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HomeMy WebLinkAboutB14-0393 cut sheet.pdfINSTALLATION & OPERATING INSTRUCTIONS Catalog No. 1000.65.2 Effective: 07-26-12 Replaces: NEW P/N 241480 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 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 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 appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference. Models 300A–850A Types H & WH 2 WARNINGS 4 Pay Attention to These Terms 4BEFORE INSTALLATION 5 Product Receipt 5 Model Identification 5 Ratings and Certifications 5 Installations at Elevation 5 Component Locations 6 General Information 6GENERAL SAFETY 7 Time/Temperature Relationships in Scalds 7INSTALLATION8 Installation Codes 8 Equipment Base 8 Clearances 8 Combustion and Ventilation Air 9 Conventional Combustion Air Supply 11 Water Piping 12 Hydronic Heating 13 Gas Supply 17 Electrical Power Connections 19 Field Wiring Connection 21 Venting 25 Venting Installation Tips 28 Venting Configurations 28 Condensate Management 33 Outdoor Installation 34 Controls 34 Operating Instructions 37WIRING DIAGRAM 44START-UP 45 Pre Start-up 45 Pre Start-up Check 45 Initial Start-up 45 Preparation 46 Start-Up 46 OPERATION 49 Lighting Instructions 49 To Turn Off Gas to Appliance 49TROUBLESHOOTING49 XFyre Error Codes 49 Heater Errors 49 Heater Faults 49 XFyre Fault Text 50 Sensor Resistance Values 52MAINTENANCE53 Suggested Minimum Maintenance Schedule 53 Preventive Maintenance Schedule 53APPENDIX56 Inside Air Contamination 56 Important Instructions for the Commonwealth of Massachusetts 57WARRANTY58START-UP CHECKLIST 59 CONTENTS 3 4 DANGER: Indicates 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. CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored. NOTE: Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. WARNINGS Pay Attention to These Terms DANGER:Make sure the gas on which the boiler will operate is the same type as that specified on the boiler rating plate. WARNING:Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the boiler. Instead, shut off the gas supply at a location external to the boiler. WARNING:Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water. WARNING:To minimize the possibility of improper operation, serious personal injury, fire, or damage 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 of fresh air to the boiler. WARNING - CALIFORNIA PROPOSITION65: 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 disconnect switch may be required to de-energize the equipment before servicing. WARNING:UL recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications wherein there is a potential for an explosive mixture of fuel gas to accumulate and their installation should be in accordance with the detector manufacturer's recommendations and/or local laws, rules, regulations, or customs. WARNING:Both natural gas and propane have an odorant added to aid in detecting a gas leak. Some people may not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar with the smell of natural gas or propane, ask your local gas supplier. Other conditions, such as "odorant fade," which causes the odorant to diminish in intensity, can also hide, camouflage, or otherwise make detecting a gas leak by smell more difficult. WARNING:This appliance produces condensate from the flue products that is acidic and highly corrosive. Raypak recommends the use of a condensate neutralizer kit to avoid long-term damage to the drainage system and to meet local code requirements. WARNING: Vent connectors serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure. If an XFyre heater is installed to replace an existing heater, the vent system MUST be verified to be of the correct size and of one of the Category IV vent materials identified in this manual. If it is NOT, it MUST be replaced. 5 BEFORE INSTALLATION 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.) Installation and service must be performed by a qualified installer, service agency or gas supplier. If, after reviewing this manual, you still have questions which this manual does not answer, please contact your local Raypak representative or visit our website at www.raypak.com. Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment. Product Receipt On receipt of your heater it is suggested that you visu- ally check for external damage to the shipping crate. If the crate is damaged, make a note to that effect on the Bill of Lading when signing for the shipment. Next, remove the heater from the shipping packaging. Report any damage to the carrier immediately. On occasion, items are shipped loose. Be sure that you receive the correct number of packages as indi- cated on the Bill of Lading. Claims for shortages and damages must be filed with the carrier by consignee. Permission to return goods must be received from the factory prior to shipping. Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted. All returned goods are subject to a restocking charge. When ordering parts, you must specify the model and serial number of the heater. When ordering under war- ranty conditions, you must also specify the date of installation. Purchased parts are subject to replacement only under the manufacturer’s warranty. Debits for defec- tive replacement parts will not be accepted. Parts will be replaced in kind only per Raypak’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 the form H7-850A or similar depending on the heater size and configuration. The letter(s) in the first group of characters identifies the application (H = Hydronic Heating, WH = Domestic Hot Water). The number which follows identifies the firing mode (7 = electron- ic modulation). The second group of characters identifies the size of the heater (three numbers repre- senting the approximate MBTUH input), and, where applicable, a letter indicating the manufacturing series. Ratings and Certifications Standards: •ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired Hot Water Boilers •ANSI Z21.10.3 · CSA 4.3 - latest edition, Gas Water Heaters •CAN 3.1 - latest edition, Industrial and Commercial Gas-Fired Package Boilers •SCAQMD Rule 1146.2 •CSA certified low-lead (<.25%) compliance with California AB1953 and Vermont Legislative Act 193 requirements. All Raypak heaters are National Board Registered, and design-certified and tested by the Canadian Standards Association (CSA) for the U.S. and Canada. Each heater is constructed in accordance with Section IV of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code and bears the ASME “H” stamp. This heater also complies with the latest edition of the ASHRAE 90.1 Standard. Installations at Elevation Rated inputs are suitable for up to 2000 ft elevation without de-rating. Consult your local representative or the factory for installations at altitudes over 2000 ft above sea level. No hardware changes are required to the heaters for installations up to 10,000 ft (adjust- ments may be required). WARNING:Altering any Raypak pressure vessel by installing replacement heat exchangers or any ASME parts not manufactured and/or approved by Raypak will instantly void the ASME and CSA ratings of the vessel and any Raypak warranty on the vessel. Altering the ASME or CSA ratings of the vessel also violates national, state, and local approval codes. General Information Table A: Basic Data 6 NOTE: JACKET TOP SLOPES FROM FRONT TO REAR CONTROL/SENSORWIRING Component Locations Fig. 1: Component Locations — Sides Fig. 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 4 500A 500 100 2”1”1”4 4 700A 700 140 2”1-1/4”1-1/4”6 6 850A 850 170 2”1-1/4”1-1/4”6 6 Model 850 shown. Component locations may vary slightly in smaller models. 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 180°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 initial setting for the temperature control is 125°F. Safety and energy conservation are factors to be con- sidered when setting the water temperature on the thermostat. The most energy-efficient operation will result when the temperature setting is the lowest that satisfies the needs of the application. Water temperature over 125°F can cause instant severe burns or death from scalds. Children, disabled and elderly are at highest risk of being scalded. •Feel water before bathing or showering. •Temperature limiting valves are available. Maximum water temperatures occur just after the heater’s burner has shut off. To determine the water temperature being delivered, turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer. NOTE:When this heater is supplying general purpose hot 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 local plumbing authority for further information. Water temperature over 125°F can cause instant severe bu rns or death from scalds. Children, disabled, and elderly are at highest risk of being scalded. See instruction manual before set- ting temperature at water heater. Feel water before bathing or show- ering. Temperature limiting valves are available, see manual. Time/TemperatureRelationships in Scalds The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications. Water Temp. Time to Produce Serious Burn 120°F More than 5 minutes 125°F 1-1/2 to 2 minutes 130°F About 30 seconds 135°F About 10 seconds 140°F Less than 5 seconds 145°F Less than 3 seconds 150°F About 1-1/2 seconds 155°F About 1 second Table courtesy of The Shriners Burn Institute Table C: Time to Produce Serious Burn Model No.Heater Water Volume (gallons) 300A 2.9 400A 3.6 500A 4.2 700A 5.0 850A 5.8 Table B: Heater Water Volume CAUTION:Hotter water increases the risk of scalding! There is a hot water scald potential if the thermostat is set too high. If the heater needs to be secured to the ground, use the holes in the anchoring legs on the heater. 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. above the top of the heater. This will allow the heater to be serviced in its installed location without movement or removal of the heater. Service clearances less than the minimum may require removal of the heater to service either the heat exchanger or the burner components. In either case, the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater. Outdoor Installations These heaters are design-certified for outdoor installa- tion. Heaters must not be installed under an overhang unless clearances are in accordance with local instal- lation codes and the requirements of the gas supplier. Three sides must be open in the area under the over- hang. Roof water drainage must be diverted away from heaters installed under overhangs. Equipment Base The heater must be mounted on a level, structural- ly sound surface.The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting. Gas-fueled equipment 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 water (dripping, spraying, rain, etc.) during appliance operation or service (circulator replacement, control replacement, etc.). 8 Table D: Clearances — Indoor Installations INSTALLATION Installation Codes Installations must follow these codes: •Local, state, provincial, and national codes, laws, regulations and ordinances •National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition (NFGC) •National Electrical Code, ANSI/NFPA 70 - latest edition (NEC) •Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, (CSD-1) when required •For Canada only: CAN/CSA B149 Natural Gas and Propane Installation Code and CSA C22.1 C.E.C. Part 1 (C22.1)*DO NOT install on carpeting. CAUTION:This boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the structure. When such locations cannot be avoided, it is recommended that a suitable catch pan, adequately drained, be installed under the appliance. The pan must not restrict air flow. Heater Side Min. Clearances from Combustible Surfaces Minimum Service Clearances Floor*0”0” Rear 24”24” Right Side 0”0” Left Side 0”0” Top 12”24” Front Open 24” Vent 1”1” CAUTION:The boiler must be mounted on a level base to allow condensate to drain properly from the heat exchanger. The condensate is acidic and highly corrosive. NOTE: The following instructions are intended for simple applications. For more detailed configurations and set-up, consult the VERSA IC Control I&O Manual (Catalog #5000.72). NOTE: The top jacket of the boiler is sloped from front to rear. 9 Fig. 4: Minimum Clearances from Combustible Surfaces — Indoor and Outdoor Installations Table E: Clearances — Outdoor Installations TOP VIEW FRONT VIEW Combustion and Ventilation Air Indoor Units This heater must be supplied with sufficient quantities of non-contaminated air to support proper combustion and equipment ventilation. Combustion air can be sup- plied via conventional means where combustion air is drawn from the area immediately surrounding the heater, or via direct vent, where combustion air is drawn directly from outside. All installations must com- ply with the requirements of the NFGC (U.S.) or 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 not covered by the warranty. If operated in a construction environment, a clean source of combustion air must be provided directly to the boiler. CAUTION:Combustion air must not be contaminated by corrosive chemical fumes which can damage the boiler and void the warranty. (See the Appendix.) NOTE:It is recommended that the intake vent be insulated in cold climates to minimize sweating.Venting not shown for clarity. Heater must be vented per instructions in this manual Heater Side Min. Clearances from Combustible Surfaces Minimum Service Clearances Rear 24”24” Right Side 0”0” Left Side 0”0” Top Unobstructed 24” Front Open 24” Vent Termination 12”12” U.S. Installations 1 Canadian Installations 2 A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) C Clearance to permanently closed window * * D Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- tance of 2 ft (61cm) from the centerline of the terminal 5 ft (1.5m) * E Clearance to unventilated soffit * * F Clearance to outside corner * * G Clearance to inside corner 6 ft (1.83m) * H Clearance to each side of center line ex- tended above meter/regulator assembly * 3 ft (91 cm) within a height 15 ft above the me- ter/regulator assembly I Clearance to service regulator vent outlet * 6 ft (1.83m) J Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance 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 paved sidewalk or paved driveway located on public property 7 ft (2.13m) 7 ft (2.13m) t M Clearance under veranda, porch, deck or balcony * 12 in. (30 cm) TT 1 In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code 2 In accordance with the current CAN/CSA-B149 Installation Codes t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that se rves both dwellings TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of term inal and underside of veranda, porch, deck or balcony is greater than 1 ft (30cm) * Clearances in accordance with local installation codes and the requirements of the gas supplier Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations Table F: Vent/Air Inlet Termination Clearances 10 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- tion air is being supplied to the heater. See the Maintenance section of this manual for information on checking the filter and establishing service intervals. Direct Vent If outside air is drawn through the intake pipe directly to the unit for combustion: 1.Install the combustion air ducting kit. 2.Install combustion air direct vent in accordance with Fig. 24 (horizontal) or Fig. 26 (vertical) of this manual. 