X-FIRE 300A–850A Installation & Operating Instructions Manual

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

INSTALLATION & OPERATING

Models

300A–850A

Types H & WH

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.

Catalog No. 1000.65.2C

INSTRUCTIONS

Effective: 06-15-15

Replaces: 08-02-13

P/N 241480 Rev. 4

Table of Contents

Need help?

Do you have a question about the 300A–850A and is the answer not in the manual?

Questions and answers

Summary of Contents for X-FIRE 300A–850A

Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 300A–850A Types H & WH 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.
Page 2 Rev. 4 reflects the following: Changes to: pages 5, 13, 14, 15, 16, 17, 22, 23, 24, 25, 26, 27, 29, 30, 33, 35, 37, 39, 40, 41, 42, 44, 45, 52 and 53. Additions: “Flushing/Cleaning of System Piping” and “Cold Water Operation” sections added, starting on page 13. Deletions: None...
Page 3: Table Of Contents
CONTENTS WARNINGS Operating Instructions WIRING DIAGRAM Pay Attention to These Terms BEFORE INSTALLATION START-UP Product Receipt Pre Start-up Model Identification Pre Start-up Check Ratings and Certifications Initial Start-up Installations at Elevation Preparation Component Locations Start-Up OPERATION General Information GENERAL SAFETY Lighting Instructions Time/Temperature Relationships To Turn Off Gas to Appliance...
Page 4: Warnings
WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored.
Page 5: Before Installation
BEFORE INSTALLATION 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 Raypak strongly recommends that this manual be re- characters identifies the application (H = Hydronic viewed thoroughly before installing your XFyre heater.
Page 6: Component Locations
Component Locations Model 850 shown. Component locations may vary slightly in smaller models. Fig. 1: Component Locations — Sides CONTROL/SENSOR WIRING Fig. 2: Component Locations — Top Fig. 3: Component Locations — Rear General Information MBTUH Gas conn. Vent Size Water Model Input...
Page 7: General Safety
Heater Water Volume Model No. (gallons) 300A 400A 500A 700A 850A Table B: Heater Water Volume GENERAL SAFETY To meet commercial hot water use needs, the high Water temperature over 125°F can limit safety control on this water heater will shut off the cause instant severe burns or death main gas valve before the outlet temperature reaches from scalds.
Page 8: Installation
INSTALLATION If the heater needs to be secured to the ground, use the holes in the anchoring legs on the heater. NOTE: The following instructions are intended for Clearances simple applications. more detailed configurations and set-up, consult the VERSA IC Control I&O Manual (Catalog #5000.72).
Page 9: Combustion And Ventilation Air
Combustion and Ventilation Air TOP VIEW 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.
Page 10 Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening;...
Page 11: Conventional Combustion Air Supply
Combustion Air Filter TruSeal option in place, the unit meets Direct Vent requirements. TruSeal is generally used when damag- ing contaminants are present in the mechanical room. This heater is supplied with an integral combustion air All ducting must be self-supported. filter.
Page 12: Water Piping
outdoors or spaces (crawl or attic) that freely com- opening(s) having a cross section area of not less municate with the outdoors. than 1 in. per 7,000 BTUH (320 mm per kW) up to and including 1 million BTUH, plus 1 in. a.
Page 13: Cold Water Operation
nections to the heater and the rest of the system prior NOTE: Minimum pipe size for in/out connections is to operation. This is particularly true for hydronic sys- 1-1/2 NPT for model 300A and 2 NPT for models tems using expensive glycol-based anti-freeze. 400A, 500A, 700A and 850A.
Page 14: Hydronic Heating
Hydronic Heating The following applications are approved configurations supported by Raypak for CWP systems. Pump Selection CAUTION: Damage due to internal condensation may occur if the heater inlet water temperature does In order to ensure proper performance of your heater not exceed 50ºF (10ºC) within 7 minutes of startup.
