HomeMy WebLinkAboutB11-0330 /(.1
\ 6
03-26-2014 Inspection Request Reporting Page 1
4:04 pm Vail, CO - City Of Mt(-5-1 2
Requested Inspect Date: Thursday,March 27 2014
Site Address: 193 GOR CREEK DR VAIL
193 Gore Creek Dr.
A/P/D Information
Activity B11-0330 Type: COMBO Sub Type: AMF Status: ISSUED
Const Type Occupancy: Use: Insp Area:
Owner SLIFER, RODNEY E.&ELIZABETH W. -JT
Contractor: ROCKY MOUNTAIN CONSTRUCTION GROUP Phone: 970-476-4458
Description: boiler and vent replacement
Requested Inspection(s)
Item: 390 MECH-Final Requested Time: 08:00 AM
Requestor: ROCKY MOUNTAIN CONSTRUCTION GROUP Phone: 970-476-4458
Assigned To SGR MER Entered By: JMONDRAGON K
Action Time Exp:,
Comment r q ired S om engineer on terminiation of flue piping inside open air type chase
Inspection History
Item 200 MECH-Rough
Item 120 ELEC-Rough
Item 542 PLAN-FINAL **Approved**
01/27/12 Inspector: bgibson Action: AP APPROVED
Comment:
Item: 190 ELEC-Final **Approved**
10/26/11 Inspector: sgremmer Action: AP APPROVED
Comment:
Item: 390 MECH-Final
02/01/12 Inspector: JRM Action: CR CORRECTION REQUIRED
Comment: required letter from engineer on terminiation of flue piping inside open air type chase
REPT131 Run Id: 14757
NOTE: TH/S PERMIT MUST BE POSTED ON JOBSITE AT ALL T/MES
_�
,.
TOW�v' OF F'r� '
Town of Vail, Community Development, 75 South Frontage Road, Vail, Colorado 81657
p. 970.479.2139, f. 970.479.2452, inpsections 970.479.2149
COMBINATION BLDG PERMIT Permit #: B11-0330
Job Address: 193 GORE CREEK DR VAIL
Location......: 193 Gore Creek Dr.
Parcel No....: 210108213003
OWNER SLIFER, RODNEY E. & ELIZABET 09/13/2011
230 BRIDGE ST
VAIL
CO 81657
APPLICANT ROCKY MOUNTAIN CONSTRUCTION 09/13/2011
120 WILLOW BRIDGE RD, STE 7
VAIL
CO 81657
License: C000003088
CONTRACTOR ROCKY MOUNTAIN CONSTRUCTION 09/13/201
120 WILLOW BRIDGE RD, STE 7
VAIL
CO 81657
License: C000003088
Description:
boiler and vent replacement
Occupancy:
Type Construction:
Phone: 970-476-4458
Phone:970-476-4458
Project #:
Applied.....:
Issued. . . :
PRJ 11-0513
09/13l2011
09/15/2011
Valuation: $147,000.00
...............................................,,........»..,.,.,................. FEE SUMMARY ...........,....,...«.,,..........,».................................,�_........
Building Permit -----------> $1,256.95 Bidg Plan Check ----------> $817.02 Use Tax Fee-----------------------> $2,740.00
Electrical Permit ---------> $115.00 Elec Plan Check -----------> $74.75 Restuarant Plan Review--------> $0.00
Mechanical Permit ------> $2,840.00 Mech Plan Check ---------> $710.00 Additional Fees--------------------> $0.00
Plumbing Permit --------> $0.00 Plmb Plan Check ---------> $0.00 Recreation Fee--------------------> $0.00
Investigation-----------------------> $0.00
Will Call------------------------------> $10.00
TOTAL PERMIT FEES-------------> $8,563.72
Payments------------------------------> $8,563.72
BALANCE DUE-----------------------> $0.00
DECLARATIONS
I hereby acknowledge that I have read this application, i 'n full the information required, completed an accurate plot plan, and state that all the information
as required is correct. I agree to comply with the information a lo o comply with all Town ordinances and state laws, and to build this structure
according to the town's zoning and subdi '' n revi approved, atec[L ional Building and Residential Codes and other ordinances of the Town
applicable thereto. �'\
REQUESTS INSPE T N ALL BE MADE TWENTY-FO HOURS IN ADVANCEBY°T�LEPHONE AT 970.479.2149 OR AT OUR OFFICE FROM
8:00 AM P �
�l�S� l �
Si nature of Own or Date
1-�-LL��
Print Name
combination permit_012811
t
�
�����i•+..� 1
+..»...x....+.+w+++...xx..+w.........+....+.x.+........w.......xx...w.......+..xxx......w.w.++..+.nxa......+....x.x..w.....+e.«...x........+w..xxw.....+.».v..ww......»+............»
CONDITIONS OF APPROVAL TO BE MET PRIOR TO FINAL SIGN OFF
Permit #: B11-0330 Address: 193 GORE CREEK DR VAIL
Owner: SLIFER, RODNEY E. & ELIZABETH W. -JT Location: 193
Gore Creek Dr.
. �., � ................................................... �.......,.............................,.....,,....,...............,................,..............,...,......,........,.,.....
combination permit_012811
i
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* * r.,r,r,r t t * * * * *,r * * * r * r,r w,r,r *,r,r,r,r,r * «w w *,r,r * * * * ,r ,r * «* w ,t * t t * * * * * * * * * * t * * ,r * «* «* ,t * * * � * ,r,r t r,r ««,r,t * * * * * * * * «,+«* * * *,r,r , t, t, t *, r r,r w rr * t,r,r * x * t * * * * * r,r «w * � w w,r,r * * «x *,r,r w * rr * * ««w
REQUIRED INSPECTIONS AND STATUSES
Permit #: 611-0330 Address: 193 GORE CREEK DR VAIL
Owner: SLIFER, RODNEY E. & ELIZABETH W. -JT Location: 193
Gore Creek Dr.
***««***.*******„*************«,.****««*«****x***********«*,.**************,,.****,.*********.,******,.*******«*******«**********.«„*„*.**«*«*««*«*******««
Item: 00200 MECH-Rough
Item: 00120 ELEC-Rough
Item: 00542 PLAN-FINAL
Item: 00190 ELEC-Final
Item: 00390 MECH-Final
combination permit_012811
*******************************+***�**+********+*****++**********************************+**
TOWN OF VAIL, COLORADO Statement
******************++*****+****************+****************+*+***************************++*
Statement Number: R110001230 Amount: $7,578.51 09/15/201104:46 PM
Payment Method: Check Init: LC
Notation: #1122 / ROCKY
MOUNTAIN CONSTRUCTION GROUP, INC.
-----------------------------------------------------------------------------
Permit No: B11-0330 Type: COMBINATION BLDG PERMIT
Parcel No: 2101-082-1300-3
Site Address: 193 GORE CREEK DR VAIL
Location: 193 Gore Creek Dr.
Total Fees: $8,563.72
This Payment: $7,578.51 Total ALL Pmts: $8,563.72
Balance: $0.00
**********************************************************************************�*********
ACCOUNT ITEM LIST:
Account Code
--------------------
BP 00100003111100
MP 00100003111100
PF 00100003112300
UT 11000003106000
Description Current Pmts
------------------------------ ------------
BUILDING PERMIT FEES 1,256.95
MECHANICAL PERMIT FEES 2,840.00
PLAN CHECK FEES 741.56
USE TAX 4% 2,740.00
-----------------------------------------------------------------------------
BUILDING PERMIT APPLICATION
(Separate applications are required for alarm R sprinkler)
Project Street Address:
L� 2� C�( �1���'z-� � i�e (�� � r�c.e m�r�r
(Number) (Street)
(Suite #)
Building/Compiex Name: � Qe �-�(FE�c_ �L !� 2 A
Contractor Information
Business Name: �oc.�� ry� ;('� ;� 5-��,.�-f-� o,-,(� 2 �� u P
BusinessAddress: I�-���w�c.c) i'�2a��� S,-e 7
City V�� � State: C.,e ZP: � 1� s�
Contact Name: ��''�-`� �-� u�� vn �� C�
Project#:_ Y'�II-��,j
DRB#: �j ��Dy �
Building Permit #: �) � - � � �j ('�
Lot #: Block # Subdivision:
Work Class: New ( ) Addition ( ) Alteration ( )
Type of Building:
Single-Family ( ) Duplex (
Commercial (•- j ther ( )_
) Multi-Family ( )
Contact Phone: -7 1 �1 `� �i � � Z�I b' Work Type: Interior ( � Exterior ( ) Both ( )
Contact E-Mail: rYU,Y �_�r k� n„n �n,-a � rl ���s ���c t�icrn
/ Valuation of
Contractor Registration Number.
���Z`' `y �'�"�' Work Included Plans Included Wor1c
X Electrical ( ✓jYes ( )No (,�Yes ( )No � 1V�1_J
-��___
Mechanical (�Yes ( )No ( c�}Yes ( )No � ���T_
Owner/Owner's Representative Signature (Required)
Plumbing ( )Yes ( )No ( )Yes ( )No �
Project Inform�tiqn
Owner Name: y� D D S c_. i�_��
Parcel #: _ 2( c 1 e �' �1 I 3 0�� ���
(For Parcel #, confact Eagle CouMy Assessors p{fice at (970-328-8640 or visit
www•eaglecounry.usfpatie)
Detailed Scope and Location of Wor1c:
(use additional sheet if necessary)
( )Yes ( )No ( )Yes ( )No
Value of all work being performed: ���UU
(value based on IBC Section 109.3 & IRC Section 108.3�
Electrical Square Footage
�' 1.-, c�p •-1.) i� ilC.J � Jk � v r ��c ri ak
For Office Use Onl •
FeePaid: S5 ,Z�- �3�qy
Received From: ��-� /��" �� (,� �,11
Cash Check # I l2t 21 (
CC: Visa / MC Last 4 CC # exp date:
Auth #
4� l� v
Date Received:__ -�
;I� (�C�(�,Ii'\'�C� ''
��D;
� �+ � �� �p 12 2011
�L �
i e� i� �� �v f� °�e e� 6?_.
01-Jan-I 1
�
TOWN OF VAIL'
Project Street Address:
193 Gore Creek Drive
(Number) (Street)
Depar�ment of Community Development
, 75 South Frontage Road
' Vail, CO 81657
� • • Te1:970-479-2128
www.vailgov.com
' Development Review Coordinator
BUILDING PERMIT APPLICATION
(Separate applications are required for alarm & sprinkler)
Building/Complex Name: Gore Creek Plaza
Contractor Information
Business Name: Double M, Inc
Business Address: P•O. Box 1462
���, Gypsum State: CO
Contact Name: Mike Medina
Contact Phone: �970) 376-4862
(Suite #)
Zip: 81637
Contact E-Mail: mikemedina@doubleminc.com
i
i(_ _ � ' ,/ � � �,� -��
Owner/Owner's Representative Signature (Required)
Applicant Information
Applicant Name: Slifer Management Company
Applicant Phone: �9�0) 926-7911
Applicant E-Mail: simonette@slifermgmt.com
Project Information Gore Creek Plaza
Owner Name:
Parcel #: 210108213011-018
(For Parcel #, coMact Eagle County Assessors OHfce at (970-328-8640 or visit
www.eagtecour�ty. uslpatie)
Project #:
DRB #:
Building Permit #:
Lot #: Block # Subdivision:
Work Class: New ( ) Addition ( ) AReration ( ✓ )
Type of Building:
Single-Family ( ) Duplex ( ) Multi-Family ( )
Commercial ( ✓ ) Other ( )
Work Type: Interior (✓) Euterior () Both ()
Valuation of
Work Included Plans Included Work
Electrical ( � )Yes ( )No ( � )Yes ( )No 5,000
Mechanical ( )Yes ( � )No ( )Yes ( )No
Plumbing ( )Yes ( � )No ( )Yes ( )No
Building ( )Yes ( � )No ( )Yes ( )No
Value of all work being performed: � 5,0000
(value based on IBC Sectlon 109.3 & IRC Section 108.3� �
Electrical Square Footage 600
", �
Detailed Scope and Location of Work: Connect new pumps and boilers to existing load and circuits.
