Raypak XFYRE 500 User manual

up to 99%
Efficiency!
Can be vented with PVC
MBTU Models
300 •400 •500 •700 •850
CSA Verified lead Content
Less Than .25% Pb Ultra Low Emissions

2
Up to 99% part load!
Xtreme Outdoor
Performance
XFyreTCondensing Modulating Boiler
- The Green Choice
Raypak’s new XFyreTis a natural extension of our successful
XThermTmodulating vertical boiler line (1,1.5, 2 Million BTUH). Raypak
offers new features not found in other mod-con style boilers and
combines these desirable features into one complete boiler package.
XFyre is the only condensing boiler (300 to 850MBTUH) with CSA out-
door certification. Utilizing cabinet and control technology already
proven in over 250,000 Raypak pool heaters,the XFyre comes to
market as a seasoned veteran of outdoor environments. Mechanical
engineers, architects and building owners now have extreme instal-
lation flexibility,high efficiency,space saving footprint, zero side
clearance, direct vent capability,PVC venting and full service access.
Installers enjoy ease-of-commissioning, reliability, serviceability and
long-term performance.Small space,no longer a problem. Raypak’s
vertical water connections allow the units to be installed side by
side, further reducing the footprint on multi-boiler installations. Our
compact design makes it possible to install 6.8 million BTUH in
under 67 ft2of floor space,plus front and rear clearance. Tie them all
together with the built in Cascade Control and you have a boiler
system with a 40:1 turndown that operates at 94% thermal efficien-
cy! This is an Xtreme green retrofit system.
XFyre Combustion System
Modulation is nothing new to Raypak. We have been honing our gas
modulation experience for over 50 years. The Raypak XFyre will pre-
cisely track the heating load with its built-in Computer Control
System and built-in outdoor reset function, eliminating costly over-
shooting. Utilizing the latest European technology for the combus-
tion-components, the optimum fuel-air ratio is maintained through-
out the entire range of the load-tracking operation. Our 5:1 turn-
down ensures efficiency is maintained throughout the firing rate and
actually increases during part load, right when you want it! The
XFyre automatically self-tunes to accommodate the widest range of
gas supply pressures. The high quality integrated blower-gas valve is
self-correcting and allows smooth operation with fluctuating gas
supply pressures. The Raypak XFyre is cutting edge technology with
atmospheric simplicity.
Vent Flexibility
Category IV -CSA-certified 94% efficiency at
full fire for hydronic boilers and 95% for domes-
tic water heaters
(Up to 99% at part load!)
When the job requires high efficiency, XFyre
meets your needs.Combined vent and combus-
tion air duct length of up to 200 equivalent feet.
Vent your project in PVC, CPVC or Stainless.
XFyre is CSA certified for all three. The XFyre ships PVC ready with
no extras to purchase!
Key Features
•5 models from 300,000 to 850,000 BTUH
•94% thermal efficiency hydronic and 95% water heaters
•AB-1953 Low Lead Verified
•All models CSA indoor/outdoor certified
•Small footprint, less than 9-1/2 square feet
•Top side water connections - allows side by side installation
•All models are equipped with 316L welded stainless steel heat
exchanger and copper plumbing. ASME Section IV constructed
and stamped. National Board registered.
•Multiple pump outputs - Boiler Pump,System Pump,
Indirect Pump
•Dual flame sensing - Flame sensor and spark ignition rod
•Modulating gas valve and burner,up to 5:1 turndown
•Meets all current Low NOx regulations,including the new
(<20ppm) SCAQMD revisions
•Whisper quiet operation
•On-board diagnostic center,real English, no codes.
•0-10 VDC BMS Interface (setpoint or direct drive)
•Built-in cascade function for up to 8 boilers
•Built-in outdoor reset functionality
•Complete cabinet protects all controls and wiring
•Tough rust-resistant powder coat finish
•Easy to service - removable air filter
•PVC-CPVC-Stainless vent certified
•Suitable for altitudes up to 10,000 ft. (derate may apply)
Options
•Outdoor air sensor (B-32)
•Indirect sensor
•TruSealTdirect vent kit (D-21 factory installed, D-22 Loose)
•PC interface cable
•Condensate neutralizer (Z-12)

