xFyre 300A, 500A, 400A, 700A, 850A Installation & Operating Instructions

INSTALLATION & OPERATING

INSTRUCTIONS

Models 300A–850A

Types H & WH

WARNING: Improper installation, adjustment, alteration, service or maintenance can

cause property damage, personal injury, exposure to hazardous materials* or loss of
life. Review the information in this manual carefully. *This unit contains materials that
have been identified as carcinogenic, or possibly carcinogenic, to humans.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or
the gas supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.

Catalog No. 1000.65.2B Effective: 08-02-13 Replaces: 06-10-13 P/N 241480 Rev. 3

Rev. 3 reflects the following:
Changes to: Pump Selection on page 13, Table I on page 17, Table J on page 18, Table L on page 19, Fig. 22 on page 28,

Termination on page 29, Fig. 23 on page 30, Wiring Diagram on page 44, Table Y on page 47
Additions: Table G on page 13, Warning on page 29, Thermal Fuse (with Fig. 37) and Burner Door Limit (with Fig. 38) on
page 37.
Deletions: None

2

CONTENTS

WARNINGS 4

Pay Attention to These Terms 4

BEFORE INSTALLATION 5

Product Receipt 5
Model Identification 5
Ratings and Certifications 5
Installations at Elevation 5
Component Locations 6
General Information 6

GENERAL SAFETY 7

Time/Temperature Relationships
in Scalds 7

INSTALLATION 8

Installation Codes 8
Equipment Base 8
Clearances 8
Combustion and Ventilation Air 9
Conventional Combustion Air Supply 11
Water Piping 12
Hydronic Heating 13
Gas Supply 17
Electrical Power Connections 19
Field Wiring Connections 21
Venting 25
Venting Installation Tips 28
Venting Configurations 28
Condensate Management 33
Outdoor Installation 34
Controls 34

Operating Instructions 37

WIRING DIAGRAM 44
START-UP 45

Pre Start-up 45
Pre Start-up Check 45
Initial Start-up 45
Preparation 46
Start-Up 47

OPERATION 49

Lighting Instructions 49
To Turn Off Gas to Appliance 49

TROUBLESHOOTING 49

XFyre Error Codes 49
Heater Errors 49
Heater Faults 49
XFyre Fault Text 50
Sensor Resistance Values 52

MAINTENANCE 53

Suggested Minimum
Maintenance Schedule 53
Preventive Maintenance
Schedule 53

APPENDIX 56

Inside Air Contamination 56
Important Instructions for the
Commonwealth of Massachusetts 57

WARRANTY 58
START-UP CHECKLIST 59

3

WARNINGS

Pay Attention to These Terms

ndicates the presence of immediate hazards which will cause severe

DANGER:

I
personal injury, death or substantial property damage if ignored.

WARNING:

CAUTION:

NOTE:

DANGER: Make sure the gas on which the boiler

will operate is the same type as that specified on the
boiler rating plate.

WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the boiler. Instead, shut off
the gas supply at a location external to the boiler.

WARNING: Do not use this boiler if any part has
been under water. Immediately call a qualified
service technician to inspect the boiler and to
replace any part of the control system and any gas
control which has been under water.

WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the boiler:

Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.

WARNING: Both natural gas and propane have an
odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.

WARNING: UL recognized fuel gas detectors are
recommended in all enclosed propane and natural
gas applications wherein there is a potential for an
explosive mixture of fuel gas to accumulate and their
installation should be in accordance with the
detector manufacturer's recommendations and/or
local laws, rules, regulations, or customs.

• 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: 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 heater is installed to replace an
existing heater, the vent system MUST be verified to
be of the correct size and of one of the Category IV
vent materials identified in this manual. If it is NOT,
it MUST be replaced.

WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the

State of California to cause cancer, birth defects or
other reproductive harm.

WARNING: This appliance produces condensate
from the flue products that is acidic and highly
corrosive. Raypak recommends the use of a
condensate neutralizer kit to avoid long-term
damage to the drainage system and to meet local
code requirements.

WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.

