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  5. Installation & Operating Instructions Manual

Raypak 259 Installation & Operating Instructions Manual

Manual is about: Gas-Fired Pool & Spa Heater

Summary of 259

  • Page 1

    Installation & operating instructions 84 professional gas-fired pool & spa heater catalog no. 6000.65d effective: 01-15-15 replaces: 06-10-14 p/n 241464 rev. 5 warning: if these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. W...

  • Page 2

    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. Recommended level(s) fiberglass pools fiberglass spas other poo...

  • Page 3

    3 contents 2 water chemistry 4 warnings 4 pay attention to these terms 7 lighting & shutdown instructions 8 pool & spa water chemistry 8 automatic chlorinators & chemical feeders 8 cold weather operation 8 winterizing the pool & spa heater 10 code requirements 11 clearances 11 outdoor heater install...

  • Page 4

    4 danger: indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Warning: indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Ca...

  • Page 5: Part One

    5 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 ...

  • Page 6

    6 section 3 - maintenance and care procedures to be followed one month after start-up and then semi- annually. 1. Inspect and operate all controls, gas valve and pressure relief valve. 2. On indoor heaters, clean room intake openings to ensure adequate flow of combustion and ventila- tion air. 3. Ke...

  • Page 7

    7 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. Warning: should overheating occur or the gas supply fail to shut off, turn off the manual gas control to the heater..

  • Page 8

    8 chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water chemistry according to the chart on page 2. If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchang- er tube, reducing heater efficiency and...

  • Page 9: Part Two

    9 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-...

  • Page 10

    10 section 3 - installation instructions california proposition 65 warning: this product contains chemicals known to the state of california to cause cancer, birth defects or other reproductive harm. Important notice these instructions are intended only for the use by qualified personnel, specifical...

  • Page 11

    11 outdoor heater installation these heaters are design-certified for outdoor installation, when equipped with the approved tops designated for outdoor use. Warning: the heater shall not be located in an area where water sprinklers, or other devices, may cause water to spray through the cabinet louv...

  • Page 12

    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. For u.S. Installations, the po...

  • Page 13

    13.

  • Page 14

    14 indoor heater installation locate the 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 clearance is shown on the nameplate, and in the “clearances” section on pa...

  • Page 15

    15 u.S. Installations 1 canadian installations 2 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 (1.2m) below or to side of opening; 1 foot (30 cm) above opening 3 ft (91 cm) c clearance to permanently closed w...

  • Page 16

    16 b. All air from outdoors: when air is supplied directly from outside the building, each opening shall have a minimum net free area as noted: combustion and ventilation air (indoor units only) the heater must have both combustion and ventilation air. Minimum requirements for net free air supply op...

  • Page 17

    17 general appliance categories heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Category i – a heater which operates with a non-pos- itive vent static pressure and with a vent gas tempera- ture that avoid...

  • Page 18

    18 support of vent stack the weight of the vent stack or chimney must not rest on the heater vent connection. Support must be pro- vided in compliance with applicable codes. The vent should also be installed to maintain proper clearances from combustible materials. Use insulated vent pipe spacers wh...

  • Page 19

    19 canadian installations refer to latest edition of the b149 installation code. A vent shall not terminate: 1. Directly above a paved sidewalk or driveway which is located between two single-family dwell- ings and serves both dwellings. 2. Less than 7 ft (2.13 m) above a paved sidewalk or paved dri...

  • Page 20

    20 horizontal through-the-wall venting (category iii) horizontal through-the-wall venting 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 al...

  • Page 21

    21 horizontal through-the-wall direct venting model no. Vent size (in.) maximum horizontal vent length (ft)* 409 6” 80 259 409 5” 40 259 80 259 4” 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 tha...

  • Page 22

    22 direct vent - vertical direct vent—vertical installation these installations utilize the heater-mounted blower to draw combustion air from outdoors and force the heated flue products through the vent pipe under posi- tive pressure. The vent material must be in accor- dance with the above instruct...

  • Page 23

    23 above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. The air inlet opening must be installed 1 ft above the roof line or above normal snow levels that might ob- struct combustion air flow. This dimension is critical to the correct operation of the hea...

  • Page 24

    24 gas supply connections gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve locat- ed outside the heater jacket. All gas piping should be tested after installation in accordance with local codes. Caution: the heater and its manual shut-off valve must ...

  • Page 25

    25 maximum equivalent pipe length (ft) natural gas 1000 btu/ft 3 0.60 specific gravity @ 0.5 in. Wc pressure drop propane gas 2500 btu/ft 3 1.53 specific gravity @ 0.5 in. Wc pressure drop input 3/4” 1” 1-1/4” 1-1/2” model (kbtu) n p n p n p n p 259 250.0 15 35 50 125 210 480 445 409 399.0 * 15 20 5...