(use addftional sheet if necessary)
For Office Use Only:
Fee Paid:
Received From:
Cash Check # _
CC: Visa / MC Last 4 CC #
Auth #
. s• + ►
� �� �_ _
exp date:
Date Received: � � f] r 7��� i� � ;V/ �
� � � (� � � ��' � �_/
�
� � � SEP 12 2011
TOWN OF VAIL
BOILER 1 BOI�ER 2 BOILER 3 CONTROL CIRC PUMP
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SNOWMELT PUMPS
P-8 Pi 9 P-10
FLOOR PLAN
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PUAIPS WILL BE CONNECIID TO EbST1NG LOAD
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WI R I N G D I A G R A M _________ I '`
NO SCALE
Air System Design Load Summary for 14 zones-GCP
'roject Name: Gore Creek Plaza - VAIL 2 07/OS/2011
'repared by: BREMA Engineering LLC 04:04PN
? tOADS
ow � Skylight Sotar Loads
Transrrnssion
Transmission
ow 7ransrrussion
�ht Transmission
Loads
Transmission
iead Lighting
Lighting
ic Equ�pment
fety Factor
Total Zone Loads
ie Condfioning
num Wail Load
num Roof Load
num Lighting Load
:urn Fan Load
itilation Load
�piy Fan Load
ace Fan Coil Fans
cY Heat Gain i Loss
Totai System Loads
ntrai Cooiing CoN
Mra! Heat(ng Coif
te Heating Unit Coils
Total Conditioning
DESIGN COOLiNG DESIGN HEATING
COOLlNG DATA AT Auc� 1600 HEATING UATA Ai DES HTG
COOLING OA DB i WB 82.0 °F ; 60.0 °F FIEFtTiNG OA QB / WB -19.0 °F /-19.0 °F
Sensibie L:�tent Sensibie Latent
�etaifs (BTUJhr) (BTUlhr) Detai(s (BTU�hr) (BTi!!hr}
2841 ft= 91811 - 2841ftz - -
10Q67 ft' -3241 - 10067 ft� 37428 -
4999 ft= 10192 - 4399 ft= 19292 -
2721 ftz t16� - 2721 ft= i8740.3 -
120 ft' 43 - 120 fk� 6899 -
A72 ft= 6722 - 472 ft= 20477 -
5326 Rz -1565 - 5326 ft= 4481 -
Oft� 0 - Oft� 0
a �c= o - o rt= e -
2t27� W 65961 - 0 0
OW 0 - 0 0 -
OW 0 - 0 0
135 31191 39500 0 0 0
- 0 0 - 0 0
- a a - a o
0% i 0°k, 0 0 0"k 0 0
- 202275 39500 - ?75980 0
- t84&68 39500 - 274615 0
0% 0 - 0 0
o� o - o a -
0°k 0 - 0 0 -
13535 CFM 0 - 13535 CFM 0
2705 CFM 13634 -19620 2705 CFM 192560 C
13535 C�M Q - 13535 CFM 0 -
- o - - n
3°b 6068 - 3°� 8279 -
- 20d370 19880 - 4T5455 0
- 229775 19892 - 0 0
- -25405 - - 475455 -
- 0 - - Q
- 204370 19892 - 475455 0
Positive values are ctg loads Positive vaiues are h#g loads
Negative values are htg loads Negative values are cig loads
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Hourly Analysis Program v.4.4 Page 1 of 1
Air System Design Load Summary for 14 zones-GCP
'roject Name: Gore Creek Plaza - VAIL 2 07/05/2011
�repared by: BREMA Engineering LLC 04:04PN
ZONE LOADS
Window E� Skylight Solar Loads
N`Jail Transmission
Roof Transmission
Window Transrrussion
Skylight Transmission
DoorLoads
Floor Transmission
Partitions
Overhead Lighting
Task LighNng
Electric Equipment
People
lnfiftration
Safety Factor
» Total Zone Loads
Zone Condfioning
Plenum Wail Load
Pienum Roof Load
Plenum Lighting Load
Return Fan Load
Ventilation Load
Suppty Fan Load
5pace Fan Coi! Fans
DucY Neat Gain 1 Loss
» Totai System Loads
�entra! Cooling Coii
Cenirai Heating Coil
Zone Heating Unit Coiis
» Total Conditioning
DESIGN COOLING DESIGN HEATING
COdLING DATA AT Aug 1600 HEA7ING DATA AT DES HTG
COQLlNG OA QB ! WB 82.0 °F ; 60A °F HEATING OA DB ! WB -19.0 °F !-18.0 °F
Sensibie Latent Sensibte Latenf
Defails (BTU/hr) (BTU/hr) detaifs {BTUfir) lBTlflhr}
2841 ft� 91811 - 2841ft' - -
10067 ftZ -3241 - 10067 ft� 37428
A999 ft= 1d192 - 4999 ft= 19292 -
2729 f3� 1169 - 2721 ft� 187403 -
120 ft� 43 - 120 fta 6899 -
A72 ft= 6722 - 472 ft= 20477 -
5326 ftz -1565 - 5326 ftz -0481 -
0 ft2 0 - 0 ft� 0 -
0 ft� 0 - 0 ftz 0 -
21272 W 65961 - 0 0
ow o - o a
QW 0 - 0 0
435 31191 39500 0 0 0
- 0 0 - Q 0
- 0 0 - 0 fl
0°.6 i 0°!0 0 0 0% 0 0
- 202275 39500 - ?75980 0
- 184668 39500 - 274615 �J
0°� 0 - Q 0
0% Q - 0 0 -
0°� d - 6 0 -
13535 CFM 0 - 13535 CFM 0 -
2705 CFM 13634 -19620 2705 CFM 192560 0
43535 CFM 0 - 13535 CFM 0
- 0 - - 0 -
3°k 6068 - 3°� 8<'79
- 204370 19880 - 475�155 0
- 229775 19892 - 0 0
- -25405 - - 475455 -
- 0 - - 0 -
- 204370 19892 - 475455 0
Positive values are cig ioads Positive vaiues are htg ioads
Negative values are htg loads Neyative values are cig toads
p�a�.R�G!s�
; PG�p S. De�9���y�
�� �� �
35036 �
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Hourly Analysis Program v.4.4 Page 1 of 1
Air System Design Load Summary for 14 zones-GCP
�roject Name: Gore Creek Plaza - VAIL 2 07/OS/2011
�repared by: BREMA Engineering LLC 04:04PN
ZONE LOADS
Window & Skylight Solar Loads
1n,Yal! Transmission
Roof Transmission
L�i+ndow Transmission
Sicyfighf 7ransmissiort
Doo; Loads
Floor Transmission
iead Lighting
Lighting
�ic Equtpment
fety Factor
Total Zone Loads
ne Conditioning
;num Wail Load
�num Roof Laad
rnum Lighting Load
turn Fan load
ntilation Load
pply Fan Load
ace Fan Coi! Fans
ct Heat Gain % Loss
Total System Loads
ntral Coafing Cod
ntral Heating Coil
ne Heating Unii Coils
Total Conditioning
DEStGN COOLtNG DESIGN HEATING
COOLlNG L�ATA AT Aug 1600 HEA7ING DATA AT DES HTG
GOOLING OA DB t WB 62.0 °F t 60.4 °F HEATlNG OA D6/ WB -19.0 °F !-19.0 °F
Sensible i.atent Ser:sibie Lafent
Defaifs (BTU/hr) (BTUlhr} Detaiis (BNfir) (BTU/hr}
2841 ftz 91811 - 2841 ft' - -
t0067 ftz -3241 - 10067 ft� 37428 -
d999 ft= 16192 - 4899 ft= 19292
2721ft= 1161 - 2721 ft= 187403 -
12Q ft' 43 - 120 ftz 6899 -
472 ft= 6722 - 472 ff= 24477
5326 ft2 -1565 - 5326 ft= 4481 -
0 ftz 0 - 0 ftz 0 -
Oft= 0 - Oftz 0 -
21272 W 65961 - Q 0 -
ow o - o a -
OW 0 - 0 0 -
135 31191 39500 0 0 0
- � 0 - 0 0
- o a - o 0
0"h r 0°,6 4 0 0°r6 0 0
- 202275 39500 - 275980 0
- 184&68 395Q0 - 274615 0
0% Q - 0 0 -
o� o - o a -
0°k 0 - d 0
13535 CFM 0 - 13535 CFM 0
2705 CFM 13634 -19620 2705 CFM 192560 0
13535 GFM Q - 13535 CFM 4
- 0 - - � -
3°k 6068 - 3°.6 8279
- 204370 19880 - 475455 0
- 229775 19892 - 0 0
- -25405 - - 475455 -
- d - - 0
- 204370 19892 - 475455 0
Positive values are cMg loads Positive values are htg ioads
Negative values are htg loads Negative vatues are clg toads
�P�O REG/�
p� •G�p S. D��9.��
: 2P 90 :
. c� �. :
; � 35036 ;
Hourly Analysis Program v.4.4 Page 1 of 1
INSTALLATION & OPERATING
1 NSTRUCTIONS
�R�
�:��
-
-
Models 300-850
Types H & WH
pESlc(y
� ,�,
H -���-
cEHIFIEo
CE4TIflE0
WARNING: Improper installation, adjustment, alteration, service or maintenance can'
I cause property damage, personai injury, exposure to hazardous materiais* 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.
�
, I � I ,
Catalog No. 1000.65B Effective: 09-10-10 Replaces: 08-05-10 P/N 241366 Rev. 3
Rev. 3 includes the following:
Changes to: Table I on page 16, Fig. 35 on page 42, Table S on page 43
Additions: None
Deletions: None
CONTENTS
WARNINGS
Pay Attention to These Terms
BEFORE INSTALLATION
Product Receipt
Model Identification
Ratings and Certifications
Installations at Elevation
Component Locations
General Information
Time/Temperature Relationships
in Scalds
GENERAL SAFETY
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 Connection
Venting
Venting Installation Tips
Venting Configurations
Outdoor Installation
Controls
Operating Instructions
4
4
5
5
5
5
5
6
6
7
7
8
8
8
8
9
11
12
13
16
17
19
23
25
26
31
32
35
3
WIRING DIAGRAM
START-UP
Pre Start-up
Pre Start-up Check
Initial Start-up
Preparation
Start-Up
OPERATION
Lighting Instructions
To Turn Off Gas to Appliance
XFyre Error Codes
Heater Errors
Heater Faults
TROUBLESHOOTING
XFyre Fault Text
Sensor Resistance Values
MAINTENANCE
Suggested Minimum
Maintenance Schedule
Preventive Maintenance
Schedule
APPENDIX
Inside Air Contamination
Important Instructions for the
Commonwealth of Massachusetts
WARRANTY
START-UP CHECKLIST
40
41
41
41
41
42
42
44
44
45
45
45
45
45
46
48
49
.•
49
52
52
53
54
55
WARN I NGS
Pay Attention to These Terms
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.
CAUTION• Indicates the presence of hazards or unsafe practices which could cause
' minor personal injury or product or property damage if ignored.
NOTE: Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
DANGER: Make sure the gas on which the boiler WARNING - CALIFORNIA PROPOSITION
will operate is the same type as that specified on the 65: This product contains chemicals known to the
boiler rating plate. State of California to cause cancer, birth defects or
other reproductive harm.
WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect CAUTION: If this boiler is to be installed above
the electrical supply to the boiler. Instead, shut off radiation level, it must be provided with a low water
the gas supply at a location external to the boiler. cut-off device at the time of boiler installation.
WARNING: Do not use this boiler if any part has CAUTION: This boiler requires forced water
been under water. Immediately call a qualified circulation when the burner is operating. See
service technician to inspect the boiler and to minimum and maximum flow rates. Severe damage
replace any part of the control system and any gas will occur if the boiler is operated without proper
control which has been under water. water flow circulation.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the boiler:
• Always keep the area around the boiler free of
combustible materials, gasoline, and other
flammable liquids and vapors.
Boiler should never be covered or have any
blockage to the flow of fresh air to the boiler.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
4
CAUTION: If this boiler is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consuit factory
for details.
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.
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. (Refer to the warranty at the back of this
manual.) Installation and service must be performed
by a qualified instailer, service agency or gas supplier.
If, after reviewing this manual, you still have questions
which this manual does not answer, please contact
your local Raypak representative or visit our website at
www.raypak.com.
Thank you for purchasing a Raypak product. We hope
you will be satisfied with the high quality and durability
of our equipment.
Product Receipt
WARNING: Pump motors should NOT be
supported by any type of stand or support from
above due to possible misalignment of pump and
motor which may occur.
On receipt of your heater it is suggested that you visu-
ally check for external damage to the shipping crate. If
the crate is damaged, make a note to that effect on the
Bill of Lading when signing for the shipment. Next,
remove the heater from the shipping packaging.
Report any damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that
you receive the correct number of packages as indi-
cated on the Bill of Lading.
Claims for shortages and damages must be filed with
the carrier by consignee. Permission to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.
When ordering parts, you must specify the model and
serial number of the heater. When ordering under war-
ranty conditions, you must also specify the date of
installation.
Model Identification
The model identification number and heater seriai
number are found on the heater rating plate located on
the upper rear jacket panel of the heater. The model
number will have the form H7-850 or similar depend-
ing 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). The second group of char-
acters identifies the size of the heater (three numbers
representing the approximate MBTUH input), and,
where applicable, a letter, indicating the manufacturing
series.
Ratings and Certifications
Standards:
• ANSI Z21.13 � CSA 4.9 - latest edition, Gas-Fired
Hot Water Boilers
• ANSI Z21.10.3 � CSA 4.3 - latest edition, Gas
Water Heaters
• CAN 3.1 - latest edition, Industrial and
Commercial Gas-Fired Package Boilers
• SCAQMD Rule 1146.2
• CSA verified compliance with California AB1953
and Vermont Legislative Act 193 requirements.
All Raypak heaters are National Board Registered,
and design-certified and tested by the Canadian
Standards Association (CSA) for the U.S. and Canada.
Each heater is constructed in accordance with Section
IV of the American Society of Mechanical Engineers
(ASME) Boiler and Pressure Vessel Code and bears
the ASME "H" stamp. This heater also complies with
the latest edition of the ASHRAE 90.1 Standard.
WARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers or any
ASME parts not manufactured andlor approved by
Raypak will instantly void the ASME and CSA ratings
of the vessel and any Raypak warranty on the
vessel. Altering the ASME or CSA ratings of the
vessel also violates national, state, and local
approval codes.
