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  5. Installation & Operating Instructions Manual

XFyre 300A Installation & Operating Instructions Manual

Manual is about: Types H & WH

Summary of 300A

  • Page 1

    Installation & operating instructions catalog no. 1000.65.2b effective: 08-02-13 replaces: 06-10-13 p/n 241480 rev. 3 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. 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...

  • 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 combustion and ventilation air indoor units this heater must be supplied with sufficient quantities of non-contaminated air to support proper comb...

  • 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

    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 rating of all equipment in the enclosure. B. Where communicating with the outdoo...

  • 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

    Feedwater regulator raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the highest point of the system. Install a check valve or back flow device upstream of the regulator, with a manual shut-off valve as required by local codes. Piping all high points ...

  • Page 15

    15 fig. 7: mode 1 - applications with primary/secondary piping fig. 8: mode 2 - single boiler with indirect on system loop 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 ...

  • Page 16

    Sensor (s5) determines the indirect call/tank setpoint. During an indirect call for heat the boiler firing rate is determined by the water temperature at the indirect supply sensor (s6) and the target max setting when using the indirect dhw sensor (s5). The boiler pump (p1) runs during all heat call...

  • Page 17

    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 he...

  • Page 18

    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. Gas supply pressure a minimum of 4.0 in. Wc upstream gas pressure under full load and...

  • Page 19

    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 20

    Check the power source: ac = 108 vac minimum, 132 vac max ab = 108 vac minimum, 132 vac max bc = check the power source 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...

  • Page 21

    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 22

    Wiring the outdoor sensor 1. There is no connection required if an outdoor sen- sor is not used in this installation. 2. If using an outdoor sensor, connect the sensor wires to the terminals marked outdoor sen- sor (see wiring diagram). Caution should be used to ensure neither of these terminals bec...

  • Page 23

    Versa master 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 run communication cables parallel with, or close to or against, high voltage (120 volt or gr...

  • Page 24

    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. Connect to terminals 10, 11, and 12 (see fig. 19). The output is rated for pilot duty only (2a maximum). ...

  • Page 25

    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 26

    Vent terminal location 1. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. 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 p...

  • Page 27

    U.S. Installations refer to the latest edition of the national fuel gas code. Vent termination requirements are as follows: 1. Vent must terminate at least 4 ft below, 4 ft hori- zontally from or 1 ft above any door, window or gravity air inlet to the building. 2. The vent must not be less than 7 ft...

  • Page 28

    Venting installation tips support piping: • horizontal runs—at least every 5 ft (1.5m) • vertical runs—use braces • under or near elbows venting configurations for heaters connected to gas vents or chimneys, vent installations shall be in accordance with the nfgc (u.S.), or b149 (canada), or applica...

  • Page 29

    Termination the vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the highest point of the roof that is within 8 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft hori-zontal distance...

  • Page 30

    Fig. 23: typical common venting horizontal through-the-wall direct venting (category iv) note: heaters rotated to show venting connections. An extractor is required for this configuration. Fig. 24: horizontal through-the-wall venting refer to table f and local codes. Fig. 25: horizontal through-the-...

  • Page 31

    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 32

    Direct vent—vertical installation these installations utilize the heater-mounted blower to draw combustion air from outdoors and vent com- bustion products to the outdoors. * subtract 10 ft per elbow. Max. 4 elbows. Table q: category iv horizontal vent & horizontal direct vent the total length of ai...

  • Page 33

    This type of installation can cause non-warrantable problems with components and poor operation of the boiler due to the recirculation of flue products. Multi- ple vent caps installed in the same horizontal plane must have a 4 ft clearance from the side of one vent cap to the side of the adjacent ve...

  • Page 34

    Freeze protection to enable freeze protection, dip switch position 7 (on the pim) must be turned on (up position). This is the default position. If the water temperature drops below 45˚f on the outlet or inlet sensors, the boiler pump is enabled. The pump is turned off when both the inlet and outlet...

  • Page 35

    Caution: this appliance has provisions to be connected to more than one supply source. To reduce the risk of electric shock, disconnect all such connections before servicing. Caution: risk of electric shock: more than one disconnect switch may be required to de-energize the equipment before servicin...

  • Page 36

    Fig. 34: high/low gas pressure switch flow switch this standard, dual-purpose control shuts off the boil- er in case of pump failure or low water flow. The flow switch ships mounted and wired. Fig. 33: low water cut-off flue temperature limit the heater is equipped with a fixed setting manual reset ...

  • Page 37

    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. Fig. 36: condensate float switch condensate float switch the heater is equipped with a condensate flo...

  • Page 38

    Through available items within a selected menu. And, the up and down buttons allow for setting changes to items in the adjust menu. Refer to fig. 39 for dis- play and key locations. For detailed descriptions of the various screens, con- sult the versa ic control i&o manual (catalog #5000.72). Adjust...

  • Page 39

    Table t: adjust menu item application range description default boiler 1 all on off enable or disable the operation of boilers. 4 boiler range, 1 is enabled by default on target h 1,2,3 rset setp rset = outdoor reset, setp =setpoint setp tank setp wh off, 50°f to 150°f ems = energy management system...

  • 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 table u: boiler view menu item application description ignition all current state of ignition limit temp all limit temperature aux te...

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

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

  • 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. T...

  • Page 44

    Wiring diagram 44.

  • Page 45

    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 vent. ...

  • Page 46

    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 install...

  • Page 47

    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-up c...

  • Page 48

    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 properly....

  • Page 49

    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 normal r...

  • Page 50

    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 errors c...

  • Page 51

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

  • Page 52

    3/16” note: if receiving a no flame, check the gap spacing between points on the electrode by holding two quarters together and sliding them through the gap. There should be no resistance. Fig. 43: direct spark igniter water sensor / outdoor sensor water temperature (°f) resistance (ohms) 32 32550 4...

  • Page 53

    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 free f...

  • Page 54

    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 fr...

  • Page 55

    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 foll...

  • Page 56

    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 cons...

  • Page 57

    (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 fueled ...

  • Page 58

    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 by...

  • Page 59

    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 ...

  • Page 60: Www.Raypak.Com

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