  • Page 26

    26 note: to avoid water damage or scalding due to valve operation, drain pipe must be connected to valve outlet and run to a safe place of discharge. Drain pipe must be the same size as the valve discharge connec- tion throughout its entire length and must pitch down- ward from the valve. No shut-of...

  • Page 27

    27 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 sup- ply. 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 ...

  • Page 28

    28 plumbing—water connections 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: 1. Locate the plug on the left-hand side of the unit. 2. Remov...

  • Page 29

    29 the conversion is performed using the following pro- cedures: left hand plumbing 1. Rotate and remove the prv and reducer bushing from in/out header. 2. Rotate and remove the t&p gauge. 3. Remove cover from flow switch and disconnect wiring. 4. Rotate and remove flow switch from in/out head- er. ...

  • Page 30

    30 straight plumbing setup (front view) 90° plumbing setup (top view) recommended plumbing setups 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. This diagram is raypak’s recommendation, ...

  • Page 31

    31 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 fil...

  • Page 32

    32 wiring diagram.

  • Page 33

    33 section 4 - servicing instructions general location of controls direct vent access panel right access panel bonding lug location temperature sensor air pressure switch vent pressure switch prv left access panel bonding lug location (optional) drain valve hl1 & hl2 high limits t&p gauge flow switc...

  • Page 34

    34 lcd display temp adjust buttons mode button on off 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 rem...

  • Page 35

    35 the pool heater touchpad, located on the upper front panel of the heater, allows the user to select either pool or spa operation, and to adjust the setpoint temperature. The lcd display window indicates the mode (off, spa, pool) and the actual water temper- ature. A manual power switch provided t...

  • Page 36

    36 resets board to factory default settings. Resets faults in the history file. Change from fahrenheit to celsius. Spa setpoint maximum adjustment. Pool setpoint maximum adjustment. Set factory defaults refer to step one above to access the program screen. Set factory defaults should appear on the s...

  • Page 37

    37 status and diagnostics the digital thermostat models are programmed to display a variety of status and diagnostic messages, depend- ing on the operating conditions. Note: the lcd temperature display may not agree with the temperature reading of your pool or spa ther- mometer. The heater reads the...

  • Page 38

    38 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...

  • Page 39

    39 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 minim...

  • Page 40

    High limit removal 1. Shut off main electrical power switch to heater. 2. Remove front door. 3. Remove defective high limit and replace with a new high limit. 4. Replace inspection panel. Note: an erratic high limit is often characteristic of an internal heat exchanger problem, e.G. Scale build-up, ...

  • Page 41

    41 igniter .18” ± .03” .26” min along length of rods orifice removal 1. Locate and close the external manual shut-off valve. 2. Loosen the external gas union. 3. Locate and remove front door panel. 4. Locate and remove the (4) bolts & nuts holding the gas orifice in place. See the figure above. 5. C...

  • Page 42

    42 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. P...

  • Page 43

    43 power on is the water temperature displayed? No yes push mode button to select "pool" or "spa" push up or down button to scroll to desired temperature no water temperature and set temperature displayed? Yes “purge” no no yes yes water temp displayed? (rectified) heater fired? End • check on/off s...

  • Page 44

    44 23-h 2-c 5-v 6-v 1-v 2-v 3-v 4-v 2-s 1-s 8-s 9-s 11-s 10-s 7-s 6-s 7-f 5-b 4-b 2-g 1-g 1-b 1-h 2-b 7-m 13-s 8-m 12-s 22-s 21-s 16-s 17-s 18-s 20-s 2-j 23-s 26-s 9-c 8-c 1-j 19-s 14-s 3-s 3-c 5-m 6-m 10-c 4-s 5-h 2-h 1-m 2-m 6-c 7-c 6-h 5-s 1-f 5-f 6-f 1-p 2-p 2-f 3-f 4-f 25-s 9-m ~ 15-s 24-s 11-m...

  • Page 45

    45 note: to supply you with the correct part, it is impor- tant 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 h...

  • Page 46

    46.

  • Page 47

    47 (b) exemptions: the following equipment is exempt from 248 cmr 5.08(2)(a)1 through 4: 1. The equipment listed in chapter 10 entitled "equipment not required to be vented" in the most current edition of nfpa 54 as adopted by the board; and 2. Product approved side wall horizontally vented gas fuel...

  • Page 48: Www.Raypak.Com

    Www.Raypak.Com raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (805) 278-5468 litho in u.S.A. 48.