Raypak X94 Installation & Operating Instructions Manual
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Raypak X94 Installation & Operating Instructions Manual

Professional gas-fired pool & spa heater
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INSTALLATION & OPERATING
X94
Professional
Gas-Fired
Pool & Spa
Heater
Low NOx Model
SR-410
WARNING: If the information in 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 or other combustible materials in
the vicinity of this or any other appliance. To do so
may result in an explosion or fire.
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 supplier'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 suppli-
er.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
Catalog No. 6000.66
INSTRUCTIONS
Effective: 10-15-14
AVERTISSEMENT: Assurez-vous de bien suivre
les instructions données dans cette notice pour
réduire au minimum le risqué d'incendie ou
d'explosion ou pour éviter tout dommage matériel,
toute blessure ou la mort.
Ne pas entreposer ni utilizer d'essence ou ni
d'autres vapeurs ou liquids inflammables à proim-
ité de cet appareil ou de tout autre appareil.
CE FAIRE SI VOUS SENTEZ UNE ODEUR
DE GAS:
•
Ne pas tenter d'allumer d'appareil.
•
Ne touchez á aucun interrupteur; ne pas vous
server des téléphones se trouvant dans la
bâtiment.
•
Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivre les instructions
du fournisseur.
•
Si vous ne pouvez rejoinder le fournisseur,
appelez le service es incendies.
L'installation et l'entretien doivent être assurés par
un installeur qualifié ou par le fournisseur de gaz.
Replaces: NEW
P/N 241494 Rev. 1

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  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS Professional Gas-Fired Pool & Spa Heater Low NOx Model SR-410 AVERTISSEMENT: Assurez-vous de bien suivre WARNING: If the information in these instructions les instructions données dans cette notice pour réduire au minimum le risqué d’incendie ou are not followed exactly, a fire or explosion may d’explosion ou pour éviter tout dommage matériel, result causing property damage, personal injury or...

  • 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 Transformer Wiring WARNINGS Plumbing—Water Connections Pay Attention to These Terms Loose Plumbing Parts Setup Recommended Plumbing Setups PART ONE Wiring Diagram OWNER'S OPERATING INSTRUCTIONS SECTION 1 SECTION 4 START-UP PROCEDURES SERVICING INSTRUCTIONS SECTION 2 General Location of Controls CAUTION Control Adjustments SECTION 3...

  • Page 4: Warnings

    ASME and/or CSA ratings of the replace any part of the control system and any gas vessel and any Raypak warranty on the vessel. control which has been under water. Altering the ASME and/or CSA ratings of the vessel AVERTISSEMENT: N’utilisez pas cet appareil s’il...

  • Page 5: Part One

    Control Adjustments subsection (starting on page 34). SECTION 1 - START-UP PROCEDURE 1. Clean air louvers of dust, lint and debris. CAUTION: The X94 manifold and blower suction 2. Keep heater area clear and free from com- pressures measured at this point are negative, and bustibles, flammable liquids and chemicals.
  • Page 6 heater will enter a post-purge period and then retry 6. Persons taking medications which induce drowsi- the ignition cycle or lockout, depending on the ness, such as tranquilizers, antihistamines, or anti- heater configuration. coagulants, should not use spas or hot tubs. 20.
  • Page 7 WARNING: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control to the heater. AVERTISSEMENT: En cas de surchauffe ou si l’alimentation en gaz ne s’arrête pas, fermez manuellement le robinet d’arrêt de l’admission de gaz. CAUTION: Propane gas is heavier than air and will settle on the ground.

  • Page 8: Pool & Spa Water Chemistry

    1. The time clock must be in the "ON" position. COLD WEATHER OPERATION IMPORTANT FREEZE INFORMATION 2. Your pump strainer basket may be full. If so, remove debris. MODERATE CLIMATE: Heater operation can con- tinue during short-term cold spells. When tempera- 3.

  • 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 Electronics and controls -32°F to +175°F (-35.5ºC to +79.5ºC) Condensate drains and trap*...

  • Page 11: Clearances

    *Do not install on carpeting. OUTDOOR HEATER INSTALLATION X94 Professional heaters are design-certified for outdoor installation, when equipped with the approved vent ter- minals designated for outdoor use. The heaters are designed for outdoor operation in non-freezing conditions only. Freezing conditions may cause condensate to freeze in the condensate drain line and trap causing the unit to shut down from a blocked condensate drain.
  • Page 12 Heaters must not be installed under an overhang of less than five 5’ (1.52 m) from the top of the heater, and the vent terminal must be a minimum of 5’ (1.52 m) from any overhang. See Page 18 for vent terminal location requirements.