3.Ventilation of the space occupied by the heater(s) is recommended and can be provided by an open- ing(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area should be at least 1 in² of free area per 20,000 BTUH (111 mm² per kW) of total input rating of all equipment in the room when the opening is communicating directly with the out- doors or through vertical duct(s). The total cross-sectional area should be at least 1 in² of free area per 10,000 BTUH (222 mm² per kW) of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct(s). Damage to the equip- ment due to inadequate ventilation of the space is not a warrantable failure. 4.In cold climates, and to mitigate potential freeze- up, Raypak highly recommends the installation of a motorized sealed damper on the air intake to prevent the circulation of cold air through the heater during the non-operating hours. TruSeal™ Combustion Air In addition to the 4 previous steps, combustion air may be ducted directly to the heater by using PVC, CPVC or sealed single-wall galvanized ducting. The duct will attach directly to the air collar located on the rear of the heater when the combustion air ducting kit is installed, using three or four sheet metal screws (not supplied) equally positioned 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 mechanical room. All ducting must be self-supported. Conventional Combustion AirSupply U.S. Installations All Air from Inside the Building The confined space shall be provided with TWO per- manent openings communicating directly with an additional room(s) of sufficient volume so that the com- bined volume of all spaces meets the criteria for a room large in comparison (NFGC). The total input of all gas utilization equipment installed in the combined space shall be considered in making this determina- tion. Each opening shall have a minimum free area of 1 in.2 per 1,000 BTUH (2,225 mm2 per kW) of the total input rating of all gas utilization equipment in the con- fined space, but not less than 100 in.2 (645 cm2). One opening shall commence within 12 in. (305 mm) of the top, and one opening shall commence within 12 in. (305 mm) of the bottom of the enclosure. The mini- mum dimension of air openings shall be not less than 3 in. (76 mm) in any direction. All Air from Outdoors The confined space shall communicate with the out- doors in accordance with one of the methods below. The minimum dimension of air openings shall not be less than 3 in. (76 mm) in any direction. Where ducts are used, they shall be of the same cross-sectional area as the net free area of the openings to which they connect. 1.Two permanent openings, one commencing within 12 in. (305 mm) of the top, and one com- mencing within 12 in. (305 mm) of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely com- municate with the outdoors. CAUTION:Use TruSeal combustion air if damaging airborne contaminants are or may be present in the boiler area. See the Appendix of this manual regarding air contamination. NOTE:To ensure proper cooling and ventilation of components, do not block any air openings in the cabinet 11 a.Where directly communicating with the out- doors or where communicating to the outdoors through vertical ducts, each open- ing shall have a minimum free area of 1 in.2 per 4,000 BTUH (550 mm2 per kW) of total input rating of all equipment in the enclosure. 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 mm2 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 enclosure, shall be permitted where the equipment has clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (152 mm) from the front of the appliance. The opening shall directly communicate with the out- doors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors, and shall have a minimum free area of: a.1 in.2 per 3,000 BTUH (740 mm2 per kW) of the total input rating of all equipment located in the enclosure, and b.Not less than the sum of the areas of all vent connectors in the confined space. 1.Ventilation of the space occupied by the heater shall be provided by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area of such an opening(s) shall be at least 10% of the area required in 2. and 3. (below), but in no case shall the cross-sectional area be less than 10 in.2 (65 cm2). 2.For heaters using a barometric damper in the vent system, there shall be a permanent air supply 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 12 WARNING: Do not use the “one permanent opening” method if the equipment room is under negative 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 14,000 BTUH (160 mm2 per kW) in excess of 1 million BTUH. This opening(s) shall be either located at or ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down and terminated 18 in. (450 mm) from the floor, but not near piping. This air supply opening require- ment shall be in addition to the air opening for ventilation air required in 1. (above). 3.For heaters when air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator, drafthood or similar flue gas dilution device installed in the same space, in addition to the opening for ventilation air required in 1., there shall be a permanent air supply open- ing(s) having a total cross-sectional area of not less than 1 in.2 for each 30,000 BTUH (74 mm2 per kW) of total rated input of the burner(s), and the location of the opening(s) shall not interfere with the intended purpose of the opening(s) for ventila- tion air referred to in 1. This opening(s) can be ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down 18 in. (450 mm) from the floor, but not near piping. 4.Refer to the B149 Installation Code for additional information. Water Piping General The heater should be located so that any water leaks will not cause damage to the adjacent area or struc- tures. WARNING:Care must be taken to ensure that the equipment room is not under negative pressure conditions. NOTE:Refer to the VERSA IC Manual (Catalog #5000.72) for detailed instructions regarding the var- ious applications supported by the VERSA IC control system. WARNING:Pump motors should NOT be supported by any type of stand or support from above due to possible misalignment of pump and motor which may occur. 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 valve. The relief valve shall be mounted with its spindle vertical (see Fig. 1, 2 and 3 on page 6). Relief valve discharge piping shall provide no less than the cross sectional area of the relief valve outlet and must be routed to a safe point of discharge. Installation must comply with all national, state and local codes. Temperature & Pressure Gauge The temperature and pressure gauge is shipped loose for field installation and must be installed within 12 inches of the boiler outlet (if possible) in an easily readable location. Installation must comply with ASME Section IV as well as all applicable national, state and local codes. Hydrostatic Test Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in operation. The heat exchanger is ASME certified for 160 psi maximum working pressure. However, Raypak does recommend hydrostatic testing of the piping con- 13 nections to the heater and the rest of the system prior to operation. This is particularly true for hydronic sys- tems using expensive glycol-based anti-freeze. Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply. Leaks must be repaired at once to prevent damage to the heater. NEVER use petroleum-based stop-leak compounds. To perform hydrostatic test: 1.Connect fill water supply. With bleed valve open, fill heater with water. When water flows from bleed valve, shut off water. Close bleed valve. Carefully fill the rest of the system, making 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 throughout test. 3.Check for leaks. Repair if found. Hydronic Heating Pump Selection In order to ensure proper performance of your heater system, you must install a correctly-sized pump. Ray- pak recommends designing for a ∆T within the range of 15°F to 35°F (8°C to 19°C). See Table G for accept- able flow rates for each model (∆T is the temperature difference between the inlet and outlet water when the heater is firing at full rate). Feedwater Regulator Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the highest point of the system. Install a check valve or back flow device upstream of the regulator, with a manual shut-off valve as required by local codes. Piping All high points should be vented. A heater installed above radiation level must be provided with a low wa- ter cut-off device (sales order option F-10). This heater, when used in connection with a refrigeration system, must be installed so that the chilled medium is piped in parallel with the heater with appropriate valves to prevent the chilled medium from entering the heater. WARNING:Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns. Do not pipe to any area where freezing could occur. Refer to local codes. CAUTION:This boiler requires forced water circulation when the burner is operating. See Table G and Table H for minimum and maximum flow rates and water pump selection. The pump must be interlocked with the boiler to prevent heater operation without water circulation. NOTE:Minimum pipe size for in/out connections is 1-1/2” NPT for model 300A and 2” NPT for models 400A, 500A, 700A and 850A. Verify proper flow rates and ∆T as instructed in this manual. WARNING:The pressure relief valve must be installed at the outlet of the boiler. No valve is permitted to be installed between the boiler and the relief valve. NOTE:The continuous inlet water temperature must be no less than 50°F. The piping system of a hot water heater connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air, must be equipped with flow control valves or other automatic means to prevent gravity circulation of the heater water during the cooling cycle. It is highly recommend- ed that the piping be insulated. 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 high-recovery, low-mass heaters which are not subject to thermal shock. Applications & Modes The VERSA IC Control system is designed for a wide range of applications. The installer/design engineer should refer to the following Modes to determine which best fits the intended application and functionality for the unit being installed. 14 Table G: Heater Rates of Flow and Pressure Drops Notes: Basis for minimum flow is ∆T . Basis for maximum flow is gpm. Model No. 20°F ∆T 30°F ∆T 35°F ∆T Min. Flow Max. Flow gpm ∆P (ft)gpm ∆P (ft)gpm ∆P (ft)gpm ∆P (ft)∆T gpm ∆P (ft)∆T 300A 28 17 19 8 16 6 14 5 39 36 28 16 400A 38 18 25 7 21 5 19 4 39 47 29 16 500A 47 16 31 7 27 5 24 4 39 56 23 17 700A 66 30 44 13 38 9 34 7 39 70 34 19 850A 80 40 53 17 46 12 41 10 39 80 40 20 Fig. 6: Air-Separation/Expansion Tank Type H models of XFyre have three modes available to them to address the various applications the units can be applied to. Type WH units will only have the WH configuration available to them for use with potable water applications when directly connected to a hot water storage tank. Mode 1 (Type H Units Only) This mode selection is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4). The system temperature is controlled by the System sensor (S3). The Boiler Pump (P1) runs during any call for heat. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the warm weather shut down (WWSD) temperature setting (if utilized). The Boiler Pump and System Pump are delayed “off” as user defined in the ADJUST menu. Mode 2 (Type H Units Only) This mode selection is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4) with indirect DHW on the sys- tem loop (with or without priority). The system temperature is controlled by the System sensor (S3). The Indirect DHW sensor (S5) determines the indirect call/tank setpoint. The system temperature is boosted to Target Max when using the Indirect DHW sensor (S5) during an indirect call for heat. Priority mode tog- NOTE:MODE 1 can also be used for process heat- ing applications in conjunction with a buffer/storage tank when operating temperatures above 150°F are required. Care must be given to ensuring water hard- ness is less than 5 grains per gallon to ensure scale free operation. 15 Fig. 7: MODE 1 - Applications with Primary/Secondary Piping Fig. 8: MODE 2 - Single Boiler with Indirect on System Loop Key: S1: Boiler Outlet SensorS2: Boiler Inlet Sensor S3: System SensorS4: Outdoor Air Sensor S5: Indirect Tank SensorS6: Supply Sensor to Indirect P1: Boiler PumpP2: System Pump P3: Indirect DHW Pump gles off the System Pump (P2) when an indirect call for heat is present. The Boiler Pump (P1) runs during any call for heat. The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The Boiler Pump (P1) and System Pump (P2) delay “off” as user defined in the ADJUST menu. