. [...]

17 Electrical P ow er Connections Installations must follow these codes: • National Electrical Code and any other national, state, provincial or local codes or regulations hav- ing 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 XFyr[...]

Check the power source: AC = 108 V AC Minimum, 132 V AC MAX AB = 108 V AC Minimum, 132 V AC MAX BC = <1 V AC Maximum 18 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 Controller s I t is strongly recommended that all individually[...]

19 Field W iring Connections Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. CA UTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause im- p roper and dangerous operation. V eri fy proper operation after servicing. D ANGER: SHOCK HAZARD Fig[...]

20 W iring the Outdoor Sensor 1. There is no connection required if an outdoor sen- sor is not used in this installation. 2 . 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 t[...]

21 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 try[...]

22 * * - Ma y be c onfigured as DHW SENSOR f or single boiler C asc ade with Indirect Fig. 18: XFyre Cascade Master Cascade Master Pump and Sensor W iring 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 HEA TER l[...]

23 Cascade F ollow er Pump and Sensor W iring 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. 2. If you are using an indirect fired water tank con- nected directly to the follower boiler , connect the pump for it to the terminals marked DHW PUMP NEUT (#8),[...]

24 T able K: V enting Category Requirements V ent T er minal Location 1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 2. Give special attention to the location of the vent termination to avoid possibility of property dam- age or personal injury . 3. Gases may form a white vapor plu[...]

25 U .S. Installations Refer to the latest edition of the National Fuel Gas Code. V ent termination requirements are as follows: 1. V ent must terminate at least 4 ft below , 4 ft hori- zontally from or 1 ft above any door , window or gravity air inlet to the building. 2. The vent must not be less than 7 ft above grade when located adjacent to publ[...]

26 T able L: Category IV V ertical V ent & V ertical Direct V ent 1 V ent 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. T er mina tion The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the [...]

27 m on venting system are located and other spaces of the building. T urn on clothes dryers and any appliance not connected to the common venting system. T urn on any exhaust fans, such as range h oods and bathroom exhausts, so they will oper- ate at maximum speed. Do not operate a summer e xhaust fan. Close fireplace dampers. (d) Place in operati[...]

28 Fig. 21: T ypical Common V enting Horizontal Thr ough-the-Wall Direct V enting (Categor y IV) Note: Heaters rotated to show venting connections. 12” MIN ABO VE SNOWLINE Fig. 22: Horizontal Through-the-W all V enting Refer to T able F and local codes. Fig. 23: Horizontal Through-the-W all Direct V enting Refer to T able F and local codes.[...]

29 NO TE: While a drain connection is required in the v ent of all XFyre installations, the drain can be ac- 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- t or for condensing stacks or an inline vertical or horizontal collector available[...]

30 Direct V ent—V er tical Installation These installations utilize the heater-mounted blower to draw combustion air from outdoors and vent com- bustion products to the outdoors. * Subtract 10 ft per elbow . Max. 4 elbows. T able O: Category IV Horizontal V ent & Horizontal Direct V ent The total length of air supply pipe cannot exceed the di[...]

31 This type of installation can cause non-warrantable problems with components and poor operation of the b oiler due to the recirculation of flue products. Multi- 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). Combustion air supplied from outdoo[...]

32 Controls WARNING: Installation, adjustment and service of controls, including timing of various operating func- tions, 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: T urn off the power to the boile[...]

33 Flow Switc h 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 Fig. 28: Low W ater Cut-Off Low W ater Cut-Off (Optional) The optional low water cut-off automatically shuts down the burner whenever water level drops below [...]

34 5 . If t h e a pp l i a nc e f a i ls t o s t ar t , r e fe r t o t h e T roubleshooting section in the back of this manu- al. User Menu The user menu consists of several items that can be adjusted. T o 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 p[...]

35 are listed in T able I on page 16. Automatic modulation does not take place when the controller is in T est 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. T o activa te the service mode, press the U[...]

36 S tatus Menu 1 Items S creen No. Default Information Displayed Range Descripti on S uppl y XXX ºF -13-248 ºF Heater outlet water temperature Return XXX ºF -13-248 ºF Heater i nlet water t emperatu re C H Set 160 ºF 50-190 ºF Heater outlet water setpoint for hydronic heating Suppl y XXX ºF -13-248 ºF Heater outlet water temperature r e t [...]

37 S tatus Menu 2 Items S creen No. Default Information Displayed Range Descripti on Analog DHW T emp (if active) T emp/Fan Anal og 0-10V i nput setpoint or fan modulati on control Analog sig XX.X V 0-10.0V Anal og 0-10V s ignal Status Menu 3 Items (Cascade Mode only) Screen No. Default Information Displayed Range Descripti on ) T T ( H F C r o y d[...]

38 Installer Menu Items (continued) Screen No. Default Information Displayed Range Descripti on e r u t a r e p m e t t n i o p t e s t e s e r r o o d t u o m u m i n i M p m e T n i M t e s e R g n i t t e S F º 0 9 1 - 2 3 F º 5 9 e r u t a r e p m e t m u m i n i m c i n o r d y H p m e T n i M c i n o r d y H g n i t t e S F º 0 9 1 - 2 3 F[...]

