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(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 gas fueled

equipment installed in a room or structure separate from the

dwelling, building or structure used in whole or in part for res-

idential purposes.

(c)  MANUFACTURER  REQUIREMENTS  -  GAS  EQUIP-

MENT  VENTING  SYSTEM  PROVIDED.  When  the

manufacturer  of  Product  Approved  side  wall  horizontally

vented gas equipment provides a venting system design or

venting system components with the equipment, the instruc-

tions  provided  by  the  manufacturer  for  installation  of  the

equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting sys-

tem design or the venting system components; and

2. A complete parts list for the venting system design or vent-

ing system.

(d)  MANUFACTURER  REQUIREMENTS  -  GAS  EQUIP-

MENT  VENTING  SYSTEM  NOT  PROVIDED.  When  the

manufacturer  of  a  Product Approved  side  wall  horizontally

vented gas fueled equipment does not provide the parts for

venting  the  flue  gases,  but  identifies  "special  venting  sys-

tems",  the  following  requirements  shall  be  satisfied  by  the

manufacturer:

1. The referenced "special venting system" instructions shall

be  included  with  the  appliance  or  equipment  installation

instructions; and

2. The "special venting systems" shall be Product Approved

by  the  Board,  and  the  instructions  for  that  system  shall

include a parts list and detailed installation instructions.

(e)  A  copy  of  all  installation  instructions  for  all  Product

Approved  side  wall  horizontally  vented  gas  fueled  equip-

ment,  all  venting  instructions,  all  parts  lists  for  venting

instructions,  and/or  all  venting  design  instructions  shall

remain with the appliance or equipment at the completion of

the installation.

GAS PRESSURE SUPERVISION

The  Commonwealth  of  Massachusetts  requires  listed  high

and low gas pressure switches (manual reset) for any model

with a maximum firing input greater than 1,000,000 Btu/Hr in

accordance with 248 CMR 7.04(11)(d).  

A gas  pressure  regulator  (field  supplied)  is  required  in  the

gas train ahead of the heater, for heaters having input rates

greater than 1,000,000 Btu/Hr, in accordance with 248 CMR

7.04 Figure 3B requirements.

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:

(a) For all side 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  and  where  the

side wall exhaust vent termination is less than seven (7) feet

above finished grade in the area of the venting, including but

not limited to decks and porches, the following requirements

shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS.

At the time of installation of the side wall horizontal vented

gas fueled equipment, the installing plumber or gasfitter shall

observe that a hard wired carbon monoxide detector with an

alarm  and  battery  back-up  is  installed  on  the  floor  level

where the gas equipment is to be installed. In addition, the

installing  plumber  or  gasfitter  shall  observe  that  a  battery

operated  or  hard  wired  carbon  monoxide  detector  with  an

alarm  is  installed  on  each  additional  level  of  the  dwelling,

building or structure served by the side wall horizontal vent-

ed gas fueled equipment. It shall be the responsibility of the

property owner to secure the services of qualified licensed

professionals  for  the  installation  of  hard  wired  carbon

monoxide detectors

a.  In  the  event  that  the  side  wall  horizontally  vented  gas

fueled equipment is installed in a crawl space or an attic, the

hard wired carbon monoxide detector with alarm and battery

back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can

not be met at the time of completion of installation, the owner

shall  have  a  period  of  thirty  (30)  days  to  comply  with  the

above  requirements;  provided,  however,  that  during  said

thirty (30) day period, a battery operated carbon monoxide

detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each

carbon  monoxide  detector  as  required  in  accordance  with

the  above  provisions  shall  comply  with  NFPA  720  and  be

ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be

permanently mounted to the exterior of the building at a min-

imum height of eight (8) feet above grade directly in line with

the  exhaust  vent  terminal  for  the  horizontally  vented  gas

fueled heating appliance or equipment. The sign shall read,

in print size no less than one-half (1/2) inch in size, "GAS

VENT  DIRECTLY  BELOW.  KEEP  CLEAR  OF  ALL

OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side

wall  horizontally  vented  gas  fueled  equipment  shall  not

approve the installation unless, upon inspection, the inspec-

tor  observes  carbon  monoxide  detectors  and  signage

installed  in  accordance  with  the  provisions  of  248  CMR

5.08(2)(a)1 through 4.

Important Instructions for the Commonwealth of Massachusetts

Summary of Contents for 300A-850A

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: ...llowing Changes to pages 5 13 14 15 16 17 22 23 24 25 26 27 29 30 33 35 37 39 40 41 42 44 45 52 and 53 Additions Flushing Cleaning of System Piping and Cold Water Operation sections added starting on...