  • Page 13: Florida Building Code

    FLORIDA BUILDING CODE 2010 ULTIMATE WIND SPEED = 170 MPH, 3 SECOND GUST NOMINAL WIND SPEED = 132 MPH EXPOSURE = C Gas Heater Model No. 410 Fig. 3: Hurricane Tie Down Instructions...

  • Page 14: Indoor Heater Installation

    Table 1: Specifications and Dimensions Notes: The model number prefix indicates: (S=Stainless Steel Heat Exchanger), (R=Raypak) Model number suf- fix indicates: pilot type (E = Digital) and fuel type (P = Propane, N = Natural Gas). Example: Model number SR-410-EN indicates a unit with digital (IID) ignition using natural gas with a stainless steel heat exchang- Heaters are rated for natural gas and propane up to 4,500 feet (1,371.6 m).
  • Page 15 Fig. 5: 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;...

  • 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 damaging exterior finishes. Use a rust-resistant sheet metal backing plate against brick or mason- ry surfaces. The weight of the vent stack or chimney must not rest on the heater vent connection. Support must be pro- 12.

  • Page 19: Venting Installation Tips

    (0.91 m) horizontally of the vertical center-line of the regulator. Vent pipe condensate drains are also required for installation of the X94 Professional. Follow vent man- 5. Within 3’ (0.91 m) of any gas service regulator ufacturer instructions for location of condensate drains vent outlet.

  • Page 20: Venting Configurations

    Fig. 6: Vertical Venting Venting Configurations For heaters connected to gas vents or chimneys, vent installations shall be in accordance with the NFGC (U.S.), or B149 (Canada), or applicable provisions of local building codes. Vertical Venting (Category IV) Installation CAUTION: A listed vent cap terminal adequately sized, must be used to evacuate the flue products from the building.
  • Page 21 Table 5: Category IV Vent Requirements * Subtract 10’ (3.05 m) per elbow. Max. 4 elbows. ** Only Duravent polypropylene is approved for the X94 Professional. The connection from the appliance vent to the stack should have a minimum clearance of 4’ (1.22 m) hori-...

  • Page 22: Horizontal Through-The-Wall Venting (Category Iv)

    1’ (0.3 m) above ground level and to vent the combustion products to the outdoors. above normal snow levels. A Raypak-approved vent Combustion air is taken from inside the room and the cap must be used. The vent terminal must be located vent is installed horizontally through the wall to the out- NO CLOSER than 12”...

  • Page 23: Direct Vent - Horizontal

    Direct Vent - Horizontal Through- condensate trap must be installed per applicable the-Wall codes. 2. The intake vent must be insulated through the Installation length of the horizontal run. These installations utilize the heater-mounted blower Termination to draw combustion air from outdoors and vent com- bustion products to the outdoors.
  • Page 24 Fig. 10: Outdoor Venting Fig. 11: 3 in 1 Multi-Vent Adapter...

  • Page 25: Direct Vent-Vertical

    Direct Vent—Vertical with the NFGC (U.S.) or B149 (Canada). Vent pipes supported only by flashing and extended Installation above the roof more than 5’ (1.52 m) should be securely guyed or braced to withstand snow and wind These installations utilize the heater-mounted blower loads.

  • Page 26: Gas Supply Connections

    GAS SUPPLY CONNECTIONS GAS PRESSURE ADJUSTMENT LOCATIONS Fig. 14: Gas Valve PIPE SIZING FOR GAS CONNECTIONS Fig. 13: Gas Supply Connections Gas piping must have a sediment trap ahead of the Maximum Equivalent Pipe Length (ft) heater gas controls, and a manual shut-off valve locat- Natural Gas 1000 BTU/FT ed outside the heater jacket.

  • Page 27: Flow Rates

    AUXILIARY BYPASS VALVE ADJUSTMENT FLOW RATES MODEL PIPE SIZE MIN. GPM MAX. GPM* To set bypass: With clean filter, adjustment is made by feeling the inlet and outlet pipes at the heater. Outlet 1-1/4”–1-1/2” - 2” (151.4 LPM) (473.2 LPM) pipes should be slightly warmer than inlet and comfort- able to the touch.

  • Page 28: Electrical Wiring

    TRANSFORMER WIRING ELECTRICAL WIRING 120 VAC WIRING NOTE: If it is necessary to replace any of the origi- The heater requires 5 amps of 120V/1ph/60Hz power. nal wiring, use 105°C wire or its equivalent, and/or To wire the 120V power supply to the heater, connect 150°C wire or its equivalent, like the original wiring.

