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.
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. 37) and Burner Door Limit (with Fig. 38) on page 37.
CONTENTS WARNINGS Pay Attention to These Terms BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connections Venting Venting Installation Tips Venti
WARNINGS Pay Attention to These Terms DANGER: WARNING: CAUTION: NOTE: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
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 characters identifies the application (H = Hydronic Heating, WH = Domestic Hot Water). The number which follows identifies the firing mode (7 = electronic modulation).
Component Locations NOTE: JACKET TOP SLOPES FROM FRONT TO REAR Model 850 shown. Component locations may vary slightly in smaller models. Fig. 1: Component Locations — Sides CONTROL/SENSOR WIRING Fig. 2: Component Locations — Top General Information Model No. 300A 400A 500A 700A 850A Fig. 3: Component Locations — Rear MBTUH Input Gas conn. (NPT) Water conn. Max. Min.
Model No. Heater Water Volume (gallons) 400A 3.6 300A 500A 700A 850A 2.9 4.2 5.0 5.8 Table B: Heater Water Volume 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 purpose hot water, the recommended initial setting for the temperature control is 125°F.
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 simple applications. For more detailed configurations and set-up, consult the VERSA IC Control I&O Manual (Catalog #5000.72). Clearances Indoor Installations Installation Codes Installations must follow these codes: • • • • • Heater Side Min.
TOP VIEW Heater Side Min. Clearances from Combustible Surfaces Minimum Service Clearances Right Side 0” 0” Rear Left Side 24” 0” 24” 0” Top Unobstructed 24” Vent Termination 12” 12” Front Open 24” 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 boiler that is not covered by the warranty.
Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 1 2 t TT * 2 U.S. Installations Canadian Installations 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.
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 that pass through the combustion system and heat exchanger but will not protect against chemical inside air contamination (See Appendix).
a. Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.2 per 4,000 BTUH (550 mm2 per kW) of total input rating of all equipment in the enclosure. 14,000 BTUH (160 mm2 per kW) in excess of 1 million BTUH. This opening(s) shall be either located at or ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (152 mm) above the floor level. The duct can also “goose neck” through the roof.
nections to the heater and the rest of the system prior to operation. This is particularly true for hydronic systems using expensive glycol-based anti-freeze. Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply. NOTE: Minimum pipe size for in/out connections is 1-1/2” NPT for model 300A and 2” NPT for models 400A, 500A, 700A and 850A. Verify proper flow rates and ∆T as instructed in this manual.
Air-Separation/Expansion Tank Feedwater Regulator All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig. 6 above. Raypak recommends that a feedwater regulator be installed 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.
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 heating applications in conjunction with a buffer/storage tank when operating temperatures above 150°F are required.
Fig. 10: WH Units - Single Water Heater with Tank H Units - Single Boiler with Process Tank Fig. 9: MODE 3 - Single Boiler with Indirect on Boiler Loop 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 calls regardless of priority.
Gas Supply Potable Water and Space Heating CAUTION: When this heater is used for both potable water and space heating, observe the following to ensure proper operation. DANGER: Make sure the gas on which the heater will operate is the same type as specified on the rating plate. 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water.
Gas Supply Pressure A minimum of 4.0 in. WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 10.5 in. WC under load and no-load conditions for natural gas. A minimum of 4.0 in. WC upstream gas pressure under full load and a maximum gas supply pressure setpoint of 13.0 in. WC is required for propane gas. The gas pressure regulator(s) supplied on the heater is for low-pressure service.
Model No. 300A 400A 3/4” NPT N 15 1” NPT P N 30 700A 1-1/2” NPT N P N P 270 414 96 220 45 100 175 400 390 15 40 65 150 150 30 500A P 1-1/4” NPT 70 120 42 850A 25 275 96 55 350 55 125 Natural Gas – 1,000 BTU/ft3, 0.60 specific gravity at 0.5 in. WC pressure drop Propane Gas – 2,500 BTU/ft3, 1.53 specific gravity at 0.6 in. WC pressure drop 2” NPT N P 310 795 175 450 Table K: Maximum Equivalent Pipe Length Electrical Power Connections for pilot duty only.
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. All high voltage wires must be the same size (105°C, stranded wire) as the ones on the unit or larger. Fig. 13: Multi-meter Making the Electrical Connections Refer to Fig. 12–20. 1.
Field Wiring Connections CAUTION: Wiring errors can cause improper and dangerous operation. See the wiring diagram in this manual. Verify proper operation after servicing. DANGER: SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components. SUGGESTED ROUTING OF SENSOR & CONTROL WIRING CONTROL/SENSOR WIRING VERSA CONTROL PLATFORM IGNITION MODULE (PIM) RATING PLATE HIGH VOLTAGE POWER AND PUMP WIRING LOCATION Fig.
Wiring the Outdoor Sensor CAUTION: Sensor and control wiring must NOT be run in conduit or chases with line voltage. 1. There is no connection required if an outdoor sensor is not used in this installation. Wiring the Optional 0–10 Volt Building Control Signal 2. If using an Outdoor Sensor, connect the sensor wires to the terminals marked OUTDOOR SENSOR (see wiring diagram). Caution should be used to ensure neither of these terminals becomes connected to ground. 1.
