Raypak 300, 850 operating instructions Venting, Cascade Follower Pump and Sensor Wiring, General

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Cascade Follower Pump

Cascade Follower Pump

and Sensor Wiring

1.Connect the boiler pump to the terminals marked

BOILER PUMP NEUT (#6), BOILER PUMP HOT (#5), and GROUND (#4) at the rear terminal strip.

2.If you are using an indirect fired water tank con- nected directly to the follower boiler, connect the pump for it to the terminals marked DHW PUMP NEUT (#8), DHW PUMP HOT (#7), and GROUND (#3) at the rear terminal strip.

If you desire, an alarm bell or light can be connected to the alarm contacts of the follower boiler. Optionally, the normally-closed alarm contact may be used to turn a device off if the boiler goes into lockout mode. The alarm contacts are rated 5 amps at 120 VAC.

To connect an alarm device, connect the power for the device to the ALARM COM terminal. Connect the alarm device hot wire to the ALARM NO terminal. Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device.

To connect a device that should be powered off during a boiler lockout condition, follow the same instructions as above except use the ALARM NC terminal rather than the ALARM NO terminal.

Note that in a cascade system the alarm output of the boiler addressed as #1 will also be active if the master boiler has a lockout condition. The alarm output of boil- ers addressed as 2–7 will only sound if a lockout condition occurs on that specific boiler.

CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the boiler.

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 K for appliance category requirements. 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: Condensate drains for the vent piping are required for installations of the XFyre. Follow vent manufacturer instructions for installation and location of condensate drains in the vent. Condensate drain traps must be primed with water to prevent gas flue leak and must be routed to an appropriate container for neutralization before dis- posal, as required by local codes.

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.

CAUTION: Raypak recommends the use of a con- densate neutralizer, sales order option Z-12.

Use only approved PVC or CPVC vent materials (in Canada, ULC-S636 approved plastic materials must be used) or special gas vent pipes listed for use with Category IV gas burning heaters, such as the AL29-4C stainless steel vents offered by Heat Fab Inc. (800- 772-0739), Protech System, Inc. (800-766-3473), Z-Flex (800-654-5600) or American Metal Products (800-423-4270). Pipe joints must be positively sealed. Follow the vent manufacturer’s installation instructions carefully. Vent installations 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.

