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  5. Installation & Operating Instructions Manual

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

Summary of 300A–850A

  • Page 1

    Installation & operating instructions catalog no. 1000.65.2c effective: 06-15-15 replaces: 08-02-13 p/n 241480 rev. 4 warning: improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, exposure to hazardous materials* or loss of life. Review th...

  • Page 2

    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

    Warnings 4 pay attention to these terms 4 before installation 5 product receipt 5 model identification 5 ratings and certifications 5 installations at elevation 5 component locations 6 general information 6 general safety 7 time/temperature relationships in scalds 7 installation 8 installation codes...

  • Page 4

    4 danger: indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Warning: indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Ca...

  • Page 5

    5 before installation raypak strongly recommends that this manual be re- viewed thoroughly before installing your xfyre heater. Please review the general safety information before installing the heater. Factory warranty does not apply to heaters that have been improperly installed or oper- ated. (re...

  • Page 6

    General information table a: basic data 6 note: jacket top slopes from front to rear control/sensor wiring component locations fig. 1: component locations — sides fig. 2: component locations — top fig. 3: component locations — rear model no. Mbtuh input water conn. (npt) gas conn. (npt) vent size (i...

  • Page 7

    7 general safety to meet commercial hot water use needs, the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 180°f. However, water temperatures over 125°f can cause instant severe burns or death from scalds. When supplying general...

  • Page 8

    If the heater needs to be secured to the ground, use the holes in the anchoring legs on the heater. Clearances indoor installations when installed according to the listed minimum clear- ances from combustible construction, these heaters can be serviced without removing permanent structur- al constru...

  • Page 9

    9 fig. 4: minimum clearances from combustible surfaces — indoor and outdoor installations table e: clearances — outdoor installations top view front view fig. 5: anchoring detail combustion and ventilation air indoor units this heater must be supplied with sufficient quantities of non-contaminated a...

  • Page 10

    U.S. Installations 1 canadian installations 2 a clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) b clearance to window or door that may be opened 4 ft (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) c clearance to permanently closed wind...

  • Page 11

    Combustion air filter this heater is supplied with an integral combustion air filter. This filter will reduce the amount of particulates that pass through the combustion system and heat exchanger but will not protect against chemical inside air contamination (see appendix). The filter must be checke...

  • Page 12

    Outdoors or spaces (crawl or attic) that freely com- municate with the outdoors. A. Where directly communicating with the out- doors or where communicating to the outdoors through vertical ducts, each open- ing shall have a minimum free area of 1 in. 2 per 4,000 btuh (550 mm 2 per kw) of total input...

  • Page 13

    Relief valve installation and piping the heater is supplied with a section iv “hv” stamped relief valve sized for the full input of the unit. The relief valve assembly is shipped loose and must be mount- ed directly to the heater outlet. No valve shall be installed between the heater and the relief ...

  • Page 14

    The following applications are approved configurations supported by raypak for cwp systems. Cold water protection: h models - closed loop closed loop heating systems that will experience extended and/or repeated warmup periods where the inlet water temperature remains below 50ºf (10ºc) lasting more ...

  • Page 15

    15 table h: heater rates of flow and pressure drops notes: basis for minimum flow is ∆t . Basis for maximum flow is gpm. Model no. 20°f ∆t 30°f ∆t 35°f ∆t min. Flow max. Flow gpm ∆p (ft) gpm ∆p (ft) gpm ∆p (ft) gpm ∆p (ft) ∆t gpm ∆p (ft) ∆t h7-300a 28 17 19 8 16 6 14 5 39 36 28 16 h7-400a 38 18 25 7...

  • Page 16

    16 fig. 8: mode 1 - hydronic multi-boiler fig. 10: mode 2 - single boiler with indirect on system loop fig. 9: mode 1 - hydronic multi-boiler master 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 ...

  • Page 17

    Mode 2 (type h units only) this mode selection is for hydronic heating systems with single or multiple boilers (maximum 4 boilers) in primary/secondary piping configuration with or without outdoor air reset (s4) with indirect dhw on the sys- tem loop (with or without priority). See fig. 9. The syste...

  • Page 18

    18 potable water and space heating 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water. 2. Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water used for space...

  • Page 19

    19 caution: for proper operation, no more than a 30% drop in gas supply pressure from no-load to full- load conditions is acceptable. Under no circumstances should the pressure be outside the listed operational range. For propane gas. The gas pressure regulator(s) sup- plied on the heater is for low...

  • Page 20

    Electrical power connections installations must follow these codes: • national electrical code and any other national, state, provincial or local codes or regulations hav- ing jurisdiction. • safety wiring must be nec class 1. • heater must be electrically grounded as required by the nec. • in canad...

