Raypak AVIA 264 Quick Reference Manual
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Raypak AVIA 264 Quick Reference Manual

Pool & spa heater, tool box
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AVIA Pool & Spa Heater
Tool Box Quick Reference Guide

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Summary of Contents for Raypak AVIA 264

  • Page 1 AVIA Pool & Spa Heater Tool Box Quick Reference Guide...

  • Page 2: Water Chemistry

    Water Chemistry 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 Levels Fiberglass Pools Fiberglass Spas Other Pool & Spa Types Water Temp.
  • Page 3 Model & Serial number located on rating plate. Model & Serial number located on carton label. Before you call Raypak service, make sure you have the MODEL NUMBER and SERIAL NUMBER.

  • Page 4: Minimum Clearances

    Minimum Clearances Location Indoor Installation Unobstructed Front 0” Floor 0” Back 0” Right Side 3” (76 mm) from Panel - Water Side Left Side 3” (76 mm) from Panel - Vented Side Location Outdoor Installation Unobstructed Front 0” Floor 0” Back 0”...
  • Page 5 Minimum Clearances* – Outdoor DO NOT install near sprinklers. DO NOT install within 3 feet (0.9 m) of a heat pump or an outdoor condensing unit. *Check state and local codes before proceeding. The minimum clearances provided are defined by NFGC (National Fuel Gas Code).
  • Page 6 Minimum Clearances – Indoor The heater must have both combustion air and ventilation air. • Ventilation air opening 12”(305 mm) max from the ceiling • Combustion air opening 12”(305 mm) max from the floor All air from outdoors, each opening shall have a net free area as shown in table.
  • Page 7 Gas Line Sizing Maximum Equivalent Pipe Length ft (m) Natural Gas 1000 BTU/FT 0.60 Specific Gravity @ 0.5 in. WC Pressure Drop Propane Gas 2500 BTU/FT 1.53 Specific Gravity @ 0.5 in. WC Pressure Drop Size 3/4” Size 1” Size 1-1/4” Size 1-1/2” Model No. (4.6) (10.7) (12.2) (38.1) (64.0) (146.3) (135.6) (4.6) (8.8) (16.8) (29.0) (68.6) (65.5) (85.3)

  • Page 8: Gas Pressure Test

    Gas Pressure Test Required Pressure Manifold Pressure Min. Max. Inlet Gas Pressure 3.5” 10.5” Natural Gas -0.3” (Dynamic) (Static) 8.0” 13.0” Propane Gas -0.3” (Dynamic) (Static) • Propane requires an external “pounds to inches” regulator Gas Valve Manifold Gas Pressure Gas Valve...
  • Page 9 Gas Line Sediment Trap Sediment Trap should be located as close to the inlet of the appliance as practical. Check state and local codes before proceeding. Some states do not recognize the NFGC.

  • Page 10: Circuit Board

    Circuit Board Model 264 Model 404 Printed circuit board. Boards cannot be interchanged.
  • Page 11 Wiring Diagram – Common Wiring...

  • Page 12: Power Connections

    Power Connections 120VAC 240VAC Supply side Supply side Heater Heater 6 wires 6 wires *NOTE: Heater will not work properly if wired to a 208VAC power source.

  • Page 13: Wiring Diagram - 240V

    Wiring Diagram – 240V Factory installed CAUTION: The heater is pre-wired with a 240V connector (white connector) to the blower. Using the wrong corresponding connector will cause electrical damage. 240V Blower Jumper...

  • Page 14: Wiring Diagram - 120V

    Wiring Diagram – 120V CAUTION: The heater is pre-wired with a 240V connector to the blower. If the supply voltage is 120V, replace the connector with the supplied 120V (red connector). Using the wrong corresponding connector will cause electrical damage. 120V Blower Jumper...

  • Page 15: Auxiliary Output

    Auxiliary Output The AVIA heater offers an integrated dry contact relay for local and remote control of ON/OFF devices like pumps, water features, valves and lights. Auxiliary output is available in terminal P9 “AUX”. Use the supplied harness to control ON/OFF functions or power switching. AUX terminal can be used as direct control or as pilot relay to a higher rating relay or power contactor. Auxiliary Terminal Terminal Wire...

