INSTALLATION & OPERATING INSTRUCTIONS 84 Professional Gas-Fired Pool & Spa Heater Low NOx Models 259 & 409 WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. 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.
WATER CHEMISTRY (Corrosive water voids all warranties) For your health and the protection of your pool equipment, it is essential that your water be chemically balanced. The following levels must be used as a guide for balanced water. Recommended Level(s) Water Temp. (Deg. F) pH Total Alkalinity (PPM) Calcium Hardness (PPM) Salt (PPM) Free Chlorine (PPM)* Fiberglass Pools Fiberglass Spas Other Pool & Spa Types 7.3 to 7.4 7.3 to 7.4 7.6 to 7.
2 4 4 5 5 6 6 7 8 8 8 8 9 9 10 10 10 11 11 13 14 14 16 16 17 18 18 19 19 19 21 22 23 24 24 25 25 25 25 25 25 26 26 27 28 28 Water Chemistry WARNINGS Pay Attention to These Terms CONTENTS Wiring Diagram 33 34 34 35 37 38 38 38 39 39 39 40 40 40 40 41 41 41 41 General Location of Controls Control Adjustments Control Panel Removal Thermostat Operation - Direct Spark Board Status and Diagnostics Remote Control Installation and Operation Remote Operation Activating the Remote Remote Control Wiring 2
WARNINGS—Pay Attention to These Terms DANGER: WARNING: CAUTION: NOTE: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
PART ONE OWNER'S OPERATING INSTRUCTIONS FOR YOUR SAFETY - READ BEFORE OPERATING WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. INTRODUCTION Your pool/spa heater has been designed for years of safe and reliable pool/spa water heating. It is available with electronic ignition. This manual provides installation, operation, maintenance, and service information for these heaters.
19. Once the pre-purge period ends, the igniter will begin to spark just prior to the gas valve opening. The gas valve will open for a 4 second trial for ignition. If flame is proven, the heater will operate to meet heat demand. If flame is not proven, the heater will enter a post-purge period and then retry the ignition cycle or lockout, depending on the heater configuration. 20. Once gas is flowing, the manometer reading will drop to -0.40” +/- .1” WC. 21.
WARNING: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control to the heater. CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters.
POOL & SPA WATER CHEMISTRY COLD CLIMATE: Prolonged operation with water temperatures below 50°F is not recommended. When starting the heater with water temperatures below 50°F, operate the heater continuously until higher temperatures are reached. Operating the heater for prolonged periods with pool water below 50°F can seriously damage the heater, and is not covered by the warranty. Chemical imbalance can cause severe damage to your heater and associated equipment.
PART TWO INSTALLATION AND SERVICE INSTRUCTIONS SECTION 1 - RECEIVING EQUIPMENT The manufacturer recommends that this manual be reviewed thoroughly before installing your pool/spa heater. If there are any questions that this manual does not answer, please contact the factory or your local representative. On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the carton is damaged, a note should be made on the Bill of Lading when signing for the equipment.
SECTION 2 - GENERAL SPECIFICATIONS These heaters are design-certified and tested under the latest requirements of the ANSI Z21.56 / CSA 4.7 Standard for Gas-Fired Pool Heaters. All heaters can be used either indoor or outdoors. Ambient Temperature Rating of Heater Components -32°F to + 175°F Electronic Ignition Heater* *Requires 120 or 240VAC Power Supply Rated inputs are suitable for up to 2,000 feet elevation.
CLEARANCES ALL HEATERS For clearances from combustible surfaces, see the chart below. When installed according to the listed minimum clearances from combustible construction, the pool heater can still be serviced without removing permanent construction around the heater. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION However, for ease of servicing, Raypak recommends a clearance of at least 24” in the front and at least 18" on the water connection side.
Heaters must not be installed under an overhang of less than three 3 ft from the top of the heater. Three sides must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters. For U.S. installations, the point from where the flue products exit the heater must be a minimum of 4 ft below, 4 ft horizontally from, or 1 ft above any door, window or gravity inlet into any building.