Installations at Elevation
Rated inputs are suitable for up to 2000 ft elevation
Purchased parts are subject to replacement only without de-rating. Consult your local representative or
under the manufacturer's warranty. Debits for defec- the factory for installations at altitudes over 2000 ft
tive replacement parts will not be accepted. Parts will above sea level. No hardware changes are required to
be replaced in kind only per Raypak's standard war- the heaters for installations up to 10,000 ft(adjust-
ranties. ments may be required).
5
Component Locations
�ow sv
ii�iT
• �
FRONT OF
HEATER
Model 300 shown. Component locations may vary slightly in larger models. y�v• �
Fig. 1: Component Locations — Sides
WATER COMPONENT LOCATIONS – TOP
Fig. 2: Component Locations — Top
General Information
FLUE
OUTLET
COMPONENT LOCATIONS — REAR
ELECTRICAL
CONNEC110NS
Fig. 3: Component Locations — Rear
MBTUH yyater Gas conn. Vent Size
Model Input conn. (NPT) (inches)
No.
Max. Min. �NPT� N P Flue Intake
300 300 60 1-1/2" 3/4" 3/4" 4 4
400 399 80 2" 1" 1" 4 4
500 500 100 2" 1" 1" 4 4
700 700 140 2" 1-1/4" 1-1/4" 6 6
850 850 170 2" 1-1/4" 1-1/4" 6 6
Table A: Basic Data
6
Model No. Heater Water Volume
(gallons)
300 2.9
400 3.6
500 4.2
700 5.0
850 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
210°F. However, water temperatures over 125°F can
cause instant severe burns or death from scalds.
When supplying general purpose hot water, the rec-
ommended initial setting for the temperature control is
125°F.
Safety and energy conservation are factors to be con-
sidered when setting the water temperature on the
thermostat. The most energy-efficient operation will
result when the temperature setting is the lowest that
satisfies the needs of the application.
Water temperature over 125°F can
cause instant severe burns or death
from scalds.
Children, disabled, and elderly are
at highest risk of being scalded.
See instruction manual before set-
ting temperature at water heater.
Feel water before bathing or show-
ering.
Temperature limiting valves are
available, see manual.
Water temperature over 125°F can cause instant
severe burns or death from scalds. Children, disabled Time/Temperature
and elderly are at highest risk of being scalded. R@�at1011S�'11pS 111 SC1�C�S
• Feel water before bathing or showering.
• Temperature limiting valves are available.
NOTE: When this heater is supplying general
purpose hot water for use by individuals, a
thermostatically controlled mixing valve for reducing
point of use water temperature is recommended to
reduce the risk of scald injury. Contact a licensed
plumber or the local plumbing authority for further
information.
Maximum water temperatures occur just after the
heater's burner has shut off. To determine the water
temperature being delivered, turn on a hot water
faucet and place a thermometer in the hot water
stream and read the thermometer.
CAUTION: Hotter water increases the risk of
scalding! There is a hot water scald potential if the
thermostat is set too high.
The following chart details the relationship of water
temperature and time with regard to scald injury and
may be used as a guide in determining the safest
water temperature for your applications.
Water Time to Produce Serious
Temp. Burn
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About1 second
Table courtesy of The Shriners Burn Institute
Table C: Time to Produce Serious Burn
INSTALLATION
Installation Codes
Installations must follow these codes:
• Local, state, provincial, and national codes, laws,
regulations and ordinances
• National Fuel Gas Code, ANSI Z223.1/NFPA 54 –
latest edition (NFGC)
• National Electrical Code, ANSI/NFPA 70 - latest
edition (NEC)
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1,
(CSD-1) when required
• For Canada only: CAN/CSA B149 Natural Gas
and Propane Installation Code and CSA C22.1
C.E.C. Part 1 (C22.1)
Equipment Base
The heater must be mounted on a level, structurally
sound surface. The heater is approved for installation
on a combustible surface but must NEVER be
installed on carpeting. Gas-fueled equipment installed
in enclosed parking garages must be located at least
18 in. above the floor.
CAUTION: The boiler must be level to allow
condensate to drain properly from the heat
exchanger.
CAUTION: This boiler should be located in an area
where water leakage will not result in damage to the
area adjacent to the appliances or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable catch pan, adequately
drained, be installed under the appliance. The pan
must not restrict air flow.
In addition, the heater shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation or service (circulator replacement, control
replacement, etc.).
If the heater needs to be secured to the ground, use
the holes in the anchoring legs on the heater.
8
Clearances
Indoor Installations
Heater Min. Clearances Minimum
Side from Combustible Service
Surfaces Clearances
Floor" 0" 0"
Rear 24" 24"
Right Side 0" 0"
Left Side 0" 0"
Top 12" 24"
Front Open 24"
Vent 1" 1"
'DO NOT install on carpeting.
Table D: 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 construction around the heater. However, for ease
of servicing, we recommend a clearance of at least 24
in. in front, at least 24 in. on the rear and 24 in. above
the top of the heater. This will allow the heater to be
serviced in its installed location without movement or
removal of the heater.
Service clearances less than the minimum may
require removal of the heater to service either the heat
exchanger or the burner components. In either case,
the heater must be installed in a manner that will
enable the heater to be serviced without removing any
structure around the heater.
Outdoor Installations
These heaters are design-certified for outdoor installa-
tion. Heaters must not be installed under an overhang
unless clearances are in accordance with local instal-
lation codes and the requirements of the gas supplier.
Three sides must be open in the area under the over-
hang. Roof water drainage must be diverted away
from heaters installed under overhangs.
I9?��
��;��;�r51�1:1
v�ncn� c�nrrcE
(ALL INSTALLATIONS)
?4"
tVICE
RANCE
24"
SERVICE
CLEARANCE
Venting not shown for clarity. Heater must be vented per
instructions in this manual
Fig. 4: Minimum Clearances from Combustible
Surfaces — Indoor and Outdoor Installations
9
Heater Min. Clearances Minimum
Side from Combustible Service
Surfaces Clearances
Rear 24" 24"
Right Side 0" 0"
Left Side 0" 0"
Top 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
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.
Indoor Units
This heater must be supplied with sufficient quantities
of non-contaminated air to support proper combustion
and equipment ventilation. Combustion air can be sup-
plied via conventional means where combustion air is
drawn from the area immediately surrounding the
heater, or via direct vent, where combustion air is
drawn directly from outside. All installations must com-
ply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the boiler and void the warranty. (See
the Appendix.)
NOTE: It is recommended that the intake vent be
insulated in cold climates to minimize sweating.
Fig. 5: Minimum Clearances from VenUAir Inlet Terminations — Indoor and Outdoor Installations
U.S. Installations� Canadian InstallationsZ
A Clearance above grade, veranda, porch, 1 ft(30 cm) 1 ft (30 cm)
deck, or balcony
Clearance to window or door that may be 4 ft(1.2m) below or to side
B opened of opening; 1 foot (30 cm) 3 ft (91 cm)
above opening
C Clearance to permanently closed window * *
Vertical clearance to ventilated soffit located
above the terminal within a horizontal dis- � � ,
� tance of 2 ft(61cm) from the centerline of the 5 ft 1.5m
terminal
E Clearance to unventilated soffit * *
F Clearance to outside corner * *
G Clearance to inside corner 6 ft(1.83m) *
Clearance to each side of center line ex- 3 ft (91 cm) within a height
H tended above meter/regulator assembly * 15 ft above the me-
ter/regulator assembly
I Clearance to service regulator vent outlet * 6 ft(1.83m)
Clearance to non-mechanical air supply inlet 4 ft(12m) below or to side
J to building or the combustion air inlet to any of opening; 1 ft(30 cm) 3 ft (91 cm)
other appliance above opening
K Clearance to mechanical air supply inlet 3 ft(91 cm) above if within 6 ft (1.83m)
10 ft (3m) horizontally
� Clearance above paved sidewalk or paved 7 ft (2.13m) 7 ft (2.13m) t
driveway located on public property
M Clearance under veranda, porch, deck or * 12 in. (30 cm) TT
balcony
' In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
Z In accordance with the current CAN/CGA-B149 Installation Codes
t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves
both dwellings
TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and
underside of veranda, porch, deck or balcony is greater than 1 ft(30cm)
" Clearances in accordance with local installation codes and the requirements of the gas supplier
Table F: VenUAir Inlet Termination Ciearances
10
Combustion Air Filter
This heater is supplied with an integral combustion air
filter. This fiiter 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
checked periodically to verify that adequate combus-
tion air is being supplied to the heater. See the
Maintenance section of this manual for information on
checking the filter and establishing service intervals.
Direct Vent
If outside air is drawn through the intake pipe directly
to the unit for combustion:
1. Install the combustion air ducting kit.
2. Install combustion air direct vent in accordance
with Fig. 23 (horizontal) or Fig. 24 (vertical) of this
manual.
3. Provide adequate ventilation of the space occu-
pied by the heater(s) by an opening(s) for
ventilation air at the highest practical point com-
municating with the outdoors. The total
cross-sectional area shall be at least 1 in.2 of free
area per 20,000 BTUH (111 mm2 per kW) of total
input rating of all equipment in the room when the
opening is communicating directly with the out-
doors or through vertical duct(s). The total
cross-sectional area shall be at least 1 in.2 of free
area per 10,000 BTUH (222 mm2 per kW) of total
input rating of all equipment in the room when the
opening is communicating with the outdoors
through horizontal duct(s).
4. In cold climates, and to mitigate potential freeze-
up, Raypak highly recommends the installation of
a motorized sealed damper on the air intake to
prevent the circulation of cold air through the
heater during the non-operating hours.
TruSealT"' Combustion Air
In addition to the 4 previous steps, combustion air may
be ducted directly to the heater by using PVC, CPVC
or sealed single-wall galvanized ducting. The duct will
attach directly to the air collar located on the rear of the
heater when the combustion air ducting kit is installed,
using three or four sheet metal screws (not supplied)
equally positioned around the circumference of the
duct. The screws and duct connection point must be
sealed with RTV (not supplied). TruSeal is generally
used when damaging contaminants are present in the
11
mechanical room. All ducting must be self-supported.
CAUTION: Use TruSeal combustion air if
damaging airborne contaminants are or may be
present in the boiler area. See the Appendix of this
manual regarding air contamination.
Conventional Combustion Air
Supply
U.S. Installations
All Air from Inside the Building
The confined space shall be provided with TWO per-
manent openings communicating directly with an
additional room(s) of sufficient volume so that the com-
bined volume of all spaces meets the criteria for a
room large in comparison (NFGC). The total input of all
gas utilization equipment installed in the combined
space shall be considered in making this determina-
tion. Each opening shall have a minimum free area of
1 in.2 per 1,000 BTUH (2,225 mm2 per kW) of the total
input rating of all gas utilization equipment in the con-
fined space, but not less than 100 in.2 (645 cm2). One
opening shall commence within 12 in. (305 mm) of the
top, and one opening shall commence within 12 in.
(305 mm) of the bottom of the enclosure. The mini-
mum dimension of air openings shall be not less than
3 in. (76 mm) in any direction.
All Air from Outdoors
The confined space shall communicate with the out-
doors in accordance with one of the methods below.
The minimum dimension of air openings shall not be
less than 3 in. (76 mm) in any direction. Where ducts
are used, they shall be of the same cross-sectional
area as the net free area of the openings to which they
connect.
Two permanent openings, one commencing
within 12 in. (305 mm) of the top, and one com-
mencing within 12 in. (305 mm) of the bottom of
the enclosure, shall be provided. The openings
shall communicate directly, or by ducts, with the
outdoors or spaces (crawl or attic) that freely com-
municate with the outdoors.
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 mm2 per kW} of total
input rating of all equipment in the enclosure.
b. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in.2 per 2,000
BTUH (1,100 mm2 per kW) of total input rat-
ing of all equipment in the enclosure.
2. One permanent opening, commencing within 12
in. (305 mm) of the top of the enclosure, shall be
permitted where the equipment has clearances of
at least 1 in. (25 mm) from the sides and back and
6 in. (152 mm) from the front of the appliance. The
opening shall directly communicate with the out-
doors or shail communicate through a vertical or
horizontal duct to the outdoors or spaces that
freely communicate with the outdoors, and shall
have a minimum free area of:
a. 1 in.2 per 3,000 BTUH (740 mm2 per kW) of
the total input rating of all equipment located in
the enclosure, and
b. Not less than the sum of the areas of all vent
connectors in the confined space.
and terminated 18 in. (450 mm) from the floor, but
not near piping. This air supply opening require-
ment shall be in addition to the air opening for
ventilation air required in 1. (above).
WARNING: Care must be taken to ensure that the
equipment room is not under negative pressure
conditions.
3
WARNING: Do not use the "one permanent
opening" method if the equipment room is under
negative pressure conditions.
4
Canadian Instaliations
CAUTION: All combustion air must be drawn from
the air outside of the building; the mechanical equip-
ment room must communicate directly with the
outdoors.
Ventilation of the space occupied by the heater
shall be provided by an opening(s) for ventilation
air at the highest practical point communicating
with the outdoors. The total cross-sectional area of
such an opening(s) shall be at least 10% of the
area required in 2. and 3. (below), but in no case
shall the cross-sectional area be less than 10 in.2
(65 cm2).