Page 3: ...ing Connections 22 Venting 26 Venting Installation Tips 29 Venting Configurations 29 Condensate Management 34 Outdoor Installation 35 Controls 36 Operating Instructions 39 WIRING DIAGRAM 46 START UP 4...

Page 4: ...CALIFORNIA PROPOSITION 65 This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING Risk of electrical shock More than one disco...

Page 5: ...k s standard war ranties Model Identification The model identification number and heater serial number are found on the heater rating plate located on the upper rear jacket panel The model number has...

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

Page 7: ...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 the...

Page 8: ...ed 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 water dripping spraying rain...

Page 9: ...all local codes See Fig 5 Table F 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 n...

Page 10: ...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 paved...

Page 11: ...to ducting combustion air to the unit the unit may be fully separated from room air by installing the TruSeal option This may be done either at the fac tory sales option D 21 or in the field sales op...

Page 12: ...th the outdoors Canadian Installations opening s having a cross section area of not less than 1 in 2 per 7 000 BTUH 320 mm2 per kW up to and including 1 million BTUH plus 1 in 2 per 14 000 BTUH 160 mm...

Page 13: ...auge pressure has been maintained throughout test 3 Check for leaks Repair if found Flushing Cleaning of System Piping Many of the chemicals used to perform this function will harm the heat exchanger...

Page 14: ...rred method is an injection loop An injec tor pump approach has the added value of being able to adjust very quickly to changes in the system water coming back to the heater The integrated VERSA IC co...

Page 15: ...D Hybrid sequencer sales option B 36 Proper place ment and method of installation are critical for proper operation of the system See Fig 7 The sensor must be installed in a drywell in conjunction wit...

Page 16: ...y connected to a hot water storage tank For detailed information about applications and modes see VERSA IC manu al catalog 5000 72 Mode 1 Type H Units Only This mode selection is for hydronic heating...

Page 17: ...ly sensor S6 and the Target Max setting when using the Indirect DHW sensor S5 The Boiler Pump 17 Fig 11 MODE 3 Single Boiler with Indirect on Boiler Loop Fig 12 WH Units Single Water Heater with Tank...

Page 18: ...lieve test pressure in the gas supply line prior to re connecting the heater and its manual shut off valve to the gas supply line FAIL URE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE Over pressu...

Page 19: ...s 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 CAUTION Support gas supply piping...

Page 20: ...larger than hp or 5A must use a sepa rate power supply and run the power through an external field supplied pump contactor Use appropri ately sized wire as defined by NEC CSA and or local codes All p...

Page 21: ...g 14 18 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 22: ...LARM CONTROL SENSOR WIRING HIGH VOLTAGE POWER AND PUMP WIRING LOCATION RATING PLATE SUGGESTED ROUTING OF SENSOR CONTROL WIRING Fig 16 Rear Wiring Location Fig 18 XFyre Single Heater Control PLATFORM I...

Page 23: ...ts to the PIM so it can activate the Indirect DHW pump and Boiler pump if needed If an optional Indirect DHW sensor is connected to J2 1 and J2 2 the PIM will pass this signal to the VERSA This allows...

Page 24: ...does not create a short to ground Fig 20 XFyre Cascade System Wiring 24 Wiring the Cascade System Communication Bus 1 Designate the primary boiler as the master boiler boiler1 by leaving dip switch 2...

Page 25: ...18 This connection must be pro vided through dry contacts closure NOTE This dry contacts closure can come from a room thermostat or a remote relay No power of any kind should be applied to either of...

Page 26: ...ufacturer s installation instructions carefully Centrotherm polypropylene vent material is also approved to be used on XFyre products A vent adapter sales option D 33 must be used to ensure a proper s...

Page 27: ...ions of the local building codes Support of Vent Stack The weight of the vent stack or chimney must not rest on the heater vent connection Support must be pro vided in compliance with applicable codes...

Page 28: ...n The venting system must conform to local codes and or the current National Fuel Gas Code ANSI Z223 1 NFPA 54 The system setpoint must not exceed 180 F 28 damaging exterior finishes Use a 300 series...

Page 29: ...s 300A 400A and 500A and 6 in 152mm for Models 700A and 850A 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 ho...

Page 30: ...serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure If an XFyre is installed to replace an exist ing unit the vent sys...

Page 31: ...hrough the Wall Venting Refer to Table F and local codes Fig 28 Horizontal Through the Wall Direct Venting Refer to Table F and local codes a Seal any unused openings in the common venting system b Vi...

Page 32: ...s not considered in the overall length of the venting system The vent must be installed to prevent flue gas leakage Care must be taken during assembly to ensure that all joints are sealed properly and...

Page 33: ...the XFyre product Table Q Category IV Horizontal Vent Ducted Combustion Air CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s i...

