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Wiring 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 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 installa-

tion.

2. The XFyre boiler will operate an indirect fired

water heater with either a thermostat type aquas-

tat 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 DHW DIFF. The demand will con-

tinue until the sensor measures that the indirect

water heater temperature is above the setpoint.

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 con-

nected to ground.

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

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. 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.

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 rec-

ommends that the total maximum length of

communication bus cables not exceed 200 feet.

Summary of Contents for H 300 Series

Page 1: ...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 applia...

Page 2: ...2 Rev 3 includes the following Changes to Table I on page 16 Fig 35 on page 42 Table S on page 43 Additions None Deletions None...

Page 3: ...ring Connection 19 Venting 23 Venting Installation Tips 25 Venting Configurations 26 Outdoor Installation 31 Controls 32 Operating Instructions 35 WIRING DIAGRAM 40 START UP 41 Pre Start up 41 Pre Sta...

Page 4: ...mage 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...

Page 5: ...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 depend ing on the heater size a...

Page 6: ...Fig 3 Component Locations Rear Model No MBTUH Input Water conn NPT Gas conn NPT Vent Size inches Max Min N P Flue Intake 300 300 60 1 1 2 3 4 3 4 4 4 400 399 80 2 1 1 4 4 500 500 100 2 1 1 4 4 700 700...

Page 7: ...ot 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 t...

Page 8: ...pment installed in enclosed parking garages must be located at least 18 in above the floor In addition the heater shall be installed such that the gas ignition system components are protected from wat...

Page 9: ...and B149 Canada and all local codes 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...

Page 10: ...e 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 L Clearance above pav...

Page 11: ...itioned 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 mechanica...

Page 12: ...tive pressure conditions CAUTION All combustion air must be drawn from the air outside of the building the mechanical equip ment room must communicate directly with the outdoors Canadian Installations...

Page 13: ...g sure to eliminate any entrapped air by using high point vents Close feed valve Test at standard operating pressure for at least 24 hours 2 Make sure constant gauge pressure has been maintained throu...

Page 14: ...everse Return with Primary Secondary Piping Maximum 4 times the pipe diameter or 12 whichever is less Maximum 4 times the pipe diameter or 12 whichever is less Model No 20 F T 30 F T 40 F T Min Flow M...

Page 15: ...peration NOTE If local codes require a vacuum relief valve acquire one locally and install per valve manufacturer s instructions T Temperature rise F P Pressure drop through heat exchanger ft SHL Syst...

Page 16: ...he gas supply during any pressure testing of the gas supply system at test pressures in excess of 1 2 psi 3 45 kPa Gas Supply Pressure A minimum of 4 0 in WC and a maximum of 10 5 in WC upstream gas p...

Page 17: ...1 1 4 NPT 1 1 2 NPT 2 NPT N P N P N P N P N P 300 15 30 45 100 175 400 390 400 30 70 120 275 270 414 500 15 40 65 150 150 350 700 42 96 96 220 310 795 850 25 55 55 125 175 450 may power up to two pump...

Page 18: ...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 he...

Page 19: ...hown 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 connect ed to ground 2 Mou...

Page 20: ...om 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...

Page 21: ...n Fig 17 above It is best to wire the boilers using the shortest wire runs rather than try ing to wire them in the order that they are addressed The communication bus jacks on the customer connection...

Page 22: ...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 SYS TEM PUMP...

Page 23: ...emperature that may cause excessive condensate production in the vent Category III A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensat...

Page 24: ...rials 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...

Page 25: ...nt shall not terminate 1 Directly above a paved sidewalk or driveway which is located between two single family dwell ings and serves both dwellings 2 Less than 7 ft 2 13 m above a paved sidewalk or p...

Page 26: ...in 152mm for Models 700 and 850 The connection from the appliance vent to the stack must be as direct as possible and shall be the same di ameter as the vent outlet The horizontal breaching of a vent...

Page 27: ...ning 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 F...

