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INSTALLATION & OPERATING
84 Professional
Gas-Fired
Pool & Spa
Heater
Lo 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.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas sup-
plier'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. 6000.65
INSTRUCTIONS
Effective: 05-17-12
Replaces: NEW
P/N 241464 Rev. 1
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Related Manuals for Raypak B-R259
Summary of Contents for Raypak B-R259
- Page 1 INSTALLATION & OPERATING INSTRUCTIONS 84 Professional Gas-Fired Pool & Spa Heater Lo 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.
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Page 2: Water Chemistry
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 bal- anced water. Other Pool & Spa Recommended Level(s) Fiberglass Pools Fiberglass Spas Types... -
Page 3: Table Of Contents
CONTENTS Water Chemistry SECTION 4 WARNINGS SERVICING INSTRUCTIONS Pay Attention to These Terms General Location of Controls Control Adjustments PART ONE Control Panel Removal OWNER'S OPERATING INSTRUCTIONS Thermostat Operation - Direct Spark Board SECTION 1 Status and Diagnostics START-UP PROCEDURES Remote Control Installation and Operation SECTION 2 Remote Operation... -
Page 4: Warnings
Raypak will injury. instantly void the ASME and/or CSA ratings of the vessel and any Raypak warranty on the vessel. WARNING: Do not use this heater if any part has Altering the ASME and/or CSA ratings of the vessel been under water. -
Page 5: Part One
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. -
Page 6: Maintenance & Care Procedures
19. Once the pre-purge period ends, the igniter will 5. Persons with a medical history of heart disease, cir- begin to spark just prior to the gas valve opening. culatory problems, diabetes, or blood pressure The gas valve will open for a 4 second trial for igni- problems should obtain a physician's advice before tion. - Page 7 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.
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Page 8: Pool & Spa Water Chemistry
POOL & SPA WATER CHEMISTRY COLD CLIMATE: Prolonged operation with water temperatures below 50°F is not recommended. Chemical imbalance can cause severe damage to When starting the heater with water temperatures your heater and associated equipment. Maintain below 50°F, operate the heater continuously until your water chemistry according to the chart on page 2. -
Page 9: Part Two
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 represen- tative. -
Page 10: General Specifications
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 Electronic Ignition Heater* -32°F to + 175°F *Requires 120 or 240VAC Power Supply... -
Page 11: Clearances
CLEARANCE FROM construction around the heater. COMBUSTIBLE CONSTRUCTION However, for ease of servicing, Raypak recom- INDOOR INSTALLATIONS: mends a clearance of at least 24” in the front and Top* - 30” Back - 1”... - Page 12 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.
- Page 13 FLORIDA AND TEXAS HURRICANE TIE-DOWN METHOD WIND SPEED = 186 MPH, 3 SECOND GUST EXPOSURE = C 19-5/8” 32-1/2” 27-1/4” 3” Min. Conc. 2” x 6” x 1/8” Pallet Pad by others Anchor Bracket (4 Total) (Kit# 011636) 1/4” x 1-3/4” S.S. Tapcon Bolt & Washer (Field Supplied) NOTE: Use hole closest to unit with washer overlapping edge of unit.
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Page 14: Indoor Heater Installation
INDOOR HEATER INSTALLATION For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly commu- nicate 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. - Page 15 Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening;...
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Page 16: Combustion And Ventilation Air
3. In cold climates, and to mitigate potential freeze-up, Raypak highly recommends the installation of a motor- ized sealed damper to prevent the circulation of cold air through the heater during the non-operating hours. -
Page 17: Venting
VENTING CAUTION: Proper installation of flue venting is Category III – A heater which operates with a positive vent pressure and with a vent gas temperature that critical for the safe and efficient operation of the avoids excessive condensate production in the vent. heater. -
Page 18: Support Of Vent Stack
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 pro- 11. -
Page 19: Venting Installation Tips
Venting Installation Tips Canadian Installations Refer to latest edition of the B149 Installation code. Support piping: A vent shall not terminate: • horizontal runs—at least every 5 ft • vertical runs—use braces 1. Directly above a paved sidewalk or driveway •... - Page 20 Double-wall Type B vent should be used to promote VENT CAP draft and to minimize condensation in the vent. The connection from the appliance vent to the stack must be as direct as possible. The horizontal breach- ing 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.