  • Page 16: Auxiliary Output - Wiring

    Load on P9 must not exceed 3 Amps. If the load is larger than 3 Amps, use P9 auxiliary output to drive a field-installed contactor. For pumps, blowers, and other applications rated above 3 Amps, use field-supplied relay (Raypak kit# 008784F). Use the Normally Closed (NC) and Normally Open (NC) Raymote terminals to drive a 3-way valve. This configuration typically uses an external 24VAC supply.
  • Page 17 Start-Up Operating Displays 1. Power on, all digits display 1 second. 2. Software revision displays 1.5 seconds. 3. Normal display indicates mode of operation and inlet water temperature from “Pool” or “Spa”. 4. Press MODE button to Select “Pool” or “Spa” temperature setpoint, press UP or DOWN arrows to adjust temperature between 50ºF (10ºC) minimum and 104ºF (40ºC) maximum.

  • Page 18: Operating Displays

    Operating Displays 1. Unit Heating until demand is satisfied, water temperature reached. 2. Blower “Post-Purge” for 3 minutes. 3. When Pool/Spa SET temperature is satisfied “No Demand” will display.
  • Page 19 Sequence of Operation SUPPLY (Power to Heater) 1. 120/240 VAC from circuit breaker to transformer and blower relay (see page 12). 2. 24 VAC out of transformer, toggle switch ON. 3. 24 VAC to PC board, and user interface. 4. LCD display ON. APPLY 24 VAC to Ignition/Gas Control 1. Call for Heat... Pool/Spa selected, TEMP set above water temp. 2. ALL SAFETIES SATISFIED (Pressure/Air Switches , High Limit Switch 1 and 2, Cabinet Limit Sensor). 3.
  • Page 20 Remote Wiring Connections and Setup Pool 24V Hot Part Number 652187 Remote Wire Wire Harness Connection A remote may be wired to provide an “On-Off” switching function (two wire) or as a three-way “Pool-Off-Spa” selector switch (three wire). Modern automation systems use a two-wire configuration and can operate the heater in either Pool or Spa mode (see remote wiring on page 22). Water temp will not exceed the setting on the heater, regardless of the automation set temp. To access the full range of temp settings with the remote, the heater should be set (at the control pad) to the maximum safe temperature.

  • Page 21: Remote Operation

    Remote Operation 1. Pre-set Pool/Spa Set temperature (Set at 104°F if Remote has independent thermostat). 2. Turn Power OFF to heater, wire REMOTE to 3-wire pigtail, turn Power ON. 3. Set heater mode to OFF on touch pad. Press UP and DOWN buttons simultaneously for 3 seconds until REMOTE displays on LCD. (This will ENABLE remote operation and DISABLE the arrow keys and MODE button.) 4.
  • Page 22 Remote Error Displays 1. Remote Error - Remote is wired improperly. Orange/black (Spa) and black/orange (Pool) are receiving power at the same time. 2. Remote operation has been initiated and UP and DOWN arrows and MODE key on the touchpad are disabled 3. Exit Remote Mode to adjust Pool/Spa set temperature. Press UP and DOWN buttons for 3 seconds to disable Remote mode.
  • Page 23 User Interface – Self-Diagnostics Can Be Displayed in Pool, Spa, Remote & EOL Modes LCD Message Description Troubleshooting Recovery Internal Fault Bad RAM, ROM, flame circuit, A/D Check for board defects Internal error cleared converter, or safety variable corruption Replace board EEPROM Fault Memory failure EEPROM Fault cleared Low Voltage Controller is receiving a voltage below...

  • Page 24: Temperature Sensors

    Temperature Sensors 1. Heat Demand is when water temperature is 1ºF (0.5ºC) or more below Pool/Spa SET Temperature 2. Sensor Failure Temperature readings more than 2ºF (1ºC) different from each sensor see (2a) Sensor Open (cut wire/bad connection) see (2b) Sensor Short (bare wire touching cabinet) see (2c) Part Number 601697 Part Number 602330 Sensor Connection 100K Dual Thermistor 10K Dual Thermistor (Inlet Temp Sensor) (Outlet Temp Sensor)
  • Page 25 Temperature Sensor – Lockout 1. Low-Temp Lockout - a. Inlet Water Temperature below 36ºF (2ºC). Heater will not operate (Prolonged operation with inlet temperatures below 50ºF (10ºC) will create condensation that will damage the heater). b. For cold weather operation, consider maintaining a preset temperature of 50ºF to 70ºF (10ºC - 21ºC), or the lowest point at which condensation does not occur.