Page 15 may be exposed to circulating refrigerated air, must be CAUTION: Be careful when installing the drywell equipped with flow control valves or other automatic not to over-tighten the well as this can damage the means to prevent gravity circulation of the heater well and may prevent the sensor from fitting water during the cooling cycle.
Page 16 Maximum distance not to exceed 4 pipe diameters or 12” whichever is less MASTER Fig. 8: MODE 1 - Hydronic Multi-Boiler Fig. 10: MODE 2 - Single Boiler with Indirect Fig. 9: MODE 1 - Hydronic Multi-Boiler on System Loop Type H models of XFyre have three modes available enabled for heating and the outdoor air temperature is to them to address the various applications the units lower than the warm weather shut down (WWSD) tem-...
Page 17 Maximum distance not to exceed 4 pipe diameters or 12” whichever is less Fig. 12: WH Units - Single Water Heater with Tank Fig. 11: MODE 3 - Single Boiler with Indirect H Units - Single Boiler with Process Tank on Boiler Loop Mode 2 (Type H Units Only) (P1) runs during all heat calls regardless of priority.
Page 18: Domestic Hot Water
Domestic Hot Water WARNING: Plumbing between the heater and tank in excess of 75 equivalent feet will require custom When designing the water piping system for domestic pump selection. Damage due to low flow may occur hot water applications, water hardness should be con- and is not a warrantable failure.
Page 19 for propane gas. The gas pressure regulator(s) sup- plied on the heater is for low-pressure service. 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.
Page 20: Electrical Power Connections
Electrical Power Connections 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- Installations must follow these codes: rate power supply and run the power through an external field supplied pump contactor.
Page 21: Making The Electrical Connections
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.
Page 22: Field Wiring Connections
Field Wiring Connections DANGER: SHOCK HAZARD CAUTION: Wiring errors can cause improper and dangerous operation. See the wiring diagram in this manual. Verify proper operation after servicing. Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components.
Page 23 Heating Sensor Installation 4. Mount the outdoor sensor on an exterior surface of the building, preferably on the north side in an 1. Only use the System sensor provided with the area that will not be affected by direct sunlight and unit.
Page 24 VERSA MASTER Fig. 20: XFyre Cascade System Wiring Wiring the Cascade System be connected to the XFyre boiler. This signal Communication Bus 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 1.
Page 25 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. 21). The output is rated for pilot duty only (2A maximum).
Page 26: Venting
Category I – A heater which operates with a non-pos- itive vent static pressure and with a vent gas SYSTEM Connections SUPPLY temperature that avoids excessive condensate pro- PUMP used during duction in the vent. (120V) “Limp Along” Category II – A heater which operates with a non-pos- mode only itive vent static pressure and with a vent gas PUMP...
Page 27 Combustion Exhaust Heater Venting Certified Vent Combustion Air Air Supply Configuration Category Materials Inlet Material Vertical Venting From Inside Building (Canada Only: ULC- Horizontal Through- (Non-Direct Venting) S636 PVC and CPVC) the-Wall Venting Stainless Steel, AL29-4C, Galvanized Steel, Vertical Venting Sch 40 PVC or CPVC From Outside Building PVC, ABS,...
Page 28 damaging exterior finishes. Use a 300-series stainless steel backing plate against brick or masonry surfaces. 1” MINIMUM (TYP) 11. DO NOT extend exposed vent pipe outside of building beyond the minimum distance required VENT CAPS STACKED VERTICALLY FLUE GASES MOVING IN PARALLEL for the vent termination.
Page 29: Venting Installation Tips
Vertical Vent Vent & Vertical Certified Vent Material Combustion Height (ft) Intake Air Inlet Model Air Intake Air Vent Max. Pipe Size Length* Min. Max. Material (in.) (ft) (Canada Only: ULC- 300A (Canada Only: S636 PVC and CPVC) ULC-S636 PVC Stainless Steel, and CPVC) AL29-4C, ANSI/ASTM...
Page 30: Common Venting
building openings must be consistent with the NFGC (U.S.) or B149 (Canada). Vents supported only by 8’ OR LESS flashing and extending above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. NOTE: When using PVC “T”...