Page 28: ...l Direct Venting Category IV Note Heaters rotated to show venting connections 12 MIN ABOVE SNOWLINE Fig 22 Horizontal Through the Wall Venting Refer to Table F and local codes Fig 23 Horizontal Throug...

Page 29: ...d 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...

Page 30: ...ope of not more than 1 4 inch per foot of hori zontal 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 be...

Page 31: ...cally 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...

Page 32: ...mes 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...

Page 33: ...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 The optional high gas pressure...

Page 34: ...e 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 con...

Page 35: ...n 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 User Menu...

Page 36: ...P t a e H r o F l l a C a h t i W s r u o H h 0 n O H C d n a m e D W H D a h t i W s r u o H h 0 n O W H D s n o i t i n g I l u f s s e c c u S f o r e b m u N x 0 n o i t i n g I d o o G Fault Hist...

Page 37: ...i r c s e D e g n a R d e y a l p s i D n o i t a m r o f n I t l u a f e D o N n e e r c S r e l l o r t n o C e h t f o e d o M l a n o i t a r e p O e d o M l a n o i t a r e p O Hydronic e r u t...

Page 38: ...O e t a R t u p n I m u m i x a M f o n o i t c u d e R s w o l l A d e e p S n a F x a M g n i t t e S 0 0 1 0 5 0 0 1 n o i t a r e p O e d a c s a C n o N r o e d a c s a C g i f n o C e d a c s a...

Page 39: ...MENU Scroll through the list of adjustable items by pressing the LEFT or RIGHT arrow keys Once the desired item is dis played press the ENTER MENU key to select it The screen will begin to flash Press...

Page 40: ...40 WIRING DIAGRAM...

Page 41: ...ions If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas con trol knob Never use tools If the knob will not turn by hand do not try to repair i...

Page 42: ...e user interface 4 This boiler is equipped with a standard four try ignition module it will try for ignition up to four times before going into lockout If the boiler is equipped with the optional sing...

Page 43: ...by more than 0 2 in WC STOP Call the factory for directions on what to do next Safety Inspection 1 Check all thermostats and high limit settings 2 During the following safety checks leave manome ters...

Page 44: ...me delay 8 Check to see that the high limit control is set above the design temperature requirements of the system For multiple zones Check to make sure the flow is adjusted as required in each zone 9...

Page 45: ...ded in the XFyre Fault Text section on the follow ing page Heater Faults 1 When a fault condition occurs the controller will illuminate the red fault indication light and display a fault code in the f...

Page 46: ...e at a time to see if LOU code clears Replace faulty part Check low voltage wire harness in boiler for shorts 4 If LOU only occurs when burner tries to light check gas valve for excessive current draw...

Page 47: ...menu and assuring that there is less than a 50 F rise from the return sensor to the supply sensor 3 Troubleshoot the sensor by following steps in SUPPLY THERMISTR F02 IGNITION FAILURE F09 1 Watch the...

Page 48: ...Sensors Water Temperature F Resistance ohms 32 32550 41 25340 50 19870 59 15700 68 12490 77 10000 86 8059 95 6535 104 5330 113 4372 122 3605 131 2989 140 2490 149 2084 158 1753 167 1481 176 1256 185...

Page 49: ...ensate drain is inspected and ensure that condensate is being directed to appropriate con densate management system or drain as required by local codes 3 Check that area is free from combustible mater...

Page 50: ...ire Carbon dioxide should be 8 5 to 9 0 at full fire for natural gas and between 9 0 to 9 5 for propane gas Carbon monoxide should be 150 ppm 5 Check valve coil for 60 cycle hum or buzz Check for leak...

Page 51: ...then vacuum the debris from the coils Be sure to fol low the precautions listed for working with ceramic fibers 4 Spray the coils with clear water making sure to con fine the spray to the area being...

Page 52: ...may however choose to use outside combustion air for one or more of these reasons 1 Installation is in an area containing contaminants listed below which will induce acidic condensation 2 You want to...

Page 53: ...wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth...

Page 54: ...contamination of combustion air or use of chemical additives to water PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned...

Page 55: ...e _____________ Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material _________________...

Page 56: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A...

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