INDOOR HEATER INSTALLATION For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with an occupied area. Refer to the latest edition of CAN/CSA-B149 for specific requirements. Locate heater as close as is practical to a chimney or gas vent. The heater must always be vented to the outside. See the Venting section (beginning on page 17) for details. Minimum allowable space is shown on the nameplate.
Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations 1 1 2 t TT * 2 U.S. Installations Canadian Installations A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm) B Clearance to window or door that may be opened 4 ft (1.
COMBUSTION AND VENTILATION AIR (Indoor Units Only) The heater must have both combustion and ventilation air. Minimum requirements for net free air supply openings are one opening that is 12 inches from the ceiling for ventilation, and one opening that is 12 inches from the floor for combustion air as outlined in the latest edition of the National Fuel Gas Code, ANSI Z223.1(CanadaCAN/CSA-B149) and any local codes that may have jurisdiction. A.
VENTING 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. CAUTION: Proper installation of flue venting is critical for the safe and efficient operation of the heater. 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.
Support of Vent Stack 10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations. The weight of the vent stack or chimney must not rest on the heater vent connection. Support must be provided 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. 11.
Venting Installation Tips Canadian Installations Refer to latest edition of the B149 Installation code. Support piping: A vent shall not terminate: • • • 1. Directly above a paved sidewalk or driveway which is located between two single-family dwellings and serves both dwellings. WARNING: Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness, corrosion or deterioration. 2. Less than 7 ft (2.
The connection from the appliance vent to the stack must be as direct as possible. 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 terminal. 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 physical damage or separation of joints.
Model No. 409 Vent Size (in.) 259 409 259 259 6” 5” 4” Maximum Horizontal Vent Length (ft)* 80 40 80 40 * Subtract 10 ft. per elbow, maximum 4 elbows 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.
Direct Vent—Vertical 2. The intake vent must be insulated through the length of the horizontal run. Installation Termination These installations utilize the heater-mounted blower to draw combustion air from outdoors and force the heated flue products through the vent pipe under positive pressure. The vent material must be in accordance with the above instructions for vent materials. Vent material must be listed by a nationally recognized test agency.
Model No. 409 259 409 259 Certified Vent Material Category III 259 Vent Size (in.) Maximum HorizontalVent Length (ft)** Combustion Air Intake Pipe Material 6 80 Galvanized Steel, PVC, ABS, CPVC 5 4 ** Subtract 10 ft per elbow. Max. 4 elbows. 40 80 40 Air Intake Max. Length** (ft) 4” Ø 80 Category III Horizontal Vent & Horizontal Direct Vent stainless steel vents offered by Heat Fab Inc. (800772-0739), Protech System, Inc.
A few reasons why the rear stackless top may be considered are: 2. a) It reduces the chance of water infiltration, especially in snowy areas. 3. b) It relieves lot line restrictions. 4. c) It is easier to service the heater. Care must be taken when locating the heater 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.
FLOW RATES GAS PRESSURE ADJUSTMENT LOCATIONS MODEL 259 409 GAS INLET Natural Gas 1000 BTU/FT3 0.60 Specific Gravity @ 0.5 in. WC Pressure Drop Propane Gas 2500 BTU/FT3 1.53 Specific Gravity @ 0.5 in. WC Pressure Drop Input 3/4” Model (KBTU) N 399.0 15 * P 35 15 N 1” 1-1/4” P N 55 95 P 1-1/2” N 50 125 210 480 445 20 BYPASS SPRING P 225 215 480 *A 3/4” gas line can be used for up to 5 ft maximum length from the gas valve in addition to the sediment trap.
AUXILIARY BYPASS VALVE ADJUSTMENT ELECTRICAL WIRING NOTE: If it is necessary to replace any of the original wiring, use 105°C wire or its equivalent, and/or 150°C wire or its equivalent, like the original wiring. To set bypass: With clean filter, adjustment is made by feeling the inlet and outlet pipes at the heater. Outlet pipes should be slightly warmer than inlet and comfortable to the touch. If pipe is hot, close bypass; if cold, open bypass. WARNING: 240 VAC power supply.
TRANSFORMER WIRING 120 VAC WIRING For 120 VAC input power to the unit, connect the pair of black wires to the “L1” or hot leg of the power supply. Connect the red/white wire and the white wire to the “Ret” or neutral leg of the power supply. Attach the wire nut to the red wire. There should be no connection to the red wire for 120 VAC operation.
