Raypak 300 - Manual

7 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...

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....

9 Fig. 4: Minimum Clearances from Combustible Surfaces — Indoor and Outdoor Installations Table E: Clearances — Outdoor Installations 24” SERVICE CLEARANCE 24” SERVICE CLEARANCE 24” SERVICE CLEARANCE Combustion and Ventilation Air Indoor Units This heater must be supplied with sufficient quantities ...

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 che...

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 mm 2 per kW) of total input rat- ing of all equipment in the enclosure. 2. One permanent opening , commencing within 12 in. (305 mm) of the top of the enclo...

Relief Valve Installation 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 ...

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...

15 Potable Water 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. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space...

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 n...

17 Electrical Power 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 Ca...

19 Field Wiring Connections Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause im- proper and dangerous operation. Verify proper operati...

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

23 Cascade Follower Pump and Sensor Wiring 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...

24 Table K: Venting Category Requirements Vent Terminal 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...

25 U.S. Installations Refer to the latest edition of the National Fuel Gas Code. Vent termination requirements are as follows: 1. Vent 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...

26 Table L: Category IV Vertical Vent & Vertical Direct Vent 1 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. Termination The vent terminal should be vertical and should termi- nate outsi...

27 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 oper- ate at maximum speed. Do not operate a summer exhaust fan. ...

29 NOTE: While a drain connection is required in the vent 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- tor for condensing stacks or an inl...

30 Direct Vent—Vertical 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. Table O: Category IV Horizontal Vent & Horizontal Direct Vent The total lengt...

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

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 d...

34 5. If the appliance fails to start, refer to the Troubleshooting section in the back of this manu- al. 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...

39 50 32 41 167 158 149 131 122 113 104 77 59 68 86 95 212 203 194 185 176 201˚ S U P P LY O U T LE T T E M P E R A T U R E (F ) -24 -59 -41 OUTSIDE TEMPERATURE (F) -9 9 27 63 45 81 99 FUNCTION 9 FUNCTION 11 F U N C T IO N 8 F U N C T IO N 1 0 0 68˚ 5˚ DEFAULT RESET CURVE OUTDOOR RESET CURVE Factory...

41 START-UP Pre Start-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 ven...

42 Preparation Check Power Supply With multi-meter at incoming power, check voltage between: Hot - Common (≈120 VAC) Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) Attach Manometers to Measure Pressures 1. Turn off main gas valve. 2. Attach (1) 12” scale manometer to an upstream bleedle valve ...

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 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. E...

44 Post Start-Up Check Check off steps as completed: 1. Verify that the boiler and heat distribution units or storage 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. Verify that air has been purged from the sys...

45 TROUBLESHOOTING DANGER: 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 pow...

46 Error Text 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,...

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 Temperature Sensors Water Temperature (°F) Resistance (ohm...

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 fre...

51 Combustion Chamber Coil Cleaning Instructions Before 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 f...

52 Areas where contaminated combustion air commonly exists: • 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 c...

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 To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented ...

55 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 wi...