Page 31 Note: Heaters rotated to show venting connections. An extractor is required for this configuration. Fig. 26: Typical Common Venting Horizontal Through-the-Wall Direct Venting (Category IV) Refer to Table F and local codes. Refer to Table F and local codes. Fig. 27: Horizontal Through-the-Wall Venting Fig.
Page 32 Installation Vent Size Volume of Flue Model No. (inches) Products (CFM) These installations utilize the heater-mounted blower to draw combustion air and to vent the combustion 300A products to the outdoors. The combustion air intake 400A and the vent are installed horizontally through the wall to the outdoors.
Page 33 Vertical Vent Vent & Vertical Certified Vent Material Combustion Height (ft) Intake Air Inlet Model Air Intake Air Vent Max. Pipe Size Length* Min. Max. Material (in.) (ft) (Canada Only: ULC- 300A (Canada Only: S636 PVC and CPVC) ULC-S636 PVC Stainless Steel, and CPVC) AL29-4C, ANSI/ASTM...
Page 34: Condensate Management
The vent must be installed to prevent the potential ac- particulate and chemical contaminants. To avoid a cumulation of condensate in the vent pipes. It is blocked flue condition, keep the vent cap clear of required that: snow, ice, leaves, debris, etc. WARNING: No substitutions of flue pipe or vent 1.
Page 35: Outdoor Installation
max volume of condensate produced is 1 GPH per Adjacent brick or masonry surfaces must be pro- 100,000 BTUH input. Design the drain system accord- tected to prevent condensate from damaging ingly. exterior finishes. Use a 300-series stainless steel backing plate against brick or masonry surfaces. CAUTION: In general, the condensate piping from the appliance must have a downward slope of ¼”...
Page 36: Controls
If the water temperature drops below 45˚F on the NOTE: Ignition modules are common for all model Outlet or Inlet sensors, the Boiler pump is enabled. sizes. However, model-specific operating parame- The pump is turned off when both the Inlet and Outlet ters are defined by their respective ID cards.
Page 37: Flow Switch
ADJUSTABLE SETTING FIXED SETTING Fig. 35: Flue Temperature Limit Fig. 33: High Limit (Auto Reset) Units provided with a PVC vent connector are also provided with a limit rated for PVC vent material. A NOTE: Adjustable limits must be set higher than the higher rated limit...
Page 38: Blocked Vent Switch
Condensate Float Switch ent for proper valve/regulator performance. The low gas pressure switch automatically shuts down the boil- er if the inlet gas supply drops below the factory setting The heater is equipped with a condensate float switch of 3.0 in. WC for natural gas or propane gas. to prevent operation when the condensate water level is too high.
Page 39: Operating Instructions
control panel to begin normal operation. 4. The unit requires closure across the enable/dis- able to operate. BURNER DOOR LIMIT 5. If the appliance fails to start, refer to the Troubleshooting section of this manual. User Interface The user interface consists of several Menu options. Fig.
Page 40: Setup Menu
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 (see Table S) is the default menu. It displays sensor temperatures, the modulation rate of the blower, heater cascade status, pump operation and CFH information.
Page 41 Item Application Range Description Default TARGET H MODE 1,2,3 RSET <> SETP SETP RSET = Outdoor Reset, SETP =Setpoint TANK SETP OFF, 50 F to 150 F 125 F Tank setpoint temperature TANK DIFF 2 F to 10 F Tank Differential temperature MODE H MODE 1,2,3 1,2,3...
Page 42 Boiler View Menu The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information Item Display Range User Settings When is it Displayed Description BOILER 1 ON <> OFF FT_Bus 1 is connected Enables Boiler for operation BOILER 2 ON <>...
Page 43 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. Item Application Description RUN TIME Burner 1 Burner run time (hours). Press UP/DOWN for 1 sec to clear. Cycles Burner Number of burner cycles.
Page 44 Toolbox Menu The Toolbox Menu logs all error codes from the VERSA and PIM, as well as other functions. Up to 15 error codes can be logged. Item Description Lookup Active Error Look up and display the active error info. Select ON to start the function.
Page 45: Reset Ratio
RESET RATIO (See Fig. 42) 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.
Page 46: Wiring Diagram
