Raypak XFyre 300A Installation & Operating Instructions Manual

Relief Valve Installation and PipingThe heater is supplied with a Section IV “HV” stampedrelief valve sized for the full input of the unit. The reliefvalve assembly is shipped loose and must be mount-ed directly to the heater outlet. No valve shall beinstalled between the heater and the relief valve. Therelief valve shall be mounted with its spindle vertical(see Fig. 1, 2 and 3 on page 6). Relief valve dischargepiping shall provide no less than the cross sectionalarea of the relief valve outlet and must be routed to asafe point of discharge. Installation must comply withall national, state and local codes.Temperature & Pressure GaugeThe temperature and pressure gauge is shipped loosefor field installation and must be installed within 12inches of the boiler outlet (if possible) in an easilyreadable location. Installation must comply with ASMESection IV as well as all applicable national, state andlocal codes.Hydrostatic TestUnlike many types of heaters, this heater does not re-quire hydrostatic testing prior to being placed inoperation. The heat exchanger is ASME certified for160 psi maximum working pressure. However, Raypakdoes recommend hydrostatic testing of the piping con-13nections to the heater and the rest of the system priorto operation. This is particularly true for hydronic sys-tems using expensive glycol-based anti-freeze.Raypak recommends conducting the hydrostatic testbefore connecting gas piping or electrical supply.Leaks must be repaired at once to prevent damage tothe heater. NEVER use petroleum-based stop-leakcompounds.To perform hydrostatic test:1. Connect fill water supply. With bleed valve open,fill heater with water. When water flows from bleedvalve, shut off water. Close bleed valve. Carefullyfill the rest of the system, making sure to eliminateany entrapped air by using high-point vents. Closefeed valve. Test at standard operating pressure forat least 24 hours.2. Make sure constant gauge pressure has beenmaintained throughout test.3. Check for leaks. Repair if found.Hydronic HeatingPump SelectionIn order to ensure proper performance of your heatersystem, you must install a correctly-sized pump. Ray-pak recommends designing for a ∆T within the rangeof 15°F to 35°F (8°C to 19°C). See Table G for accept-able flow rates for each model (∆T is the temperaturedifference between the inlet and outlet water when theheater is firing at full rate).Feedwater RegulatorRaypak recommends that a feedwater regulator be in-stalled and set at 12 psi minimum pressure at thehighest point of the system. Install a check valve orback flow device upstream of the regulator, with amanual shut-off valve as required by local codes.PipingAll high points should be vented. A heater installedabove radiation level must be provided with a low wa-ter cut-off device (sales order option F-10). Thisheater, when used in connection with a refrigerationsystem, must be installed so that the chilled medium ispiped in parallel with the heater with appropriatevalves to prevent the chilled medium from entering theheater.WARNING: Pressure relief valve discharge pipingmust be piped near the floor and close to a drain toeliminate the potential of severe burns. Do not pipeto any area where freezing could occur. Refer tolocal codes.CAUTION: This boiler requires forced watercirculation when the burner is operating. See TableG and Table H for minimum and maximum flow ratesand water pump selection. The pump must beinterlocked with the boiler to prevent heateroperation without water circulation.NOTE: Minimum pipe size for in/out connections is1-1/2” NPT for model 300A and 2” NPT for models400A, 500A, 700A and 850A. Verify proper flow ratesand ∆T as instructed in this manual.WARNING: The pressure relief valve must beinstalled at the outlet of the boiler. No valve ispermitted to be installed between the boiler and therelief valve.NOTE: The continuous inlet water temperaturemust be no less than 50°F.