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect call for heat is present with priority. Mode 3 (Type H Units Only) This mode selection is for hydronic heating systems with single or multiple boilers (Maximum 4 boilers) in primary/secondary piping configuration with or without Outdoor Air Reset (S4) with indirect DHW on the boil- er loop (with priority). The system temperature is controlled by the Supply sensor (S3) whenever the indirect call for heat is not active. The DHW Supply sensor (S5) determines the indirect call/tank setpoint. During an indirect call for heat the boiler firing rate is Domestic Hot Water When designing the water piping system for domestic hot water applications, water hardness should be con- sidered. Table H indicates the suggested flow rates for soft and medium water. Hard water must be softened for direct heating with the XFyre. Water hardness is expressed in grains per gallon. Fig. 9: MODE 3 - Single Boiler with Indirect on Boiler Loop NOTE:If local codes require a vacuum relief valve, acquire one locally and install per valve manufacturer’s instructions. Fig. 10: WH Units - Single Water Heater with Tank H Units - Single Boiler with Process Tank 16 determined by the water temperature at the Indirect Supply sensor (S6) and the Target Max setting when using the Indirect DHW sensor (S5). The Boiler Pump (P1) runs during all heat calls regardless of priority. The Indirect DHW Pump (P3) runs during an indirect call for heat with no “off” delay. The Boiler Pump (P1) and System Pump (P2) delay “off” as user defined in the ADJUST menu. The system pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD tem- perature setting (if utilized) unless an indirect call for heat is present. WH – Direct DHW Configuration When the unit is ordered as a “WH” configuration the only application available to it is direct DHW with sin- gle or multiple heaters (Maximum 4 heaters). The tank temperature is controlled by the System sensor (S3). The Boiler Pump (P1) runs during any call for heat. The System Pump (P2) output is active whenever the system is enabled. The Boiler Pump is delayed “off” after the Tank Target temperature is achieved and as user defined in the ADJUST menu. NOTE:A Tank Aquastat can be used in lieu of the Indirect DHW Sensor (S5). See the Versa IC manu- al for additional details. NOTE:WH units will operate to a maximum tank temperature of 150F. For temperatures required above 150F an “H” model boiler must be used and great care must be given to ensuring water hardness is less than 5 grains per gallon to ensure scale free operation. MODE 1 should be used and configured for setpoint operation for process heating applica- tions. 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 heating. 3.If the heater will be used to supply potable water, it shall not be connected to any heating system or components previously used with a non-potable water heating appliance. 4.When the system requires water for space heating at temperatures higher than 140°F (60°C), a means such as a mixing valve shall be installed to temper the water in order to reduce scald hazard potential. CAUTION:When this heater is used for both potable water and space heating, observe the following to ensure proper operation. ∆T = Temperature rise, °F. ∆P = Pressure drop through heat exchanger, ft. SHL = System head loss, ft (based on heater and tank placed no more than 5 ft apart and equivalent length of 75 ft of tubing and fittings). gpm = Gallons per minute, flow rate. MTS = Minimum tubing size. CAUTION:For scale free operation with Medium water (5–15 grains per gallon of total hardness), the operating control must NOT be set higher than 140°F. For higher than 140°F operation, or Hard water (>16 grains per gallon of total hardness), a water softener/treatment sys- tem must be utilized. Table H: Domestic Water Heater Flow Rate Requirements Model No.0–15 grains per gallon ∆T gpm ∆P MTS SHL 300A 24 24 13 1-1/2 17 400A 20 38 18 2 20 500A 20 47 16 2 19 700A 20 66 30 2 36 850A 23 69 29 2 36 WARNING: Plumbing between the heater and tank in excess of 75 equivalent feet will require custom pump selection. Damage due to low flow may occur and is not a warrantable failure. Consult with your local Raypak representative. 17 NOTE:The 75 eq. feet of tubing typically represents 25 linear feet of tubing and 50 eq. feet of fittings. 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. Refer to Table J for maximum pipe lengths. Gas Supply Connection The heater must be isolated from the gas supply pip- ing system by closing the upstream manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1/2 psi (3.45 kPa). Relieve 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-pressurized gas valves are not covered by warranty. The heater and its gas connections shall be leak-tested before placing the appliance in operation. Use soapy water for leak test. DO NOT use an open flame. DANGER:Make sure the gas on which the heater will operate is the same type as specified on the rat- ing plate. CAUTION:The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1/2 psi (3.45 kPa). CAUTION:For proper operation, no more than a 30% drop in gas supply pressure from no-load to full- load conditions is acceptable. Under no circumstances should the pressure be outside the listed operational range. Gas Supply Pressure A minimum of 4.0 in. WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 10.5 in. WC under load and no-load condi- tions for natural gas. A minimum of 4.0 in. WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 13.0 in. WC is required for propane gas. The gas pressure regulator(s) sup- plied on the heater is for low-pressure service. If upstream pressure exceeds 1/2 psi at any time, an intermediate gas pressure regulator, of the lockup type, must be installed. This regulator should be placed a minimum distance of 10 times the pipe diam- eter upstream of the heater gas controls. When connecting additional gas utilization equipment to the gas piping system, the existing piping must be checked to determine if it has adequate capacity for the combined load. The gas valve pressure regulator on the heater is nominally preset as noted in Table I. During normal operation, carbon dioxide should be 8.5 to 9.0% at full fire for natural gas and between 9.5 and 10.0% for propane gas. Carbon monoxide should be ‹150 ppm. Fig. 11: Gas Supply Connection 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 sparingly only on male pipe ends, leaving the two end threads bare. CAUTION:Support gas supply piping with hangers, not by the heater or its accessories. Make sure the gas piping is protected from physical damage and freezing, where required. NOTE: Manifold pressures should be ±0.3 in. WC. Table I: Manifold Gas Pressure Settings Model No. Manifold Pressure (in. WC) Natural Gas Propane Gas High Low High Low 300A -1.0 0.0 -1.2 0.0 400A -1.8 0.0 -1.1 0.0 500A -1.1 -0.1 -1.1 0.0 700A -1.4 0.0 -1.9 -0.1 850A -2.0 -0.1 -1.1 0.0 18 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 Canada, CSA C22. 1 C.E.C. Part 1. The XFyre 300A–850A heaters are wired for 120 VAC single-phase 60 Hz power. Consult the wiring diagram shipped with the heater. Before starting the heater, check to ensure proper voltage to the heater and pump(s). A larger circuit breaker may be needed for pumps larger than 1/4 hp. The boiler pump (up to 1 hp) and the indirect DHW pump (up to ¼ hp) get their power supply directly from the heater power supply (connections are located in the rear wiring box). The system pump relay is rated Natural Gas – 1,000 BTU/ft3, 0.60 specific gravity at 0.5 in. WC pressure drop Propane Gas – 2,500 BTU/ft3, 1.53 specific gravity at 0.6 in. WC pressure drop Table J: Maximum Equivalent Pipe Length Model No. 3/4” NPT 1” NPT 1-1/4” NPT 1-1/2” NPT 2” NPT N P N P N P N P N P 300A 15 30 45 100 175 400 390 400A 30 70 120 275 270 414 500A 15 40 65 150 150 350 700A 42 96 96 220 310 795 850A 25 55 55 125 175 450 for pilot duty only. XFyre heaters may power up to 2 pumps directly. Install a circuit breaker sized sufficient- ly for both the heater and the pump(s). An indirect DHW pump larger than ¼ 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 primary wiring should be 125% of minimum rating. The indirect and system pumps outputs are fuse protected. If any of the original wire as supplied with the heater must be replaced, it must be replaced with 105°C wire or its equivalent. All 120VAC field wiring connections to the XFyre heater are made inside the rear wiring box as shown in Fig. 12. Low voltage wiring is connected to the VERSA control board and the Platform Ignition Module (PIM) at the front of the unit. Sensors, enable/disable contacts, (optional) 0-10VDC control wiring, and cas- cade connections are wired into the VERSA and PIM field wiring plugs. See the wiring diagram on page 44. 19 Heater Model No. STANDARD PUMP MODELS H WH Pump Model HP Amps Pump Model HP Amps 300A 0012 1/8 1.3 1611 1/4 5.7 400A 0012 1/8 1.3 1630 1/2 6.9 500A 1611 1/4 5.7 1630 1/2 6.9 700A 1630 1/2 6.9 1634 1 14 850A 1630 1/2 6.9 1634 1 14 Table K: Standard Pump Sizes and Amperages Check the power source: AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX BC = <1 VAC Maximum Check the Power Source WARNING:Using a multi-meter, check the following voltages at the circuit breaker panel prior to connecting any equipment. Make sure proper polarity is followed and house ground is proven. (See Fig. 13.) Fig. 12: Wiring Connections Fig. 13: Multi-meter NOTE: Minimum 18 AWG, 105°C, stranded wire must be used for all low voltage (less than 30 volts) external connections to the unit. Solid conductors should not be used because they can cause excessive tension on contact points. Install conduit as appropriate. All high voltage wires must be the same size (105°C, stranded wire) as the ones on the unit or larger. Making the Electrical Connections Refer to Fig. 12–20. 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 heater. 2.Turn off all power to the heater. Verify that power has been turned off by testing with a multi-meter prior to working with any electrical connections or components at the J-box inside the heater. 3.Observe proper wire colors while making electri- cal connections. Many electronic controls are polarity sensitive. Components damaged by im- proper electrical installation are not covered by warranty. 4.Provide overload protection and a disconnect means for equipment serviceability as required by local and state code. 5.Install heater controls, thermostats, or building management systems in accordance with the applicable manufacturers’ instructions. 6.Conduit should not be used as the earth ground. NOTE:A grounding electrode conductor shall be used to connect the equipment grounding conductors, the equipment enclosures, and the grounded service conductor to the grounding electrode. NOTE:Current draw noted on rating plate does not include pump current. 20 Field Wiring Connections Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. CAUTION:Wiring errors can cause improper and dangerous operation. See the wiring diagram in this manual. Verify proper operation after servicing. DANGER: SHOCK HAZARD ** CAN BE MODIFIED TO ACCEPT 4-20mA CONSULT VERSA IC MANUAL ALARM CONTROL/SENSORWIRING HIGH VOLTAGE POWERAND PUMP WIRINGLOCATION RATING PLATE SUGGESTED ROUTING OFSENSOR & CONTROLWIRING Fig. 14: Rear Wiring Location Fig. 16: XFyre Single Heater Control PLATFORMIGNITION MODULE(PIM) VERSACONTROL Fig. 15: Front Wiring Locations Wiring the Thermostat Connect the Enable/Disable terminals to the PIM (shown in Fig. 16). Alternately, any dry contact closure (includ- ing a remote thermostat) across these terminals will enable the XFyre unit to run. Caution should be used to ensure neither of the terminals becomes connected to ground. 21 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 sensor wires to the terminals marked OUTDOOR SEN- SOR (see wiring diagram). Caution should be used to ensure neither of these terminals becomes connected to ground. 3.Use a 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.When the Indirect DHW call for heat is active, the PIM communicates this to the VERSA. The VERSA calculates the optimal operation and sends the firing rate and pump output requests 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 the VERSA to optimize the Indirect DHW demand to maintain the Indirect DHW setpoint. The Indirect DHW thermostat switch closure is not required when using the Indirect DHW sensor. If a VERSA is not present the PIM shall activate the Indirect DHW pump whenever the Indirect DHW call is active. The Boiler pump may also be activated based on the Indirect DHW piping configuration setting. 3.Connect the indirect tank sensor to the terminals marked INDIRECT DHW SENSOR (see wiring diagram). Caution should be used to ensure nei- ther of these terminals becomes connected to ground. Wiring the Optional 0–10 VoltBuilding Control Signal 1.A signal from an energy management system may be connected to the XFyre boiler. This signal should be a 0-10 volt positive DC signal, and an energy management system can be used to con- trol either the setpoint temperature or the firing rate of the XFyre boiler. 2.To enable this remote control function, set dip switch 5 to the UP position on the PIM. Dip switch 5 Toggles between an EMS (UP) signal or a demand signal from the VERSA (DOWN). Dip switch 2 on the PIM toggles between a Direct Drive (UP) input and a Target Temperature (DOWN) setpoint. 3.For a 4-20mA application, refer to the VERSA IC manual. 4.Connect an Energy Management system or other auxiliary control signal to the terminals marked 0- 10V (+ /-) on the PIM (see Fig. 16). Caution should be used to ensure that the +0-10V connection does not create a short to ground. Wiring the Cascade System Communication Bus 1. Designate the primary boiler as the master boiler/boiler1 by leaving dip switch 2 on the VERSA in the ON position. All other VERSA con- trols require dip switch 2 to be toggled OFF, designating them as followers. Follower VERSA’s are ignored by their corresponding PIM’s. Use standard 18 AWG wire to connect the master VERSA to the PIM on the followers. A total of 3 fol- lowers can be connected to the VERSA on the master. For systems requiring more than 4 con- nected boilers, an external sequencer such as the Raypak Temp Tracker Mod+ Hybrid can be used. NOTE:Alternately, a thermostat contact closure can be used in lieu of the sensor for indirect operation. Connect the thermostat to the terminals marked IND REMOTE THERMOSTAT. CAUTION:Sensor and control wiring must NOT be run in conduit or chases with line voltage. 