  • Page 26: Control Logic - Flow Chart

    Control Logic - Flow Chart START • Check On/Off switch (under lid on control panel) • Check for 240 or 120 volts to the transformer Power On (time clock, circuit breaker, wire connections) • Check for 24 volts to Circuit Board (P6 connector) Is the Display lit? Check for damaged or loose wires and terminals.
  • Page 27 Control Logic - Flow Chart Check for damaged or loose wires and terminals. Blower “Pre-Purge” Diff Sw Closed for 45 sec Check Blower and Air Pressure switch: - Replace Pressure switch if failing open or close. Diff Sw Open Spark - Replace Blower if operation is intermittent.
  • Page 28 Safety Circuit – Components Part numbers below apply to polymer header models. For part numbers applicable to specific models, refer to the parts list in your Instructions and Operation manual. Part Number 080308 Part Number 602178 Part Number 602263 Part Number 651284 Bypass Assembly Cabinet Limit Switch Vent Temprature Sensor Water Pressure Switch Part Number 602332 Part Number 602323 Part Number 602322...

  • Page 29: Safety Circuit

    Safety Circuit 1. Water Pressure Switch - Verify adequate water flow and pressure (Clean Pool Filter/ Strainer basket). 2. High Limit Switches 1 and 2 Fault - Verify adequate water flow. Adjust (partially close) external bypass. Check Unitherm Governor and internal bypass. Inspect for scale, restricted flow. 3. Cabinet Limit Switch - Verify vent connection and all other sealing points of contact to combustion chamber.
  • Page 30 Safety Circuit 1. Fireman’s Switch - When used with mechanical time clock, a Fireman’s switch turns the heater OFF about 15 minutes before the pump is turned off. This is a function of the switch, not the circuit. Recommended for single speed pumps. Circuit can also be used as heater enable/disable signal, when needed. 2. Vent Temperature Sensor - Monitors flue vent temperature. a. short b. open - check wiring integrity, c. over temp. d. low temp, e. extreme low (will shut down the unit)

  • Page 31: Service Menus

    Service Menus 1. Service menus provide service and diagnostic information. Press the SERVICE key once to access the basic Service Menu. The second button press can occur at any time while viewing the basic service menu. Scroll the list with UP and DOWN arrows. a. Flame Strength (< 1.0 microamps is weak), b.
  • Page 32 Service Menus – Fault History The ability to recall the MOST RECENT Service Displays. Can be read ANY TIME heater is operational in Off, Pool, Spa and Remote modes by pressing SERVICE key 1 time and then DOWN key 3 times. Press UP or DOWN keys to scroll through displays to see the last 10 Faults. 1. First Line displays the actual fault that occurred, followed by numerical listing in the order they occurred: Last Err,1,2,3,4,5,6,7,8,9 (oldest).

  • Page 33: Program Mode

    Program Mode To access PROGRAM menu, press and hold SERVICE and MODE keys simultaneously for 5 to 7 seconds until “Language” appears on the display. Press the SERVICE key sequentially until the desired program event is reached. LCD Message Operation LCD Message Operation Language...

  • Page 34: Control Lockout

    Control Lockout The heater is equipped with a Control Lockout feature to prevent unauthorized tampering or adjustment of the control settings. To lock out the controls 1. Press the MODE and DOWN keys simultaneously for 5-seconds. 2. Choose a three-digit PIN, using the UP and DOWN keys to select the digits and the MODE key to lock in selections.
  • Page 35 Inlet-Outlet Header – Polymer Bypass Assembly Header Gasket Water Pressure Switch (264)P/N 019053F P/N 019052F P/N 006737F Temp. Inlet Sensor (404)P/N 019056F P/N 019059F P/N 009577F See page 24 Inlet/Outlet Header P/N 019049F Temp. Outlet Sensor P/N 019043F See page 24 Return Header Unitherm Governor P/N 019051F P/N 019062F Heat Exchanger Baffle See page 36 (264)P/N 019047F (404)P/N 019048F...
  • Page 36 Unitherm Governor The UNITHERM GOVERNOR helps prevent condensation and scale. It is a thermostatic mixing valve used to control and regulate the water temperature in the heat exchanger. Low temperatures in the exchanger can cause condensation. This indicates that the heat exchanger is running cool. This may be caused by too much flow. Make sure the pump is not supplying more than 100GPM. Adjust flow accordingly.
  • Page 37 ProTek Shield Assembly This heater is equipped with a ProTek Shield Assembly (located on the inlet connection). This component provides protection to the heat exchanger against galvanic corrosion, when properly bonded to the heat exchanger. It should be replaced when the size of the ProTek Shield annode is reduced to about 40% of the original size.
  • Page 38 Flow Rates and Pressure Drops Heat Exchanger Pressure Drops Min/Max Flow Rates Pressure Drop Ft of Head Pipe Size Model Min GPM Max GPM (m of Head) Flow GPM in. (mm) (lpm) 206/404 2 (50.8) 40 (151) 100 (379) 40 (151) 7.2 (2.2) 13.4 (4.1) 50 (189)
  • Page 39 Internal Bypass Valve The Automatic Bypass Assembly allows the heater to be connected to a wide variety of pumps. With every job site having different flow rates, the Bypass automatically adjusts to provide the proper flow rate to the heater, up to 100GPM max. If the flow rate exceeds 100GPM condensation may form and erosion of the copper tubes may occur. It is then recommended that an external bypass be installed before the heater.
  • Page 40 PRV Installation These illustrations depict the correct installation of a pressure relief valve (PRV). All piping must be of suitable metal construction by applicable code. PRV Kit P/N 018936F Polymer Header (Residential Models) Be sure to consult your local building code regarding distance of effluent from floor.

