Raypak XFYRE 500 Guide

USER’S INFORMATION MANUAL
CATALO NO. 1000.651 Effective: 05-21-09 Replaces: NEW P/N 241369 Rev. C
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light ny ppli nce.
• Do not touch ny electric l switch; do
not use ny phone in your building.
• Immedi tely c ll your g s supplier
from neighbor's phone. Follow the
g s supplier's instructions.
• If you c nnot re ch your g s supplier,
c ll the fire dep rtment.
Do not store or use g soline or other fl mm ble
v pors nd liquids or other combustible
m teri ls in the vicinity of this or ny other
ppli nce. To do so m y result in n explosion
or fire.
Inst ll tion nd service must be performed by
qu lified inst ller, service gency or the g s
supplier.
WARNING: If the inform tion in this m nu l is
not followed ex ctly, fire or explosion m y
result c using property d m ge, person l
injury or loss of life.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAZ:
• Ne p s tenter d’ llumer d’ pp reils.
• Ne touchez à ucun interrupteur. Ne p s
vous servir des téléphones d nsle bâtiment
où vous vous trouvez.
• Appelez immédi tement votre fournisseur
de g z depuis un voisin. Suivez les
instructions du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur
de g z, ppelez le sservice des incendies.
Ne p s entreposer ni utiliser d’essence ni
d’ utres v peurs ou liquides infl mm bles d ns
le voisin ge de cet pp reil ou de tout utre
pp reil.
L’inst ll tion et l’entretien doivent être ssurés
p r un inst ll teur ou un service d’entretien
qu lifié ou p r le fournisseur de g z.
AVERTISSEMENT: Assurez-vous de bien
suivres les instructions données d ns cette
notice pour réduire u minimum le risque
d’incendie ou d’explosion ou pour éviter tout
domm ge m tériel, toute blessure ou l mort.
Models 300, 500 & 850
Type H

2
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.
DANGER: Make sure the gas on which the boiler
will operate is the same type as that specified on the
boiler rating plate.
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 heater.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
CAUTION: This boiler requires forced water
circulation when the burner is operating. Severe
damage will occur if the boiler is operated without
proper water flow circulation.
CAUTION: If this boiler is to be installed above
radiation level, it must be provided with a low water
cut-off device at the time of boiler installation.
CAUTION: If this boiler is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
WARNINGS
Pay Attention to These Terms
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.
WARNING: Should overheating occur or the gas
supply fail to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead, shut off
the gas supply at a location external to the
appliance.
AVERTISSEMENT: En cas de surchauffe ou si
l’admission de gaz ne peut être coupée, ne pas
couper ni débrancher l’alimentation électrique de la
pompe. Fermer plutôt le robinet d’admission de gaz
à l’extérieur de l’appareil.
NOTE: This manual should be maintained in legible
condition and kept adjacent to the boiler or in
another safe place for future reference.

3

4
A. Cet appareil ne comporte pas de veilleuse. Il est
muni d’un dispositif d'allumage qui allume automa-
tique-ment le brûleur. Ne tentez pas d’allumer le
brûleur manuellement.
B. AVANT DE FAIRE FONCTIONNER, reniflez tout
autour de l'appareil pour déceler une odeur de
gaz. Reniflez près du plancher, car certains gaz
sont plus lourds que l'air et peuvent s'accumuler
au niveau du sol.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAZ:
- Ne pas tenter d'allumer d'appareil.
-Ne touchez à aucun interrupteur; ne pas
vous servir des téléphones se trouvant dans
le bâtiment.
- Appelez immédiatement votre fournisseur de gaz
depuis un voisin. Suivez les instructions du four-
nisseur.
- Si vous ne pouvez rejoindre le fournisseur,
appelez le service des incendies.
C. Ne poussez ou tournez la manette d'admission du
gaz qu'à la main; ne jamais utiliser d'outil. Si la
manette reste coincée, ne pas tente de la réparer;
appelez un technicien qualifié. Le fait de forcer la
manette ou de la réparer peut déclencher une
explosion ou un in-cendie.
D. N'utilisez pas cet appareil s'il a été plongé dans
l'eau, même partiellement. Faites inspecter l'ap-
pareil par un technicien qualifié et remplacez toute
partie du sys-tème de contrôle et toute commande
qui ont été plongés dans l'eau.
AVERTISSEMENT: Quiconque ne respecte pas à
la lettre les instructions dans la présente notice
risque de déclencher un incendie ou une explosion
entraî-nant des dommages, des blessures ou la
mort.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE
INSTRUCTIONS DE MISE EN MARCHE
1. ARRÊTEZ! Lisez les instructions de sécurité sur la
portion supérieure de cette étiquette.
2. Réglez le thermostat à la température la plus
basse.
3. Coupez l'alimentation électrique de l'appareil.
4. Cet appareil ne comporte pas de veilleuse. Il est
muni d’un dispositif d'allumage qui allume automa-
tique-ment le brûleur. Ne tentez pas d’allumer le
brûleur manuellement
5. Enlever le panneau de porte du réchauffeur.
6. Enfoncer légèrement le bouton de commande de
gaz et le tourner dans le sens horaire a la position
(Off).
7. Attendre cinq (5) minutes pour laisser échapper
tout le gaz. Reniflez tout autour de l’appareil, y
compris près du plancher, pour déceler une odeur
de gaz. Si vous sentez une odeur de gaz,
ARRÊTEZ! Pas-sez à l’étape B des instructions
de sécurité sur la portion supérieure de cette éti-
quette. S'il n'y a pas d’odeur de gaz, passer à
l'étape suivante.
8. Tourner le bouton de commande de gaz dans le
sens antihoraire à la position (ON).
9. Reposer le panneau de porte du réchauffeur.
10. Rétablir toutes les alimentations électriques de
l'appa-reil.
11. Réglez le thermostat à la température désirée.
12. Si l'appareil ne se met pas en marche, suivre les
ins-tructions intitulées "Comment couper l’admis-
sion de gaz de l’appareil” et appelez un technicien
qualifie ou le fournisseur de gaz.
COMMENT COUPER L’ADMISSION DE GAZ DE L’APPAREIL
1. Réglez le thermostat à la température la plus
basse.
2. Coupez l'alimentation électrique de l'appareil s'il
faut procéder à l'entretien.
3. Enlever le panneau de porte du chauffe-eau.
4. Tourner le bouton de commande de gaz dans le
sens horaire à la position (OFF). S'assurer que le
bouton reste contre l'arrêt.
5. Replacer le panneau de porte du chauffe-eau.