For heaters using a barometric damper in the vent
system, there shall be a permanent air supply
opening(s) having a cross section area of not less
than 1 in.2 per 7,000 BTUH (320 mm2 per kW) up
to and including 1 million BTUH, plus 1 in.2 per
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. The duct is preferred to be straight down
12
For heaters when air supply is provided by natural
air flow from outdoors for a power burner and
there is no draft regulator, drafthood or similar flue
gas dilution device installed in the same space, in
addition to the opening for ventilation air required
in 1., there shall be a permanent air supply open-
ing(s) having a total cross-sectional area of not
less than 1 in.2 for each 30,000 BTUH (74 mmz per
kW) of total rated input of the burner(s), and the
location of the opening(s) shall not interfere with
the intended purpose of the opening(s) for ventila-
tion air referred to in 1. This opening(s) can be
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.
The duct is preferred to be straight down 18 in.
(450 mm) from the floor, but not near piping.
Refer to the B149 Installation Code for additional
information.
Water Piping
General
The heater should be located so that any water leaks
will not cause damage to the adjacent area or struc-
tures.
CAUTION: This boiler requires forced water
circulation when the burner is operating. See Table
G and Table H for minimum and maximum flow rates
and water pump selection. The pump must be
interlocked with the boiler to prevent heater
operation without water circulation.
NOTE: Minimum pipe size for in/out connections is
1-1/2" NPT for model 300 and 2" NPT for models
400, 500, 700 and 850. Verify proper flow rates and
�T as instructed in this manual.
NOTE: The continuous inlet water temperature
must be no less than 50°F.
Relief Valve Installation and Piping
WARNING: Pressure relief valve discharge piping
must be piped near the floor and close to a drain to
eliminate the potential of severe burns. Do not pipe
to any area where freezing could occur. Refer to
local codes.
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 valve. The
relief valve shall be mounted with its spindle vertical
(see Fig. 1, 2 and 3 on page 6). Relief valve discharge
piping shall provide no less than the cross sectional
area of the relief valve outlet and must be routed to a
safe point of discharge. Installation must comply with
all national, state and local codes.
WARNING: The pressure relief valve must be
installed at the outlet of the boiler. No valve is
permitted to be installed between the boiler and the
relief valve.
Terr�perature 8� Pressure Gauge
The temperature and pressure gauge is shipped loose
for field installation and must be installed within 12
inches of the boiler outlet (if possible) in an easily
readable location. Installation must comply with ASME
Section IV as well as all applicable national, state and
local codes.
Hydrostatic Test
Unlike many types of heaters, this heater does not re-
quire hydrostatic testing prior to being placed in
operation. The heat exchanger has already been fac-
tory-tested and is rated for 160 psi operating pressure.
However, Raypak does recommend hydrostatic test-
ing of the piping connections 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.
Leaks must be repaired at once to prevent damage to
the heater. NEVER use petroleum-based stop-leak
compounds.
13
To perform hydrostatic test:
Connect fill water supply. With bleed valve open,
fill heater with water. When water flows from bleed
valve, shut off water. Close bleed valve. Carefully
fill the rest of the system, making sure to eliminate
any entrapped air by using high-point vents. Close
feed valve. Test at standard operating pressure for
at least 24 hours.
2. Make sure constant gauge pressure has been
maintained throughout test.
3. Check for leaks. Repair if found.
Hydronic Heating
Pump Selection
In order to ensure proper performance of your heater
system, you must install a correctly-sized pump. Ray-
pak recommends designing for a OT within the range
of 20°F to 40°F (5°C to 20°C). See Table G for accept-
able flow rates for each model (OT is the temperature
difference between the inlet and outlet water when the
heater is firing at full rate).
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 should be vented. A heater installed
above radiation level must be provided with a low wa-
ter cut-off device (sales order option F-10). This
heater, when used in connection with a refrigeration
system, must be installed so that the chilled medium is
piped in parallel with the heater with appropriate
valves to prevent the chilled medium from entering the
heater.
The piping system of a hot water heater connected to
heating coils located in air handling units where they
may be exposed to circulating refrigerated air, must be
equipped with flow control valves or other automatic
means to prevent gravity circulation of the heater
water during the cooling cycle. It is highly recommend-
ed that the piping be insulated.
Air-Separation/Expansion Tank
EXPANSION TANK
AIR SEPARATOR
WITH BLEED VALVE
� u
Fig. 6: Air-Separation/Expansion Tank
All heaters should be equipped with a properly sized
expansion tank and air separator fitting as shown in
Fig. 6 above.
Three-Way Valves
Three-way valves intended to regulate system water
temperatures by reducing flow in the boiler should not
be used. Raypak heaters are high-recovery, low-mass
heaters which are not subject to thermal shock.
`Maximum 4 times the pipe diameter or 12", whichever is less.
Fig. 7: Single Heater — Low-Temperature (Heat Pump)
Application with Primary/Secondary Piping
*Maximum 4 times the pipe diameter or 12", whichever is less.
Fig. 8: Dual Heaters (Reverse/Return)
with Primary/Secondary Piping
Domestic Hot Water
When designing the water piping system for domestic
hot water applications, water hardness should be con-
sidered. Table H indicates the suggested flow rates for
soft and medium water. Hard water must be softened
for direct heating with the XFyre. Water hardness is
expressed in grains per gallon.
Model 20°F OT 30°F 4T 40°F 4T Min. Flow Max. Flow
No. gpm 4P (ft) gpm �P (ft) gpm 4P (ft) gpm OP (ft) OT gpm OP (ft) 4T
300 28 17 19 8 14 5 14 5 40 36 28 16
400 38 18 25 7 19 4 19 4 40 47 29 16
500 47 16 31 7 24 4 24 4 40 56 23 17
700 66 30 44 13 33 7 33 7 40 70 34 19
850 80 40 53 17 40 9 40 9 40 80 40 20
Notes: Basis for minimum flow is 4T . Basis for maximum flow is gpm.
Table G: Heater Rates of Flow and Pressure Drops
14
��
FROM SYSTEM
Fig. 9: Single Domestic Hot Water Heater
and Storage Tank
c� n
Fig. 10: Multiple Boilers — Reverse Return,
Primary/Secondary Piping with Indirect DHW
NOTE: If local codes require a vacuum relief valve,
acquire one locally and install per valve
manufacturer's instructions.
Potable Water and Space Heating
CAUTION: When this heater is used for both
potable water and space heating, observe the
following to ensure proper operatian.
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 heating.
3. If the heater will be used to supply potable water,
it shall not be connected to any heating system or
components previously used with a non-potable
water heating appliance.
4. When the system requires water for space heating
at temperatures higher than 140°F (60°C), a
means such as a mixing valve shall be installed to
temper the water in order to reduce scald hazard
�o potential.
Model Soft (0-4 grains per gallon) Medium (�15 grains per gallon)
No. 4T gpm 4P MTS SHL �T gpm 4P MTS SHL
300 30 19 8 1-1/2 10 24 24 17 1-1/2 19
400 30 25 7 2 8 20 38 18 2 21
500 30 31 7 2 8 20 47 16 2 20
700 30 44 13 2 17 20 66 30 2 38
850 32 51 16 2 20 24 67 28 2 36
4T = Temperature rise, °F.
�P = Pressure drop through heat exchanger, ft.
SHL = System head loss, ft(based on heater and tank placed no more than 5 ft apart and equivalent length of 25 ft of tubing).
gpm = Gallons per minute, flow rate.
MTS = Minimum tubing size.
CAUTION: For scale free operation with Medium water (5-15 grains per gallon of total hardness), the operating control must NOT
be set higher than 130°F. For higher than 130°F operation, or Hard water (>16 grains per gallon of total hardness), a water sof-
tener/treatment system must be utilized.
Table H: Domestic Water Heater Flow Rate Requirements
15
Gas Supply CAUTION: Do not use Teflon tape on gas line pipe
thread. A pipe compound rated for use with natural
DANGER: Make sure the gas on which the heater and propane gases is recommended. Apply
wili operate is the same type as specified on the rat- sparingly only on male pipe ends, leaving the two
ing plate. end threads bare.
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve lo-
cated outside the heater jacket. It is recommended
that a union be installed in the gas supply piping adja-
cent to the heater for servicing. The gas supply
pressure to the heater must not exceed 10.5 in. WC for
natural gas or 13.0 in. WC for propane gas. A pounds-
to-inches regulator must be installed to reduce the gas
supply pressure if it is higher than noted above. This
regulator should be placed a minimum distance of 10
times the pipe diameter upstream of the heater gas
controls. Refer to Table J for maximum pipe lengths.
Gas Supply Connection
CAUTION: The heater must be disconnected from
the gas suppiy during any pressure testing of the gas
supply system at test pressures in excess of 1/2 psi
(3.45 kPa).
The heater must be isolated from the gas supply pip-
ing system by closing the upstream manual shut-off
valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than
1/2 psi (3.45 kPa). Relieve test pressure in the gas
supply line prior to re-connecting the heater and its
manual shut-off valve to the gas supply line. FAILURE
TO FOLLOW THIS PROCEDURE MAY DAMAGE
THE GAS VALVE. Over-pressurized gas valves are
not covered by warranty. The heater and its gas con-
nections shall be leak-tested before placing the
appliance in operation. Use soapy water for leak test.
DO NOT use an open flame.
SEDIMENT
TRAP
JACKEi
Fig. 10: Gas Suppiy Connection
WREN�H�N�
NIPPLE
16
CAUTION: Support gas supply piping with
hangers, not by the heater or its accessories. Make
sure the gas piping is protected from physical
damage and freezing, where required.
Gas Supply Pressure
A minimum of 4.0 in. WC and a maximum of 10.5 in.
WC upstream gas pressure is required under load and
no-load conditions for natural gas. A minimum of 4.0
in. WC and a maximum of 13.0 in. WC is required for
propane gas. The gas pressure regulator(s) supplied
on the heater is for low-pressure service. If upstream
pressure exceeds these values, an intermediate gas
pressure regulator, of the lockup type, must be
installed.
When connecting additional gas utilization equipment
to the gas piping system, the existing piping must be
checked to determine if it has adequate capacity for
the combined load. The gas valve pressure regulator
on the heater is nominally preset as noted in Table I.
During normal operation, carbon dioxide should be 8.5
to 9.0% at full fire for natural gas and between 9.0 and
9.5% for propane gas. Carbon monoxide should be
<150 ppm.
Manifold Pressure (in. WC)
Model Natural Gas Propane Gas
N o.
High Low High Low
300 -0.2 -0.1 -0.2 -0.1
400 -0.2 -0.1 -0.2 -0.1
500 -0.4 -0.1 -0.4 -0.1
700 -1.5 -0.2 -2.2 -0.2
850 -2.7 -0.2 -1.6 -0.1
NOTE: Manifold pressures should be t0.3 in. WC.
Table I: Manifold Gas Pressure Settings
Model 3/4" NPT 1" NPT 1-1/4" NPT 1-1/2" NPT 2" NPT
No. N P N P N P N P N P
300 15 30 45 100 175 400 390
400 30 70 120 275 270 414
500 15 40 65 150 150 350
700 42 96 96 220 310 795
850 25 55 55 125 175 450
Natural Gas — 1,000 BTUlft3, 0.60 specific gravi;y ai 0.5 in. WC pressure drop
Propane Gas — 2,500 BTU/ft3, 1.53 specific gravity at 0.6 in. WC pressure drop
Table J: Maximum Equivalent Pipe Length
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 Canada, CSA C22. 1 C.E.C. Part 1.
The XFyre 300-850 heaters are wired for 120 V sin-
gle-phase 60 Hz power. Consult the wiring diagram
shipped with the heater. Before starting the heater,
check to ensure proper voltage to the heater and
pump(s). A larger circuit breaker may be needed for
pumps larger than 1/4 hp.
Boiler pumps up to 1 hp and DHW pumps up to 1/4 hp
get their power supply directly from the heater power
supply (connections in rear wiring box). XFyre heaters
�O
�L��M COM O O
�
MC O
GM �UMP MEUTO O
Il�lf 120Y Q
DII� PUMP XOT O
p [y �
PYY���MEIfTO
r�iwd° `tN°oT QQ O
BROUMD O O O
O�
6ROUMD O O �
O�
MEUT��LO O O
O�
i1CR (NOTIO O O
� �/M lOIfSC �EV2 �
Fig. 11a: Wiring Electrical Connections
17
may power up to two pumps directly (1 hp max boiler
pump, 3 A max DHW pump) and may control a third
system pump, depending on the configuration of the
controller and the installation requirements. Install a
circuit breaker sized su�ciently for both the heater and
the pump(s). DHW pumps larger than 1/4 hp or 3 A
must use a separate power supply and run the power
through an external field supplied pump contactor. Use
appropriately-sized wire as defined by NEC, CSA
and/or local codes. All primary wiring should be 125%
of minimum rating.
If any of the original wire as supplied with the heater
must be replaced, it must be replaced with 105°C wire
or its equivalent.
All 120 VAC field wiring connections to the XFyre
heater are made inside the rear wiring box as shown
in Fig. 11a. Power to the XFyre heater should be con-
nected to terminals 1, 2, and 3 as shown in Fig. 11a.
Low voltage wiring is connected to the field wiring
board at the front of the unit. Sensors, Thermostat (TT)
fY87s1 H�!
a� F� T9t O _
BOILER O
PIIMP NEUTO
BOILER 6 O
PUMP NOT �
6ROUMD O O O
O�
6ROUMD O � O
O�
MEUTRALO O O
O C
120 V O �
BL�CII (IqT)O � �
Fig. 11b: Wiring Electrical Connections
Cascade Master
contacts, optional 0-10 VDC control wiring and cas-
cade connections are wired into the front mounted
field wiring board as shown in Fig. 15-19.