  • Page 41: Igniter/Flame Sensor

    Igniter/Flame Sensor Igniter Igniter Removal. 1. Remove top cover. 2. Disconnect spark cable from igniter. 3. Use M10 socket, remove the two nuts holding the igniter. 4. Carefully remove igniter and gasket. 5. When replacing igniter, be sure to add a new gasket when installing igniter.

  • Page 42: Gas Conversion

    Gas Conversion Gas Orifice Bracket O-Ring Orifice Location Orifice Usage Pockets / Model Kit # GAS ORIFICE P/N Gas Type Finish Notches 018866F 352040 Natural None 018867F 352041 018868F 352046 Propane Black 018869F 352047 *NOTE: Verify gas type with production order. Wrong gas orifice will cause ignition failure, rumbling or violent ignition.

  • Page 43: Air Pressure Switches

    Air Pressure Switches There are 3 different air pressure switches. None of the switches are interchangeable. 1. Vent Switch - Indicates increased vent pressure due to blockage. 2. Differential Pressure Switch - Detects blockage in combustion chamber. Indicates blower activation 3. Air Pressure Switch - Detects blower inlet blockage. Each switch has a colored decal to help identify the switch.
  • Page 44 Raymote - Quick Start Guide Sign-Up with the Raymote App If you do not receive the invitation email, check your Junk folder. Available for: Sign-up Create an account Create a password from email Turn on the AVIA Heater On your phone, click add new device...
  • Page 45 Raymote - Quick Start Guide Stand close to the AVIA heater to connect to the Raymote app Android View iOS View Select your Wi-Fi network and enter your password The AVIA is connecting to your Wi-Fi Make sure to have a strong Wi-Fi signal near the heater.
  • Page 46 • Confirm that your Wi-Fi signal strength is strong enough to reach the heater (walls and fences may affect Wi-Fi signal) • Reduce distance between Wi-Fi router and the heater • Add a Wi-Fi range extender • Enable a new Wi-Fi access point For more support visit: www.raypak.com/raymote...
  • Page 47 AVIA TROUBLESHOOTING 805-278-5300 POWERED BY Mon-Fri 6:00 AM TO 4:30 PM PACIFIC TIME Applications applications-engineering@raypak.com Support for products sizing and guidance on installation parameters, venting codes for Raypak Engineering products. Technical technical-support@raypak.com Technical troubleshooting and mechanical break- down support for Raypak Products.
  • Page 48 3. What is the incoming power? 120 or 240 VAC? 208 will not work properly. 4. What is the incoming gas pressure? 5. If the unit can fire, what is the pressure at the manifold (burner pressure)? 6. Is the gas line rigid or flex-line? THIS IS NOT A SUBSTITUTE FOR THE INSTALLATION AND OPERATION MANUAL. THIS MANUAL IS INTENDED TO HELP THE SERVICE TECHNICIAN WITH BASIC TROUBLESHOOTING. Learn more at Raypak.com Litho in U.S.A. ©2022 Raypak, Inc. RP-P-600-5 REV A Effective 12-02-22 Replaces NEW...

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Avia 404

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