WIRING DIAGRAM...
Page 47: Start-Up
BEFORE OPERATING, smell all around the appliance NOTE: The wiring diagrams in this manual show all area for gas. Be sure to smell near the floor because standard options. Refer to the large wiring diagram some gas is heavier than air and will settle on the floor. provided with your boiler for options installed on your specific unit(s).
Page 48: Preparation
Preparation 3. Attach a 12” scale manometer to the upstream fit- ting on the gas supply pipe to the heater (Measure point “A” in Fig. 44, field-supplied on the 700A and WARNING: Do not turn on gas at this time. 850A).
Page 49: Start-Up
Start-Up Manifold Check 1. Check manifold gas pressure at the manifold pres- 1. Turn power on. sure tap (connection “B” in Fig. 42). This pressure should read per the values in Table Y for natural 2. Turn on the boiler. Approximately 10 seconds after and propane gas.
Page 50 Follow-Up • 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 Safety checks must be recorded as performed. step is incremented. Turn boiler on.
Page 51: Operation
c. Thermostat is set above water temperature. 10. Observe several operating cycles for proper oper- ation. d. Gas is on at the meter and the boiler. 11. Set the boiler thermostat to desired temperature. e. Incoming dynamic gas pressure to the gas valve is NOT less than 4.0 in.
Page 52: Xfyre Fault Text
3. Press and release the RESET key to clear the WARNING: Do not use this appliance if any part fault on the user interface and resume operation. has been under water. Improper or dangerous Be sure to observe the operation of the unit for a operation may result.
Page 53 LED Error Code Listing Active errors detected are indicated by LED lights on the PIM. Error Mode Error Mode Recommended Troubleshooting Normal Operation Red LED OFF Red LED Steady ON, Check that the proper ID Card is securely connected. Perform a power and system ID Card Fault Green Power LED OFF reset.
Page 54: Sensor Resistance Values
Sensor Resistance Values 3/16” Water Sensor / Outdoor Sensor Water Temperature (°F) Resistance (ohms) 32550 25340 19870 15700 12490 10000 8059 6535 5330 4372 3605 2989 2490 2084 NOTE: If receiving a NO FLAME, check the gap spacing between the points on the electrode by using either a 3/16 drillbit or a key 1753 between the gap.
Page 55: Maintenance
MAINTENANCE condensate is being directed to appropriate con- densate management system or drain, as required by local codes. Suggested Minimum Maintenance Schedule 3. Check that area is free from combustible materi- als, gasoline, and other flammable vapors and liquids. Regular service by a qualified service agency and maintenance must be performed to ensure maximum 4.
Page 56 3. Check burner flame. (Should see light blue flame 5. Check valve coil for 60 cycle hum or buzz. Check at full input rate). for leaks at all valve fittings using a soapy water solution (while unit is operating). Test other oper- Weekly ating parts of all safety shut-off and control valves and increase or decrease settings (depending on...
Page 57 Combustion Chamber Coil Cleaning WARNING: Instructions The combustion chamber insulation in this product Before beginning this procedure, you must have on contains ceramic fiber material. Ceramic fibers can hand the following items: be converted to cristobalite in very high temperature applications.
Page 58: Appendix
APPENDIX Inside Air Contamination Combustion air can be contaminated by certain vapors Areas where contaminated combustion air commonly in the air which raise the acidity of the condensate. exists: Higher acidity levels attack many materials including stainless steel, which is commonly used in high effi- •...
Page 59: Important Instructions For The Commonwealth Of Massachusetts
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance (b) EXEMPTIONS: The following equipment is exempt from with regulation 248 CMR 4.00 and 5.00 for installation of 248 CMR 5.08(2)(a)1 through 4: through – the – wall vented gas appliances as follows: 1.
Page 60: Warranty
LIMITED PARTS WARRANTY XFYRE – TYPE H and WH MODELS 300A-850A SCOPE Raypak, 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.
Page 61: Start-Up Checklist
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.
Page 64 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.