3
1. Water Inlet
As low as 50°F entering. All copper and brass factory
installed vertical plumbing connections. Vertical
plumbing allows boilers to be installed side by side or
in tight places if need be.Male NPT connections.
2. Water Outlet
All copper and brass factory installed vertical plumb-
ing connections.Male NPT connections.
3. Low Voltage Wiring Board
Allows easy front access to thermostat connections,
Outdoor sensor,DHW sensor,Alarm contacts and BMS
input signal (0-10VDC).Built-in cascade control using
CAT 3 or CAT 5 computer network cables to connect
with the communication bus between boilers. Every
unit comes factory equipped with Cascade control.
Simply remove the front door for quick access and
daisy chain the boilers together.
4. Control Cover
Helps prevent sun damage to the LCD display and
protects the control panel from dust, dirt and water.
4a. Control Interface
Easy to use microprocessor control with a 2x20 LCD
scrolling display.Monitor flame strength (mA), fan
speed (RPM),BMS input signal (0-10V),sensor temps and
setpoints. Built-in outdoor reset feature saves energy-
requires optional outdoor air sensor.Control also pro-
vides indirect priority function. Full diagnostic control
constantly monitoring 18 events. Fault code history
records the last 10 fault events and can be recalled to
help with troubleshooting. Well thought out
ergonomic control pad gives tactile feedback to the
user. No need to second guess your actions, wonder-
ing if you have engaged the buttons or not. The user
is reassured with a tactile pop every time a button is
successfully toggled. Everything you need from set-up
to service is at your fingertips,and all in one location.
5. Air Fuel Ratio Gas Valve
XFyre uses a German, precision manufactured, main
gas valve considered by most to be second to none.
This high tech gas valve works in perfect unison with
the combustion air blower. The result is smooth and
quiet light-offs while delivering a 5:1 turn down.
With this much flexibility,XFyre is the right boiler for
almost any size job.
6. Intake Air Filter
Every XFyre comes standard with a front access,
removable Merv 8 media, combustion air filter.
7. Manual Reset High Limit
8. Condensate Trap
The XFyre has a built-in condensate trap located at
the rear of the unit. The trap and the overfill conden-
sate sensor are accessible through their own access
panel.
9. Vent Switch
Senses possible obstructions in the flue vent pipe.
10. Flow Switch
The XFyre keeps its flow switch safe and dry inside
the cabinet, which protects it during shipping and in
the boiler room.
11. “Duo” Style Heat Exchanger
The XFyre uses a combined 316L stainless steel pri-
mary and secondary heat exchanger. Weld-sealed
technology eliminates gaskets and o-rings. Special
glycol is not required for hydronic applications. ASME
Section IV constructed and stamped. National Board
registered.
12. Direct Spark Ignition
XFyre's state-of-the-art combustion control system
utilizes the finest dual electrode igniter to start the
combustion cycle.After ignition, the spark rod also
acts as a second flame sensor.
12a. Flame Sense Electrode
After a call for heat, a seperate flame electrode moni-
tors flame rectification. This helps to ensure proper
carry over while also constantly monitoring the flame
over 50 times every second.
13. Internal Tru-SealTConnection
Allows the XFyre to be direct vented up to 200 com-
bined equivalent feet (vent and air intake) in a hori-
zontal or vertical vent system.
14. Smart Blower Technology
Utilizing a whisper quiet, all metal, technologically
advanced combustion blower.Air and fuel are mixed
precisely by the computer control center.
15. Mounting Feet
Built-in mounting feet located right under the center
of gravity allows for quick and easy Tapcontanchor-
ing.
16. Weather-Proof Jacket
Heavy gauge galvanized steel with a UV-resistant
Polytuf powder coat finish is impervious to weather
and corrosion. Raypak has one of the finest, top-of -
the-line powder coat systems on the west coast
regardless of industry. We laugh at a 1000 hour salt
spray test. Independent test documentation available
upon request.
Think Raypak
Think Green
Model 850 Model 300

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1. Flue Outlet
Category IV- PVC, CPVC and Stainless steel certified.
The XFyre ships PVC ready,no extras to purchase!
2. High Voltage Wiring Box
120VAC main incoming power connections. Boiler
pump wiring and DHW pump wiring. Alarm power
out.
3. Gas Inlet
The XFyre will operate at 100% full rate with gas pres-
sures as low as 4.0”w.c.
4. Condensate Drain and Trap
3/4”-NPT PVC connection for condensate removal.
Inset photo shows condensate trap,overfill sensor and
pressure switch for the flue.Raypak offers optional
condensate neutralizer kits (option Z-12) that can be
plumbed between the heater and the drain.
5. Direct Vent Capability
Every XFyre is direct vent capable.By installing an
optional combustion air pipe adapter,your XFyre is
ready for direct vent. For factory installation, order
(option D-21) TruSealTat time of order.
6. Rating Plate Location
7. Gas Valve and Boiler Control
Raypak uses German-made,high quality Dungs gas
valves, considered the finest modulating gas valves
produced today. To the right of the gas valve is the
boiler computer control center,which always keeps the
blower, gas valve, direct spark ignition and flame
supervision in perfect harmony.
8. Inlet and Outlet Connections and Flow Switch
The vertical inlet and outlet connections are all copper
and brass fitted with male pipe thread connections.
The flow switch is fully contained within the cabinet,
protecting it from the elements and boiler room
mishaps. Servicing of the Flow switch can be done
from the top or left side.
9. Removable Air Filter
Simple front access; just remove the front door. The fil-
ter just slides right out for quick and easy inspection
and replacement. The high capacity filter is rated
MERV 8.
Xtreme Access
7
8
4
9
The XFyre is purpose built for the
contractor and service professional.
Loosen wing-nutsRemove Front Door Pullout filter media
FRONT ACCESS INTAKE AIR FILTER
1
Completely serviceable from the front, top and both sides!