22 VERSA MASTER 2. It is recommended that the shortest length cable possible be used to reach between the boilers. Do not run unprotected cables across the floor or where they will become wet or damaged. Do not run communication cables parallel with, or close to or against, high voltage (120 volt or greater) wiring. Raypak recommends that the total maxi- mum length of each set of communication bus cables not exceed 200 feet. 3.Route the FT_BUS wires from the front along the top rails and out the back of the cabinets (as shown in Fig. 14). 4.Connect the FT_BUS wires to the PIM by pressing down on the slots with a small screwdriver and then inserting the wires into the holes. See Fig. 18. Fig. 17: XFyre Cascade System Wiring Fig. 18: FT_BUS Wire Connection 23 Fig. 19: XFyre Cascade Master Pumps Cascade System Pump and Sensor Wiring 1.On the boiler designated as the Master, connect the system pump wiring to the terminal block at the rear of the unit. Connect to terminals 10, 11, and 12 (See Fig. 19). The output is rated for pilot duty only (2A maximum). 2.Connect the boiler pump wires to the terminal block at the rear of their unit. Connect to terminals 4, 5, and 6 (See Fig. 19). 3.Connect the system supply sensor to terminals 3 and 4 on the J2 connector located on the Master PIM (See Fig. 16). 4.Connect the Outdoor sensor (if used) to terminals 5 and 6 on the J2 connector located on the Master PIM (See Fig. 16). 5.Connect the Enable/Disable wiring to terminals 9 and 10 on the J1 connector located on the Master PIM (See Fig. 16). 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 these terminals. Cascade Follower Pumpand Sensor Wiring 1.Once the primary boiler has been identified, addi- tional boilers will be designated as follower boilers. Ensure dip switch 2 on each follower VERSA is set to the OFF/Down position (See Fig. 20) 2.For each follower boiler, connect the boiler pump wires to the terminal block at the rear of each unit. Connect to terminals 4, 5, and 6 as shown in Fig. 19. 3.The System and DHW pump outputs are not used in the Cascade Follower configuration. Fig. 20: VERSA Follower N/A N/A 24 Modbus BMS Communication The VERSA IC control is equipped as standard with a communications port for connectivity to building automation via Modbus protocol. Refer to the VERSA IC manual for further information. Venting General Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Category I – A heater which operates with a non-pos- itive vent static pressure and with a vent gas temperature that avoids excessive condensate pro- duction in the vent. Category II – A heater which operates with a non-pos- itive vent static pressure and with a vent gas temperature 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 condensate production in the vent. Category IV – A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent. See Table L for appliance category requirements. Use only PVC or CPVC vent material (in Canada, ULC-S636 approved plastic material 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 Fab Inc. (800-772-0739), Protech System, Inc. (800-766-3473), Z-Flex (800- 654-5600) or American Metal Product (800-423-4270). Pipe joints must be positively sealed. Follow the vent manufacturer’s installation instructions carefully. Centrotherm™ polypropylene vent material is also approved to be used on XFyre products. A vent adapter (option D-33) must be used to ensure a prop- er seal of the flue and condensate. The vent adapter kit supplied by Raypak includes a higher temperature rated vent limit. Vent installation shall be in accordance with Part 7, Venting of Equipment, of the NFGC, ANSI Z223.1/NFPA 54, Section 7, Venting Systems and Air Supply for Appliances, of the B149 Code, or applicable provisions of the local building codes. NOTE:For additional information on appliance categorization, see the ANSI Z21.13 Standard and the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes. CAUTION:Proper installation of flue venting is critical for the safe and efficient operation of the boiler. WARNING:Contact the manufacturer of the vent material if there is any question about the appliance categorization and suitability of a vent material for application on a Category IV vent system. Using improper venting materials can result in personal injury, death or property damage. Alarm Connection An alarm bell or light may be connected to the alarm contacts on the boiler PIM. The Alarm Contacts are 3A rated dry contacts on a normally-open relay that close during fault or lockout conditions, and the maxi- mum voltage across the contacts is 30 VAC or 30 VDC. Connections are made at J1 pins 1 and 2. In a cascade system, the alarm output of the master boiler will be active if either the master boiler or fol- lower(s) have a lockout condition. The alarm output of the follower boilers will only energize if a lockout condition occurs on that specific boiler. WARNING:Do not use foam core or cellular core PVC/CPVC pipe for venting. WARNING:DO NOT insulate PVC or CPVC vent pipe. 25 CAUTION:When using stainless steel vent in a cli- mate where freezing may occur, a double wall vent pipe must be used. 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 injury. 3.Gases may form a white vapor plume in winter. The plume could obstruct a window view if the ter- mination is installed near windows. 4.The bottom of the vent terminal and the air intake shall be located at least 12 in. above grade, includ- ing normal snow line. NOTE:During winter months check the vent cap and make sure no blockage occurs from build-up of snow or ice. 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. The vent should also be installed to maintain proper clearances from combustible materials. Use insulated vent pipe spacers where the vent passes through combustible roofs and walls. When using PVC or CPVC venting on models 300A, 400A and 500A, insert the vent pipe 3-5 inches into the flue outlet and provide rigid support to the vent, so that it will not shift laterally. 5.Single-wall Category IV metal vent pipe shall not be used outdoors in cold climates for venting gas- fired equipment without insulation. 6.Through-the-wall vents for Category IV appli- ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimen- tal to the operation of regulators, relief valves, or other equipment. 6.Locate and guard vent termination to prevent acci- dental contact by people or pets. 7.DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. 9.DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations. 10.Locate or guard vent to prevent condensate from damaging exterior finishes. Use a 300-series stainless steel backing plate against brick or masonry surfaces. 11.DO NOT extend exposed vent pipe outside of building beyond the minimum distance required for the vent termination. Condensate could freeze and block vent pipe. NOTE:When using PVC “T” vent termination, insert the two round stainless mesh screens provid- ed with the unit into the tee. Combustion Air Supply Exhaust Configuration Heater Venting Category Certified Vent Materials Combustion Air Inlet Material From Inside Building (Non-Direct Venting) Vertical Venting IV (Canada Only: ULC- S636 PVC and CPVC) Stainless Steel, AL29-4C, Sch 40 PVC or CPVC Polypropylene* Horizontal Through- the-Wall Venting From Outside Building (Direct Venting) Vertical Venting Galvanized Steel, PVC, ABS, CPVCHorizontal Through- the-Wall Venting Table L: Venting Category Requirements * Only Centrotherm™ polypropylene is approved for the XFyre product. WARNING:Condensate is acidic and highly corrosive. NOTE:When using Centrotherm™ Polypropylene “T” vent termination, insert two Centrotherm™ termination screens into the dis- charge end of the tee. 26 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 ft above grade when located adjacent to public walkways. 3.Terminate vent at least 3 ft above any forced air inlet located within 10 ft. 4.Vent must terminate at least 4 ft horizontally, and in no case above or below unless 4 ft horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment. 5.Terminate vent at least 6 ft away from adjacent walls. 6.DO NOT terminate vent closer than 5 ft below roof overhang. 7.The vent terminal requires a 12 in. vent terminal clearance from the wall. 8.Terminate vent at least 1 ft above grade, including normal snow line. 9.Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane. Installations in Canada Refer to latest edition of the B149 Installation Code. A vent 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 paved driveway located on public property. 3.Within 6 ft (1.8 m) of a mechanical air supply inlet to any building. 4.Above a meter/regulator assembly within 3 ft (915 mm) horizontally of the vertical centerline of the regulator. 5.Within 6 ft (1.8 m) of any gas service regulator vent outlet. 6.Less than 1 ft (305 mm) above grade level. 7.Within 3 ft (915 mm) of a window or door which can be opened in any building, any non-mechani- cal air supply inlet to any building or the combustion air inlet of any other appliance. 8.Underneath a verandah, porch or deck, unless the verandah, porch or deck is fully open on a mini- mum of two sides beneath the floor, and the distance between the top of the vent termination and the underside of the verandah, porch or deck is greater than 1 ft (305 mm). Fig. 21: Vent Cap Configurations WARNING:The Commonwealth of Massachusetts requires that sidewall vented heaters, installed in every dwelling, building or structure used in whole or in part for residential purposes, be installed using special provisions as outlined on page 53 of this manual. 27 Venting Installation Tips Support piping: •horizontal runs—at least every 5 ft (1.5m) •vertical runs—use braces •under or near elbows Venting Configurations For heaters connected to gas vents or chimneys, vent installations shall be in accordance with the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes. Vertical Venting (Category IV) Installation The maximum and minimum venting length for this Category IV appliance shall be determined per the NFGC (U.S.) or B149 (Canada). Table M: 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. ** Only Centrotherm polypropylene is approved for the XFyre product. Fig. 22: Vertical Venting Model No.Certified Vent Material Vent and Intake Air Vent Size (in.) Vertical Vent Height1 (ft)Combustion Air Intake Pipe Material Vertical Air Inlet Max. Length* (ft)Min.Max. 300A (Canada Only: ULC-S636 PVC and CPVC) Stainless Steel, AL29-4C, ANSI/ASTM D1785 Sch 40 PVC, ANSI/ASTM F441 Sch 40 CPVC Polypropylene** 4 0 100 Galvanized Steel, PVC, ABS, CPVC 100 400A 500A 700A 6 850A CAUTION: This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer’s instructions. Failure to install a condensate drain in the venting system will void all warranties on this boiler. Condensate is acidic and highly corrosive NOTE:Ensure adequate clearances to allow annual inspection of the venting system. 28 Termination The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the highest point of the roof that is within 10 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft hori- zontal distance is maintained) electric meters, gas meters, regulators and relief equipment. The distance of the vent terminal from adjacent public walkways, adjacent buildings, open windows and building openings must be consistent with the NFGC (U.S.) or B149 (Canada). Vents supported only by flashing and extending above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. Common Venting The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters. This is covered in the NFGC under “Engineered Vent Sys- tems”. Table N provides volumes of flue products at full fire for the calculation of appropriate vent and extrac- tor sizing for common venting. NOTE:A vent adapter (field-supplied) may be re- quired to connect the Category IV vent to the boiler. WARNING: Vent connectors serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure. If an XFyre boiler is installed to replace an existing boiler, the vent system MUST be verified to be of the correct size and of Category IV AL29-4C vent material, approved PVC/CPVC construction, or Centrotherm™ polypropylene (in Canada, ULC- S636 approved plastic materials must be used). If it is NOT, it MUST be replaced. NOTE:For extractor sizing, typical CO2 levels are 8.5% for natural gas and 9.5% for propane gas and flue temperatures of less than 220°F. NOTE: Data for 100% firing rate. Table N: Volume of Flue Products Data CAUTION:A listed vent cap terminal suitable for connection to the Cat IV vent materials, adequately sized, must be used to evacuate the flue products from the boilers. Model No.Vent Size (inches) Volume of Flue Products (CFM) 300A 4 90 400A 120 500A 150 700A 6 210 850A 250 At the time of removal of an existing boiler, the follow- ing steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remain- ing connected to the common venting system are not in operation: (a) Seal any unused openings in the common venting system. (b) Visually inspect the venting system for proper size and horizontal pitch and make sure there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. (c) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. NOTE:Vent and intake piping must be supported so that the weight of the venting is not transfered to the unit. Horizontal runs of vent and intake piping must be supported to prevent sagging. NOTE:When using PVC “T” vent as termination, insert the round stainless mesh screens provided with the unit into the tee ends. The minimum flue pipe diameter for conventional vent- ing is: 4 in. (102mm) for Models 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 horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot from the heater to the vent termi- nal. The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clearances and to prevent physi- cal damage or separation of joints. NOTE:When using Centrotherm™ Polypropylene “T” vent termination, insert two Centrotherm™ termination screens into the tee ends. 29 Fig. 23: Typical Common Venting Horizontal Through-the-Wall DirectVenting (Category IV) Note: Heaters rotated to show venting connections. Fig. 24: Horizontal Through-the-Wall Venting Refer to Table F and local codes. Fig. 25: Horizontal Through-the-Wall Direct Venting Refer to Table F and local codes. 