4

BEFORE INSTALLATION

Raypak strongly recommends that this manual be re­viewed thoroughly before installing your XFyre heater.
Please review the General Safety information before

nstalling the heater. Factory warranty does not apply

i
to heaters that have been improperly installed or oper­ated. (Refer to the warranty at the back of this
manual.) Installation and service must be performed
by a qualified installer, 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.

he upper rear jacket panel. The model number has

t
the form H7-850A or similar depending on the heater
size and configuration. The letter(s) in the first group of
characters identifies the application (H = Hydronic

eating, WH = Domestic Hot Water). The number

H
which follows identifies the firing mode (7 = electron­ic modulation). The second group of characters
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:

Thank you for purchasing a Raypak product. We hope
you will be satisfied with the high quality and durability
of our equipment.

Product Receipt

On receipt of your heater it is suggested that you visu­ally 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 indi­cated 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 war­ranty conditions, you must also specify the date of
installation.

Purchased parts are subject to replacement only
under the manufacturer’s warranty. Debits for defec­tive replacement parts will not be accepted. Parts will
be replaced in kind only per Raypak’s standard war­ranties.

Model Identification

• 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 certified low-lead (<.25%) 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.

Installations at Elevation

WARNING: Altering any Raypak pressure vessel

by installing replacement heat exchangers or any
ASME parts not manufactured and/or 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.

Rated inputs are suitable for up to 2000 ft elevation
without de-rating. Consult your local representative or
the factory for installations at altitudes over 2000 ft
above sea level. No hardware changes are required to
the heaters for installations up to 10,000 ft (adjust­ments may be required).

The model identification number and heater serial
number are found on the heater rating plate located on

5

N

O

TE

: JA

C

K

E

T

T

O

P

S

L

O

P

E

S

FR

O

M

FR

O

N

T

T

O

R

E

A

R

CONTROL/SENSOR
WIRING

Component Locations

Model 850 shown. Component locations may vary slightly in smaller models.

Fig. 1: Component Locations — Sides

Fig. 2: Component Locations — Top

General Information

Model

No.

Max. Min. N P Flue Intake

300A 300 60 1-1/2” 3/4” 3/4” 4 4

400A 399 80 2” 1” 1” 4 4

500A 500 100 2” 1” 1” 4 4

700A 700 140 2” 1-1/4” 1-1/4” 6 6

850A 850 170 2” 1-1/4” 1-1/4” 6 6

MBTUH

Input

Water
conn.

Gas conn.

(NPT)

(NPT)

Table A: Basic Data

6

Fig. 3: Component Locations — Rear

Vent Size

(inches)

Water temperature over 125°F can
cau s e i nsta n t s e v er e b u r ns or d eath
from scalds.

Children, disabled, and elderly are
at highest risk of being scalded.

See instruction manual before set­ting temperature at water heater.

Feel water before bathing or show­ering.

Temperature limiting valves are
available, see manual.

Water

Temp.

Time to Produce Serious

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 About 1 second

Table courtesy of The Shriners Burn Institute

Model No.

Heater Water Volume

300A 2.9

400A 3.6

(gallons)

5

00A

.2

4

700A 5.0

850A 5.8

Table B: Heater Water Volume

GENERAL SAFETY

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

Safety and energy conservation are factors to be con­sidered 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.

Time/Temperature
Relationships in Scalds

• 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.

Table C: Time to Produce Serious Burn

7

INSTALLATION

NOTE: The following instructions are intended for

simple applications. For more detailed
configurations and set-up, consult the VERSA IC
Control I&O Manual (Catalog #5000.72).

f the heater needs to be secured to the ground, use

I
the holes in the anchoring legs on the heater.

Clearances

Indoor Installations

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.

NOTE: The top jacket of the boiler is sloped from
front to rear.

Heater

Side

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 clear­ances from combustible construction, these heaters
can be serviced without removing permanent structur­al 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.

Min. Clearances

from Combustible

Surfaces

Minimum

Service

Clearances

CAUTION: The boiler must be mounted on a level
base to allow condensate to drain properly from the
heat exchanger. The condensate is acidic and

highly corrosive.

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.).

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 installa­tion. Heaters must not be installed under an overhang
unless clearances are in accordance with local instal­lation codes and the requirements of the gas supplier.
Three sides must be open in the area under the over­hang. Roof water drainage must be diverted away
from heaters installed under overhangs.