Field-Connected Controllers
It is strongly recommended that all individually-pow-
ered control modules and the heater should be
supplied from the same power source.
NOTE: Field-supplied isolation relays should be
installed when field-connected controllers are
mounted more than 50 equivalent feet (18 AWG)
from heater.
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.
.:e��.
.
� :
�
�
�
.�
�
�
�
�
I//
�/
I/�
%I
�% ..—....—..
�i� '
' � �
i�i �-�
' ■■1
'� ■■
Fig. 12: Wiring Connections
��
nnn n
uuu.0
� �
Fig. 13: Multi-meter
Making the Electrical Connections
Refer to Fig. 11 a-19.
1. Verify that circuit breaker is properly sized by
referring to heater rating plate. A dedicated circuit
breaker should be provided and sized for the
heater and all pumps powered through the heater.
NOTE: Current draw noted on rating plate does not
include pump current.
2. Turn off all power to the heater. Verify that power
has been turned off by testing with a multi-meter
prior to working with any electrical connections or
components.
3. Observe proper wire colors while making electri-
cal connections. Many electronic controls are
polarity sensitive. Components damaged by im-
proper electrical installation are not covered by
warranty.
4. Provide overload protection and a disconnect
means for equipment serviceability as required by
local and state code.
5. Install heater controls, thermostats, or building
management systems in accordance with the
applicable manufacturers' instructions.
WARNING- Using a multi-meter, check the 6. Conduit should not be used as the earth ground.
following voltages at the circuit breaker panel prior to
connecting any equipment. Make sure proper
polarity is followed and house ground is proven. NOTE: A grounding electrode conductor shall be
(See Fig. 13.) used to connect the equipment grounding
Check the power source: conductors, the equipment enclosures, and the
grounded service conductor to the grounding
AC = 108 VAC Minimum, 132 VAC MAX electrode.
AB = 108 VAC Minimum, 132 VAC MAX
BC = <1 VAC Maximum
18
Field Wiring Connections
DANGER: SHOCK HAZARD
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause im-
proper and dangerous operation. Verify proper
operation after servicing.
Make sure electrical power to the heater is discon-
nected to avoid potential serious injury or damage to
components.
Fig. 14: Rear Wiring Location
Fig. 15: Front Wiring Location
19
OCAT3 / CAT 5 CONNEC710N POIN�S O
OPTIONAL
0-10 VOLT � J3 � J4
INPUT
GSCADE BUS / ZONE CONTROL ONLY
THERMOSTAT( T
�
OUTDOOR �
SENSOR
DHW
SENSOR S
r OPTIONAL ALARM �
� �
� LIGFfT LIGFif �
OFF ON
I WHEN WHEN
� LOCKOUT LOCKOUT �
�
DHW
PUAIP
PUNP
COM
NC
BOILER GRD
BOILER NEUT
BOILER HOT
GROUND
NEUTRAL
120 VOLTS
BLACK(HOT)
■■
■■
■■
■ ■
■■
�
�
< �,
n�
0
D �
�
�� `m
w T
w � N
� m � o
o x
� r � �
N �
T� fA C
y 'O �
m � �
v
�
u
�
0
u �
a ?
v i ❑❑
m ❑❑ m
c
m � ❑❑
LINE VOLTAGE lO o 0 0 �
IN 120 VAC
Fig. 16: XFyre Single Heater Control
Wiring the Thermostat
1. Connect the room thermostat to the terminals
marked THERMOSTAT in the electrical junction
box (shown in Fig. 16). Alternately, any dry contact
closure across these terminals will enable the
XFyre unit to run. Caution should be used to
ensure neither of the terminals becomes connect-
ed to ground.
2. Mount the thermostat on an inside wall as central
as possible to the area being heated, but away
from drafts or heat producing devices, such as tel-
evision sets, that could effect the ability of the
thermostat to measure the room temperature
accurately.
3. If the thermostat is equipped with an anticipator,
and it is connected directly to the XFyre boiler, the
anticipator should be set at .1 amps. If the thermo-
stat is connected to other devices, the anticipator
should be set to match the power requirements of
the device it is connected to. See the instruction
manual for the connected devices for further infor-
mation.
Wiring the Outdoor Sensor
1. There is no connection required if an outdoor sen-
sor is not used in this installation.
2.
3.
If using an Outdoor Sensor, connect the wires for
sensor to the terminals marked OUTDOOR SEN
(shown in Fig. 16) in the electrical junction box.
Caution should be used to ensure neither of these
terminals becomes connected to ground.
Use a minimum 22 AWG wire for runs of 100 feet
or less, and minimum 18 AWG wire for runs of up
to 150 feet.
4. Mount the outdoor sensor on an exterior surface of
the building, preferably on the north side in an
area that will not be affected by direct sunlight and
that will be exposed to varying weather conditions.
Wiring the Indirect Sensor
1. There is no indirect sensor connection required if
an indirect water heater is not used in the installa-
tion.
2. The XFyre boiler will operate an indirect fired
water heater with either a thermostat type aquas-
tat installed in the indirect tank or a Raypak tank
sensor. When a tank sensor is used, the XFyre
control will automatically detect its presence and a
demand for heat from the indirect water heater will
be generated when the tank temperature falls
below the user settable setpoint by more than the
user selectable DHW DIFF. The demand will con-
tinue until the sensor measures that the indirect
water heater temperature is above the setpoint.
3. Connect the indirect tank sensor to the terminals
marked DHW SENSOR (shown in Fig. 16) in the
electrical junction box. Caution should be used to
ensure neither of these terminals becomes con-
nected to ground.
20
Wiring the Optional 0-10 Volt
Building Control Signal
A signal from a building management system may
be connected to the XFyre boiler to enable remote
control. This signal should be a 0-10 volt positive
DC signal. When this input is enabled using the
installer menu, a building control system can be
used to control either the setpoint temperature or
the heat output of the XFyre boiler. The control
interprets the 0-10 volt signal as follows. When the
signal is between 0 and 1 volt, the XFyre boiler will
be in stand by mode, not firing. When the signal
rises above 1 volt, the XFyre boiler will ignite. As
the signal continues to rise towards its maximum
of 10 volts, the XFyre boiler will increase either in
setpoint temperature or firing rate, depending on
the setting of screen 17 in the installer menu. See
the Installer Menu section for details on the setting
of screens 16 and 17 for this option.
Connect a building management system or other
auxiliary control signal to the terminals marked
+0-10 V and -0-10 V in the electrical junction box
(shown in Fig. 16) Caution should be used to
ensure that the +0-10 V connection does not
become connected to ground.
Wiring the Cascade System
Communication Bus
1. Use standard CAT3 or CAT5 computer network
patch cables to connect the communication bus
between each of the boilers. These cables are
readily available at any o�ce supply, computer,
electronic, department or discount home supply
store in varying lengths.
It is recommended that the shortest length cable
possible be used to reach between the boilers and
create a neat installation. Do not run unprotected
cables across the floor or where they will become
wet or damaged. Avoid running communication
cables parallel with, or close to or against, high
voltage (120 volt or greater) wiring. Raypak rec-
ommends that the total maximum length of
communication bus cables not exceed 200 feet.
Fig. 17: XFyre Cascade System Wiring
3. Create a hole to route the communication cables
through where the dimples are in the side of the
cabinet (see Fig. 15), or route the wires to the rear
junction box and out of the cabinet.
4. Connect the boilers in a daisy chain configuration
as shown in Fig. 17 above. It is best to wire the
boilers using the shortest wire runs rather than try-
ing to wire them in the order that they are
21
addressed. The communication bus jacks on the
customer connection panel are interchangeable
so you can use either one or both in any order to
connect the cable to. If you have connected the
boilers to each other properly, two of the boilers
will have one open connection port on them.
O GT3 / CAT 5 CONNECTION �� O 5. Connect the boiler pump to the terminais marked
OPTiONAL � (�n�j BOILER PUMP NEUT (#6), BOILER PUMP HOT
0—IINPUOLT �s ��+ (#5), and GROUND (#4).
GSCADE BUS / ZONE CONfROL ONLY
THERMOSTAT ( T
+o-,ov � ��
OUTDOOR p rHER►+oSTA7 �
SENSOR n+ERMOSrnT � �� `"
OU7DOOR SEN. ❑❑�
OUIDOOR SEN. � �
SENSOR
SYSTEM S sErua� � A
SENSOR � o
�
� N
f7
O
D�
l7
SYS7EM �
PUMP PWR 0
M PUM �� L
0 m
SYSTEM TO IX BOLLERGND � � �
PUMP �W�L IX eatEFi u � u � N
� � � o �
F
BOILER GND ❑ � N � a m c
BOILER BOILER NEIJr w � �
m
PUTAP gp��R HO7 � � �
GROUND " �Z'
NEUTRAL � u 5
z
120 VOLTS � i i ❑❑
� m
BUCK(HOT) � ❑❑ �
N � ❑❑
m
:REEN (GRDUNOI �
LINE VOLTAGE lO ooi
IN 120 VAC o 0 0
*- May be configured as DHW SENSOR for
single boiler Cascade with Indirect
Fig. 18: XFyre Cascade Master
Cascade Master Pump and
Sensor Wiring
1. On the boiler designated as the Cascade Master,
apply the System Sensor and DHW Sensor decals
(included) to the field wiring board as shown in Fig.
18. Apply the SYSTEM PUMP and EXT HEATER
labels to the wiring electrical connections terminal
strip as shown in Fig. 11 b on page 17.
2. Connect the system pump hot wire to terminal #11,
marked SYSTEM PUMP (see Fig 11 b).
3. Connect the system pump neutral to terminal #6,
marked BOILER PUMP NEUT, and the pump
ground wire to terminal #3, marked GROUND, at
the rear terminal strip.
4. Connect a jumper wire from terminal #1, marked
120 V BLACK (HOT), terminal #11, marked SYS-
TEM PUMP POWER, at the rear terminal strip.
22
6. Connect the system pipe sensor to the terminals
marked SYS SENSOR, as shown in Fig. 18.
7. Connect the outdoor sensor (if used) to the termi-
nals marked OUTDOOR SEN.
8. Connect the signal to start the system to the termi-
nals marked THERMOSTAT.
NOTE: This signal can come from a room
thermostat or a dry contact closure. No power of any
voitage should be fed into either of these terminals.
r�aa
oPrwr�
DFIW �
SENSOR �
�-------- �
I � I
� ucHr ucHr �
� WHEN WHEN �
LOCKOUT LOCKOUT
i i
�
------TO —
�PT10N4� �
�
WMP -�
PUMP
GREEN
CAT3 / CAT 5 CONNECTION POINIS O
1=J 3 I—J �
CASCADE BUS / ZONE CONfROL ONLY
-0-70V U
+0-10V �
7HERMO5fAT �
7HERMOSTAT �
OUTDOOR SEN �
OUTDOOR SEN �
DHW SENSOR
DHW SENSOR n
o COM
NC
DFiW GND
DHW NEUT
DHW HOT
)ILER 6ND
)ILER NEl1�
�ILER HOT
GROUND
NEUTRAL
120 VOL75
BLACK(HOn
L1NE VOLTAGE °°
IN 120 VAC O o 0
❑❑
❑❑
�� N
� ❑❑
❑❑
�
0
A
< �,
n D
O
D�
H
❑❑�
�� m
U
4 � �
D m � Z
; � F
v �
N � �
� N C
N � ;
C �
�
v
w
0
u zs-
� �
� � ❑❑
° °❑°❑ m
y
�
Fig. 19: XFyre Cascade Follower
Cascade Follower Pump
and Sensor Wiring
1. Connect the boiler pump to the terminals marked
BOILER PUMP NEUT (#6), BOILER PUMP HOT
(#5), and GROUND (#4) at the rear terminal strip.
2. If you are using an indirect fired water tank con-
nected directly to the follower boiler, connect the
pump for it to the terminals marked DHW PUMP
NEUT (#8), DHW PUMP HOT (#7), and GROUND
(#3) at the rear terminal strip.
If you desire, an alarm bell or light can be connected
to the alarm contacts of the follower boiler. Optionally,
the normally-closed alarm contact may be used to turn
a device off if the boiler goes into lockout mode. The
alarm contacts are rated 5 amps at 120 VAC.
To connect an alarm device, connect the power for the
device to the ALARM COM terminal. Connect the
alarm device hot wire to the ALARM NO terminal.
Connect the neutral or return of the alarm device to the
neutral or return of the power for the alarm device.
To connect a device that should be powered off during
a boiler lockout condition, follow the same instructions
as above except use the ALARM NC terminal rather
than the ALARM NO terminal.
Note that in a cascade system the alarm output of the
boiler addressed as #1 will also be active if the master
boiler has a lockout condition. The alarm output of boil-
ers addressed as 2-7 will only sound if a lockout
condition occurs on that specific boiler.
CAUTION: Proper instaliation of flue venting is
criticai for the safe and e�cient operation of the
boiler.
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 avoids excessive condensate pro-
duction in the vent.
23
Category II — A heater which operates with a non-pos-
itive vent static pressure and with a vent gas
temperature that may cause excessive condensate
production in the vent.