30 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 inline vertical or horizontal collector available from several of the listed vent manufacturers. CAUTION: This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer’s instructions. Failure to install a condensate drain in the venting system will void all warranties on this boiler. Installation These installations utilize the heater-mounted blower to draw combustion air and to vent the combustion products to the outdoors. The combustion air intake and the vent are installed horizontally through the wall to the outdoors. Adequate ventilation air must be sup- plied to the equipment room in accordance with the NFGC (U.S.) or B149 (Canada). The total length of the horizontal through-the-wall direct vent system should not exceed 200 equivalent ft in length. If combined vent/intake run exceeds 200 WARNING:No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants. equivalent ft, an appropriately sized 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 provide approximately the same equivalent length. The vent cap is 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 are airtight. The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is required that: 1.The vent must be installed with condensate drains as directed by the vent manufacturer. 2.The vent must be installed with a slight upward slope of not less than 1/4 inch per foot of horizon- tal 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 below grade. The vent cap must be installed at least 1 ft above ground level and above normal snow levels. Only Raypak-approved vent caps may be used. The vent terminal must be located NO CLOSER than 12” off the wall. Model No.Size (in.)Approved Intakes Approved Plastic Terminals Approved SS Terminals 300A 4 PVC 90° Elbow, Sch 40 Galvanized 90° Elbow, SS 90° Elbow, ABS 90° Elbow 4" PVC/CPVC Tee Sch 40*, Centrotherm™ Polypropylene FasNSeal FSTT4, Z-Vent 2SVSTTF04400A 500A 700A 6 6" PVC/CPVC Tee Sch 40*, Centrotherm™ Polypropylene FasNSeal FSTT6, Heat Fab 9690TEE850A Table O: Horizontal Vent and Air Intake Terminals *Must be ULC-S636 materials in Canada. WARNING:Condensate is acidic and highly corrosive. 31 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 P: Category IV Horizontal Vent & Horizontal Direct Vent The total length of air supply pipe cannot exceed the distances listed in Table M. Each elbow used is equal to 10 ft of straight pipe. This will allow installation in any arrangement that does not exceed the lengths shown in Table M. The vent cap is not considered in the overall length of the venting system. Care must be taken during assembly that all joints are sealed properly and are airtight. The vent must be installed to prevent the potential ac- cumulation of condensate in the vent pipes. It is required that: 1.The vent must be installed with a condensate drain as directed by the vent manufacturer. 2.The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of hori- zontal run to the vent terminal. Termination The vent cap MUST be installed on the exterior of the building. The vent cap cannot be installed in a well or below grade. The vent cap must be installed at least 1 ft above ground level and above normal snow levels. The vent cap MUST NOT be installed with any com- bustion air inlet directly above a vent cap. This vertical spacing would allow the flue products from the vent cap to be pulled into the combustion air intake installed above. CAUTION:This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer’s instructions. Failure to install a condensate drain in the venting system will void all warranties on this boiler. Note that the condensate is acidic and highly corrosive. Fig. 26: Direct Vent - Vertical Model No.Certified Vent Material Vent and Intake Air Vent Size (in.) Horizontal Vent Length (ft) Combustion Air Intake Pipe Material Air Inlet Max. Length (ft)*Min.Max. 300A (Canada Only: ULC-S636 PVC and CPVC) Stainless Steel, AL29-4C, Sch 40 PVC/CPVC, Centrotherm™ Polypropylene 4 0 100 Galvanized Steel, PVC, ABS, CPVC 100 400A 500A 700A 6 850A 32 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 vent cap(s). Combustion air supplied from outdoors must be free of particulate and chemical contaminants. To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc. Condensate Management The condensate must be drained properly to protect the appliance and drainage system. The condensate from the boiler is acidic. Its pH is between 3.2 and 4.5. Raypak recommends neutralizing the condensate with a Condensate Neutralizer kit (Z-12). The neutralizer kit is connected to the drain system and contains lime- stone (calcium carbonate) chips to neutralize the pH level of the condensate. The kit may be added to avoid long-term damage to the drainage system and to meet local code requirements. Vent pipe condensate drains are also required for installation of the XFyre. Follow vent manufacturer instructions for location of condensate drains in the vent. The vent condensate should also be routed through a neutralization kit, as required by local code requirements. The neutralizer kit must be sized to the condensate generated by the appliance and the vent.WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.CAUTION:In general, the condensate piping from the appliance must have a downward slope of ¼” per horizontal foot. Condensate drain traps must be primed with water to prevent gas flue leaks. Neutralizers should be checked at least once per year, and the chips should be replenished as neces- sary. When replacing the chips, they should be no smaller than ¾” to avoid blockage in the condensate piping. Fig. 27 is a visual guide only. Follow the man- ufacturer’s instructions for the installation of the neutralization kit and condensate drains. Fig. 27: Visual Guide for Condensate Piping 33 Freeze Protection To enable freeze protection, dip switch position 7 (on the PIM) must be turned on (UP position). This is the default position. If the water temperature drops below 45˚F on the Outlet or Inlet sensors, the Boiler pump is enabled. The pump is turned off when both the Inlet and Outlet temperatures rise above 50˚F. If either the Outlet or Inlet temperature drops below 38°F, the VERSA starts the burner at the minimum fir- ing rate. The burner cycle will terminate when both the Inlet and Outlet temperatures rise above 42°F. Controls Outdoor Installation Outdoor models must be vented with listed vent mate- rial per the following instructions and installed with the optional factory-supplied outdoor vent kit. A special vent terminal (Option D-11) is provided in accordance with CSA requirements. These must be installed as illustrated in Fig. 28. Care must be taken when locating the unit outdoors, because the flue gases discharged from the vent cap can condense as they leave the cap. Improper location can result in damage to adjacent structures or building finish. For maximum efficiency and safety, the follow- ing precautions must be observed: 1.Outdoor models must be installed outdoors and must use the outdoor vent cap available from the manufacturer (sales order option D-11). 2.Periodically 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 and free of combustible and flammable materials. 3.Do not locate adjacent to any window, door, walk- way, or gravity air intake. The vent must be located a minimum of 4 ft horizontally from such areas. 4.Install above grade level and above normal snow levels. 5.Vent terminal must be at least 3 ft above any forced air inlet located within 10 ft. 6.Adjacent brick or masonry surfaces must be pro- tected to prevent condensate from damaging exterior finishes. Use a 300-series stainless steel backing plate against brick or masonry surfaces.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:Turn off power to the boiler before installing, adjusting or servicing any controls. Failure to do so may result in board damage, malfunction, property damage, personal injury, or death. Model No. Size (in.) Approved Plastic Terminals Approved SS Terminals 300A 4 PVC Tee Sch 40*, Centrotherm™ Polypropylene FasNSeal FSTT4, Z-Vent 2SVSTTF04400A 500A 700A 6 PVC Tee Sch 40*, Centrotherm™ Polypropylene FasNSeal FSTT6, Heat Fab 9690TEE850A *Must be ULC-S636 materials in Canada. Table Q: Outdoor Vent Terminals NOTE:The vent cap must be listed and approved by the boiler manufacturer in accordance with its listing (sales order option D-11). NOTE:Condensate can freeze on the vent terminal. Frozen condensate on the vent terminal can result in a blocked flue condition. NOTE: MUST BE EXTERNALLY SUPPORTED Fig. 28: Outdoor Venting 34 CAUTION:This appliance has provisions to be connected to more than one supply source. To reduce the risk of electric shock, disconnect all such connections before servicing. CAUTION:Risk of electric shock: More than one disconnect switch may be required to de-energize the equipment before servicing. Ignition Control Functions When there is a call for heat, and all safeties are closed, then the combustion air blower starts to purge air from the combustion chamber. After the pre-purge, the igniter is energized. The standard ignition module will lock-out after failing to light 3 times during a call for heat. To reset the lock-out, press and release the RESET button located on the user interface. The con- trol will automatically reset after 1 hour. When in lock-out the control will run the blower through a post- purge cycle. The single-try ignition module (part of the CSD-1 option) will attempt to light only one time before lock- 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 Reset The heater is equipped with a fixed setting manual reset high limit temperature device as standard and it may have an additional optional adjustable manual reset high temperature device. Standard The fixed setting manual reset high limit is built into the PIM, it utilizes a dual element sensor located on the outlet (see Fig. 29). To reset a high limit lock-out, press and release the RESET button located on the user interface. Optional The Optional adjustable setting manual reset high limit is located behind the front panel. To reset a high limit lockout, press the reset button on the adjustable man- ual reset limit as well as the reset button located on the user interface. STANDARDLIMIT SENSOR OPTIONAL ADJUSTABLESETTING Fig. 29: High Limit (Manual Reset) High Limit — Auto Reset (Optional) The heater may be equipped with a fixed auto-reset high limit temperature device and/or an adjustable auto-reset high limit temperature device. The optional auto reset high limit is located on the brass outlet adapter inside the unit, and the adjustable auto-reset high limit is located inside and behind the front panel. Fig. 30: High Limit (Auto Reset) FIXED SETTING ADJUSTABLESETTING NOTE:Ignition modules are common for all model sizes. However, model-specific operating parame- ters are defined by their respective ID cards. NOTE:Adjustable limits must be set higher than the expected outlet temperature of the unit during nor- mal operation, to prevent short cycling and nuisance trips. 35 Flow Switch This standard, dual-purpose control shuts off the boil- er in case of pump failure or low water flow. The flow switch ships mounted and wired. Fig. 33: Low Water Cut-OffFlue Temperature Limit The heater is equipped with a fixed setting manual reset high limit temperature device on the vent, for use with non-metallic vent material. The high temperature limit is located inside the unit near the vent adapter. The VERSA monitors the limit and displays any fault associated with the limit on the user interface. To reset the limit, access it and press down on the red button. The unit is provided with a limit rated for PVC vent material. A higher rated limit is provided when using Centrotherm™ polypropylene venting. The limit is removed when using Category IV stainless steel vent- ing. Low Water Cut-Off (Optional) The optional low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay pre- vents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig. 31: Flow Switch Fig. 32: Flue Temperature Limit High & Low Gas Pressure Switches(Optional) The optional low gas pressure switch connection mounts upstream of the gas valve (on the inlet flange to the gas valve) and is accessible through the remov- able access panels on the front or top of the boiler to reset the gas pressure switch, as necessary. It is used to ensure that sufficient gas pressure is present for proper valve/regulator performance. The low gas pres- sure 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 switch connection mounts down-stream of the gas valve. Special ports are located on the backside of the gas valve and are accessible from the front or top of the boiler (to reset the gas pressure switch), as necessary. If the gas pressure regulator in the valve fails, the high gas pres- sure switch automatically shuts down the burner. Operation of either the High or Low Gas Pressure Switch will turn on an LED inside the switch housing. Push the top of the plastic switch housing as shown in Fig. 34 to reset a tripped pressure switch. The LED will go out when the switch is reset. 36 Operating Instructions Remove the front door. If you smell gas, STOP. Follow listed safety instructions. If you do not smell gas, fol- low the next steps. 1. Turn on all electric power to appliance. 2. Adjust the temperature setpoint of the XFyre as desired. The factory default setting is 180°F for H models and 125°F for WH models. 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 control user interface will display GAS PRESS. This is a low gas pressure switch lock-out from the factory-installed low gas pres- sure switch. You will also see a yellow LED illuminated under the cover of the low gas pres- sure switch. Once the gas is turned on, reset the gas pressure switch by FIRMLY pressing on top of the plastic cover over the red reset button. The yellow LED will go out after the switch has been reset. Press and release the RESET key on the control panel to begin normal operation. 