8

TOP VIEW

FRONT VIEW

Heater

Side

Min. Clearances

from Combustible

urfaces

S

Minimum

Service

learances

C

Rear 24” 24”

Right Side 0” 0”

Left Side 0” 0”

Top Unobstructed 24”

Front Open 24”

Vent

Termination

Table E: Clearances — Outdoor Installations

12” 12”

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 sup­plied 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 com­ply with the requirements of the NFGC (U.S.) or B149
(Canada), and all local codes.

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

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.

9

U.S. Installations

1

Canadian Installations

2

A

Clearance above grade, veranda, porch,
deck, or balcony

1 ft (30 cm) 1 ft (30 cm)

B

Clearance to window or door that may be
opened

4 ft (1.2m) below or to side

of opening; 1 foot (30 cm)

above opening

3 ft (91 cm)

C Clearance to permanently closed window * *

D

Vertical clearance to ventilated soffit located
above the terminal within a horizontal dis­tance of 2 ft (61cm) from the centerline of the
terminal

5 ft (1.5m) *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner 6 ft (1.83m) *

H

Clearance to each side of center line ex­tended above meter/regulator assembly

*

3 ft (91 cm) within a height

15 ft above the me-

ter/regulator assembly

I Clearance to service regulator vent outlet * 6 ft (1.83m)

J

Clearance to non-mechanical air supply inlet
to building or the combustion air inlet to any
other appliance

4 ft (1.2m) below or to side

of opening; 1 ft (30 cm)

above opening

3 ft (91 cm)

K Clearance to mechanical air supply inlet

3 ft (91 cm) above if within

10 ft (3m) horizontally

6 ft (1.83m)

L

Clearance above paved sidewalk or paved
driveway located on public property

7 ft (2.13m)

7 ft (2.13m) t

M

Clearance under veranda, porch, deck or
balcony

* 12 in. (30 cm) TT

1

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code

2

In accordance with the current CAN/CSA-B149 Installation Codes

t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that se rves

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 term inal 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

Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table F: Vent/Air Inlet Termination Clearances

10

Combustion Air Filter

This heater is supplied with an integral combustion air
filter. This filter will reduce the amount of particulates
that pass through the combustion system and heat
exchanger but will not protect against chemical inside
air contamination (See Appendix). The filter must be
checked periodically to verify that adequate combus­tion 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. 24 (horizontal) or Fig. 26 (vertical) of this
manual.

3. Ventilation of the space occupied by the heater(s)
is recommended and can be provided by an open­ing(s) for ventilation air at the highest practical
point communicating with the outdoors. The total
cross-sectional area should be at least 1 in² 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 out­doors or through vertical duct(s). The total
cross-sectional area should be at least 1 in² 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). Damage to the equip­ment due to inadequate ventilation of the space is
not a warrantable failure.

ealed with RTV (not supplied). TruSeal is generally

s
used when damaging contaminants are present in the
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

anual regarding air contamination.

m

NOTE: To ensure proper cooling and ventilation of
components, do not block any air openings in the
cabinet

Conventional Combustion Air
Supply

U.S. Installations

All Air from Inside the Building

The confined space shall be provided with TWO per­manent openings communicating directly with an
additional room(s) of sufficient volume so that the com­bined 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 determina­tion. Each opening shall have a minimum free area of
1 in.2 per 1,000 BTUH (2,225 mm2per kW) of the total
input rating of all gas utilization equipment in the con­fined 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 mini­mum dimension of air openings shall be not less than
3 in. (76 mm) in any direction.

All Air from Outdoors

4. In cold climates, and to mitigate potential freeze­up, 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.

TruSeal™ 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

The confined space shall communicate with the out­doors 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.

1. Two permanent openings, one commencing
within 12 in. (305 mm) of the top, and one com­mencing 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 com­municate with the outdoors.

11

a. Where directly communicating with the out-

doors or where communicating to the
outdoors through vertical ducts, each open-
ing shall have a minimum free area of 1 in.
per 4,000 BTUH (550 mm2per kW) of total
input rating of all equipment in the enclosure.