  • Page 21

    21 check the power source: ac = 108 vac minimum, 132 vac max ab = 108 vac minimum, 132 vac max bc = warning: using a multi-meter, check the following voltages at the circuit breaker panel prior to connecting any equipment. Make sure proper polarity is followed and house ground is proven. (see fig. 1...

  • Page 22

    Field wiring connections make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. Caution: wiring errors can cause improper and dangerous operation. See the wiring diagram in this manual. Verify proper operation after servicing. Danger: sh...

  • Page 23

    23 heating sensor installation 1. Only use the system sensor provided with the unit. 2. The sensor wires can be extended up to 500 ft using a shielded 2-conductor cable. 3. Do not run sensor wires in conduit with line voltage wiring. 4. Install a 3/8” id 1/2 npt immersion well. 5. If installing the ...

  • Page 24

    Versa master be connected to the xfyre boiler. This signal 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 rate of the xfyre boiler. 2. To enable this remote control function, set dip switch 5 to the up ...

  • Page 25

    Fig. 21: ft_bus wire connection 25 g w bk g w bk g w bk g (12 awg) (12 awg) (12 awg) p/n 902017 rev 1 hot (120v) 1 2 3 4 5 6 7 8 9 10 11 12 hot (120v) boiler pump 1 hp max dhw pump 5a max system supply pump com gnd hot (120v) com gnd hot (120v) com gnd common ground w bk fig. 22: xfyre cascade maste...

  • Page 26

    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 av...

  • Page 27

    27 2. Give special attention to the location of the vent termination to avoid possibility of property dam- age or personal injury. 3. Gases may form a white vapor plume in winter. The plume could obstruct a window view if the ter- mination is installed near windows. 4. The bottom of the vent termina...

  • Page 28

    8. Terminate vent at least 1 ft above grade, including normal snow line. 9. Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane. See fig. 24. Installations in canada refer to latest edition of the b149 installation code. A ve...

  • Page 29

    4. Above a meter/regulator assembly within 3 ft (915 mm) horizontally of the vertical centerline of the regulator. 5. Within 6 ft (1.8 m) of any gas service regulator vent outlet. 6. Less than 1 ft (305 mm) above grade level. 7. Within 3 ft (915 mm) of a window or door which can be opened in any bui...

  • Page 30

    Building openings must be consistent with the nfgc (u.S.) or b149 (canada). Vents supported only by flashing and extending above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. Common venting raypak does not support common venting under pos- itive pressur...

  • Page 31

    At the time of removal of an existing boiler, the follow- ing steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remain- ing connected to the common venting system are not in operation: 31 fig. 26: typical comm...

  • Page 32

    Note: while a drain connection is required in the vent of all xfyre installations, the drain can be ac- complished in several different ways. The figures in this manual show the drain in a vent tee, however, this can also be accomplished using an inline collec- tor for condensing stacks or an inline...

  • Page 33

    Termination the vent cap must be mounted on the exterior of the building. The vent cap cannot be installed in a well or below grade. The vent cap must be installed at least 1 ft above ground level and above normal snow levels. Only raypak-approved vent caps may be used. The vent terminal must be loc...

  • Page 34

    Particulate and chemical contaminants. To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc. Condensate management the condensate must be drained properly to protect the appliance and drainage system. The condensate from the boiler is acidic. Its ph is between...

  • Page 35

    Max volume of condensate produced is 1 gph per 100,000 btuh input. Design the drain system accord- ingly. Outdoor installation outdoor models must be vented with listed vent mate- rial per the following instructions and installed with the optional factory-supplied outdoor vent kit. A special vent te...

  • Page 36

    Optional the optional adjustable-setting manual-reset high limit is located behind the front panel. To reset a high limit lockout, press the reset button on the adjustable manual reset limit as well as the reset button located on the user interface. High limit — auto reset (optional) the heater may ...

  • Page 37

    Low water cut-off (optional) the low water cut-off (sales option f-10) automatical- ly shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay pre-vents premature lockout due to temporary conditions such as power fluctuations or air pockets. High ...

  • Page 38

    Fig. 39: condensate float switch condensate float switch the heater is equipped with a condensate float switch to prevent operation when the condensate water level is too high. The heater shutting down from the conden- sate float switch is indicative of a blocked drain or problem with the condensate...

  • Page 39

    Operating instructions remove the front door. If you smell gas, stop. Follow listed safety instructions. If you do not smell gas, fol- low the next steps. 1. Turn on all electric power to appliance. 2. Adjust the temperature setpoint of the xfyre as desired. The factory default setting is 180°f for ...

  • Page 40

    40 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

    Table t: adjust menu item application range description default target h mode 1,2,3 rset setp rset = outdoor reset, setp =setpoint setp tank setp wh off, 50°f to 150°f tank setpoint temperature 125°f tank diff wh 2°f to 10°f tank differential temperature 3 mode h mode 1,2,3 1,2,3 piping and applicat...