4. The unit requires closure across the enable/dis- able to operate. 5. If the appliance fails to start, refer to the Troubleshooting section in the back of this manu- al. Fig. 36: Condensate Float Switch Condensate Float Switch The heater is equipped with a condensate float switch to prevent operation when the condensate water level is too high. The heater shutting down from the conden- sate float switch is indicative of a blocked drain or problem with the condensate management system. The condensate float switch is located inside at the left rear of the heater, and can be accessed through the back panel. Fig. 34: High/Low Gas Pressure Switch Blocked Vent Switch The heater is equipped with a blocked vent pressure switch to prevent the operation of the boiler when a significant amount of air flow is blocked at the vent. The switch is located at the left rear of the unit. Fig. 35: Blocked Vent Switch 37 Adjusting the XFyre Setpoint To adjust the setpoint on the XFyre: Use the MENU key to scroll to the ADJUST menu, then use the ITEM key to scroll to the SETPOINT item. Adjust the Setpoint using the UP and DOWN arrow keys. Minimum is 50°F, Maximum is the PIM value, and the default is 180°F for H models and 125°F for WH models. View Menu The VIEW menu is the default menu. It displays sen- sor temperatures, the modulation rate of the blower, heater cascade status, pump operation and CFH infor- mation. Some of the items displayed are mode specific and are only observable when its corresponding mode is active. Setup Menu To change settings use the MENU key to scroll to the ADJUST menu. The ADJUST menu allows the installer to make adjustments to items shown in Table R. Refer to the VERSA IC Control I&O Manual (Catalog #5000.72) for detailed setup instructions. User Interface 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 selected menu. And, the UP and DOWN buttons allow for setting changes to items in the ADJUST menu. Refer to Fig. 37 for dis- play and key locations. For detailed descriptions of the various screens, con- sult the VERSA IC Control I&O Manual (Catalog #5000.72). Fig. 37: User Interface Table R: View Menu Item Application Description OUTDOOR H 1,2,3 Outdoor air temperature Boil Target H 1,2,3 Current target temperature SUPPLY H 1,2,3 Current system supply temperature Boil OUTLET All Current boiler outlet temperature Boil INLET All Current boiler inlet temperature Boil ∆T All Current temperature difference between boiler outlet and boiler inlet DHW SUPPLY H 2,3 Current indirect DHW supply temperature TANK DHW WH Current tank temperature BOILER STATUS All IDLE, PREP, IGN, MOD RATE %, POST, SOFT 38 Table S: Adjust Menu Item Application Range Description Default BOILER 1 All ON <> OFF Enable or Disable the operation of boilers. 4 boiler range, 1 is enabled by default ON TARGET H 1,2,3 RSET <> SETP RSET = Outdoor Reset, SETP =Setpoint SETP TANK SETP WH OFF, 50°F to 150°F EMS = Energy Management System (Analog Target Temp)125°F TANK DIFF WH 2°F to 10°F Tank Differential temperature 3 MODE H 1,2,3 1,2,3 Piping and application configuration.1 SETPOINT H 1,2,3 50°F to PIM value*Boiler target temperature while a heat demand is present for set- point operation 180°F OUT START H 1,2,3 35°F to 85°F Outdoor starting temperature 70°F OUT DESIGN H 1,2,3 -60°F to 45°F Outdoor design temperature 10°F Boil START H 1,2,3 35°F to 150°F Starting boiler target temperature when the outdoor temperature is at outdoor start 70°F Boil DESIGN H 1,2,3 70°F to 200°F Design boiler target temperature when the outdoor temperature is at outdoor design 180°F Boil MASS All 1<>2<>3 Thermal mass of the boiler 1 TARGET MAX H 1,2,3 100°F to PIM value*Maximum target boiler temperature 192°F TARGET MIN H 1,2,3 OFF, 50°F to 190°F Minimum target boiler temperature 50°F TARGET DIFF H 1,2,3 2°F to 42°F Differential for target boiler temperature 10°F DHW SENSOR H 1,2,3 OFF <> ON Selects whether a DHW sensor is used for pool heating OFF DHW DIFF H 2,3 2°F to 10°F Differential for the target indirect DHW tank temperature 6°F IND SUPPLY H 2,3 OFF, 50°F to PIM value*Target boiler temperature for the DHW heat exchanger during indi- rect DHW operation 180°F DHW PRIORITY H 2 OFF <> ON Selects whether or not Indirect DHW priority is active during indi- rect DHW operation OFF PRI OVR H 2,3 Au, 0:10hr to 2:00hr Sets the length of the priority override time Au BOIL PURGE All 0:20min to 20:00min Sets the length of the boiler pump purge 20 seconds SYS PURGE All OFF, 0:20min to 20:00min Sets the length of the system pump purge 20 seconds WWSD H 1,2,3 40°F to 100°F The system warm weather shutdown temperature 70°F UNITS All deg F <> deg C Show units using icons in display deg F MODBUS All OFF<>MNTR<> TEMP<>RATE ModBus Operating Mode: Off, Monitor, Temp Control, Rate Control OFF ADDRESS All 1 to 247 ModBus slave address 1 DATA TYPE All RTU <> ASCI Modbus data type RTU BAUD RATE All 2400<>9600<>19K2<> 57K6<>115K 19K2 PARITY All NONE<>EVEN<>ODD EVEN 39 Boiler View Menu The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information Table T: Boiler View Menu Item Application Description IGNITION All Current State of Ignition LIMIT TEMP All Limit Temperature AUX TEMP H 3 Auxiliary Temperature EMS Vdc All Current EMS signal in Volts DC FIRE RATE All PIM firing rate SPEED X1000 BLOWER All Blower speed, Revolutions/Minute HIGH LIMIT All High Limit Setting H L OFFSET All High Limit Offset OPERATOR All Operator Limit Potentiometer (PIM) AUTO DIFF H 1,2,3 Current auto differential PUMP PREPt All Duration of pump prepurge BLOW PREPt All Duration of blower prepurge BLOW PREPr All Blower % during prepurge BLOW POSTt All Duration of blower postpurge BLOW POSTr All Blower % during postpurge MIN RATE All Minimum modulation rate % during operation START RATE All Start modulation rate % during ignition MAX RATE All Maximum modulation rate % during operation FLAME CUR All Flame current in micro-amps IGN TYPE All PIM board type MASS All Thermal mass of the boiler ID CARD All Identifies OEM identity card PIM ID All Identifies OEM PIM PCB SW ID All PIM software identification number 40 Monitor Menu The Monitor Menu records and displays critical Boiler information, such as, Cycle times, Run times, and Maximum/Minimum temperature readings depending on the setup. Table U: Monitor Menu Item Application Description RUN TIME Burner 1 All Burner run time (hours). Press UP/DOWN for 1 sec to clear. Cycles Burner All Number of burner cycles. Press UP/DOWN for 1 sec to clear. RUN TIME Boiler pump All Boiler pump run time (hours). Press UP/DOWN for 1 sec to clear. RUN TIME System pump All System pump run time (hours). Press UP/DOWN for 1 sec to clear. RUN TIME DHW pump H 2,3 DHW pump run time (hours). Press UP/DOWN for 1 sec to clear. OUTLET HI All Records the highest boiler outlet temperature. Press UP/DOWN for 1 sec to clear. OUTLET LO All Records the lowest boiler outlet temperature. Press UP/DOWN for 1 sec to 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. OUTDOOR HI H 1,2,3 Records the highest outdoor temperature. Press UP/DOWN for 1 sec to clear. OUTDOOR LO H 1,2,3 Records the lowest outdoor temperature. Press UP/DOWN for 1 sec to clear. SYSTEM HI All Records the highest supply temperature. Press UP/DOWN for 1 sec to clear. SYSTEM LO All Records the lowest supply temperature. Press UP/DOWN for 1 sec to clear. IND HI H 1,2,3 Records the highest Indirect supply temperature. Press UP/DOWN for 1 sec to clear. IND LO H 1,2,3 Records the lowest Indirect supply temperature. Press UP/DOWN for 1 sec to clear. DHW HI WH Records the highest DHW temperature. Press UP/DOWN for 1 sec to clear. DHW LO WH Records the lowest DHW temperature. Press UP/DOWN for 1 sec to clear. 41 Toolbox Menu The Toolbox Menu logs all error codes from the BTCII and PIM, as well as other functions. Up to 15 error codes can be logged for a maximum of 24 days. Table V: Toolbox Menu Outdoor Reset Concept The Temperature controller can change the System Set Point based on outdoor temperature (Outdoor Reset). The temperature controller varies the temper- ature of the circulating heating water in response to changes in the outdoor temperature. The heating water temperature is controlled through the modula- tion and/or sequencing of the cascade. The Temperature controller can also control the sys- tem circulating pump with an adjustable Outdoor Cutoff. When the outdoor temperature is above the Outdoor Cutoff, the pump is turned off and no heating water is circulated through the system. When the out- door temperature drops below the Outdoor Cutoff, the system pump relay is activated and the heating water circulates through the system. The temperature of the heating water is controlled by the Reset Ratio, Water Offset, and changes with the outdoor temperature. Reset Ratio/Outdoor Reset When a building is being heated, heat escapes through the walls, doors, and windows to the colder outside air. The colder the outside temperature, the more heat escapes. If you can input heat into the build- ing at the same rate that it is lost out of the building, then the building temperatures will remain constant. The Reset Ratio is an adjustment that lets you achieve this equilibrium between heat input and heat loss. The starting point for most systems is the 1.00 (OD):1.00 (SYS) (Outdoor Temperature: Heating Water Temperature) ratio. This means that for every degree the outdoor 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 outdoor air (OUT START), and 180°F water temperature (Boil DESIGN) at 10°F out- door air (OUT DESIGN). Each building has different heat loss characteristics. A very well insulated building will not lose much heat to the outside air, and may need a Reset Ratio of 2.00 (OD):1.00 (SYS) (Outdoor: Water). This means the outdoor temperature would have to drop 2 degrees to increase the water temperature 1 degree. On the other hand, a poorly insulated building may need a Reset Ratio of 1.00 (OD):2.00 (SYS). This means that for each degree the outdoor temperature dropped the water temperature will increase 2 degrees. The VERSA control Reset Ratio allows for full customiza- tion to match any buildings heat loss characteristics. A heating curve that relies not only on Outdoor temper- ature but also on the type of radiation will improve heat comfort. The user can fine tune these adjustments based on the specific building need. 42 Item Description Lookup Active Error Look up and display the active error info. USER TEST Select ON to start the function. The setting returns to default after the test is run. (See Page 47 for details.) MAX HEAT Select ON to start the function. The setting will time out to OFF after 24 hours or can be set to OFF again by the user. (See VERSA IC Manual for details.) P/N 104901 Software number of the Raypak VERSA DEFAULTS Resets to factory settings. Press UP and DOWN for 1 second to show CLR and load factory defaults to all settings. This will also clear all history. HISTORY lookup logged error Displayed when an error code is present. 1 indicates the most recent error code. Press UP and DOWN for 1 second to clear the error logs. RESET RATIO The control uses the four following settings to determine the reset ratio: Boiler Start (Boil START) The Boil START temperature is the theoretical boiler supply water temperature that the heating system requires when the outdoor air temperature equals the OUT START temperature setting. The Boil START is typically set to the desired building temperature. Outdoor Start (OUT START) The OUT START temperature is the outdoor air temperature at which the control provides the Boil START water temperature to the system. The OUT START is typically set to the desired building temperature. Outdoor Design (OUT DESIGN) The OUT DESIGN is the outdoor air temperature that is the typical coldest annual temperature where the building is located. Thistemperature is used when completing 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 OUT DESIGN temperature. Warm Weather Shut Down (WWSD) When the outdoor air temperature rises above the WWSD setting, the control turns on the WWSD segment in the display. When the control is in Warm Weather Shut Down, the Dem 1 segment is displayed if there is a heat demand. However, the control does not operate the boiler to satisfy this demand. The control continues to respond to DHW demands. Decreasing Outdoor Temperature Increasing Water TemperatureBoilSTART OUTDESIGN Boil DESIGN STARTOUT 43 Reset Ratio The controller uses the following four settings to cal- culate the Reset Ration (RR): For example, when using the default values, the RR is: RR = (70 - 10) / (180 - 70) = 0.55 Therefore, the RR is 0.55:1 (Outdoor:Water). RESET RATIO =(OUTDOOR START – OUTDOOR DESIGN) (BOILER DESIGN – BOILER START) Fig. 38: Reset Ratio WIRING DIAGRAM 44 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 vent. Air Purge (Domestic Hot Water Heaters) Purge all air from system before lighting heater. This can be normally accomplished by opening a down- stream valve. Venting System Inspection 1.Check all vent pipe connections and flue pipe ma- terial. 2.Make sure vent terminations are installed per code and are clear of all debris or blockage. For Your Safety This appliance has a direct spark igniter. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand. WARNING:If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell near the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS: •Do not try to light any appliance. •Do not touch any electrical switch; do not use any telephone in your building. •Immediately call your gas supplier from a neigh- bor’s telephone. Follow the gas supplier’s instructions. •If 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 repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion. •Do not use this appliance if any part has been under water, immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. •Check around unit for debris and remove com- bustible products, i.e. gasoline, etc. Pre Start-up Check 1.Verify the heater is filled with water. 2.Check system piping for leaks. If found, repair immediately. 