. Where communicating with the outdoors

b

through horizontal ducts, each opening shall

2

have a minimum free area of 1 in.

per 2,000
BTUH (1,100 mm2per kW) of total input rat­ing 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 out­doors or shall 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.2per 3,000 BTUH (740 mm2per 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.

WARNING: Do not use the “one permanent
opening” method if the equipment room is under
negative pressure conditions.

Canadian Installations

CAUTION: All combustion air must be drawn from

the air outside of the building; the mechanical equip­ment room must communicate directly with the
outdoors.

1. 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.
(65 cm2).

4,000 BTUH (160 mm

1

2

er kW) in excess of 1

p
million BTUH. This opening(s) shall be either
located at or ducted to a point not more than 18 in.

2

(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

nd terminated 18 in. (450 mm) from the floor, but

a
not near piping. This air supply opening require­ment 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. 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 open­ing(s) having a total cross-sectional area of not
less than 1 in.

2

for each 30,000 BTUH (74 mm2per
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 ventila­tion 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.

4. Refer to the B149 Installation Code for additional
information.

Water Piping

NOTE: Refer to the VERSA IC Applications Guide

(Catalog #5000.72) for detailed instructions regard­ing the various applications supported by the
VERSA IC control system.

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.

2

General

2. 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

2

than 1 in.

per 7,000 BTUH (320 mm2per kW) up

to and including 1 million BTUH, plus 1 in.

The heater should be located so that any water leaks
will not cause damage to the adjacent area or struc­tures.

2

per

12

NOTE: Minimum pipe size for in/out connections is
1-1/2” NPT for model 300A and 2” NPT for models
400A, 500A, 700A and 850A. Verify proper flow rates

nd ∆T as instructed in this manual.

a

NOTE: The continuous inlet water temperature
must be no less than 50°F.

CAUTION: This boiler requires forced water
circulation when the burner is operating. See Table H
and Table I 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.

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.

nections to the heater and the rest of the system prior
to operation. This is particularly true for hydronic sys­tems using expensive glycol-based anti-freeze.
Raypak recommends conducting the hydrostatic test
before connecting gas piping or electrical supply.

eaks must be repaired at once to prevent damage to

L
the heater. NEVER use petroleum-based stop-leak
compounds.

To perform hydrostatic test:

1. 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.

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 mount­ed 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.

Temperature & 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.

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. Ray­pak recommends designing for a ∆T within the range
of 15°F to 35°F (8°C to 19°C). See Table H for accept­able flow rates for each model (∆T is the temperature
difference between the inlet and outlet water when the
heater is firing at full rate).

Raypak standard pump selection for H models is
based on a 30º ∆T, and allows for up to 75 equivalent
feet of tubing between the boiler and the system con­nections.

Standard Boiler Pump*

Boiler Model

Pump HP

H7-300A 0012 1/8

H7-400A 0012 1/8

Hydrostatic Test

Unlike many types of heaters, this heater does not re­quire hydrostatic testing prior to being placed in
operation. The heat exchanger is ASME certified for
160 psi maximum working pressure. However, Raypak
does recommend hydrostatic testing of the piping con-

H7-500A 1611 1/4

H7-700A 1630 1/2

H7-850A 1630 1/2

* Pump selection based on 30° ∆T with up to 75 eq. ft. of tubing.

Table G: Pump Selection

13

Feedwater Regulator

aypak recommends that a feedwater regulator be in-

R
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 wa­ter 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 recommend­ed that the piping be insulated.

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.

Applications & Modes

The VERSA IC Control system is designed for a wide
range of applications. The installer/design engineer
should refer to the following Modes to determine which
best fits the intended application and functionality for
the unit being installed.

Type H models of XFyre have three modes available
to them to address the various applications the units
can be applied to. Type WH units will only have the
WH configuration available to them for use with
potable water applications when directly connected to
a hot water storage tank.

Mode 1 (Type H Units Only)

This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4). The system temperature is
controlled by the System sensor (S3). The Boiler
Pump (P1) runs during any call for heat. The System
Pump (P2) runs whenever the system is enabled for
heating and the outdoor air temperature is lower than
the warm weather shut down (WWSD) temperature

Fig. 6: Air-Separation/Expansion Tank

Model

No.