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 run communication cables parallel with, or close to or against, high voltage (120 volt or greater) wiring. Raypak recommends that the total maximum length of each set of communication bus cables not exceed 200 feet. 3.
Cascade Follower Pump and Sensor Wiring 1. Once the primary boiler has been identified, additional boilers will be designated as follower boilers. Ensure dip switch 2 on each follower VERSA is set to the OFF/Down position (See Fig. 20) 2. For each follower boiler, connect the boiler pump wires to the terminal block at the rear of each unit. Connect to terminals 4, 5, and 6 as shown in Fig. 19. 3. The System and DHW pump outputs are not used in the Cascade Follower configuration. N/A Fig.
Alarm Connection NOTE: For additional information on appliance categorization, see the ANSI Z21.13 Standard and the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes. An alarm bell or light may be connected to the alarm contacts on the boiler PIM. The Alarm Contacts are 3A rated dry contacts on a normally-open relay that close during fault or lockout conditions, and the maximum voltage across the contacts is 30 VAC or 30 VDC. Connections are made at J1 pins 1 and 2.
Combustion Air Supply From Inside Building (Non-Direct Venting) From Outside Building (Direct Venting) Exhaust Configuration Vertical Venting Heater Venting Category Certified Vent Materials IV (Canada Only: ULCS636 PVC and CPVC) Stainless Steel, AL29-4C, Sch 40 PVC or CPVC Polypropylene* Horizontal Throughthe-Wall Venting Vertical Venting Horizontal Throughthe-Wall Venting * Only Centrotherm™ polypropylene is approved for the XFyre product.
U.S. Installations 8. Terminate vent at least 1 ft above grade, including normal snow line. Refer to the latest edition of the National Fuel Gas Code. 9. Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane. Vent termination requirements are as follows: 1. Vent must terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, window or gravity air inlet to the building.
Model No. 300A 400A 500A 700A 850A Certified Vent Material (Canada Only: ULC-S636 PVC and CPVC) Stainless Steel, AL29-4C, ANSI/ASTM D1785 Sch 40 PVC, ANSI/ASTM F441 Sch 40 CPVC Polypropylene** Vent and Intake Air Vent Size (in.) Vertical Vent Height1 (ft) Min. 4 0 Max. Combustion Air Intake Pipe Material Vertical Air Inlet Max. Length* (ft) Galvanized Steel, PVC, ABS, CPVC 100 100 6 1 Vent lengths are based on a lateral length of 2 ft.
The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters. This is covered in the NFGC under “Engineered Vent Systems”. Table O provides volumes of flue products at full fire for the calculation of appropriate vent and extractor sizing for common venting. The minimum flue pipe diameter for conventional venting is: 4 in. (102mm) for Models 300A, 400A and 500A, and 6 in. (152mm) for Models 700A and 850A.
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.
The total length of the horizontal through-the-wall direct vent system should not exceed 200 equivalent ft in length. If combined vent/intake run exceeds 200 equivalent ft, an appropriately sized variable-speed extractor must be used. Each elbow used is equal to 10 ft of straight pipe with a maximum of 4 elbows each on the air intake and vent. NOTE: Vent and intake piping must be supported so that the weight of the venting is not transfered to the unit.
Certified Vent Material Model No. 300A Vent and Intake Air Vent Size (in.) (Canada Only: ULC-S636 PVC and CPVC) Stainless Steel, AL29-4C, Sch 40 PVC/CPVC, Centrotherm™ Polypropylene 400A 500A 700A 850A Horizontal Vent Length (ft) Min. Max. 4 0 100 Combustion Air Intake Pipe Material Air Inlet Max. Length (ft)* Galvanized Steel, PVC, ABS, CPVC 100 6 * Subtract 10 ft per elbow. Max. 4 elbows.
This type of installation can cause non-warrantable problems with components and poor operation of the boiler due to the recirculation of flue products. Multiple 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 vent cap(s). stone (calcium carbonate) chips to neutralize the pH level of the condensate. The kit may be added to avoid long-term damage to the drainage system and to meet local code requirements.
Outdoor Installation Outdoor models must be vented with listed vent material per the following instructions and installed with the optional factory-supplied outdoor vent kit. A special vent terminal (Option D-11) is provided in accordance with CSA requirements. These must be installed as illustrated in Fig. 28. 2. 3. 4. 5. 6.
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. OPTIONAL ADJUSTABLE SETTING CAUTION: Risk of electric shock: More than one disconnect switch may be required to de-energize the equipment before servicing.
Flow Switch Low Water Cut-Off (Optional) This standard, dual-purpose control shuts off the boiler in case of pump failure or low water flow. The flow switch ships mounted and wired. The optional low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe. A 5-second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets. Fig.
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 Fig. 34 to reset a tripped pressure switch. The LED will go out when the switch is reset. The heater is equipped with a thermal fuse located at the back of the combustion chamber. The thermal fuse shuts down the boiler if the temperature rise within the combustion chamber becomes excessive.