3.Vent air from system. Air in system can interfere with water circulation. 4.Purge air from gas line to boiler. Initial Start-up Required tools •(1) 12-0-12 (24” scale) U-tube manometer •(2) 6-0-6 (12” scale) U-tube manometer •Screwdrivers (assorted sizes and shapes) •(1) Crescent wrench (8” or 10”) •(1) Multi-meter (Metric Allen wrenches will be required for servicing the gas valve, but not during start-up) NOTE:Digital manometers are not recommended. CAUTION:An air vent should be installed at the highest point in the system for proper operation. If water piping is located higher than the boiler, it should be relocated to the highest point in the installed system. NOTE:The wiring diagrams in this manual show all standard options. Refer to the large wiring diagram provided with your boiler for options installed on your specific unit(s). 45 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 shutoff valve. 2.On the 700A and 850A models, remove plugs “A” and “B,” and install 1/8” NPT fittings to allow meas- urement of the gas pressure. WARNING:If Common - Ground is > 1 VAC, STOP: Contact electrician to correct ground failure. Failure to do this may burn out 120V-24V transformer, or may cause other safety control damage or failure. Start-Up 1.Turn power on. 2.Turn on the boiler, approximately 10 seconds after the blower starts, the igniter should start to spark (observable through the observation port located at the front, bottom of the boiler) and the gas valve will open. Look into 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 with a standard three-try ignition module, it will try for ignition up to three times before going into lockout. If the boiler is equipped with the optional single-try ignition mod- ule, it will try for ignition one time before going into lockout. 5.Wait until the controller indicates 100% on the fir- ing rate display screen. This may take several minutes. (700A/850A) GAS TO BURNER B A TO BURNER (300A-500A) GAS A B Fig. 39: Gas Pressure Measurement Locations 3.Attach a 12” scale manometer to the upstream fit- ting on the gas supply pipe to the heater (Measure point “A” in Fig. 39, field-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. 39, field-supplied on the 700A and 850A). 5.Attach a 12” scale manometer between the Swirler box and Gas valve on the air hose tee. Pull the black cap to connect the manometer. Check Gas Supply Pressure 1.Slowly turn on main gas shut-off valve. 2.Read the gas supply pressure from the manome- ter; minimum supply pressure for natural gas is 4.0 in. WC, recommended supply is 7.0 in. WC, mini- mum supply pressure for propane gas is 4.0 in. WC, recommended supply is 11.0 in. WC (dynam- ic readings, full fire input). 3.If the gas pressure is greater than 14.0 in. WC, turn off the main gas shut-off valve. WARNING:Do not turn on gas at this time. NOTE:While attaching manometers, any cap or bleedle valves removed should be retained for reinstallation later. 46 Blower Check 1.Note the high fire air intake pressure on the swirler and compare to Table W. Excessively high pres- sures indicate an obstruction in the air intake or undersized/too long air intake ducting. With a clean air filter in place, record the intake air pres- sure setting on the start-up checklist. Replace the filter when the intake air pressure increases by –0.5 in. WC from the reading recorded on the start-up checklist. 2.The desired combustion CO2 is between 8.5% and 9.0% for natural gas, and between 9.5% and 10.0% for propane with CO less than 150 ppm. Combustion should be checked at high and low fire (Max. and Min. fan speed). Manifold Check 1.Check manifold gas pressure at the manifold pres- sure tap (connection “B” in Fig. 39). This pressure should read per the values in Table Y for natural and propane gas. 2.If the pressure reading differs by more than ± 0.3 in. WC, STOP – Call the factory for directions on what to do next! CAUTION:Special manifold and air settings may be required. Model Air Pressure Setting (in. WC) Setting Tolerance 300A -1.0 ± 0.2 in. WC 400A -2.0 ± 0.2 in. WC 500A -1.2 ± 0.2 in. WC 700A -1.0 ± 0.2 in. WC 850A -1.6 ± 0.2 in. WC Table W: XFyre Intake Air Pressure Settings (High Fire) Model High Fire Ignition 300A 5400 3000 400A 7750 3000 500A 8100 3000 700A 4600 3000 850A 5450 3000 Table X: XFyre Fan Speed Settings Table Y: XFyre Manifold Pressure Settings Model No. Manifold Pressure (in. WC) Natural Gas Propane Gas High Low High Low 300A -1.0 0.0 -1.2 0.0 400A -1.8 0.0 -1.1 0.0 500A -1.1 -0.1 -1.1 0.0 700A -1.4 0.0 -1.9 -0.1 850A -2.0 -0.1 -1.1 0.0 NOTE: Manifold pressures should be ±0.3 in. WC. 47 User Test Set DIP #1 on the VERSA IC control to “ON”. Set USER TEST = ON in the 'ToolBox' Menu to start the user test function. •USER TEST is displayed in the Title Field. •UP keystrokes are used to advance through the user test. •The Boil MIN/MAX steps for burner operation are only run for enabled boilers. •Local Heat/DHW/EMS demands must be present for burner operation. •On the first press of the Up button, the test step is held and "HOLD" is flashed at 1Hz. •On the second press of the Up button, the test step is incremented. •If boiler outlet temperature reaches the PIM Hi- Limit, the boiler will be ramped down to keep the temperature in a safe range. •Press of the Up button from Boiler Max will End the User Test function. Number Field Output Action SYS System Pump relay turns on. DHW DHW Pump relay turns on. PMP 1 System and Boiler Pump relays turn on. Boil 1 Ignite Boiler Burner. Min 1 Hold Boiler at Min Fire. Max 1 Ramp Boiler to Max Fire and hold. Table Z: User Test Fields Follow-Up Safety checks must be recorded as performed. Turn boiler on. After main burner ignition: 1.Check manometer for proper readings. Specifically note the change in air intake pressure. Replace the filter if necessary. (Refer to Table W.) 2.Cycle unit several times and re-check readings. 3.Remove all manometers and replace caps and screws. 4.Check for gas leaks. 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 system. 4.Verify that air has been purged from the gas pip- ing, and that the piping has been checked for leaks. 5.Confirm that the proper start-up procedures were followed. 6.Inspect burner to verify flame. 7.Test safety controls: If boiler is equipped with a low water cut-off or additional safety controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when con- trols are tested. When safety devices are restored, burners should re-ignite 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 required in each zone. 9.Check that the boiler is cycled with the thermostat. Raise the setting on the thermostat to the highest setting and verify that the boiler goes through the normal start-up cycle. Reduce to the lowest set- ting and verify that the boiler goes off. 10.Observe several operating cycles for proper oper- ation. 11.Set the boiler thermostat to desired temperature. 12.Review all instructions shipped with this boiler with owner or maintenance person, return to envelope and give to owner or place the instructions inside front panel on boiler. Finishing 1.Record all data on the “Start-up Checklist” located at the back of this manual. 2.Disconnect the manometers and reconnect the cap on the air intake and reinsert or close the seal- ing screws into the bleedle valves. 3.Start-up is complete and the boiler should be oper- ating properly. 48 Safety Inspection 1.Check all thermostats and high limit settings. 2.During the following safety checks leave manome- ters hooked up, check and record. 3.If other gas-fired appliances in the room are on the same gas main, check all pressures on the XFyre with all other equipment running. 4.Check thermostats for ON-OFF operation. 5.Check high limits for ON-OFF operation. 6.While in operation, check flow switch operation. 7.Check the low gas pressure switch (if provided). (For proper adjustment, use the attached manometers, if available, to set pressure. The scales on the switch are approximate only.) Low gas pressure switch (if provided) must be set at 3.0 in. WC for natural gas and propane gas. 8.Make sure that the high gas pressure switch (op- tional) is set to 3.0 in. WC for both natural gas and propane gas. TROUBLESHOOTING XFyre Error Codes If any of the sensors detect an abnormal condition or an internal component fails during the operation of the XFyre, the display may show an error code. This code may either be the result of a temporary condition in which case the display will revert to its normal readout when the condition is corrected, or it may be the result of a condition that the controller has evaluated as not safe to restart the unit. In this case, the unit control will be locked out, requiring the maintenance person to manually reset the control by pressing and releasing the RESET key. Heater Errors When an error condition occurs, the controller will dis- play an error code on the display module. These error codes and several suggested corrective actions are included in the XFyre Fault Text section on the follow- ing page. Heater Faults 1.When a fault condition occurs, the controller will flash a red light on the PIM and display the error code on the user interface. The alarm output will also be activated. Most fault conditions will also cause the boiler pump to run in an attempt to cool the unit. 2.Note the error code, either through the flash code on the PIM and/or from the Toolbox menu on the user interface, and reference the explanation of the fault along with troubleshooting steps in the XFyre fault text section. 3.Press and release the RESET key to clear the fault on the user interface and resume operation. Be sure to observe the operation of the unit for a period of time to ensure correct operation and no reoccurrence of fault code(s). 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 off all electrical power to the appliance. 4.This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. 5.Turn on main manual gas valve field-installed near gas inlet connection on back of boiler. 6.Wait 5 minutes to clear out any gas. Then smell for gas, especially near the floor. If you then smell gas, STOP! Follow the steps in the safety informa- tion on the front cover of this manual. If you do not smell gas, go to next step. 7.Turn on all electrical power to the appliance. 8.Set thermostat to desired setting. The appliance will operate. The igniter will spark after the pre- purge time delay (15 seconds). The main valve should open. System will try for ignition up to three times (one time on optional single-try ignition mod- ule). If flame is not sensed, lockout will commence. 9.If the appliance will not operate, follow the instruc- tions “To Turn Off Gas To Appliance,” and call your service technician or gas supplier. 10.If boiler fails to start, verify the following: a.There are no loose connections or that the service switch is off. b.High temperature limit switch or manual-reset high limit is not tripped. c.Thermostat is set above water temperature. d.Gas is on at the meter and the boiler. e.Incoming dynamic gas pressure to the gas valve is NOT less than 4.0 in. WC for natural gas or propane gas. 49 To Turn Off Gas To Appliance 1.Shut off manual gas valve field installed near gas inlet connection on back of boiler. 2.Set the thermostat to lowest setting. 3.Turn off all electrical power to the appliance if serv- ice is to be performed. CAUTION:If overheating occurs or the gas supply fails to shut off, do not turn off electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of boiler damage. Instead, shut off the gas supply to the boiler at the gas service valve. CAUTION: Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. See wiring diagram. WARNING:Do not use this appliance if any part has been under water. Improper or dangerous operation may result. Contact a qualified service technician to inspect the boiler and to repair or replace any part of the boiler that has been under water prior to placing the boiler back in operation. WARNING:When servicing or replacing any components of this unit be certain that: • The gas is off. • All electrical power is disconnected. XFyre Fault Text Error Display If there is an active error, then it is displayed as the first item in the Toolbox Menu and it is the default display for the control until the error is resolved. Table AA: Error Display Error 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. GAS PRESS Check PIM wiring. IGNITION Reset control, push and release RESET button LIMIT TRIP Boiler temperature tripped the high limit. FLAME False flame detected. Shut off gas supply, recycle power. ID CARD Identity card, check ID card and wiring. IGN CTRL Internal control fault. Reset power, replace control. DELTA T Temperature difference between the inlet and outlet exceeded the set point. Check water flow. LOW 24VAC Low 24 VAC power. Check power supply wiring and transformer. BLOW SPEED Blower speed out of range. Check blower wiring and blower. 50 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 power is off. LED Error Code Listing Active errors detected are indicated by LED lights on the PIM. Table AB: PIM LED Error Codes LED Code Error Mode Recommended Troubleshooting Off Normal Operation Red LED steady ON, Green Power LED OFF ID Card Fault Check that the proper ID card is securely connected. Perform a power and system restart. Steady ON Internal Control Failure Perform a power and system reset. If fault remains, replace PIM. 1 flash N/A N/A 2 flashes False Flame Error Check for proper gas valve closure. Clean burner and electrodes. 3 flashes Ignition Lockout Fault Check the gas supply. See table for more information. 4 flashes N/A N/A 5 flashes Low Voltage Fault Check the 24 VAC input voltage. The voltage must be above 18.0 VAC. 6 flashes N/A N/A 7 flashes Hi-Limit Fault Check for proper water flow. Check hi-limit and outlet sensor. 8 flashes Sensor Fault See VERSA for fault identification. Check sensor wiring. 9 flashes N/A N/A 10 flashes N/A N/A 11 flashes Blower Speed Fault Verify tachometer signal and connection on J5. 12 flashes N/A N/A 13 flashes Hi-Temperature Delta Fault Check pump operation. Confirm proper water flow across heat exchanger. 