H7-300A 28 17 19 8 16 6 14 5 39 36 28 16

H7-400A 38 18 25 7 21 5 19 4 39 47 29 16

H7-500A 47 16 31 7 27 5 24 4 39 56 23 17

H7-700A 66 30 44 13 38 9 34 7 39 70 34 19

H7-850A 80 40 53 17 46 12 41 10 39 80 40 20

20°F ∆T 30°F ∆T 35°F ∆T Min. Flow Max. Flow

gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) gpm ∆P (ft) ∆T gpm ∆P (ft) ∆T

setting (if utilized). The Boiler Pump and System Pump
are delayed “off” as user defined in the ADJUST
menu.

Notes: Basis for minimum flow is ∆T . Basis for maximum flow is gpm.

Table H: Heater Rates of Flow and Pressure Drops

14

Fig. 7: MODE 1 - Applications with Primary/Secondary Piping

K

ey:

S1: Boiler Outlet Sensor
S2: Boiler Inlet Sensor
S3: System Sensor
S4: Outdoor Air Sensor
S

5: Indirect Tank Sensor
S6: Supply Sensor to Indirect
P1: Boiler Pump
P2: System Pump
P3: Indirect DHW Pump

NOTE: MODE 1 can also be used for process heat­ing applications in conjunction with a buffer/storage
tank when operating temperatures above 150°F are
required. Care must be given to ensuring water hard­ness is less than 5 grains per gallon to ensure scale
free operation.

Mode 2 (Type H Units Only)

This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4) with indirect DHW on the sys­tem loop (with or without priority). The system
temperature is controlled by the System sensor (S3).
The Indirect DHW sensor (S5) determines the indirect
call/tank setpoint. The system temperature is boosted
to Target Max when using the Indirect DHW sensor
(S5) during an indirect call for heat. Priority mode tog­gles off the System Pump (P2) when an indirect call for
heat is present. The Boiler Pump (P1) runs during any
call for heat. The Indirect DHW Pump (P3) runs during
an indirect call for heat with no “off” delay. The Boiler
Pump (P1) and System Pump (P2) delay “off” as user
defined in the ADJUST menu. The System Pump (P2)
runs whenever the system is enabled for heating and
the outdoor air temperature is lower than the WWSD
temperature setting (if utilized) unless an indirect call
for heat is present with priority.

Fig. 8: MODE 2 - Single Boiler with Indirect

Mode 3 (Type H Units Only)

This mode selection is for hydronic heating systems
with single or multiple boilers (Maximum 4 boilers) in
primary/secondary piping configuration with or without
Outdoor Air Reset (S4) with indirect DHW on the boil­er loop (with priority). The system temperature is
controlled by the Supply sensor (S3) whenever the
indirect call for heat is not active. The DHW Supply

15

on System Loop

Fig. 9: MODE 3 - Single Boiler with Indirect

on Boiler Loop

Fig. 10: WH Units - Single Water Heater with Tank

H Units - Single Boiler with Process Tank

sensor (S5) determines the indirect call/tank setpoint.
During an indirect call for heat the boiler firing rate is
determined by the water temperature at the Indirect
Supply sensor (S6) and the Target Max setting when
using the Indirect DHW sensor (S5). The Boiler Pump
(P1) runs during all heat calls regardless of priority.
The Indirect DHW Pump (P3) runs during an indirect
call for heat with no “off” delay. The Boiler Pump (P1)
and System Pump (P2) delay “off” as user defined in
the ADJUST menu. The system pump (P2) runs
whenever the system is enabled for heating and the
outdoor air temperature is lower than the WWSD tem­perature setting (if utilized) unless an indirect call for
heat is present.

NOTE: A Tank Aquastat can be used in lieu of the
Indirect DHW Sensor (S5). See the VERSA IC
Applications Guide for additional details.

WH – Direct DHW Configuration

When the unit is ordered as a “WH” configuration the
only application available to it is direct DHW with sin­gle or multiple heaters (Maximum 4 heaters). The tank
temperature is controlled by the System sensor (S3).
The Boiler Pump (P1) runs during any call for heat.
The System Pump (P2) output is active whenever the
system is enabled. The Boiler Pump is delayed “off”
after the Tank Target temperature is achieved and as
user defined in the ADJUST menu.