OPTIONAL LEFT-HAND WIRING If the standard right-hand electrical wiring is not accessible or convenient, wiring can be done from the lefthand side instead. Conversion is done using the following method: PULL WIRES THROUGH LEFT SIDE PANEL 1. Locate the plug on the left-hand side of the unit. 2. Remove plug and set aside. 3. Locate the junction box. Remove the screw holding the cover in place and set the cover aside. 4. Pull the bundle of heater wires back in from the right jacket panel. 5.
LEFT INLET / RIGHT OUTLET PLUMBING The conversion is performed using the following procedures: 1. Remove thermostat sensor from Jaco fitting and set aside. 2. Remove Inlet CPVC Ring Nut and Plug. 3. Relocate and tighten CPVC Ring Nut and Plug to the right side of the In/Out Header. 4. Reroute and install the thermostat sensor to the right side of the In/Out Header. WARNING: Before performing any conversion steps, make sure that all electrical power to the heater has been turned OFF.
STRAIGHT PLUMBING SETUP (FRONT VIEW) Single Pool or Spa Heater Installation 90° PLUMBING SETUP (TOP VIEW) Recommended plumbing setups POOL HEATER WITH INTERNAL BYPASS Multiple Pool or Spa Heaters Installation THIS DIAGRAM IS RAYPAK’S RECOMMENDATION, AND IS NOT INTENDED TO REPLACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER.
Single Pool/Spa Heater Installation Multiple Pool/Spa Heaters Installation The heater requires water flow and positive pressure to fire and operate properly. It must therefore be installed downstream of the discharge side of the filter pump. A typical installation is plumbed as follows: 1. The inlet side of the filter is plumbed directly to the discharge side of the filter pump; 2. The outlet side of the filter is then plumbed to the inlet of the heater; and 3.
WIRING DIAGRAM 32
SECTION 4 - SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS GAS VALVE GAS ORIFICE WIRING BOX (SUPPLY POWER) LEFT ACCESS PANEL BLOWER RELAY TRANSFORMER FLOW SWITCH T&P GAUGE PRV HL1 & HL2 HIGH LIMITS BONDING LUG LOCATION (OPTIONAL) DRAIN VALVE DIRECT VENT ACCESS PANEL RIGHT ACCESS PANEL VENT PRESSURE SWITCH AIR PRESSURE SWITCH TEMPERATURE SENSOR 33 BONDING LUG LOCATION
CONTROL ADJUSTMENTS ON LCD DISPLAY OFF TEMP ADJUST BUTTONS MODE BUTTON CONTROL PANEL REMOVAL To remove the PC board from the heater, use the following procedure: 1. Turn off main power to the heater. 2. Remove front door to access wire harnesses. 3. Reaching underneath the PC board, carefully remove all connectors and wires from the PC board and ON/OFF toggle switch. 4. Lift the front bezel lid and remove the two lower Phillips screws. 5.
THERMOSTAT OPERATION - DIRECT SPARK (DS) BOARD TEMP MODE LCD Display Temp Buttons Program Button On/Off Switch Mode Button the pilot flame current using a bar graph and numerical display. A signal of less than 4 indicates a weak flame signal and may require service. Refer to Section 5 – Troubleshooting for possible causes and corrections.
Fahrenheit or Celsius Refer to step one above to access the program screen. Press the MODE button until Fahrenheit or Celsius appears on the digital display. The digital display is capable of displaying Celsius as well as Fahrenheit temperatures. The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display. Choose the desired temperature scale. Program Button 1) Follow the instructions on page 34 to remove the control panel.
NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa thermometer. The heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool or spa, the water temperature at the inlet to the heater may differ from that observed at a given location in the pool or spa. STATUS AND DIAGNOSTICS The digital thermostat models are programmed to display a variety of status and diagnostic messages, depending on the operating conditions.