  • Page 29: Plumbing-Water Connections

    PLUMBING—WATER CONNECTIONS The heater has standard right-hand plumbing connections, but can be converted to alternate configurations as shown below. STANDARD RIGHT-HAND CONNECTIONS LEFT-HAND CONNECTIONS LEFT-IN / RIGHT-OUT CONNECTIONS RIGHT-IN / LEFT-OUT CONNECTIONS Fig. 20: Water Connection Configurations LOOSE PLUMBING PARTS SETUP The loose parts bag contains the pieces needed to NOTE: Use appropriate CPVC or CPVC to PVC connect your plumbing to the heater, see page 9 for...

  • Page 30: Recommended Plumbing Setups

    Fig. 21: Plumbing Setup RECOMMENDED PLUMBING SETUPS 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.
  • Page 31 Fig. 23: Multiple Pool or Spa Heaters Installation Fig. 24: Single Pool/Spa Heater Installation Fig. 25: Multiple Pool/Spa Heaters Installation...

  • Page 32: Wiring Diagram

    WIRING DIAGRAM Fig. 26: Wiring Diagram...

  • Page 33: Servicing Instructions

    SECTION 4 - SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS Fig. 27: Location of Controls...

  • Page 34: Control Adjustments

    CONTROL ADJUSTMENTS Fig. 28: Control Adjustments 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.

  • Page 35: Thermostat Operation - Direct Spark Board

    THERMOSTAT OPERATION - DIRECT SPARK (DS) BOARD Program Button (SW1) period. Controls Operation The pool heater touchpad, located on the upper por- RUN SCHEDULE A/B tion of the angled corner panel of the heater, allows the RUN SCHEDULE A/B modes will operate the heater user to select the mode of operation, adjust the set- and all controlled features according to a user defined point temperature, configure the heater controls and...

  • Page 36: Installer Setup Mode

    service. Eco mode offers increased efficiency and reduced Fan RPM (view only) - Indicates Fan RPM target operating sound levels by reducing the operating fan (lower left) and actual (lower right) speeds. speed by 30%. Turbo mode operates to provide max- imum heat input for the shortest heat up times.
  • Page 37 enable and disable a pump with full time power). Return Valve (Selection available only with Valve Operation enabled) The control will also power one of the Variable Use the UP and DOWN buttons to define the valve Pump outputs to select the pump speed. Pin 5 will enable Speed 1, Pin 4 Speed 2 , Pin 3 Speed 3 positions for the Return Valve.

  • Page 38: Status And Diagnostics

    Lockout will inhibit the pool heater from firing if water In the event that the user-selected PIN is lost or does temperature is sensed below 36ºF (2.2ºC). The X94 is not clear the Control Lockout, use the Program Button to access the Installer Setup Mode to Set Factory...
  • Page 39 Display Condition H2O Sensor Fail Water temperature sensors open, shorted, or disagree Aux Ctrl Fault 2 ROM CRC failure on companion board Aux Ctrl Fault 3 RAM failure on companion board Aux Ctrl Fault 5 A/D Reference failure on companion board Aux Ctrl Fault 6 A/D Multiplexor failure on companion board Aux Ctrl Fault 8...

  • Page 40: 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 41: 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 (9.1 m), remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, cable twisting 1.5 to 2.5 inch (38.1 to 63.5 mm) lay and jacketed.

  • Page 42: Time Clock/Fireman's Switch

    TIME CLOCK/FIREMAN’S 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.

  • Page 43: Visual Inspection

    COMBUSTION SETTINGS Verify that the gas orifice matches the fuel type sup- plied. The natural brass finish orifice is for natural gas and the black oxide finish orifice is for Propane. Table 11 shows the desired ranges for CO % and limits for CO ppm.

  • Page 44: 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 45: Control Logic - Flow Chart

    CONTROL LOGIC - FLOW CHART (POOL AND SPA MODES) Power On • Check On/Off switch (under lid on control panel) Is the water • Check for 120 volts to the transformer temperature displayed? (time clock, circuit breaker, wire connections) • Check for 24 volts to Circuit Board (P6 connector) “Remote”...

  • Page 46: Replacement Parts

    SECTION 6 - REPLACEMENT PARTS...
  • Page 48 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 49 CALL DESCRIPTION MISCELLANEOUS COMPONENTS PRV 75 PSI 007223F T & P Gauge 014647F Wire Harnesses (All Unit Harnesses) 015467F Cabinet Harness 015468F Blower Harness 120V 015469F Gas Valve Harness 015470F High Limit / Flow Switch Harness 015471F Condensate Float Switch Harness 015472F Control Bezel (Includes Switch Decal) 014886F...

  • Page 50: 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 51: Installer Setup Record

    Installer Setup Record Use this sheet to record Installer Setup Mode settings. This record will simplify setup in the event it is necessary to Reset Factory Defaults or install a new control. It is also a help- ful troubleshooting tool, allowing all setup parameters to be viewed on a single page. Write down or circle the Installer Setup Item Default Setting...
  • Page 52 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

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