NOTE: WH units will operate to a maximum tank
temperature of 150F. For temperatures required
above 150F an “H” model boiler must be used and
great care must be given to ensuring water hardness
is less than 5 grains per gallon to ensure scale free
operation. MODE 1 should be used and configured
for setpoint operation for process heating applica­tions.

Domestic Hot Water

When designing the water piping system for domestic
hot water applications, water hardness should be con­sidered. Table I 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.

NOTE: If local codes require a vacuum relief valve,
acquire one locally and install per valve
manufacturer’s instructions.

16

Potable Water and Space Heating

Gas Supply

CAUTION: When this heater is used for both

potable water and space heating, observe the
following to ensure proper operation.

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
potential.

WARNING: Plumbing between the heater and tank
in excess of 75 equivalent feet will require custom
pump selection. Damage due to low flow may occur
and is not a warrantable failure. Consult with your
local Raypak representative.

NOTE: The 75 eq. feet of tubing typically represents
25 linear feet of tubing and 50 eq. feet of fittings.

DANGER: Make sure the gas on which the heater
will operate is the same type as specified on the rat­ing plate.

Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve lo­cated outside the heater jacket. It is recommended
that a union be installed in the gas supply piping adja­cent to the heater for servicing. Refer to Table K for
maximum pipe lengths.

Gas Supply Connection

CAUTION: The heater must be disconnected from

the gas supply 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 pip­ing 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 greater
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. FAIL-

URE TO FOLLOW THIS PROCEDURE MAY
DAMAGE THE GAS VALVE. Over-pressurized gas

valves are not covered by warranty. The heater and its
gas connections shall be leak-tested before placing
the appliance in operation. Use soapy water for leak
test. DO NOT use an open flame.

Model No.

WH7-300A 1611 1/4 26 18.3 21.9

WH7-400A 1630 1/2 39 21.0 19.4

WH7-500A 1630 1/2 48 20.7 19.8

WH7-700A 1634 1 69 36.0 19.3

WH7-850A 1634 1 69 36.0 23.4

∆T = 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 75 ft of tubing and fittings).
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 140°F. For higher than 140°F operation, or Hard water (>16 grains per gallon of total hardness), a water softener/treatment sys­tem must be utilized.

Table I: Domestic Water Heater Flow Rate Requirements

3–15 grains per gallon

Pump HP GPM SHL ∆T

17

Fig. 11: Gas Supply Connection

CAUTION: Do not use Teflon tape on gas line pipe
thread. A pipe compound rated for use with natural
and propane gases is recommended. Apply
sparingly only on male pipe ends, leaving the two
end threads bare.

Gas Supply Pressure

A minimum of 4.0 in. WC upstream gas pressure
under full load and a maximum gas supply pressure
setpoint of 10.5 in. WC under load and no-load condi-

ions for natural gas. A minimum of 4.0 in. WC

t
upstream gas pressure under full load and a maximum
gas supply pressure setpoint of 13.0 in. WC is required
for propane gas. The gas pressure regulator(s) sup­plied on the heater is for low-pressure service. If
upstream pressure exceeds 1/2 psi at any time, an
intermediate gas pressure regulator, of the lockup
type, must be installed. This regulator should be
placed a minimum distance of 10 times the pipe diam­eter upstream of the heater gas controls.

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 J.

During normal operation, carbon dioxide should be 8.5
to 9.0% at full fire for natural gas and between 9.5 and

10.0% for propane gas. Carbon monoxide should be
‹150 ppm.

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.

Manifold Pressure (in. WC)

Model No.

Natural Gas Propane Gas

High High

300A -1.0 ± .1 -1.0 ± .1

400A -1.5 ± .1 -1.6 ± .1

500A -1.2 ± .1 -1.3 ± .1

700A -1.4 ± .1 -1.0 ± .1

850A -1.7 ± .2 -3.4 ± .2

Table J: Manifold Gas Pressure Settings

CAUTION: For proper operation, no more than a
30% drop in gas supply pressure from no-load to full­load conditions is acceptable. Under no
circumstances should the pressure be outside the
listed operational range.

18