Page 34: ...d health of inhabitants TEST PORT FLUE VENT CONDENSATE TREATMENT CONDENSATE TRAP CONNECTION PVC PIPE 1 4 DROP PER FT VENT CONDENSATION TRAP FLOOR DRAIN OR SUMP PUMP 12 Fig 30 Guide for Condensate Pipi...

Page 35: ...ent gas flue leaks Treatment systems should be checked at least once per year and the chips should be replenished as necessary When replacing the chips they should be no smaller than to avoid blockage...

Page 36: ...out occurs To reset the lock out press and relase the RESET button located on the user interface Turning off the power to the heater WILL NOT reset the single try ignition module High Limit Manual Res...

Page 37: ...t temperature of the unit during nor mal operation to prevent short cycling and nuisance trips 37 Flow Switch This standard dual purpose control shuts off the boil er in case of pump failure or low wa...

Page 38: ...inside the switch housing Push the top of the plastic switch housing as shown in Fig 37 to reset a tripped pressure switch The LED will go out when the switch is reset Blocked Vent Switch The heater...

Page 39: ...The user interface consists of several Menu options Press the MENU button to scroll through the different menus in the interface Press the ITEM button to scroll through available items within a select...

Page 40: ...he blower heater cascade status pump operation and CFH information Some of the items displayed are mode specific and are only observable when its corre sponding mode is active Setup Menu To change set...

Page 41: ...requires IND Sensor ON 6 F IND SUPPLY H MODE 2 3 OFF 50 F to PIM value Target boiler temperature for the DHW heat exchanger during indi rect DHW operation requires IND Sensor OFF 180 F DHW PRIORITY H...

Page 42: ...been corrected and a 15 min waiting period has expired VENT WALL 22 F to 266 F N A Always model dependent Current Vent temperature LIMIT TEMP 22 F to 266 F N A Always Current Outlet Limit temperature...

Page 43: ...o clear INLET HI All Records the highest boiler inlet temperature Press UP DOWN for 1 sec to clear INLET LO All Records the lowest boiler outlet temperature Press UP DOWN for 1 sec to clear DELTA T Al...

Page 44: ...r temperature drops the tempera ture of the heating water will increase one degree With the VERSA both ends of the slope are adjustable It is factory set at 70 F water temperature Boil START at 70 F o...

Page 45: ...leting heat loss calculations for the building Boiler Design Boil DESIGN The Boil DESIGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the O...

Page 46: ...46 WIRING DIAGRAM...

Page 47: ...you cannot reach your gas supplier call the fire department Use only your hand to close the gas supply shut off valve outside the heater Never use tools If the knob will not turn by hand do not try to...

Page 48: ...ield supplied on the 700A and 850A 4 Attach a 12 scale manometer to the downstream fitting on the gas manifold Measure point B in Fig 44 field supplied on the 700A and 850A 5 Attach a 12 scale manomet...

Page 49: ...o the sight glass located at the bottom of the front panel to check igniter opera tion 3 The boiler ignites at 3000 RPM as indicated on the LCD display of the user interface 4 This boiler is equipped...

Page 50: ...gnite after pre purge time 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...

Page 51: ...inside front panel on boiler OPERATION Lighting Instructions 1 Before lighting make sure you have read all of the safety information in this manual 2 Set the thermostat to the lowest setting 3 Turn of...

Page 52: ...ror Item Description and Troubleshooting OUTLET SEN Check the outlet water sensor and its wiring LIMIT SEN Check the high limit sensor and its wiring INLET SEN Check the inlet sensor and its wiring GA...

Page 53: ...Fault Red LED 7 Flashes Check for proper water flow Check hi limit setting and outlet sensor Sensor Fault Red LED 8 Flashes See the VERSA IC Control for fault identification Check sensor and wiring N...

Page 54: ...should be no resistance Fig 46 Direct Spark Igniter Water Sensor Outdoor Sensor Water Temperature F Resistance ohms 32 32550 41 25340 50 19870 59 15700 68 12490 77 10000 86 8059 95 6535 104 5330 113 4...

Page 55: ...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 56: ...nsor 4 Conduct a combustion test at high and low fire Carbon dioxide should be 8 5 to 9 0 at full fire for natural gas and between 9 5 to 10 0 for propane gas Carbon monoxide should be 150 ppm 5 Check...

Page 57: ...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 cleaned DO NOT get the back ceramic wall of th...

Page 58: ...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 59: ...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 60: ...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 returne...

Page 61: ...e _____________ Stack Height _______ Low Water Cutoff _______________Test Category _________ sketch vent on reverse side Number of Tanks and Size Qty____ _______Gallons Vent Material _________________...

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Page 64: ...64 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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