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INSTALLATION & OPERATING
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.
• 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. 6000.65D
INSTRUCTIONS
Effective: 01-15-15
Replaces: 06-10-14
P/N 241464 Rev. 5
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Table of Contents
Related Manuals for Raypak 259
Summary of Contents for Raypak 259
- Page 1 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.
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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 Wiring Diagram WARNINGS SECTION 4 Pay Attention to These Terms SERVICING INSTRUCTIONS PART ONE General Location of Controls OWNER'S OPERATING INSTRUCTIONS Control Adjustments SECTION 1 Control Panel Removal START-UP PROCEDURES Thermostat Operation - Direct Spark Board SECTION 2 Status and Diagnostics CAUTION Remote Control Installation and 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 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 Single-Phase 60 Hertz 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.
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Page 14: Indoor Heater Installation
4” Notes: The model number prefix indicates: (B=Bronze header), (R=Raypak) Model number suffix indicates: pilot type (E = digital) and fuel type (P = propane, N = natural gas) fin tubing (X=Cupro-Nickel, C= Copper). Example: Model number BR-409-EN-X indicates a unit with digital (IID) ignition using natural gas with bronze headers and cupro-nickel tubes. - 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: Direct Vent
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 Horizontal Through-the-Wall Venting The connection from the appliance vent to the stack must be as direct as possible. The horizontal breach- (Category III) 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)
1 ft above ground level and above sealed properly and are airtight. normal snow levels. The Raypak-approved stainless steel direct vent cap must be used. The vent terminal The vent must be installed to prevent the potential ac- must be located NO CLOSER than 12”... -
Page 22: Direct Vent-Vertical
Direct Vent—Vertical Termination The flue direct vent cap MUST be mounted on the ex- Installation terior of the building. The direct vent cap cannot be installed in a well or below grade. The direct vent cap These installations utilize the heater-mounted blower must be installed at least 1 ft above ground level and to draw combustion air from outdoors and force the above normal snow levels. -
Page 23: Outdoor Installation
Certified Vent Maximum Combustion Air Air Intake Model Vent Size HorizontalVent Intake Pipe Max. Length** (ft) Material (in.) Length (ft)** Material 4” Ø Galvanized Steel, PVC, Category III ABS, CPVC ** Subtract 10 ft per elbow. Max. 4 elbows. Category III Horizontal Vent & Horizontal Direct Vent 992-VENT or 1-800-992-8368 in the US, or 1-888- above the roof more than 5 ft should be securely SEL-KIRK or 1-888-735-5475 in Canada), Protech... -
Page 24: Gas Supply Connections
sidered are: way, or gravity air intake. The vent must be locat- ed a minimum of 4 ft horizontally from such areas. a) It reduces the chance of water infiltration, espe- cially in snowy areas. Install above grade level and above normal snow levels. -
Page 25: Gas Pressure Adjustment Locations
FLOW RATES GAS PRESSURE ADJUSTMENT LOCATIONS MODEL PIPE SIZE MIN. GPM MAX. GPM* 1-1/4”–1-1/2” - 2” 1-1/4”–1-1/2” - 2” GAS INLET *When flow rates exceed maximum GPM an external auxil- iary bypass valve is required. See external bypass valve section for details. INTERNAL AUTOMATIC BYPASS VALVE GAS CONTROL A built-in automatic bypass valve is provided in the... -
Page 26: Auxiliary Bypass Valve Adjustment
AUXILIARY BYPASS VALVE ADJUSTMENT ELECTRICAL WIRING NOTE: If it is necessary to replace any of the original To set bypass: With clean filter, adjustment is made by wiring, use 105°C wire or its equivalent, and/or 150°C feeling the inlet and outlet pipes at the heater. Outlet wire or its equivalent, like the original wiring. -
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 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- lowing method: PULL WIRES THROUGH LEFT SIDE PANEL PLUG RIGHT 1. - Page 29 LEFT INLET / RIGHT OUTLET PLUMBING The conversion is performed using the following pro- 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 Recommended plumbing setups Single Pool or Spa Heater Installation POOL HEATER WITH INTERNAL BYPASS THIS DIAGRAM IS RAYPAK’S RECOMMENDATION, AND IS NOT INTENDED TO REPLACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER. Multiple Pool or Spa Heaters Installation POOL HEATER...
- Page 31 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.
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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 GAS CONNECTION 3/4 NPT 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... -
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 (SW1) 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 screen. Press the MODE button until Fahrenheit or control panel. Locate the Program Mode button Celsius appears on the digital display. The digital dis- (marked as SW1) as shown on page 35.
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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 To operate the heater with a time clock, connect the This standard, dual-purpose control, mounted and timer to the fireman’s switch connection in the heater’s wired in series with the main gas valve, shuts off wiring. -
Page 41: Visual Inspection
The gas orifice is located on the gas train, between the gas valve and the combustion blower. The air orifice ADJUSTMENT SCREW is located on the inlet side of the combustion blower. CLOCKWISE TO INCREASE MANIFOLD NOTE: Orifices for propane gas have a black oxide PRESSURE TAP finish. -
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 11-H 10-H 14-H 15-H 18-H 17-H 16-H 14-M 22-H 23-H 21-H 13-H 12-H 19-H 20-H 11-S 10-S 11-C 25-S 11-M 13-S 12-S 22-S 21-S 23-S 20-S 26-S 10-C 16-S 17-S 19-S 24-S 18-S 15-S 14-S... - 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.
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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.