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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. 1000.65.2B
INSTRUCTIONS
Effective: 08-02-13
Replaces: 06-10-13
P/N 241480 Rev. 3
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Table of Contents
Summary of Contents for xFyre 300A
- 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. 3 reflects the following: Changes to: Pump Selection on page 13, Table I on page 17, Table J on page 18, Table L on page 19, Fig. 22 on page 28, Termination on page 29, Fig. 23 on page 30, Wiring Diagram on page 44, Table Y on page 47 Additions: Table G on page 13, Warning on page 29, Thermal Fuse (with Fig.
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Page 3: Table Of Contents
Start-Up General Information OPERATION Lighting Instructions GENERAL SAFETY Time/Temperature Relationships To Turn Off Gas to Appliance in Scalds TROUBLESHOOTING XFyre Error Codes INSTALLATION Installation Codes Heater Errors Equipment Base Heater Faults Clearances XFyre Fault Text Combustion and Ventilation Air Sensor Resistance Values... -
Page 4: Pay Attention To These Terms
If an XFyre heater is installed to replace an code requirements. existing heater, the vent system MUST be verified to be of the correct size and of one of the Category IV WARNING: Risk of electrical shock. -
Page 5: Before Installation
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. Heating, WH = Domestic Hot Water). The number Please review the General Safety information before which follows identifies the firing mode (7 = electron- installing the heater. -
Page 6: Component Locations
Fig. 3: Component Locations — Rear General Information MBTUH Gas conn. Vent Size Water Model Input (NPT) (inches) conn. (NPT) Max. Min. Flue Intake 300A 1-1/2” 3/4” 3/4” 400A 2” 1” 1” 500A 2” 1” 1” 700A 2” 1-1/4” 1-1/4”... -
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... -
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
Min. Clearances Minimum Heater TOP VIEW from Combustible Service Side Surfaces Clearances Rear 24” 24” Right Side 0” 0” Left Side 0” 0” Unobstructed 24” Front Open 24” Vent 12” 12” Termination Table E: Clearances — Outdoor Installations Combustion and Ventilation Air 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... - 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;...
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Page 11: Conventional Combustion Air Supply
Combustion Air Filter sealed with RTV (not supplied). TruSeal is generally used when damaging contaminants are present in the mechanical room. All ducting must be self-supported. This heater is supplied with an integral combustion air filter. This filter will reduce the amount of particulates CAUTION: Use TruSeal combustion air if that pass through the combustion system and heat damaging airborne contaminants are or may be... -
Page 12: Water Piping
a. Where directly communicating with the out- 14,000 BTUH (160 mm per kW) in excess of 1 doors or where communicating to the million BTUH. This opening(s) shall be either outdoors through vertical ducts, each open- located at or ducted to a point not more than 18 in. ing shall have a minimum free area of 1 in. -
Page 13: Hydronic Heating
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. Verify proper flow rates Raypak recommends conducting the hydrostatic test and ∆T as instructed in this manual. - Page 14 The piping system of a hot water heater connected to heating coils located in air handling units where they Type H models of XFyre have three modes available may be exposed to circulating refrigerated air, must be to them to address the various applications the units equipped with flow control valves or other automatic can be applied to.
- Page 15 Key: S1: Boiler Outlet Sensor S2: Boiler Inlet Sensor S3: System Sensor S4: Outdoor Air Sensor S5: Indirect Tank Sensor S6: Supply Sensor to Indirect P1: Boiler Pump P2: System Pump P3: Indirect DHW Pump Fig. 7: MODE 1 - Applications with Primary/Secondary Piping NOTE: MODE 1 can also be used for process heat- ing applications in conjunction with a buffer/storage tank when operating temperatures above 150 F are...
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Page 16: Domestic Hot Water
Hard water must be softened NOTE: A Tank Aquastat can be used in lieu of the for direct heating with the XFyre. Water hardness is Indirect DHW Sensor (S5). See the VERSA IC expressed in grains per gallon. -
Page 17: Gas Supply
DO NOT use an open flame. NOTE: The 75 eq. feet of tubing typically represents 25 linear feet of tubing and 50 eq. feet of fittings. 3–15 grains per gallon Model No. Pump ∆T WH7-300A 1611 18.3 21.9 WH7-400A 1630 21.0 19.4... - Page 18 Manifold Pressure (in. WC) sure the gas piping is protected from physical Model No. Natural Gas Propane Gas damage and freezing, where required. High High 300A -1.0 ± .1 -1.0 ± .1 400A -1.5 ± .1 -1.6 ± .1 500A -1.2 ± .1 -1.3 ±...