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Page 21: Horizontal Through-The-Wall Direct Venting (Category Iii)
Horizontal Through-the-Wall Direct Venting (Category III) 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 heater. Installation These installations utilize the heater-mounted blower to vent the combustion products to the outdoors. -
Page 22: Direct Vent-Vertical
The direct vent cap Termination must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved stainless steel direct vent cap must be used. The vent The flue terminal should be vertical and should termi- terminal must be located NO CLOSER than 12”... -
Page 23: Outdoor Installation
Outdoor Installation Do not locate adjacent to any window, door, walk- The stackless top provided with the heater is the stan- way, or gravity air intake. The vent must be locat- dard venting method for outdoor installations. The ed a minimum of 4 ft horizontally from such areas. stackless top may be used in its standard top-mount- ed configuration or moved to the rear of the heater for Install above grade level and above normal snow... -
Page 24: Gas Supply Connections
Maximum Certified Vent Combustion Air Air Intake Model Horizontal Vent Size Intake Pipe Max. Length** (ft) Vent Length Material (in.) Material 4” Ø (ft)** Galvanized Steel, Category III PVC, ABS, CPVC ** Subtract 10 ft per elbow. Max. 4 elbows. t Adapters supplied by others. -
Page 25: Pipe Sizing For Gas Connections
INTERNAL AUTOMATIC BYPASS VALVE PIPE SIZING FOR GAS CONNECTIONS A built-in automatic bypass valve is provided in the Maximum Equivalent Pipe Length (ft) in/out header. The internal bypass valve automatical- Natural Gas 1000 BTU/FT ly responds to changes in water flow in the piping sys- 0.60 Specific Gravity @ 0.5 in. -
Page 26: Pressure Relief Valve Installation
ELECTRICAL WIRING PRESSURE RELIEF VALVE INSTALLATION To conform to local building codes, it may be neces- NOTE: If it is necessary to replace any of the original sary to install a 3/4" pressure relief valve, having a wiring, use 105°C wire or its equivalent, and/or 150°C capacity equal to the BTUH output of the model. -
Page 27: Transformer Wiring
TRANSFORMER WIRING 120 VAC WIRING For 120 VAC input power to the unit, connect the pair 120V HEATER of black wires to the “L1” or hot leg of the power sup- ply. Connect the red/white wire and the white wire to BLACK the “Ret”... -
Page 28: Optional Left-Hand Wiring
OPTIONAL LEFT-HAND WIRING If the standard right-hand electrical wiring is not acces- sible or convenient, wiring can be done from the left- hand side instead. Conversion is done using the fol- PULL WIRES THROUGH lowing method: LEFT SIDE PANEL PLUG RIGHT SIDE PANEL 1. - Page 29 The conversion is performed using the following pro- LEFT INLET / RIGHT OUTLET PLUMBING cedures: 1. Remove thermostat sensor from Jaco fitting and WARNING: Before performing any conversion set aside. steps, make sure that all electrical power to the 2. Remove Inlet CPVC Ring Nut and Plug. heater has been turned OFF.
- Page 30 Loose plumbing parts STRAIGHT PLUMBING SETUP 90° PLUMBING SETUP (FRONT VIEW) (TOP VIEW) Recommended plumbing setups...
- Page 31 Single Pool Heater Installation Multiple Pool Heater 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.
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Page 32: Wiring Diagram
WIRING DIAGRAM... -
Page 33: Servicing Instructions
SECTION 4 - SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS GAS VALVE GAS ORIFICE WIRING BOX (SUPPLY POWER) LEFT ACCESS BLOWER RELAY PANEL TRANSFORMER FLOW SWITCH T&P GAUGE HL1 & HL2 BONDING LUG HIGH LIMITS LOCATION (OPTIONAL) DRAIN VALVE DIRECT VENT ACCESS PANEL RIGHT ACCESS VENT PRESSURE... -
Page 34: Control Adjustments
CONTROL ADJUSTMENTS LCD DISPLAY TEMP ADJUST MODE BUTTON BUTTONS 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. -
Page 35: Thermostat Operation - Direct Spark Board
THERMOSTAT OPERATION - DIRECT SPARK (DS) BOARD TEMP MODE Program Button On/Off Switch LCD Display Temp Buttons Mode Button the pilot flame current using a bar graph and numeri- The pool heater touchpad, located on the upper front cal display. A signal of less than 4 indicates a weak panel of the heater, allows the user to select either flame signal and may require service. - Page 36 Program Button Fahrenheit or Celsius 1) Follow the instructions on page 34 to remove the Refer to step one above to access the program control panel. Locate the Program Mode button screen. Press the MODE button until Fahrenheit or (marked as SW1) as shown on page 35. Press Celsius appears on the digital display.
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Page 37: Status And Diagnostics
NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa ther- mometer. 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. -
Page 38: Remote Control Installation And Operation
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 con- trol panel allows you to select the desired pool or spa temperature. -
Page 39: Remote Control Wiring
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. -
Page 40: Time Clock/Fireman's Switch
TIME CLOCK/FIREMAN’S SWITCH FLOW SWITCH This standard, dual-purpose control, mounted and To operate the heater with a time clock, connect the wired in series with the main gas valve, shuts off timer to the fireman’s switch connection in the heater’s heater in case of pump failure or low water flow. -
Page 41: Visual Inspection
VISUAL INSPECTION IGNITER REMOVAL 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. ELECTRICAL .18” ± .03” Be sure that electrical service to the heater has prop- er overload fuse or circuit breaker protection, wire size and connections which comply with all applicable codes. -
Page 42: Troubleshooting
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. -
Page 43: Control Logic - Flow Chart
CONTROL LOGIC - FLOW CHART Power On • Check On/Off switch (under lid on control panel) Is the water • Check for 120/240 volts to the transformer temperature displayed? (time clock, circuit breaker, wire connections) • Check for 24 volts to Circuit Board (P6 connector) “Remote”... -
Page 44: Replacement Parts
SECTION 6 - REPLACEMENT PARTS... - Page 45 If determined defective by the Company and within NOTE: To supply you with the correct part, it is impor- warranty, a like part or equal substitution will be tant that you supply the heater model number, serial returned, freight collect. Credit will not be issued. number and type of gas when applicable.
- Page 46 CALL DESCRIPTION MISCELLANEOUS COMPONENTS PRV 125 PSI 011912F 011912F T & P Gauge 007399F 007399F Wire/Harness 014117F 014117F Blower Harness 120V 014118F 014118F Blower Harness 240V 014119F 014119F Control Bezel (Includes Switch Decal) 014120F 014120F Switch/Decal-Membrane 014121F 014121F Tube Sheet Gasket 014122F 014122F Heat Exchanger Seal Gasket...
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Page 47: Important Instructions For The Commonwealth Of Massachusetts
Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance (b) EXEMPTIONS: The following equipment is exempt from with regulation 248 CMR 4.00 and 5.00 for installation of 248 CMR 5.08(2)(a)1 through 4: through – the – wall vented gas appliances as follows: 1. - Page 48 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
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