REMOTE CONTROL INSTALLATION AND OPERATION CAUTION: Before installing remote controls to the heaters, read the following: The digital thermostat model is remote-ready in most cases. The digital liquid crystal display (LCD) shows the actual pool temperature, operating status, and service codes (See examples below). The touch pad on the control panel allows you to select the desired pool or spa temperature. It also indicates when a remote system is controlling the heater by displaying Remote in the display.
REMOTE CONTROL WIRING Important Installation Notes for Remote or External Wiring Configuration • Remote wiring must be run in a separate conduit. • Remote wiring must not be run parallel to high voltage lines. • For runs of under 30 feet, remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, cable twisting 1.5 to 2.5 in. lay and jacketed. • For runs over 30 feet, the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5 to 2.5 inch lay that is shielded and jacketed.
TIME CLOCK/FIREMAN’S SWITCH FLOW SWITCH To operate the heater with a time clock, connect the timer to the fireman’s switch connection in the heater’s wiring. The time clock should be of the dual switch type and set to shut off the call for heat to the pool heater 15 to 20 minutes prior to shutting down the pool pump. The fireman’s switch connection is located on the 6-pin header connected to the digital control board.
VISUAL INSPECTION 4 NOTCHES Flames can be observed through the sight glass reflection below the blower motor. A blue colored flame indicates normal operation. At least every three months a visual inspection should be made. MUST MATCH FOR CORRECT AIR/FUEL RATIO ELECTRICAL Be sure that electrical service to the heater has proper overload fuse or circuit breaker protection, wire size and connections which comply with all applicable codes.
SECTION 5 - TROUBLESHOOTING MECHANICAL IMPORTANT NOTICE These instructions are intended for the use of qualified personnel who are specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.
CONTROL LOGIC - FLOW CHART Power On Is the water temperature displayed? NO YES “Remote” and Water Temperature displayed (a remote control is controlling the heater) Push MODE button to select "Pool" or "Spa" Note: Disconnect the remote by turning the remote function off. See page 38 for instructions.
SECTION 6 - REPLACEMENT PARTS 11-H 2-C 1-C 10-H 14-H 15-H 9-H 4-C 18-H 17-H 16-H 14-M 22-H 23-H 5-C 1-V 21-H 13-H 3-H 2-V 12-H 3-V 19-H 4-V 2-S 20-H 1-S 7-V 4-R 8-S 2-R 5-V 9-S 11-S 6-V 8-V 10-S 7-S 1-R 4-H 5-S 1-F 7-H 5-B 2-G 6-S 7-F 3-R 1-G 6-F 5-R 4-B 2-F 5-F 1-P 3-F 2-P 4-F 1-B 6-H 1-M 2-M 6-C 11-M 2-B 7-C 9-M 25-S 8-M 13-S 12-S 1-H 5-H 22-S 23-S 7-M 8-C 4-S 26-S 20-S 21-S 2-J 9-C 2-H 10-C 6-M 5-M 16-S 3-C 2-C 3-S 19-S 1-J ~ 24-S 15-S 14
If determined defective by the Company and within warranty, a like part or equal substitution will be returned, freight collect. Credit will not be issued. NOTE: To supply you with the correct part, it is important that you supply the heater model number, serial number and type of gas when applicable. Any part returned for replacement under standard company warranties must be properly tagged with a return parts tag, completely filled in with the heater serial number, model number, etc.
CALL OUT M 1-M 2-M 3-M 4-M 5-M 6-M 7-M 8-M 9-M 10-M 11-M 12-M 13-M 14-M P 1-P 2-P 3-P R 1-R 2-R 3-R 4-R 5-R S 1-S 2-S 3-S 4-S 5-S 6-S 7-S 8-S 9-S 10-S 11-S 12-S 13-S 14-S 15-S 16-S 17-S 18-S 19-S 20-S 21-S 22-S 23-S 24-S 25-S 26-S V 1-V 2-V 3-V 4-V 5-V 6-V 7-V 8-V DESCRIPTION MISCELLANEOUS COMPONENTS PRV 125 PSI T & P Gauge Wire/Harness Blower Harness 120V Blower Harness 240V Control Bezel (Includes Switch Decal) Switch/Decal-Membrane Tube Sheet Gasket Heat Exchanger Seal Gasket Window Combustion Chamber B
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows: (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