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Page 19: Electrical Power Connections
, 1.53 specific gravity at 0.6 in. WC pressure drop Table K: Maximum Equivalent Pipe Length Electrical Power Connections for pilot duty only. XFyre heaters may power up to 2 pumps directly. Install a circuit breaker sized sufficient- ly for both the heater and the pump(s). An indirect Installations must follow these codes: DHW pump larger than ¼... - Page 20 Check the Power Source 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.
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Page 21: Field Wiring Connections
Connect the Enable/Disable terminals to the PIM (shown in Fig. 16). Alternately, any dry contact closure (includ- ing a remote thermostat) across these terminals will enable the XFyre unit to run. Caution should be used to ensure neither of the terminals becomes connected to ground. - Page 22 1. A signal from an energy management system may SOR (see wiring diagram). Caution should be be connected to the XFyre boiler. This signal used to ensure neither of these terminals should be a 0-10 volt positive DC signal, and an becomes connected to ground.
- Page 23 VERSA MASTER Fig. 17: XFyre Cascade System Wiring 2. It is recommended that the shortest length cable possible be used to reach between the boilers. Do not run unprotected cables across the floor or where they will become wet or damaged. Do not...
- Page 24 Connect to terminals 4, 5, and 6 as shown in Fig. 3. The System and DHW pump outputs are not used in the Cascade Follower configuration. Fig. 19: XFyre Cascade Master Pumps 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.
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Page 25: Venting
General Centrotherm™ polypropylene vent material is also approved to be used on XFyre products. A vent Appliance Categories adapter (option D-33) must be used to ensure a prop- er seal of the flue and condensate. The vent adapter... - Page 26 Polypropylene* (Direct Venting) CPVC the-Wall Venting * Only Centrotherm™ polypropylene is approved for the XFyre product Table M: Venting Category Requirements 5. Single-wall Category IV metal vent pipe shall not Support of Vent Stack be used outdoors in cold climates for venting gas- fired equipment without insulation.
- Page 27 U.S. Installations 8. Terminate vent at least 1 ft above grade, including Refer to the latest edition of the National Fuel Gas normal snow line. Code. 9. Multiple direct vent installations require a 4 ft Vent termination requirements are as follows: clearance between the ends of vent caps located on the same horizontal plane.
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Page 28: Venting Installation Tips
Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. * Subtract 10 ft per elbow. Max. 4 elbows. ** Only Centrotherm polypropylene is approved for the XFyre product. Table N: Category IV Vertical Vent & Vertical Direct Vent... -
Page 29: Common Venting
The minimum flue pipe diameter for conventional vent- common venting of multiple Category IV heaters. This ing is: 4 in. (102mm) for Models 300A, 400A and 500A, is covered in the NFGC under “Engineered Vent Sys- and 6 in. (152mm) for Models 700A and 850A. - Page 30 Note: Heaters rotated to show venting connections. An extractor is required for this configuration. Fig. 23: 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. 25: Horizontal Through-the-Wall Direct Venting Fig.
- Page 31 NOTE: While a drain connection is required in the on the air intake and vent. vent of all XFyre installations, the drain can be ac- complished in several different ways. The figures in The vent cap is not considered in the overall length of this manual show the drain in a vent tee, however, the venting system.
- Page 32 Certified Vent Intake Air Air Intake Model No. Max. Material Vent Size Pipe Length (ft)* Min. Max. (in.) Material 300A (Canada Only: 400A ULC-S636 PVC and CPVC) Galvanized Stainless Steel, Steel, 500A AL29-4C, PVC, ABS, Sch 40 PVC/CPVC, CPVC 700A Centrotherm™...
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Page 33: Condensate Management
Vent pipe condensate drains are also required for installation of the XFyre. Follow vent manufacturer Combustion air supplied from outdoors must be free of instructions for location of condensate drains in the particulate and chemical contaminants. -
Page 34: Outdoor Installation
Terminals Outdoor models must be vented with listed vent mate- Terminals rial per the following instructions and installed with the 300A optional factory-supplied outdoor vent kit. A special vent terminal (Option D-11) is provided in accordance PVC Tee Sch 40*,... - Page 35 CAUTION: This appliance has provisions to be OPTIONAL connected to more than one supply source. To ADJUSTABLE reduce the risk of electric shock, disconnect all such SETTING connections before servicing. CAUTION: Risk of electric shock: More than one STANDARD disconnect switch may be required to de-energize LIMIT SENSOR the equipment before servicing.