39 50 32 41 1 67 158 149 131 122 113 104 77 59 68 86 95 2 12 203 194 185 176 201˚ SUPPLY OUTLET TEMPERATURE (F) -24 -59 -41 OUTSIDE TEMPERATURE (F) -9 9 27 63 45 81 99 FUNCTION 9 FUNCTION 11 FUNCTION 8 FUNCTION 10 0 68˚ 5˚ DEFAULT RESET CURVE OUTDOOR RESET CURVE Factory Default NO TE: It is important to note that the user can adjust the heat cur[...]

40 WIRING DIA GRAM[...]

41 ST ART -UP Pre Star t-up Filling System (Heating Boilers) Fill system with water . Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close vent. Air Pur ge (Domestic Hot Wa ter Heaters) Pu[...]

42 Prepar ation Check P ow er Suppl y With multi-meter at incoming power , check voltage between: Hot - Common (≈120 V AC) Hot - Ground (≈120 V AC) Common - Ground (< 1 V AC) Attach Manometers to Measure Pr essur es 1. T urn off main gas valve. 2. Attach (1) 12” scale manometer to an upstream bleedle valve on the gas supply pipe to the boi[...]

43 – 0.5 in. WC from the reading recorded on the start-up checklist. 3 . The desired combustion CO2 is between 8.5% and 9.0% for natural gas and 9.0% and 9.5% for p ropane 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 arro[...]

44 P ost Star t-Up Check Check off steps as completed: 1. V erify that the boiler and heat distribution units or s torage tank are filled with water . 2. Confirm that the automatic air vent (if used) was opened two full turns during the venting proce- dure. 3. V erify that air has been purged from the system. 4. V erify that air has been purged fro[...]

45 TR OUBLESHOO TING D ANGER: When servicing or replacing components that are in direct contact with the water , be certain that: • There is no pressure in the boiler . (Pull the release on the relief valve. Do not depend on the pressure gauge reading). • The boiler water is not hot. • The electrical power is of f. XFyre Er r or Codes I f any[...]

46 Error T ext Remedy OUTDOOR SENSOR FOU ( Displays only if Screen 21 of the Installer Menu is ON) Inspect wiring from outside sensor for damage or shorted connections repairing as necessary . Measure resistance of outdoor sensor and compare to resistance chart on page 48. If not within range on chart, shorted or open, replace sensor . LINE VOL T A[...]

47 Error T ext Remedy FLUE / GAS PRESS F01 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 th[...]

48 1/4” NOTE: If receiving a NO FLAME F09 fault code, check the gap spacing between points on the electrode by holding two quarters together and sliding them through the gap. There should be a slight resistance. Fig. 36: Direct Spark Igniter T emperature Sensors W ater T emperature (°F) R esistance (ohms) 32 32550 41 25340 50 19870 59 15700 68 1[...]

49 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency . Maintenance as outlined below may be performed by the owner . Daily 1. Check that the area where the boiler is installed is free from combustible materials, gasoline, and othe[...]

50 3 . Check burner flame. (Should see light blue flame at full input rate). W eekl y F or low-pressure boilers, test low-water cut-off device. (With boiler in pre-purge, depress the low water cut-off test button. Appliance should shut-off and ignition fault light should come on. Depress reset button on front of heater control panel to reset). Mont[...]

51 Combustion Chamber Coil Cleaning Instr uctions B efore beginning this procedure, you must have on hand the following items: – a nylon, stainless steel or brass brush (not steel) – “Rydlyme” (recommended for best results) or “CLR” – Gloves, eye protection 1. Shut down the XFyre boiler by using the following steps: a. Close the gas v[...]

52 Areas where contaminated combustion air commonly e xists: • dry cleaning/laundry areas • metal fabrication plants • beauty shops • refrigeration repair shops • photo processing plants • auto body shops • plastic manufacturing plants • furniture refinishing areas and establishments • new building construction • remodeling area[...]

53 (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required T o Be V ented" in the most current edition of NFP A 54 as adopted by the Board; and 2. Prod uct Approved side wall horizontally vented gas fueled equipment installed in a room or [...]

54 LIMITED PARTS WARRANTY XFYRE – TY PE H and W MODELS 300-850 R AYP AK, I N C • 2151 Eastman Avenue • O xnard, CA 93030-9786 • (805) 278-5300 • Fax ( 800) 872-9725 • www.rayp ak.com S COPE Rayp ak, Inc. (“Ra ypak”) warrants to th e original owner that all parts of this heat er which are actually manufactured by R aypak will be free[...]

55 START-UP CHECKLIST FOR THE XFYRE This start-u p checklis t is to be co mplete ly filled o ut by t he service technician star ting up th e Rayp ak Boiler or H eater for the first time. All informati on may be used for w arra nty purposes and to ens u re tha t the ins tallation is c orrect. Additionally this form will be use d to record a ll equip[...]

56 ww w .r ay pak .c om Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.[...]