Category III —A heater which operates with a positive
vent pressure and with a vent gas temperature that
avoids excessive condensate production in the vent.
Category IV —A heater which operates with a positive
vent pressure and with a vent gas temperature that
may cause excessive condensate production in the
vent.
See Table K for appliance category requirements.
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.
CAUTION: Condensate drains for the vent piping
are required for installations of the XFyre. Follow
vent manufacturer instructions for installation and
location of condensate drains in the vent.
Condensate drain traps must be primed with water to
prevent gas flue leak and must be routed to an
appropriate container for neutralization before dis-
posai, as required by local codes.
WARNING: Contact the manufacturer of the vent
material if there is any question about the appliance
categorization and suitability of a vent material for
application on a Category IV vent system. Using
improper venting materials can result in personal
injury, death or property damage.
CAUTION: The condensate from the boiler is
acidic, with a pH of 3.2 to 4.5. Raypak recommends
neutralizing the condensate with a Condensate
Neutralizer Kit (Z-12) that can be added to avoid
long-term damage to the drainage system and to
meet local code requirements. The neutralizer kit is
connected to the drain system and contains lime-
stone (Calcium Carbonate) chips that will neutralize
the pH level of the condensate. The neutralizer
shouid be checked at least once per year, and the
chips should be replenished if necessary. When
repiacing the chips, they should be no smaller than
3/4" to avoid blockage in condensate piping.
Combustion Exhaust Heater Venting Certified Vent Combustion Air
Air Supply Configuration Category Materials Inlet Material
Vertical Venting (Canada Only: ULC-
From Inside Building
(Non-Direct Venting) Horizontal Through- S636 PVC and CPVC)
the-Wall Venting Stainless Steel,
IV AL29-4C, ANSI/ASTM
Vertical Venting D1785 Sch 40 PVC, Galvanized Steel,
From Outside Building ANSI/ASTM F441 Sch PVC, ABS,
(Direct Venting) Horizontal Through- 40 CPVC CPVC
the-Wall Venting
Table K: Venting Category Requirements
Use only approved PVC or CPVC vent materials (in
Canada, ULC-S636 approved plastic materials must
be used) or special gas vent pipes listed for use with
Category IV gas burning heaters, such as the AL29-4C
stainless steel vents offered by Heat Fab Inc. (800-
772-0739), Protech System, Inc. (800-766-3473),
Z-Flex (800-654-5600) or American Metal Products
(800-423-4270). Pipe joints must be positively sealed.
Follow the vent manufacturer's installation instructions
carefully. Vent installations shall be in accordance with
Part 7, Venting of Equipment, of the NFGC, ANSI
Z223.1/NFPA 54, Section 7, Venting Systems and Air
Supply forAppliances, of the B149 Code, or applicable
provisions of the local building codes.
WARNING: Do not use foam core or cellular core
pipe for venting.
Support of Vent Stack
The weight of the vent stack or chimney must not rest
on the heater vent connection. Support must be pro-
vided in compliance with applicable codes. The vent
should also be installed to maintain proper clearances
from combustible materials. Use insulated vent pipe
spacers where the vent passes through combustible
roofs and walls.
When using PVC or CPVC venting on models 300,
400 and 500, insert the vent pipe 3-5 inches into the
unit and provide rigid support to the vent, so that it will
not shift laterally.
Vent Terminal Location
1. Condensate can freeze on the vent cap. Frozen
condensate on the vent cap can result in a blocked
flue condition.
NOTE: During winter months check the vent cap
and make sure no blockage occurs from build-up of
snow or ice.
24
WARNING: DO NOT insulate PVC or CPVC vent
pipe.
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. Prevailing winds, in combination with below-freez-
ing temperatures, can cause freezing of
condensate and water/ice build-up on buildings,
plants or roofs.
5. The bottom of the vent terminal and the air intake
shall be located at least 12 in. above grade, includ-
ing normal snow line.
6. Single-wall Category IV metal vent pipe shall not
be used outdoors in cold climates for venting gas-
fired equipment without insulation.
7. Through-the-wall vents for Category IV appli-
ances shall not terminate over public walkways or
over an area where condensate or vapor could
create a nuisance or hazard or could be detrimen-
tal to the operation of regulators, relief valves, or
other equipment.
8. Locate and guard vent termination to prevent acci-
dental contact by people or pets.
9. DO NOT terminate vent in window well, stairwell,
alcove, courtyard or other recessed area.
10. DO NOT terminate above any door, window, or
gravity air intake. Condensate can freeze, causing
ice formations.
11. Locate or guard vent to prevent condensate from
damaging exterior finishes. Use a rust-resistant
sheet metal backing piate against brick or mason-
ry surfaces.
12. DO NOT extend exposed vent pipe outside of
building beyond the minimum distance required
for the vent termination. Condensate couid freeze
and block vent pipe.
NOTE: When using PVC vent termination, insert the
two round stainless mesh screens provided with the
unit into the tee.
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 above grade
when located adjacent to public walkways.
3. Terminate vent at least 3 ft above any forced air
inlet located within 10 ft.
WARNING: The Commonwealth of Massachusetts
requires that sidewall vented heaters, installed in
, every dwelling, buiiding or structure used in whole or
' in part for residential purposes, be installed using
special provisions as outlined on page 53 of this
manual.
Installations in Canada
Refer to latest edition of the B149 Installation Code.
A vent shall not terminate:
1. Directly above a paved sidewalk or driveway
which is located between two single-family dwell-
ings and serves both dwellings.
2. Less than 7 ft(2.13 m) above a paved sidewalk or
paved driveway located on public property.
3. Within 6 ft(1.8 m) of a mechanical air supply inlet
to any building.
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.
4. Vent must terminate at least 4 ft horizontally, and
in no case above or below unless 4 ft horizontal 7
distance is maintained, from electric meters, gas
meters, regulators, and relief equipment.
5. Terminate vent at least 6 ft away from adjacent
walls.
6. DO NOT terminate vent closer than 5 ft below roof
overhang.
7. The vent terminal requires a 12 in. vent terminai
clearance from the wall.
8. Terminate vent at least 1 ft above grade, including
normal snow line.
Within 3 ft(915 mm) of a window or door which
can be opened in any building, any non-mechani-
cal air supply inlet to any building or the
combustion air inlet of any other appliance.
8. Underneath a verandah, porch or deck, unless the
verandah, porch or deck is fully open on a mini-
mum of two sides beneath the floor, and the
distance between the top of the vent termination
and the underside of the verandah, porch or deck
is greater than 1 ft(305 mm}.
Venting Installation Tips
Support piping:
9. Multiple direct vent installations require a 4 ft . horizontal runs—at least every 5 ft(1.5m)
clearance between the ends of vent caps located .
on the same horizontal plane. . vertical runs—use braces
under or near elbows
WARNING: Examine the venting system at least
once a year. Check all joints and vent pipe
connections for tightness, corrosion or deterioration.
25
Vent and Vertical Vent Height' (ft) Combustion
Certified Vent Intake Air Air Intake Vertical Air
Model No. Material Vent Size Pipe Inlet Max.
Min. Max. Length* (ft)
(in.) Material
300 (Canada Only:
ULC-S636 PVC
400 and CPVC) 4 Galvanized
Stainless Steel, Steel,
500 AL29-4C, 0 100 PVC, ABS, 100
ANSI/ASTM D1785 CPVC
700 Sch 40 PVC,
ANSI/ASTM F441 g
850 Sch 40 CPVC
� 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.
Table L: Category IV Vertical Vent 8� Vertical Direct Vent
Venting Configurations NOTE: A vent adapter (field-supplied} may be re-
quired to connect the Category IV vent to the boiler.
For heaters connected to gas vents or chimneys, vent
installations shall be in accordance with the NFGC Termination
(U.S.), or 6149 (Canada), or applicable provisions of
local building codes. The vent terminal should be vertical and should termi-
nate outside the building at least 2 ft above the highest
Vertical Venting (Category IV) point of the roof that is within 10 ft. The vent cap
CAUTION: This venting system requires the
installation of a condensate drain in the vent piping
per the vent manufacturer's instructions. Failure to
install a condensate drain in the venting system will
void all warranties on this boiler.
Installation
The maximum and minimum venting length for this
Category IV appliance shall be determined per the
NFGC (U.S.) or 6149 (Canada).
The diameter of vent flue pipe should be sized accord-
ing to the NFGC (U.S.) and Appendix B of B149
(Canada). The minimum flue pipe diameter for con-
ventional venting is: 4 in. (102mm) for Models 300,
400 and 500, and 6 in. (152mm} for Models 700 and
850.
The connection from the appliance vent to the stack
must be as direct as possible and shall be the same di-
ameter as the vent outlet. The horizontal breaching of
a vent must have an upward slope of not less than 1/4
inch per linear foot from the heater to the vent termi-
nal. The horizontal portions of the vent shall also be
supported for the design and weight of the material
employed to maintain clearances and to prevent physi-
cal damage or separation of joints.
26
Fig. 20: Vertical Venting
SATE ifiAP
should have a minimum clearance of 4 ft horizontally
from and in no case above or below (unless a 4 ft hori-
zontal distance is maintained) electric meters, gas
meters, regulators and relief equipment.
The distance of the vent terminal from adjacent public
walkways, adjacent buildings, open windows and
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.
NOTE: When using PVC vent termination, insert the
round stainless mesh screens provided with the unit
into the tee and terminals.
CAUTION: A listed vent cap terminal suitable for
connection to the Cat IV vent materials, adequately
sized, must be used to evacuate the flue products
from the boilers.
Common Venting
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 Sys-
tems". Table M provides volumes of flue products at
full fire for the calculation of appropriate vent and
extractor sizing for common venting.
WARNING: Vent connectors serving any other
appliances shall not be connected into any portion of
mechanical draft systems operating under a positive
pressure. If an XFyre boiler is installed to repiace an
existing boiler, the vent system MUST be verified to
be of the correct size and of Category IV AL29-4C
vent material or approved PVC/CPVC construction
(in Canada, ULC-S636 approved plastic materials
must be used). If it is NOT, it MUST be replaced.
NOTE: For extractor sizing, typical COZ levels are
8.5% for natural gas and 9.5% for propane gas and
flue temperatures of approximately 150°F.
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:
(a) Seal any unused openings in the common venting
system.
27
(b) Visually inspect the venting system for proper size
and horizontal pitch and make sure there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.
(c) As much as possible, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the com-
mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will oper-
ate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
(e) After it has been determined that each appliance
remaining connected to the common venting sys-
tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.
(fl Any improper operation of the common venting
system should be corrected so that the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1 and/or CAN/CSA
B149. When re-sizing any portion of the common
venting system, the common venting system
should be re-sized to approach the minimum size
as determined using the appropriate tables in Part
11 of the National Fuel Gas Code, ANSI Z223.1
and/or CAN/CSA B149.
Model No. Vent Size Volume of Flue
(inches) Products (CFM)
300 80
400 4 105
500 130
700 180
6
850 220
NOTE: Data for 100% firing rate.
Table M: Volume of Flue Products Data
NOTE: Vent and intake piping must be supported so
that the weight of the venting is not transfered to the
unit. Horizontal runs of vent and intake piping must
be supported to prevent sagging.
Note: Heaters rotated to show venting connections.
Fig. 21: Typical Common Venting
Horizontal Through-the-Wall Direct
Venting (Category IV)
HEATER
UNIT -,
Refer to Table F and local codes.
\
\
�
\
VENT
TERMINAL
12' MIN ABOVE SNOWLINE
�
Fig. 22: Horizontal Through-the-Wall Venting
28
�ALL LOCA710N
VAPoABLE SP�
FJfiRAC70R
I
♦�
y
w - use
�errc
FIDON DRAIN
NSATE R�P)
Refer to Table F and local codes.
;HAUST
=XHAUST
CAP
INTAKE
ELBOW
�w�
Fig. 23: Horizontal Through-the-Wall Direct Venting
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 vertical or
horizontal collector available from several of the
listed vent manufacturers.
CAUTION: This venting system requires the
installation of a condensate drain in the vent piping
per the vent manufacturer's instructions. Failure to
install a condensate drain in the venting system will
void all warranties on this boiler.
Installation
These installations utilize the heater-mounted blower
to draw combustion air and to vent the combustion
products to the outdoors. The combustion air intake
and the vent are installed horizontally through the wall
to the outdoors. Adequate ventilation air must be sup-
plied to the equipment room in accordance with the
NFGC (U.S.) or B149 (Canada).
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.
The vent and air intake runs should be balanced to
provide approximately the same equivalent length.
The vent cap and air intake elbow are not considered
in the overall length of the venting system.
The vent must be installed to prevent flue gas leakage.
Care must be taken during assembly to ensure that all
joints are sealed properly and are airtight. The vent
must be installed to prevent the potential accumulation
of condensate in the vent pipes. It is required that:
1. The vent must be installed with condensate drains
as directed by the vent manufacturer.
2. The vent must be installed with a slight upward
slope of not less than 1/4 inch per foot of horizon-
tal run to the vent terminal.
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 located NO CLOSER than 12"
off the wall.
WARNING: No substitutions of flue pipe or vent
cap material are ailowed. Such substitutions would
jeopardize the safety and health of inhabitants.