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Component Locations
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.
Fig. 1: Component Loc tions — Sides
Fig. 2: Component Loc tions — Top
Fig. 3: Component Loc tions — Re r
Model 300 shown. Component locations may vary slightly in larger models.

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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 RASP 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 Maintenance
Schedule
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” in the I&O Manual.)
3. Check burner flame. (Should see light blue flame
at full input rate).
Weekly
For low-pressure heaters, test low-water cut-off
device. (With heater 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).
Daily
1. Check that the area where the heater 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 heater.
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.
early (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 heater.
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

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Monthly
1. Check flue, vent, stack, or outlet dampers.
2. Test intake air pressure. (See Table Q in the I&O
Manual.) Replace the filter when the intake air
pressure increases by –0.5 in. WC from the read-
ing recorded on the start-up checklist.
3. Test high and low gas pressure interlocks (if
equipped). (See “Safety Inspection” in the I&O
Manual.)
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” in the I&O
Manual.)
4. Check piping and wiring of all interlocks and shut-
off valves.
Annually
1. Test flame failure detection system and pilot turn-
down.
2. Test high limit and operating temperature. (See
“Post Start-Up Check” in the I&O Manual.)
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 9.0 to 9.5% for propane
gas. Carbon monoxide should be <150 ppm.
5. Check valve coil for 60 cycle hum or buzz. Check
for leaks at all valve fittings using a soapy water
solution (while heater is operating). Test other
operating 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 tested.
6. Perform leakage test on gas valves.
7. Test air switch in accordance with manufacturer’s
instructions. (Turn panel switch to the “On” posi-
tion until blower is proven, then turn the switch to
“Off.”
8. Inspect and clean burner using shop air.
9. Combustion Chamber Coil Cleaning Instructions:
Before beginning this procedure, you must have
on hand the following items:
– a nylon, stainless steel or brass brush (not steel)
– “Rydlyme” (recommended for best results) or
“CLR”
– loves, eye protection
1. Shut down the XFyre Boiler by using the follow-
ing 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 combus-
tion blower motor.
f. Remove the (6) 10MM nuts from the burner plate
assembly .
g. Pull the entire burner plate assembly with blow-
er still attached towards you, while removing or
pushing aside any wiring to allow the removal of
the assembly.
2. Using a spray bottle filled with the recommend-
ed product “RYDLYME” or “CLR”, spray liberally
on the coils, making sure the solution penetrates
and funnels down through the condensate system.
If the condensate system is blocked, let the chem-
ical penetrate for at least 15 minutes or until it
drains.
3. Use the nylon, stainless steel or brass brush (do
not use steel) and scrub coils to remove any
buildup, then vacuum the debris from the coils.
WARNIN : Follow precautions above
4. Spray the coils with clear water, making sure to
confine the spray to the area being cleaned (Try to
avoid getting 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

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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” in the I&O Manual.) Verify high
and low fire flame signal, compare to start-up data,
4. Check igniter. Clean and verify spark gap (see Fig.
36 in the I&O Manual) .
5. Check fan speed and manifold pressure. (See
“Blower Check” and “Manifold Check” in the I&O
Manual.)
6. Test safety/safety relief valves in accordance with
ASME Heater and Pressure Vessel Code Section
IV.