5
Xtremely Small Footprint
Ratings shown are for elevations up to 10,000 feet. For installations at elevations above
2,000 feet, derate may apply,please consult the factory for additional instructions.
Front 24” 24”
Rear 24” 24”
Right 0” 0”
Left 0” 0”
Top 12” 24”
Floor 0” ---
Vent 1” ---
Cert if ie d
Mi ni mu m
Service
Minimum
*Do not install on carpeting
Note: Local codes may require increased clearances
Heater
Side
Note: Current draw (Amps) is for pump only
Water hardness grains per gallon
Soft = 0-4 • Medium = 5-15 • Hard = 16-25
Water above 15gpg requires water softener.
Model MBTUH
Input
Boiler
Output Efficiency
Water Heaters
Output Efficiency
MBTUH
Input Minimum Input
300 300 282 94% 300 285 95% 60
400 399 375 94% 399 379 95% 80
500 500 470 94% 500 475 95% 100
700 700 658 94% 700 665 95% 140
850 850 799 94% 850 808 95% 170
Model
Dimensions (in.)
A
Length
Amps*
300 28 - 1/4 16 - 1/2 27 - 9/16 3/4 1 - 1/2 4 4 3 410 4.3 3
400 30 - 3/4 16 - 1/2 29 - 3/4 1 2 4 4 3 465 4.7 4
500 37 - 1/4 16 - 1/2 36 - 1/4 1 2 4 4 3 505 5.7 4
700 47 - 3/4 28 47 - 1/16 1 - 1/4 2 6 6 19 - 3/8 550 7.3 5
850 54 - 1/4 28 53 - 9/16 1 - 1/4 2 6 6 19 - 3/8 580 8.3 5
Foot-
Print
(ft2)
Ship
Weight
(lbs.)
EF
Mounting
G
NPT
H
NPT
K
Flue Ø
T
C/A Ø
V
300 1/8 1.3 1/4 5.7
400 1/8 1.3 1/2 6.9
500 1/4 5.7 1/2 6.9
700 1/2 6.9 1 14.0
850 1/2 6.9 1 14.0
Soft
Water Heater Pump Sizes
HardMedium
HP Amps HP AmpsHP Amps
XFyre
Model
*Current Draw is for heater only.
(Supply breaker must have delayed trip.)
Do not use when
hardness exceeds
15 grains per gallon

6
Xtremely Easy to Wire
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
XFyre
Model 20°F
GPM DT
40°F30°F Minimum Flow*
Rates Of Flow And Pressure Drops
300 1711 1140 855 684 570 489 428 380 342
400 2275 1517 1138 910 758 650 569 506 455
500 2851 1901 1426 1140 950 815 713 634 570
700 3992 2661 1996 1597 1331 1140 998 887 798
850 4847 3231 2423 1939 1616 1385 1212 1077 969
Temperature Rise (°F)
XFyre
Model
10080 9060 7040 503020
Recovery Rates
300 30 19 8 1.5 10 24 24 17 1.5 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
Soft (0-4 Grains Per Gallon)
Water Hardness
Hard (16-25 Grains Per Gallon) Medium (5-15 Grains Per Gallon)
XFyre
Model
Maximum Flow
GPM DT
*Closed systems only
DPDP
GPM DP GPM DPGPM DP
DTDPMTS DT
GPM SHL GPM MTS
DPSHL
Do not use when hardness
exceeds 15 grains per gallon
MTS = Minimum Tube Size, inch.
SHL = System Head Loss,ft (based on heater and tank placed no more than 5 ft apart).
DT = Temperature rise,°F
DP = Pressure drop through heat exchanger, ft
Hydronic Boiler
Water Heater
DTGPM MTS DPSHL
120VAC Wiring Center
The XFyre’s 120VAC wiring center is located on the rear
of the boiler.All incoming line voltage and pump wiring
are contained away from the 24v control wiring. Wiring
the boiler is simple and straight forward.
Low Voltage Wiring Center
Just like its big brother the XTherm, the XFyre has a
separate front mounted wiring center for all of the
low voltage connections. This makes thermostat, water
sensor, 0-10VDC BMS,and alarm contacts a breeze to
set up.No more guessing where the contact points
are buried in the boiler.Built-in cascade control using
CAT 3 or CAT 5 computer network patch cables to
connect with the communication bus between boilers.
Simply remove the front door for quick access.
120VAC Wiring Center
(rear of boiler)
Low Voltage
Wiring Center