Model No. Size Approved Intakes Approved Plastic Approved SS Terminals
(in.) Terminals
300
400 4 PVC 90° Elbow, 4" PVC Tee, FasNSeal FSTT4,
Sch 40 Sch 40* Z-Vent 2SVSTTF04
500 Galvanized 90°
E I bow,
700 SS 90° Elbow 6" PVC Tee, FasNSeal FSTT6,
850
6 Sch 40* Heat Fab 9690TEE
'Must be ULC-S636 materials in Canada.
Table N: Horizontal Vent and Air Intake Terminals
29
Vent and Horizontal Vent Height Combustion Air Inlet
Certified Vent Intake Air (ft) Air Intake
Model No. Max.
Material Vent Size Pipe
��n.� Min. Max. Material Length (ft)*
300
(Canada Only:
400 ULC-S636 PVC 4
and CPVC) Galvanized
Stainless Steel,
500 AL29-4C, 0 100 Steel, 100
ANSI/ASTM D1785 PVC, ABS,
Sch 40 PVC, CPVC
700 ANSI/ASTM F441
Sch 40 CPVC 6
850
' Subtract 10 ft per elbow. Max. 4 elbows.
Table O: Category IV Horizontal Vent 8 Horizontal Direct Vent
Direct Vent—Vertical
HEAlE
Fig. 24: Direct Vent - Vertical
The total length of air supply pipe cannot exceed the
distances listed in Table L. Each elbow used is equal
to 10 ft of straight pipe. This will allow installation in
any arrangement that does not exceed the lengths
shown in Table L.
The vent cap is not considered in the overall length of
INSUU7ED D(MAUST
�NTM° the venting system.
CAUTION: This venting system requires the
installation of a condensate drain in the vent piping
per the vent manufacturer's instructions. Failure to
install a condensate drain in the venting system will
void all warranties on this boiler.
Installation
These installations utilize the heater-mounted blower
to draw combustion air from outdoors and vent com-
bustion products to the outdoors.
30
Care must be taken during assembly that all joints are
sealed properly and are airtight.
The vent must be installed to prevent the potential ac-
cumulation of condensate in the vent pipes. It is
required that:
1. The vent must be installed with a condensate
drain as directed by the vent manufacturer.
2. The vent must be installed with a slight upward
slope of not more than 1/4 inch per foot of hori-
zontal run to the vent terminal.
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.
The vent cap MUST NOT be installed with any com-
bustion air inlet directly above a vent cap. This vertical
spacing would allow the flue products from the vent
cap to be pulled into the combustion air intake installed
above.
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 vent cap(s).
5. Vent terminal must be at least 3 ft above any
forced air inlet located within 10 ft.
6. Adjacent brick or masonry surfaces must be pro-
tected with a rust-resistant sheet metal plate.
Combustion air supplied from outdoors must be free of Freeze Protection
particulate and chemical contaminants. To avoid a
blocked flue condition, keep the vent cap clear of NOTE: The vent cap must be furnished by the boiler
snow, ice, leaves, debris, etc. manufacturer in accordance with its listing (sales
order option D-11).
WARNING: No substitutions of flue pipe or vent
cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants. NOTE: Condensate can freeze on the vent terminal.
Frozen condensate on the vent terminal can result in
a blocked flue condition.
The stainless steel flue direct vent cap must be fur-
nished by the boiler manufacturer in accordance with
its listing (sales order option D-15).
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 terminal is provided in accordance with CSA
requirements. These must be installed as illustrated in
Fig. 25.
Care must be taken when locating the unit outdoors,
because the flue gases discharged from the vent cap
can condense as they leave the cap. Improper location
can result in damage to adjacent structures or building
finish. For maximum efficiency and safety, the follow-
ing precautions must be observed:
1. Outdoor models must be installed outdoors and
must use the outdoor vent cap available from the
manufacturer (sales order option D-11).
2. Periodically check venting system. The uniYs
venting areas must never be obstructed in any
way and minimum clearances must be observed
to prevent restriction of combustion and ventilation
air. Keep area clear and free of combustible and
flammable materials.
3. Do not locate adjacent to any window, door, walk-
way, or gravity air intake. The vent must be
located a minimum of 4 ft horizontally from such
areas.
4. Install above grade level and above normal snow
levels.
31
I IAIIT
Fig. 25: Outdoor Venting
VEN T
TERMINAL
Model Size Approved Approved SS
No. (in.) P�astic Terminals
Terminals
300
400 4 PVC Tee, FasNSeal FSTT4,
Sch 40* Z-Vent 2SVSTTF04
500
700 PVC Tee, FasNSeal FSTT6,
6 Sch 40* Heat Fab 9690TEE
850
*Must be ULC-S636 materials in Canada.
Table P: Outdoor Vent Terminals
The Raypak electronic temperature control includes a
freeze protection feature. In the event the temperature
drops below 40°F at any of the temperature sensors,
the pump is turned on and will remain on until the tem-
peratures at all sensors rise to 45°F.
Controls
WARNING: ►nstallation, adjustment and service of
controls, including timing of various operating func-
tions, must be performed by a qualified installer,
service agency or the gas supplier. Failure to do so
may result in control damage, malfunction, property
damage, personal injury, or death.
WARNING: Turn off the power to the boiler before
installation, adjustment or service of any controls.
Failure to do so may result in board damage,
maifunction, property damage, personal injury, or
death.
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 servicing.
Ignition Control Functions
When there is a call for heat, the combustion air blow-
er starts to purge air from the combustion chamber.
After the pre-purge, the igniter is energized. The stan-
dard ignition module will lock out after failing to light
four times or after losing flame three times during a
single heat demand. To reset it, press and release the
ESC/RESET button located on the user interface. The
control will automatically reset after 1 hour. When in
lock out, the control will run the blower for a 1 minute
purge cycle. Turning off the power to the heater
WILL NOT reset the ignition module.
The single-try ignition module (part of the CSD-1
option) will attempt to light only one time before lock-
ing out. To reset it, press the ESC/RESET button on
the user interface.
NOTE: Each ignition module is specific to a single
model size. Care should be taken not to use a mod-
ule intended for a different model size.
32
High Limit — Manual Reset
This boiler is equipped with a fixed-setting manual re-
set high limit temperature device as standard or it may
have an optional adjustable setting manual reset high
temperature device.
The fixed-setting manual-reset high limit is located on
the outlet pipe of the heat exchanger on the left side of
the boiler (accessible through the front door for reset
as necessary).
Fig. 26: High Limit (Manual Reset)
High Limit — Auto Reset (Optional)
This heater is equipped with a fixed auto-reset high
limit temperature device.
The optional auto reset high limit is located on the heat
exchanger header, near the outlet.
Fig. 27: High Limit (Auto Reset)
Flow Switch
This standard, dual-purpose control, mounted and
wired in series with the main gas valve, shuts off the
boiler in case of pump failure or low water flow.
Fig. 27: Flow Switch
Low Water Cut-Off (Optional)
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 pre-
vents premature lockout due to temporary conditions
such as power fluctuations or air pockets.
Fig. 28: Low Water Cut-Off
High 8� Low Gas Pressure Switches
(Optional)
The optional low gas pressure switch connection
mounts upstream of the gas valve (on the inlet flange
to the gas valve) and is accessible through the remov-
able access panels on the rear of the boiler to reset the
gas pressure switch, as necessary. It is used to
ensure that sufficient gas pressure is present for prop-
er valve/regulator performance. The low gas pressure
switch automatically shuts down the boiler if the gas
supply drops below the factory setting of 3.0 in. WC for
natural gas or propane gas.
33
The optional high gas pressure switch connection
mounts down-stream of the gas valve. Special ports
are located on the backside of the gas valve and
accessible from the front of the boiler (to reset the gas
pressure switch), as necessary. If the gas pressure
regulator in the valve fails, the high gas pressure
switch automatically shuts down the burner.
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. 29 to reset a tripped pressure switch. The LED will
go out when the switch is reset.
,:___>.
�� ,
�___-.
�,
Fig. 29: High/Low Gas Pressure Switch
Blocked Vent Switch
This heater is equipped with a blocked vent pressure
switch to prevent the operation of the boiler when too
much of the vent is blocked. This switch is located on
the left side of the heater near the left rear corner.
Fig. 30: Blocked Vent Switch
Blocked Condensate Drain Sensor
This boiler is equipped with a condensate sensor to
prevent operation when the condensate water level is
too high. The boiler shutting down from the conden-
sate sensor is indicative of a blocked drain or problem
with the condensate management system. The con-
densate sensor is located inside the condensate
reservoir at the rear of the boiler.
Fig. 31: Condensate Drain Sensor
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.
Adjust the temperature setpoint of the XFyre as
desired. The factory default setting is 160°. If
changes are necessary follow "Adjusting The
XFyre SetpoinY' in this section.
On the initial start-up of units with gas pressure
switches, the control user interface will display
flue/gas press. This is a low gas pressure switch
lock-out from the factory-installed low gas pres-
sure switch. You will also see a yellow LED
illuminated under the cover of the low gas pres-
sure switch. Once the gas is turned on, reset the
gas pressure switch by FIRMLY pressing on top of
the plastic cover over the red reset button. The
yellow LED will go out after the switch has been
reset. Press and hold the ESC/RESET key on the
control panel for about 4 seconds to begin normal
operation.
4. Set the thermostat to the desired setting.
34
5. If the appliance fails to start, refer to the
Troubleshooting section in the back of this manu-
al.
NOTE: Before you can change the temperature
from the factory setting of 160 degrees, you must
make sure none of the thermostats are calling for
heat. The controller will not memorize a program
setting while in a heating cycle.
User Menu
The user menu consists of several items that can be
adjusted. To access the user menu, press and hold the
ENTER/MENU key for 5 seconds. Using the UP and
DOWN, and LEFT and RIGHT arrow keys, enter 600,
then press ENTER/MENU. Scroll through the list of
adjustable items by pressing the LEFT or RIGHT
arrow keys. Once the desired item is displayed, press
the ENTER/MENU key to select it. The screen will
begin to flash. Press the DOWN arrow key to decrease
the values, and the UP arrow key to increase them. To
store the changes, press the ENTER/MENU key. The
display returns to normal mode after one minute.
Pressing the ESC/RESET key before storing changes
will restore the original value. Refer to Fig. 32 for dis-
piay and key locations.
Adjusting the XFyre Setpoint
To adjust the temperature on the XFyre:
— Press the ENTER/MENU key for 5 seconds to
bring up the code menu. Enter 600 to access the
user menu.
— Press the DOWN arrow key to decrease the tem-
perature (minimum setpoint is 50°F).
UP arrow DOWN
key� /arrow key
E� a0�0 v �
�
� r�r \ / �u
ESC/RESET LEFT arrow RIGHT ENTER/MENU
key keY arrow key key
Fig. 32: Display Interface
User Menu Items
Screen No. Default Information Dis la ed Ran e Descri tion
� Heat Loo Cascade or heat loo set oint
159 °F 50-190 °F
2 Heat Diff Cascade or heat loo differential, below set oint
30 °F 1-45 °F Su ested settin 5° - 10°
3 DHW Set DHW Set oint
140 °F 95-180 °F
4 DHW Diff DHW Differential off differential
5 °F 1-18 °F
Tem erature Unit Tem erature unit of ineasure
5 °F °C/F
6 Clock Mode Clock mode 12 or 24 hour
MM/DD/YYYY Da 12:00:00 12/24 h
� Ciock Hour Set clock hour
MM/DD/YYYY Da 12:00:00
$ Clock Minut Set clock minute
MM/DD/YYYY Da 12:00:00
9 Clock Weekda Set da of week
MM/DD/YYYY Da 12:00:00
10 Clock Date Mode Set date format
MM/DD/YYYY Da 12:00:00
11 Clock Year Set date ear
MM/DD/YYYY Da 12:00:00
12 Clock month Set date month
MM/DD/YYYY Da 12:00:00
13 Clock date Set date da
MM/DD/YYYY Da 12:00:00
— Press the UP arrow key to increase the tempera-
ture (maximum setpoint is 200°F, but should not
exceed 180°F for "H" units or 160°F for "WH"
units).
Status Menu
Installers are also able to check the current status of
the XFyre unit parameters by pressing either the LEFT
or RIGHT arrow keys during normal operation.
The status menu can have three states depending on
the enabling of 0-10 VDC input and cascade master
control. Each state can be selected using the LEFT or
RIGHT arrow key when it is enabled.
35
Service Mode
This function is intended to simplify the gas valve
adjustment if needed. Manifold gas pressure settings
are listed in Table I on page 16. Automatic modulation
does not take place when the controller is in Test
Mode, only temperature limitation based on the XFyre
Central Heating set point occurs. The user will be
allowed to increase or decrease the fan speed by
pressing either the UP or DOWN arrow keys.
To activate the service mode, press the UP arrow and
ENTER/MENU keys together for 1 second. Once acti-
vated, you wili see in the display Service and the
actual fan speed. The measurement of the combustion
levels should always be taken at the highest and low-
est fan speed. After 10 minutes, the service mode
stops automatically. To exit the service mode, press
the UP and DOWN arrow keys together for 1 second.