2. Adjust the temperature setpoint of the XFyre as desired. The factory default setting is 180°F for H models and 125°F for WH models. If changes are necessary follow “Adjusting The XFyre Setpoint” in this section. 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 display and key locations. For detailed descriptions of the various screens, consult the VERSA IC Control I&O Manual (Catalog #5000.72). 3.
Item Application Range Description Default TARGET H 1,2,3 RSET = Outdoor Reset, SETP =Setpoint SETP OFF, 50°F to 150°F EMS = Energy Management System (Analog Target Temp) 125°F 2°F to 10°F Tank Differential temperature 3 1,2,3 Piping and application configuration.
Boiler View Menu The Boiler View displays various items regarding ignition, temperature monitoring, and modulation rates.
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 Cycles Burner All RUN TIME Burner 1 RUN TIME Boiler pump RUN TIME System pump All Burner run time (hours). Press UP/DOWN for 1 sec to clear. All Boiler pump run time (hours). Press UP/DOWN for 1 sec to clear.
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 Lookup Active Error USER TEST MAX HEAT P/N 104901 DEFAULTS HISTORY lookup logged error Description Look up and display the active error info. Select ON to start the function. The setting returns to default after the test is run. (See Page 47 for details.) Select ON to start the function.
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.
WIRING DIAGRAM 44
BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell near the floor because some gas is heavier than air and will settle on the floor. NOTE: The wiring diagrams in this manual show all standard options. Refer to the large wiring diagram provided with your boiler for options installed on your specific unit(s).
Preparation 3. Attach a 12” scale manometer to the upstream fitting on the gas supply pipe to the heater (Measure point “A” in Fig. 41, field-supplied on the 700A and 850A). WARNING: Do not turn on gas at this time. Check Power Supply 4. Attach a 12” scale manometer to the downstream fitting on the gas manifold (Measure point “B” in Fig. 41, field-supplied on the 700A and 850A). With multi-meter at incoming power, check voltage between: 5.
Start-Up Manifold Check 1. Check manifold gas pressure at the manifold pressure tap (connection “B” in Fig. 41). This pressure should read per the values in Table Y for natural and propane gas. 1. Turn power on. 2. Turn on the boiler, approximately 10 seconds after the blower starts, the igniter should start to spark (observable through the observation port located at the front, bottom of the boiler) and the gas valve will open.
• • • • 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 step is incremented. If boiler outlet temperature reaches the PIM HiLimit, the boiler will be ramped down to keep the temperature in a safe range. Press of the Up button from Boiler Max will End the User Test function. Safety checks must be recorded as performed. Turn boiler on. After main burner ignition: 1. Check manometer for proper readings.
c. 10. Observe several operating cycles for proper operation. Thermostat is set above water temperature. 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. WC for natural gas or propane gas. 12. Review all instructions shipped with this boiler with owner or maintenance person, return to envelope and give to owner or place the instructions inside front panel on boiler.
3. Press and release the RESET key to clear the fault on the user interface and resume operation. Be sure to observe the operation of the unit for a period of time to ensure correct operation and no reoccurrence of fault code(s). WARNING: Do not use this appliance if any part has been under water. Improper or dangerous operation may result.
LED Error Code Listing Active errors detected are indicated by LED lights on the PIM. LED Code Off Error Mode Normal Operation Recommended Troubleshooting Red LED steady ON, ID Card Fault Green Power LED OFF Check that the proper ID card is securely connected. Perform a power and system restart. 1 flash N/A N/A Ignition Lockout Fault Check the gas supply. See table for more information. Steady ON Internal Control Failure Perform a power and system reset. If fault remains, replace PIM.
Sensor Resistance Values 3/16” Water Sensor / Outdoor Sensor Water Temperature (°F) Resistance (ohms) 41 25340 32 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203 212 32550 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 them through the gap. There should be no resistance. 1753 1481 Fig.
MAINTENANCE condensate is being directed to appropriate condensate management system or drain, as required by local codes. Suggested Minimum Maintenance Schedule 3. Check that area is free from combustible materials, gasoline, and other flammable vapors and liquids. Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. 4. Check for and remove any obstruction to the flow of combustion or ventilation air to boiler.
3. Check burner flame. (Should see light blue flame at full input rate). 5. Check valve coil for 60 cycle hum or buzz. Check for leaks at all valve fittings using a soapy water solution (while unit is operating). Test other operating parts of all safety shut-off and control valves and increase or decrease settings (depending on the type of control) until the safety circuit opens. Reset to original setting after each device is tested. Weekly For low-pressure boilers, test low-water cut-off device.
Combustion Chamber Coil Cleaning Instructions WARNING: The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded that “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group1).
APPENDIX Inside Air Contamination Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high efficiency systems. The boiler can be supplied with corrosion-resistant, non-metallic intake air vent material. You may, however, choose to use outside combustion air for one or more of these reasons: Areas where contaminated combustion air commonly exists: 1.
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows: (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1.
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.
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.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