7
Boiler Control and
On-Board Diagnostic Center
Raypak’s XFyre comes equipped with a microprocessor control
center that displays its information on a 2x20 character LCD
display in plain English. All set-up and programming is done at
this interface.Control monitors boiler system status including
safeties, ignition faults and also stores up to 10 reported faults.
The diagnostic center even monitors and reports the flame
strength signal in microamps.Monitor blower speed, BMS
input and all water and air sensors.A normally-open and nor-
mally-closed dry contact alarm relay is provided.
Outdoor Proven
Raypak is no stranger to the outdoor environment. Our touchpad is 100% waterproof and has been proven and perfected on our
pool products.No guesswork here,just one tough boiler ready to take on jobs that others have to walk away from.
Safety Faults
•Condensate Full
•Outdoor Sensor
•Line Voltage
•Blocked Vent
•Low Water Level
•24 Volt Low
•Low Water Flow
•Temper Blocking
•High Temperature
•Flue/Gas Pressure
•Supply Thermistor
•Return Thermistor
•Supply High
Ignition Control Faults
•No Flame
•Flame Failure
•Flame When Off
•Fan Speed Error
Xtreme Control
Example Diagnostic Fault Report
Diagnostic Information
Xtreme Firing Rates
Cascade up to 8 Boilers
Deliver up to 6.8 Million BTU at a 40:1 turndown rate!
The XFyre comes standard with a built-in Cascading Boiler Control. No other controls to buy,just daisy chain the units together
with CAT 3 or CAT 5 computer network cables
(not supplied) that plug into the front mounted communication bus on each unit
(see low voltage wiring box opposite page)
.Designate a Cascade Master Boiler and set all the other boilers as Followers. It’s that sim-
ple! The XFyre has built-in Lead-Lag control. This allows rotation of the starting boiler so all boilers in the system remain active
and the run times remain equal on each unit. Rotation can even be programmed based on time,ensuring equal run times per
unit.

ASME Section IV,National Board Registered, 160 PSI •H Stamp vv
Heat Exchanger Tubes • 316L Stainless Steel vv
Stainless Steel •CSA Verified AB-1953 CA low lead compliant vv
Pressure Relief Valve • 60 PSI Vv
(loose) • 125 PSI vV
• 30, 45, 75, 150 PSI VV
Temperature & Pressure Gauge (Loose) vv
Pump • 120V, Single-Phase VV
Indoor/Outdoor Certified vv
Vent Terminal • Outdoor VV
• Through-the-Wall VV
Fully-Enclosed Controls vv
Combustible Floor Rated vv
120V Power Supply vv
On/Off Switch vv
Programmable Pump Time Delay, Single-Phase • Included in Controller vv
Terminal Block Connections •Enable / Disable vv
(Front mounted) •0-10 VDC Setpoint/Direct Drive Input vv
LCD diagnostic display with 10-Event History (2x20 character display,reads in plain English) vv
Temperature Controller with 3 Water Sensors •(up to 5:1 Turndown) vv
•Outdoor Reset Sensor N/A V
Multiple Boiler Controller • TempTracker Mod+ Hybrid, up to 16 boilers/groups VV
Direct Spark Ignition System • 1-try VV
• 4-try vv
High/Low Gas Pressure Switches VV
Blocked Vent Switch vv
High Limit Switch •Manual Reset, Fixed vv
•Automatic Reset, Fixed VV
Low Water Cut-Off, 24V • With Manual Reset and Test Buttons VV
Flow Switch vv
Modulating Combination Gas Valve vv
Combustion Air Blower vv
Additional Safety Valve • Motorized (externally mounted) VV
•Solenoid (externally mounted) VV
CSA-Certified Efficiency •94% at Full Fire N/A v
•95% at Full Fire vN/A
•99% at Part Load vv
Air Filter vv
TruSeal Direct-Vent VV
Alarm Contacts vv
CSD-1 / GE GAP Control System VV
Low NOx •Meets all current requirements vv
Condensate Drain and Trap vv
Condensate Neutralizer VV
Water
Heaters
(Type WH)
Boilers
(Type H)
vv= Standard VV= Optional
Raypak, Inc. • 2151 Eastman Avenue, Oxnard, CA 93030 • phone: [phone] • fax: [phone] • www.raypak.com
© 2009-2010 Raypak, Inc. Cat. No. 1000.22B Effective: 07-15-10 Replaces: 02-15-10