Status Menu 1 Items
Screen No. DefauR Information Displayed Range Description
� Supply XXX°F -13 to 248 °F Heater Outlet Water Temperature
Return XXX°F -13 to 248 °F Heater Inlet Water Temperature
2 CH Set 160°F 50 to 190 °F Heater Outlet Water Setpoint for Hydronic Heating Temperature
Supply XXX°F -13 to 248 °F Heater Outlet Water Temperature
* Cas Set 160°F 50 to 190 °F Cascade (System sensor) Setpoint if Master
3 System XXX°F -13 to 248 °F System Sensor Temperature if Master and Present
4 DHW Set 140°F 95 to 180 °F DHW Tank Setpoint
DHW XXX°F -13 to 248 °F DHW Tank Temperature (if sensor present)
5 Outdoor XXX°F -40 to 248 °F Outdoor Air Temperature (if sensor present, otherwise oft)
6 Flame 0.0 NA Flame lonization Signal
Fan Speed 0 RPM Fan RPM
� 0-10V 10.OV Remote Setpoint or Modulation Signal
Bus Comm No Conn Conn/No Conn Cascade Bus Connection or No Connection
8
9 Power On Oh Hours the Heater Has Been Powered
CH On Oh Hours With a Call For Heat
DHW On Oh Hours With a DHW Demand
10
Good Ignition Ox Number of Successful Ignitions
�� Fauft History 1/Fault Type (Last Error) Last Fautt Display Code
MM/DD/YYYY Day 12:00:00 Time of Last Fault
12 Fault History 2/Fault Type Fautt Display Code
MM/DD/YYYY Day 12:00:00 Time of Fault
� 3 Fault History 3/Fault Type Fauft Display Code
MM/DD/YYYY Day 12:00:00 Time of Fault
14 Fauit History 4/Fault Type Fault Display Code
MM/DD/YYYY Day 12:00:00 Time of Fault
� 5 Fault History 5/Fault Type Fautt Display Code
MM/DD/YWY Day 12:00:00 Time of Fault
16 Fault History 6/Fault Type Fautt Display Code
MM/DD/YYYY Day 12:00:00 Time of Fault
�� Fault History 7/Fault Type Fautt Display Code
MM/DD/YYYY Day 12:00:00 Time of Fault
18 Fault History 8/Fault Type Fautt Display Code
MM/DD/YYYY Day 12:00:00 Time of Fauft
19 Fault History 9/Fault Type Fautt Display Code
MM/DD/YYYY Day 12:00:00 Time of Fautt
20 Fault History 10/Fault Type Fautt Display Code
MM/DD/YYYY Day 12:00:00 Time of Fautt
� Screen 3 is displayed in Cascade Mode only
36
Status Menu 2 Items
Screen No. Default Information Dis
� Analo DHW Temp (if active
Analoa Sia. XX.X V
Status Menu 3 Items
�mp/Fan �Analog 0-10V Input Setpoint or Fan Modulation Control
10.OV Analoa 0-10V Sianal
Screen No. Default Information Dis la ed Ran e Descri tion
� Cascade Status No Follower Cascade Status, Master or Follower, Read or CFH TT
S s Pum Status On On/Off S stem Pum On or Off
2 Cascade Pwr XXX% 0-100% Cascade Demand %
Present OXXXXXXX 0-8 Heaters Present in Cascade
3 Cascade S s XXX °F -13 to 248 °F Cascade S stem Tem erature
Cascade Set 160 °F 50 to 190 °F Cascade Set oint
4 Boiler 0 XXX% 0-100% Heater Demand %
Boiler 1 XXX% 0-100% Heater Demand %
5 Boiler 2 XXX% 0-100% Heater Demand %
Boiler 3 XXX% 0-100% Heater Demand %
6 Boiler 4 XXX% 0-100% Heater Demand %
Boiler 5 XXX% 0-100% Heater Demand %
� Boiler 6 XXX% 0-100% Heater Demand %
Boiler 7 XXX% 0-100% Heater Demand %
Installer Menu Items
Screen No. Default Information Displayed Range Description
Operational Mode Operational Mode of the Controller
1
Hydronic
3 DHW Tank Max (if active) Maximum User Setting for DHW Tank Temperature
180 °F 95 to 185 °F Setting
6 DHW Pump Delay DHW Pump Delay Timing
0 Min. 0-10 Minutes Setting
� Outdoor Cutoff Cuttoff Temperature for Outdoor Temperature Reset Systems
68 °F 41 to 122 °F Setting
8 Reset Min Out Minimum Outdoor Design Temperature
5 °F -49 to 32 °F Setting
Reset Max Temp Maximum Outdoor Reset Setpoint Temperature
9
190 °F 77 to 190 °F Setting
Reset Max Out Maximum Outdoor Design Temperature
�� 68 °F 32 to 95 °F Setting
11 Reset Min Temp Minimum Outdoor Reset Setpoint Temperature
95 °F 32 to 190 °F Setting
12 Hydronic Min Temp Hydronic Minimum Temperature
90 °F 32 to 190 °F Setting
37
Installer Menu Items (continued)
Screen No. Default Information Displayed Range Description
13 Hyd Pump Delay Heater Pump Delay Timing
0 Min. 0-10 Minutes Setting
DHW Priority DHW PriorityTiming
14
30 minutes 0-60 Minutes Setting
Cascade Address Heater Cascade Address, 0 for Master, 1-7 for Followers
15
0 0-8 HeaterAddress Setting, Do Not UseAddress 8
16 0-10V 0-10V input configuration
DHW Thermistor DirecUDHW Thermistor/OFF/Boosterboard
�� 0-10V Mode Mode Selection for 0-10V Direct Input Operation
Temperature Temperature (Setpoint) or Fan Speed (Firing Rate)
�$ Step Modulation Enable or Disable Step Modulation
ON ON/OFF Setting
Temp to Indirect Heater Output Setpoint for Indirect Operation
19
1 SO °F 140 to 190 °F Setting
WPS Input Factory Configured, DO NOT CHANGE
20
Flow Switch Low Water Cutoff/Flow Switch/Water Pressure/None
21 Error Outd Sensor Enable Outdoor Sensor Error Reporting
OFF ON/OFF Setting
22 Max Fan Speed Allows Reduction of Maximum Input Rate
100% 50-100% Setting
Z3 Cascade Config Cascade or Non-Cascade Operation
OFFNIS 3 All 926/OFF All 926 for Single or Mutti-Heater Cascade
Cascade Rotation Lead Boiler Rotation Time
24
24 Hours 0-240 Hours Setting
Cascade DHW Conf
25
DHW Entire Cascade DHW Entire Cascade/DHW Master Only
System Pump Freeze Enable System Pump ('rf cascade master and controlling
26
Protect OFF OFF to 104 °F system pump) When OutdoorTemp Drops Below Setpoint
Sys Sense Fautt Enable System Sensor Error Reporting
27
ON ON/OFF Setting
Freeze Protect Heater Freeze Protection, Enable Heater Pump at Return
28
ON ON/OFF Temps below 44°F, Fires Heater'rf Temps Drop Below 37°F
29 DHW Demand Start Max for Normal DHW Operation, Min for Low Fire Start DHW
Maximum Maximum/Minimum
30 Extra Boiler Off if No Extra Boiler, 100 for Extra On/Off Boiler
OFF OFF/50-100 Setting
Sing Boil Casc Enabie Singie Boiler Cascade for Single Boiler Primary/Secondary
31
OFF ON/OFF O eration with a S stem Sensor
32 Maintenance Inter Installers Only - Enable Maintenance Mode Alarm by Date or
OFF OFF/RH/Date Runnin Hours
38
Installer Menu
The installer menu consists of several items that can
be adjusted. To access the installer menu, press and
hold the ENTER/MENU key for 5 seconds. Using the
UP and DOWN, and LEFT and RIGHT arrow keys,
enter 925, then press ENTER/MENU. Scroll through
the list of adjustable items by pressing the LEFT or
RIGHT arrow keys. Once the desired item is dis-
played, press the ENTER/MENU key to select it. The
screen will begin to flash. Press the DOWN arrow key
to decrease the values, and the UP arrow key to
increase them. To store the changes, press the
ENTER/MENU key. The display returns to normal
mode after one minute. Pressing the ESC/RESET key
before storing changes will restore the original value.
The central heating demand is detected when the
room thermostat closes. When an outside sensor is
also connected, the supply temperature will depend on
the factory default central heating curve which is suffi-
cient for most applications.
201
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OUTDOOR RESET CURVE
Factory Default
OUTS�DE TEMPERATURE (F)
Fig. 33: Outdoor Reset Curve — Factory Default
39
To set your own custom heat curve you will have to set
the following parameters. Use the graphs in Figs. 33
and 34 to assist you in the design of the curve.
1. Minimum outside design temperature: Function 8
2. Design Supply water temperature at the minimum
design outside temperature: Function 9
3. Maximum outside design temperature: Function
10
4. Design Supply Water Temperature at the maxi-
mum outside temperature: Function 11
NOTE: It is important to note that the user can
adjust the heat curve down by adjusting the central
heating temperature to a lower setting.
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203
194
l85
l76
l67
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86
77
68
59
50
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32
OUTDOOR RESETCURVE
Plot your Curve
-59 Al -24 -9 � 9 2� 45 63 81 99
OUT51 �E TEMPERATURE (F)
Fig. 34: Outdoor Reset Curoe — Plot Your Curve
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132981 �5
NOTE: The wiring diagrams in this manual show all
standard options. Refer to the large wiring diagram
provided with your boiler for options instalied on your
specific unit(s).
START-U P
Pre Start-up
Filling System (Heating Boilers)
Fill system with water. Purge ali 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.
Air Purge (Domestic Hot Water
Heaters)
CAUTION: An air vent should be installed at the
highest point in the systern for proper operation. If
water piping is located higher than the boiler, it
should be relocated to the highest point in the
installed system.
Purge all air from system before lighting heater. This
can be normally accomplished by opening a down-
stream valve.
Venting System Inspection
1. Check all vent pipe connections and flue pipe ma-
terial.
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
2. Make sure vent terminations are installed per code
and are clear of all debris or blockage.
For Your Safety
This appliance has a direct spark igniter. It is equipped
with an ignition device which automatically lights the
burners. Do not try to light the burners by hand.
41
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.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any
telephone in your building.
• Immediately call your gas supplier from a neigh-
bor's telephone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the fire
department.
• Use only your hand to push in or turn the gas con-
trol knob. Never use tools. If the knob will not turn
by hand, do not try to repair it, call a qualified serv-
ice technician. Forced or attempted repair may
result in a fire or explosion.
• Do not use this appliance if any part has been
under water, immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
• Check around unit for debris and remove com-
bustible products, i.e. gasoline, etc.
Pre Start-up Check
1. Verify the heater is filled with water.
2. Check system piping for leaks. If found, repair
immediately.
3. Vent air from system. Air in system can interfere
with water circulation.
4. Purge air from gas line to boiler.
Initial Start-up
Required tools
• (1) 12-0-12 (24" scale) U-tube manometer
• (2) 6-0-6 (12" scale) U-tube manometer
• Screwdrivers (assorted sizes and shapes)
• (1) Crescent wrench (8" or 10")
• (1) Multi-meter
(Metric Allen wrenches will be required for servicing
the gas valve, but not during start-up)
NOTE: Digital manometers are not recommended.
Preparation
WARNING: Do not turn on gas at this time.
Check Power Supply
With multi-meter at incoming power, check voltage
between:
Hot - Common (�120 VAC)
Hot - Ground (-120 VAC)
Common - Ground (< 1 VAC)
WARNING: If Common - Ground is > 1 VAC,
STOP: Contact electrician to correct ground failure.
Failure to do this may burn out 120V-24V
transformer, or may cause other safety control
damage or failure.
Attach Manometers to Measure Pressures
1. Turn off main gas valve.
2. On the 700 and 850 models, remove plugs "A" and
"B," and install 1/8" NPT fittings to allow measure-
ment of the gas pressure.
3. Attach (1) 12" scale manometer to the upstream
fitting on the gas supply pipe to the heater
(Measure point "A" in Fig. 35. Field-supplied on
the 700 and 850 models).
GAS��
GAS
�
�
(700/850)
Fig. 35: Gas Pressure Measurement Locations
42
4. Attach (1) 12" scale manometer to the down-
stream fitting on the gas manifold (Measure point
"B" in Fig. 35. Field-supplied on the 700 and 850
models).
5. Attach (1) 12" scale manometer to the tapping on
the filter box. Pull black cap from air pressure
switch tee and connect the manometer. NOTE:
Retain caps for reinstallation later.
Check Gas Supply Pressure
1. Slowly turn on main gas shut-off valve.
2. Read the gas supply pressure from the manome-
ter; minimum supply pressure for natural gas is 4.0
in. WC, recommended supply is 7.0 in. WC, mini-
mum supply pressure for propane gas is 4.0 in.
WC, recommended supply is 11.0 in. WC (dynam-
ic readings, full fire input).
3. If the gas pressure is greater than 14.0 in. WC,
turn off the main gas shut-off valve.
Start-Up
1. Turn power on.
2. Turn on the boiler, approximately 5 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. Look into the sight glass located at the
bottom of the front panel to check igniter opera-
tion.
3. The boiler ignites at 3000 RPM (as indicated on
the LCD display of the user interface).
4. This boiler is equipped with a standard four-try
ignition module, it will try for ignition up to four
times before going into lockout. If the boiler is
equipped with the optional single-try ignition mod-
ule, it will try for ignition one time before going into
IOCICOUt.
5. Wait until the controller indicates 100% on the fir-
ing rate display screen. This will take several
minutes if step modulation is enabled.