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Contents Models 300, 500 & Types H & W WHAT TO DO IF YOU SMELL GASDo not try to light any appliance INSTALLATION & OPERATING INSTRUCTIONSPage WIRING DIAGRAM START-UP CONTENTSBEFORE INSTALLATION GENERAL SAFETY INSTALLATIONPay Attention to These Terms WARNINGSModel Identification BEFORE INSTALLATIONInstallations at Elevation Product ReceiptGeneral Information Component LocationsTime/Temperature Relationships in Scalds GENERAL SAFETYOutdoor Installations INSTALLATIONInstallation Codes Indoor InstallationsIndoor Units Combustion and Ventilation AirTable F Vent/Air Inlet Termination Clearances U.S. Installations1Canadian Installations2 Direct Vent U.S. InstallationsConventional Combustion Air Supply Combustion Air FilterGeneral Canadian InstallationsWater Piping Hydrostatic Test Relief Valve Installation and PipingHydronic Heating Temperature & Pressure GaugeDomestic Hot Water Air-Separation/ExpansionTankThree-WayValves Potable Water and Space Heating Gas Supply Pressure Gas Supply ConnectionGas Supply Electrical Power Connections Field-ConnectedControllers Check the Power SourceMaking the Electrical Connections Wiring the Thermostat Field Wiring ConnectionsWiring the Cascade System Communication Bus Wiring the Outdoor SensorWiring the Indirect Sensor 3.Create a hole to route the communication cables through where the dimples are in the side of the cabinet see Fig. 15, or route the wires to the rear junction box and out of the cabinet Cascade Master Pump and Sensor Wiring General Cascade Follower Pump and Sensor WiringVenting Combustion Support of Vent StackVent Terminal Location ConfigurationVertical Venting Category Venting Installation TipsVenting Configurations Combustion Vent Size Volume ofCommon Venting Model NoFig. 22 Horizontal Through-the-WallVenting Horizontal Through-the-WallDirectVenting Category Fig. 21 Typical Common VentingApproved Intakes InstallationTermination Model NoDirect Vent-Vertical Freeze Protection Outdoor InstallationIgnition Control Functions High Limit - Manual ResetHigh Limit - Auto Reset Optional ControlsLow Water Cut-OffOptional Flow SwitchHigh & Low Gas Pressure Switches Optional Blocked Vent SwitchUser Menu Adjusting the XFyre SetpointOperating Instructions Blocked Condensate Drain SensorStatus Menu Service ModeStatus Menu 1 Items Status Menu 2 Items Installer Menu Items continued Installer Menu WIRING DIAGRAM Pre Start-upCheck For Your SafetySTART-UP Pre Start-upBlower Check PreparationStart-Up Follow-Up Safety InspectionManifold Check FinishingPost Start-UpCheck OPERATIONLighting Instructions Heater Faults TROUBLESHOOTINGXFyre Error Codes Heater ErrorsXFyre Fault Text FLUE / GAS PRESS F01 RemedyOutdoor Sensor Resistance ValuesTemperature Sensors Resistance ohmsDaily MAINTENANCESuggested Minimum Maintenance Schedule Preventive Maintenance ScheduleAs Required WeeklySemi-Annually AnnuallyNIOSH stated First Aid Combustion Chamber Coil Cleaning InstructionsInside Air Contamination APPENDIX248 CMR 5.082a1 through SCOPE LIMITED PARTS WARRANTY XFYRE - TYPE H and WHEAT EXCHANGER WARRANTY MODELSGAS SUPPLY DATA START-UPCHECKLIST FOR THE XFYREEMISSIONS SETTINGS AND TEST INFORMATION Nominal Factory Recommended Settings
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300, 850 specifications

Raypak is a renowned name in the heating industry, particularly known for its high-quality pool and spa heaters. Among their extensive product line, the Raypak 850, 500, 300, 400, and 700 models stand out for their reliability, efficiency, and cutting-edge technologies. Each model is designed to cater to different needs and applications while maintaining Raypak’s commitment to performance.

The Raypak 850 is designed for larger commercial pools or residential setups requiring high output. With a powerful heat exchanger made from copper and bronze, it ensures superior heat transfer and longevity. Its digital control system provides precise temperature regulation, enhancing user experience. Moreover, it features a durable construction with weather-resistant materials, ensuring lasting performance in various environments.

The Raypak 500 model offers a balance between efficiency and compactness. It features eco-friendly technology that reduces energy consumption without sacrificing performance. The integrated thermostat allows users to maintain consistent water temperatures, making it ideal for residential pools. This model is well-regarded for its user-friendly digital display, simplifying operation and monitoring.

For those needing a more moderate capacity, the Raypak 300 is an efficient choice. It combines robust engineering with an easy-to-use interface. Its advanced ignition system improves reliability while minimizing energy waste. The Raypak 300’s compact design allows for easy installation in various spaces, making it an excellent option for smaller pools.

The Raypak 400 heats water quickly and efficiently, making it suitable for both residential pools and spas. It features a high-capacity heating system that ensures optimal performance. With a clear LED display, users can easily monitor their settings, while the integrated diagnostics provide real-time feedback for maintenance and troubleshooting.

Lastly, the Raypak 700 model is known for its versatility and robust performance. It is equipped with advanced safety features, including a high limit switch and water flow detection mechanism, to ensure safe operation. The model's energy-efficient design enhances its eco-friendliness, making it a popular choice among environmentally conscious users.

Collectively, these Raypak models exemplify superior engineering, performance, and user-friendliness. Their innovative features ensure that they meet the varied demands of pool owners while providing reliable heating solutions for leisure and relaxation. Whether for commercial or residential use, the Raypak 850, 500, 300, 400, and 700 offer unmatched quality and efficiency.
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