14 flashes Ft-Bus Communications Fault Verify VERSA is connected and operating. Check the cable between the VERSA and PIM. 15 flashes N/A N/A 51 3/16” NOTE: If receiving a NO FLAME, check the gap spacing between points on the electrode by holding two quarters together and sliding them through the gap. There should be no resistance. Fig. 40: 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 4372 122 3605 131 2989 140 2490 149 2084 158 1753 167 1481 176 1256 185 1070 194 915 203 786 212 667 Sensor Resistance Values Table AC: Sensor Resistance Values 52 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 other flammable vapors and liquids. 2.Check for and remove any obstruction to the flow of combustion or ventilation air to boiler. Monthly 1.Check for piping leaks around pumps, mixing valves, relief valves, and other fittings. If found, repair at once. DO NOT use petroleum-based stop-leak compounds. 2.Visually inspect burner flame. 3.Visually inspect venting system for proper func- tion, deterioration or leakage. 4.Visually inspect for proper operation of the con- densate drains in the venting, and the internal condensate trap. Clean trap as necessary. If leaks are observed, repair at once. 5.Check air vents for leakage. Yearly (Beginning Of Each Heating Season) Schedule annual service call by qualified service agency. 1.Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent is normal. 2.Visually inspect venting system for proper func- tion, deterioration or leakage. Ensure that condensate 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 materi- als, gasoline, and other flammable vapors and liquids. 4.Check for and remove any obstruction to the flow of combustion or ventilation air to boiler. 5.Follow pre-start-up check in the Start-up section. 6.Visually inspect burner flame. It should be light blue at full input. Remove and visually inspect direct spark igniter and sensor for damage, crack- ing or debris build-up. 7.Check operation of safety devices. Refer to manu- facturers’ instructions. 8.Follow oil-lubricating instructions on pump (if re- quired). Over-oiling will damage pump. Water-lubricated circulators do not need oiling. 9.To avoid potential of severe burn, DO NOT REST HANDS ON OR GRASP PIPES. Use a light touch; return piping will heat up quickly. 10.Check blower and blower motor. 11.Check for piping leaks around pumps, relief valves and other fittings. Repair, if found. DO NOT use petroleum-based stop-leak. Periodically 1.Check relief valve. Refer to manufacturer’s instructions on valve. 2.Test low water cut-off (if equipped). Refer to manu- facturer’s instructions. Preventive MaintenanceSchedule The following procedures are recommended and are good practice for all XFyre installations. Daily 1.Check gauges, monitors and indicators. 2.Check instrument and equipment settings. (See “Post Start-Up Check”.) 53 3.Check burner flame. (Should see light blue flame at full input rate). Weekly For 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). Monthly 1.Check flue, vent, stack, or dampers. 2.Test intake air pressure. (See Table W.) Replace the filter when the intake air pressure increases by –0.5 in. WC from the reading recorded on the start-up checklist. 3.Test high and low gas pressure interlocks (if equipped). (See “Safety Inspection”.) Semi-Annually 1.Recalibrate all indicating and recording gauges. 2.Check flame failure detection system components. 3.Check firing rate control by checking the manifold pressure. (See “Manifold Check”.) 4.Check piping and wiring of all interlocks and shut- off valves. Annually 1.Test flame failure detection system. 2.Test high limit and operating temperature. (See “Post Start-Up Check”.) 3.Check flame sensor. 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 valve coil for 60 cycle hum or buzz. Check for leaks at all valve fittings using a soapy water solution (while unit is operating). Test other oper- ating parts of all safety shut-off and control valves and increase or decrease settings (depending on the type of control) until the safety circuit opens. Reset to original setting after each device is test- ed. 6.Perform leakage test on gas valves, if required by local codes. 7.Inspect and clean burner using shop air. 8.Clean the combustion chamber coil, using the pro- cedure on the following page. As Required 1.Recondition or replace low water cut-off device (if equipped). 2.Check drip leg and gas strainers. 3.Check flame failure detection system. (See “Post Start-Up Check”.) Verify high and low fire flame signal, compare to start-up data. 4.Check igniter. Clean and verify spark gap (see Fig. 40). 5.Check fan speed and manifold pressure. (See “Blower Check” and “Manifold Check”.) 6.Test safety/safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV. 54 Combustion Chamber Coil CleaningInstructions 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 following steps: a. Close the gas valve, shut down the unit and wait for the unit to be cool to the touch. b. Disconnect the condensate piping from the out- side connection, (not from the XFyre boiler side), so the flow from condensate reservoir can be observed. c. Disconnect electrical connections from the gas valve, spark electrode and flame rectification probe and combustion blower. d. Remove the (4) screws on the aluminum ¾” NPT connector on the right side of the gas valve. e. Disconnect the wiring connected to the com- bustion blower motor. f.Remove the (6) 10mm nuts from the burner plate assembly. g.Remove the valve/blower/burner assembly from the heat exchanger. 2. Using a spray bottle filled with the recommended product “RYDLYME” or “CLR”, spray liberally on the coils, making sure the solution penetrates and fun- nels down through the condensate system. If the condensate system is blocked, let the chemical penetrate for at least 15 minutes or until it drains. 3. Use the nylon, stainless steel or brass brush (do not use steel) to scrub coils to remove any buildup, 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 cleaned (DO NOT get the back ceramic wall of the unit wet). Flush the combustion chamber with fresh water until clear water runs from the condensate drain. At this point, the XFyre should be ready to be re-assembled. a. Inspect gaskets. b. Re-install the burner assembly. WARNING: The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded that “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group1).”: • Avoid breathing dust and contact with skin and eyes. • Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website. • Wear long-sleeved, loose fitting clothing, gloves, and eye protection. • Apply enough water to the combustion chamber lining to prevent dust. • Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly. NIOSH stated First Aid: Eye: Irrigate immediately Breathing: Fresh air. 55 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 construction •remodeling areas •open pit skimmers Check for areas and products listed above before in- stalling heater. If found: •remove products permanently, OR •install TruSeal direct vent. APPENDIX Inside Air Contamination Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high effi- ciency systems. The boiler can be supplied with corrosion-resistant, non-metallic intake air vent materi- al. You 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 reduce infiltration into your building through openings around windows and doors. 3.You are using AL29-4C stainless steel vent pipe, which is more corrosion-resistant than standard metallic vent pipe. In extremely contaminated ar- eas, this may also experience deterioration. Products causing contaminated combustion air: •spray cans containing chloro/fluorocarbons •permanent wave solutions •chlorinated waxes/cleaners •chlorine-based swimming pool chemicals •calcium chloride used for thawing •sodium chloride used for water softening •refrigerant leaks •paint or varnish removers •hydrochloric acid/muriatic acid •cements and glues •antistatic fabric softeners used in clothes dryers •chloride-type bleaches, detergents, and cleaning solvents found in household laundry rooms •adhesives used to fasten building products •similar products 56 (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 57 LIMITED PARTS WARRANTY XFYRE – TYPE H and WH MODELS 300A-850A RAYPAK, INC • 2151 Eastman Avenue • Oxnard, CA 93030-9786 • (805) 278-5300 • Fax (800) 872-9725 • www.raypak.com SCOPERaypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility. HEAT EXCHANGER WARRANTY Space Heating (Closed Loop System)Ten (10) year limited warranty from date of heater installation. This warranty applies only to boilers utilized in closed loop heating systems and hot water supply boilers that have been properly installed based upon manufacturer’s installation instructions. Year of Claim 0-5 6 7 8 9Percentage to be paid by purchaser 0 % 20% 40% 60% 80% Thermal Shock WarrantyTwenty (20) years from date of heater installation against “Thermal Shock” (excluded, however, if caused by heater operation at large changes exceeding 150°F between the water temperature at intake and heater temperature, or operating at heater temperatures exceeding 215°F). ANY OTHER PART MANUFACTURED BY RAYPAK One (1) year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records, whichever comes first. SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED. ADDITIONAL WARRANTY EXCLUSIONSThis warranty does not cover failures or malfunctions resulting from: 1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided; 2. Abuse, alteration, accident, fire, flood and the like; 3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation; 4. High velocity flow exceeding heater design rates; 5. Failure of connected system devices, such as pump or controller; 6. Use of non-factory authorized accessories or other components in conjunction with the heater system; 7. Failing to eliminate air from, or replenish water in, the connected water system; 8. Chemical contamination of combustion air or use of chemical additives to water. PARTS REPLACEMENTUnder this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer. TO MAKE WARRANTY CLAIMPromptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be received from Raypak before replacement of any part. EXCLUSIVE WARRANTY - LIMITATION OF LIABILITYThis is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not apply to you. This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective date of the warranty (date of installation) must be presented; otherwise, the effective date will be based on the date of manufacture plus thirty (30) days. Original Owner Model Number Serial Number Mailing Address Date of Installation City State Zip Code Installation Site Daytime Telephone Number Contractor/Installer 58 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 will be used to record all equipment operation functions and required settings. GAS SUPPLY DATA CLEARANCES Regulator Model & Size _________ / ______CFH Front Clearance _______________In. Gas Line Size (in room) ________________In. NPT Right Side Clearance _______________In. Length of Gas Line ________________Eq Ft Left Side Clearance _______________In. Low Gas Pressure Setting ________________In. WC Rear Clearance _______________In. High Gas Pressure Setting ________________In. WC Overhead Clearance _______________In. Gas Shut-Off Valve Type ________________ ( Ball, Lube cock) ELECTRICAL Sediment Trap ________________Y/N Voltage Supply (VAC) No Load______ Load_____ Port _______Std______Full Voltage -24 VAC _______________VAC Voltage Com to Ground _______________VAC VISUAL INSPECTION OF COMPONENTS Verify inspection was done and condition of components are in good working order with a “yes” Auto High Limit Setting Manual Reset High Limit Setting _______________deg F _______________deg F Wiring Harness _________________ Y/N Operating Control Setting _______________deg F Burner/s (flame) _________________ Y/N Refractory (visual) _________________ Y/N Sketch plumbing on reverse side Remote flame sense _________________ Y/N WATER SUPPLY Covers in place for outdoor _________________ Y/N Flow Rate in GPM or Delta T _______________If Avail Measure flow rate at full fire VENTING Pump Off Delay setting _______________Minutes Vent Size: _____________ Stack Height:_______ Low Water Cutoff _______________Test Category: _________ sketch vent on reverse side *** Number of Tanks and Size Qty____ _______Gallons Vent Material: __________________ Plumbing Size _______________ Vent Termination Type: __________________ Pump Size: _________ (boiler) Pump HP: ______ Combustion Air Openings: Low __________ in2 Impeller trim____________ Pump Model___________ Ventilation air High __________ in2 Louvers __________________ Screens________________ EMISSIONS SETTINGS AND TEST INFORMATION Nominal Factory Recommended Settings Air Intake Pressure _________________In. WC See manual or card tag Supply Gas Pressure Verify stable pressure static & _________________In. WC dynamic condition See manual or card tag Manifold Gas Pressure _________________In. WC See manual or card tag The following measurements must be obtained with a Combustion Analyzer. NOX _________________PPM Less than 20 PPM (If required by Certifying Agency) CO _________________PPM Less than 150 PPM CO2 _________________% See manual Model Number: ______________________________ Serial Number: _______________________________ *** Note: draw venting with details, such as extractors, barometric dampers, blast dampers or draft inducers Site Altitude Above Sea Level __________________Ft. Job Name _______________________________________________________________________________________ Address _________________________________________________________________________________________ Physical Location of Boiler: Indoors______; Outdoors______; Ground Level______; Roof______; Below Grade______ Mechanical Contractor / Installer _______________________________________________________________________ Date and Time of Start-up _____________Print Name and Signature of Start-up Technician_________________________ Information must be faxed to: (805) 278-5471 in order to ensure warranty consideration Attn: Service Manager High Low N/A 59 60 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.