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Page 36: Flow Switch
Flow Switch Low Water Cut-Off (Optional) This standard, dual-purpose control shuts off the boil- The optional low water cut-off automatically shuts er in case of pump failure or low water flow. The flow down the burner whenever water level drops below the switch ships mounted and wired. -
Page 37: Operating Instructions
Thermal Fuse Operation of either the High or Low Gas Pressure Switch will turn on an LED inside the switch housing. Push the top of the plastic switch housing as shown in The heater is equipped with a thermal fuse located at Fig. -
Page 38: User Interface
2. Adjust the temperature setpoint of the XFyre as through available items within a selected menu. And, desired. The factory default setting is 180°F for H the UP and DOWN buttons allow for setting changes models and 125°F for WH models. If changes are to items in the ADJUST menu. - Page 39 Item Application Range Description Default Enable or Disable the operation of boilers. 4 boiler range, 1 is BOILER 1 ON <> OFF enabled by default H 1,2,3 TARGET RSET <> SETP SETP RSET = Outdoor Reset, SETP =Setpoint TANK SETP OFF, 50 F to 150 F 125 F EMS = Energy Management System (Analog Target Temp)
- Page 40 Boiler View Menu The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information Item Application Description IGNITION Current State of Ignition LIMIT TEMP Limit Temperature AUX TEMP Auxiliary Temperature EMS Vdc Current EMS signal in Volts DC FIRE RATE PIM firing rate...
- Page 41 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 42 Toolbox Menu The Toolbox Menu logs all error codes from the BTCII and PIM, as well as other functions. Up to 15 error codes can be logged for a maximum of 24 days. Item Description Lookup Active Error Look up and display the active error info. Select ON to start the function.
- Page 43 RESET RATIO 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. The Boil START is typically set to the desired building temperature. Outdoor Start (OUT START) The OUT START temperature is the outdoor air temperature at which the control provides the Boil START water temperature to the system.
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Page 44: Wiring Diagram
WIRING DIAGRAM... -
Page 45: Pre 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 46: Preparation
1. Turn off main gas shutoff valve. 300A-500A BLACK CAP 2. On the 700A and 850A models, remove plugs “A” and “B,” and install 1/8” NPT fittings to allow meas- urement of the gas pressure. -
Page 47: Start-Up
850A -1.7 ± .2 -3.4 ± .2 5. Wait until the controller indicates 100% on the fir- Table Y: XFyre Manifold Pressures ing rate display screen. This may take several minutes. CAUTION: Special manifold and air settings may be required. -
Page 48: Safety Inspection
Post Start-Up Check 3. If other gas-fired appliances in the room are on the same gas main, check all pressures on the XFyre Check off steps as completed: with all other equipment running. 1. Verify that the boiler and heat distribution units or 4. -
Page 49: Operation
XFyre, the display may show an error code. This code may either be the result of a temporary condition in 5. Turn on main manual gas valve field-installed near which case the display will revert to its normal readout gas inlet connection on back of boiler. -
Page 50: Xfyre Fault Text
• The gas is off. • All electrical power is disconnected. XFyre Fault Text Error Display If there is an active error, then it is displayed as the first item in the Toolbox Menu and it is the default display for the control until the error is resolved. - Page 51 LED Error Code Listing Active errors detected are indicated by LED lights on the PIM. LED Code Error Mode Recommended Troubleshooting Normal Operation Red LED steady ON, Check that the proper ID card is securely connected. Perform a ID Card Fault Green Power power and system restart.
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Page 52: 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 points on the electrode by holding two quarters together and sliding 1753 them through the gap. -
Page 53: Maintenance
Schedule annual service call by qualified service agency. The following procedures are recommended and are good practice for all XFyre installations. 1. Visually check top of vent for soot. Call service person to clean. Some sediment at bottom of vent Daily is normal. - Page 54 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 55 “CLR” occupational sources is carcinogenic to humans (Group1).”: – Gloves, eye protection 1. Shut down the XFyre boiler by using the following • Avoid breathing dust and contact with skin and steps: eyes. a. Close the gas valve, shut down the unit and wait for the unit to be cool to the touch.
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Page 56: 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 57: 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 58: 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 59: 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. - Page 60 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.