  • Page 42

    42 boiler view menu the boiler view displays various items regarding ignition, temperature monitoring, and modulation rates. As well as software and hardware information table u: boiler view menu item display range user settings when is it displayed description boiler 1 on off ft_bus 1 is connected ...

  • Page 43

    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. Table v: monitor menu item application description run time burner 1 all burner run time (hours). Press up/down for 1 s...

  • Page 44

    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. Table w: toolbox menu outdoor reset concept the temperature controller can change the system set point based on outdoor temperature (outdoor reset). The tempe...

  • Page 45

    45 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 tempe...

  • Page 46

    46 wiring diagram.

  • Page 47

    47 start-up pre start-up filling system (heating boilers) fill system with water. Purge all air from the system. Lower system pressure. Open valves for normal sys- tem operation, and fill system through feed pressure. Manually open air vent on the compression tank until water appears, then close ven...

  • Page 48

    48 preparation check power supply with multi-meter at incoming power, check voltage between: hot - common (≈120 vac) hot - ground (≈120 vac) common - ground ( attach manometers to measure pressures 1. Turn off main gas shutoff valve. 2. On the 700a and 850a models, remove plugs “a” and “b,” and inst...

  • Page 49

    49 blower check 1. Note the high fire air intake pressure on the swirler and compare to table x. Excessively high pres- sures indicate an obstruction in the air intake or undersized/too long air intake ducting. With a clean air filter in place, record the intake air pres- sure setting on the start-u...

  • Page 50

    50 finishing 1. Record all data on the “start-up checklist” located at the back of this manual. 2. Disconnect the manometers and reconnect the cap on the air intake and reinsert or close the seal- ing screws into the bleedle valves. 3. Start-up is complete and the boiler should be oper- ating proper...

  • Page 51

    51 troubleshooting xfyre error codes if any of the sensors detect an abnormal condition or an internal component fails during the operation of the xfyre, the display may show an error code. This code may either be the result of a temporary condition in which case the display will revert to its norma...

  • Page 52

    52 caution: if overheating occurs or the gas supply fails to shut off, do not turn off electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of boiler damage. Instead, shut off the gas supply to the boiler at the gas service valve. Caution: wiring error...

  • Page 53

    53 led error code listing active errors detected are indicated by led lights on the pim. Table ab: pim led error codes error mode error mode recommended troubleshooting normal operation red led off id card fault red led steady on, green power led off check that the proper id card is securely connect...

  • Page 54

    54 3/16” 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 between the gap. There should be no resistance. Fig. 46: direct spark igniter water sensor / outdoor sensor water temperature (°f) resistance (ohms) 32 32550 41 ...

  • Page 55

    55 maintenance suggested minimum maintenance schedule regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. Maintenance as outlined below may be performed by the owner. Daily 1. Check that the area where the boiler is installed is fre...

  • Page 56

    56 3. Check burner flame. (should see light blue flame at full input rate). Weekly for low-pressure boilers, test low-water cut-off device. (with boiler in pre-purge, depress the low water cut-off test button. Appliance should shut-off and ignition fault light should come on. Depress reset button on...

  • Page 57

    57 combustion chamber coil cleaning instructions before beginning this procedure, you must have on hand the following items: – a nylon, stainless steel or brass brush (not steel) – “rydlyme” (recommended for best results) or “clr” – gloves, eye protection 1. Shut down the xfyre boiler by using the f...

  • Page 58

    58 areas where contaminated combustion air commonly exists: • dry cleaning/laundry areas • metal fabrication plants • beauty shops • refrigeration repair shops • photo processing plants • auto body shops • plastic manufacturing plants • furniture refinishing areas and establishments • new building c...

  • Page 59

    59 (b) exemptions: the following equipment is exempt from 248 cmr 5.08(2)(a)1 through 4: 1. The equipment listed in chapter 10 entitled "equipment not required to be vented" in the most current edition of nfpa 54 as adopted by the board; and 2. Product approved side wall horizontally vented gas fuel...

  • Page 60

    60 limited parts warranty xfyre – type h and wh models 300a-850a raypak, inc • 2151 eastman avenue • oxnard, ca 93030-9786 • (805) 278-5300 • fax (800) 872-9725 • www.Raypak.Com scope raypak, inc. (“raypak”) warrants to the original owner that all parts of this heater which are actually manufactured...

  • Page 61

    61 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 wi...

  • Page 62

    62.

  • Page 63

    63.

  • Page 64: Www.Raypak.Com

    64 www.Raypak.Com raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (805) 278-5468 litho in u.S.A..