Raypak XFyre 400A User Manual

INSTALLATION & OPERATING
INSTRUCTIONS
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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.
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Models 300A–850A
Types H & WH

Raypak XFyre 400A Specifications

General

Input BTU	400, 000 BTU/hr
Efficiency	95%
Water Connection Size	2" NPT
Voltage	120V
Fuel Type	Natural Gas

Summary

WARNINGS

Safety Alert Definitions

Defines DANGER, WARNING, CAUTION, and NOTE terms used in the manual.

GENERAL SAFETY

Scald Prevention and Water Temperature

Details risks of scalding and recommended water temperatures.

INSTALLATION

Installation Codes and Base Requirements

Lists codes and requirements for installing the heater base.

Clearances

Combustion and Ventilation Air

Conventional Combustion Air Supply

Piping, Relief Valve, and Hydrostatic Test

Hydronic Heating and Feedwater Regulator

Applications & Modes

Mode 1 and Mode 2 Configuration

Mode 3 and WH Direct DHW Configuration

Potable Water & Space Heating and Gas Supply

Gas Supply Connection and Pressure

Electrical Power Connections

Power Source and Electrical Connections

Field Wiring and Thermostat Wiring

Cascade System Communication Bus Wiring

Cascade System Wiring

Alarm Connection and Venting

Venting Installation and Configuration

Vertical Venting (Category IV)

Vent Termination Requirements

U.S. Installations

Rules for vent termination location and clearances in U.S.

Installations in Canada

Vertical Venting (Category IV)

Vent Termination and Common Venting

Horizontal Vent Installation and Termination

Direct Vent-Vertical Installation and Termination

Condensate Management

Outdoor Installation Precautions

Freeze Protection and Controls Warning

Ignition Control Functions

High Limit Controls

Manual Reset High Limit

Auto Reset High Limit (Optional)

Safety Switches

Flow Switch and Low Water Cut-Off

Flue Temperature Limit and Gas Pressure Switches

Safety Switches (Continued)

Blocked Vent and Condensate Float Switches

Operating Instructions

WIRING DIAGRAM

START-UP Procedures

Pre Start-up Checks

Safety Information

Preparation and Power Checks

Gas Pressure Measurement and Start-Up

Blower and Manifold Checks

Safety Inspection and Post Start-Up Checks

OPERATION

Lighting Instructions

Step-by-step guide for safely lighting the appliance.

Shutting Off Gas Supply

Procedure for safely shutting off the gas supply to the appliance.

TROUBLESHOOTING

XFyre Error Codes and Heater Errors

Understanding error codes and how heater errors are displayed.

Heater Faults

Steps to take when a fault condition occurs on the unit.

XFyre Fault Text

LED Error Code Listing

MAINTENANCE Schedule

Suggested Minimum Maintenance

Recommended maintenance tasks and frequency for optimal efficiency.

Daily, Monthly, and Yearly Checks

Weekly, Monthly, Semi-Annual, and Annual Maintenance

Combustion Chamber Coil Cleaning Instructions

APPENDIX

Inside Air Contamination

Massachusetts Installation Requirements

LIMITED PARTS WARRANTY

START-UP CHECKLIST FOR THE XFYRE