Raypak X94 Installation & Operating Instructions Manual Download | Manualshive

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SECTION 6 - REPLACEMENT PARTS

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Summary of Contents for X94

Page 1: ...lding 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 WARNING If the information in these instructions are not followed exactly a fire or explosion may result causing property damage ...

Page 2: ...ids PPM 3000 MAXIMUM 3000 MAXIMUM 3000 MAXIMUM Free Chlorine MUST NOT EXCEED 5 PPM Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is balanced Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water unless controlled they can lead to excessive chlorine level which can damage your heater and which ...

Page 3: ...rical Wiring 28 Transformer Wiring 29 Plumbing Water Connections 29 Loose Plumbing Parts Setup 30 Recommended Plumbing Setups 32 Wiring Diagram 33 General Location of Controls 34 Control Adjustments 34 Control Panel Removal 35 Thermostat Operation Direct Spark Board 36 Installer Setup Mode 38 Status and Diagnostics 40 Remote Control Installation and Operation 40 Remote Operation 40 Activating the ...

Page 4: ... headers or any ASME parts not manufactured and or approved by Raypak will instantly void the ASME and or CSA ratings of the vessel and any Raypak warranty on the vessel Altering the ASME and or CSA ratings of the vessel also violates national state and local approval codes WARNING Both natural gas and propane have an odorant added to aid in detecting a gas leak Some people may not physically be a...

Page 5: ...ry 6 Double check gas connections make sure no leaks are present Use soapy water to inspect 7 Double check incoming electrical power verify suf ficient supply of 120V 1ph 60Hz power to the heater 8 If installed indoors make sure flue gases are vent ed properly and that combustion and makeup air openings are adequate and clear of obstruction 9 Verify that the fuel type of the unit matches the suppl...

Page 6: ...over 102 F 39 C can cause fetal damage during the first three months of pregnancy resulting in the birth of a brain damaged or deformed child Pregnant women should stick to the 100 F 38 C maximum rule 4 Before entering the spa or hot tub users should check the water temperature with an accurate ther mometer spa or hot tub thermostats may err in reg ulating water temperatures by as much as 4 F 2 2 ...

Page 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 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 ...

Page 8: ...anual gas valve and electri cal supply to the heater 2 Disconnect the field supplied condensate drain line from the condensate trap located below the inlet outlet water connections 3 Remove the access panel below the inlet outlet water connections and connect a hose to the drain valve Direct the hose discharge to a safe drainage location 4 Open the drain valve and pull the PRV handle or open the u...

Page 9: ...amage to the carrier immediately Save the carton These items are shipped inside a box in the carton with the heater STANDARD UNIT 1 Bypass assembly P N 077087 6 4 Mounting screws and 4 washers 2 Bonding lug with mounting screw 7 2 Bird screens not shown 3 4 Intake air adapter not shown 8 4 Sch 40 PVC Tee and 4 PVC Polypropylene Stainless Steel 5 127 mm L x 4 diameter Sch 40 vent adapter P N 502117...

Page 10: ...ºC The heater must be in a non freezing environment to operate properly Frozen condensate may damage com ponents Winterize the heater prior to prolonged exposure to freezing temperatures Rated inputs are suitable for up to 4 500 1 371 m elevation At elevations above 4500 feet 1 371 m the input will be reduced by approximately 4 for each 1 000 304 8 m above sea level as high elevation reduces gas a...

Page 11: ... an outdoor condensing unit Strong air intake from this type of equipment can disturb the combustion process and cause damage or personal injury CLEARANCES ALL HEATERS For clearances from combustible surfaces see the chart below CLEARANCE FROM COMBUSTIBLE CONSTRUCTION INDOOR INSTALLATIONS Top 24 609 6 mm Back 1 25 4 mm Front Alcove Open Right Side 1 25 4 mm Vent 1 25 4 mm Left Side 1 25 4 mm Floor...

Page 12: ...1 0 3 m above any door window or gravity inlet into any building The vent discharge of the heater shall be at least 3 0 91 m above any forced air inlet or intake ducts located with in 10 3 05 m horizontally For installations in Canada pool heaters shall not be installed with the top of the vent assembly within 10 3 05 m below or to either side of any opening into the building Refer to the latest r...

Page 13: ...13 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: ...ers are rated for natural gas and propane up to 4 500 feet 1 371 6 m For elevations over 4 500 1 371 6 m consult the factory 3 Flue gases must be properly vented with CAT III for horizontal and CAT IV for vertical venting Inlet air can be ducted with 4 101 6 mm metal or PVC pipe See the venting section of this manual for complete vent ing details SPECIFICATIONS AND DIMENSIONS Heater Model MBTU Inp...

Page 15: ...t 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t M Clearance under veranda porch deck or balcony 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code 2 In accordance with the current CAN CSA B149 In...

Page 16: ...intake pipe directly to the unit for combustion 1 Install combustion air direct vent as instructed on page 22 horizontal or page 23 vertical of this manual 2 Provide adequate ventilation of the space occupied by the heater s by an opening s for ventilation air at the highest practical point communicating with the outdoors a In the US the total cross sectional area shall be at least 1 in 2 of free ...

Page 17: ...ization and suitability of a vent material for application on a Category III or IV vent system Using improper venting materials can result in personal injury death or property damage VENTING Table 4 Venting Category Requirements Combustion Air Supply Exhaust Configuration Heater Venting Category Certified Materials Must be UL 1738 or ULC S636 Combustion Air Inlet Materials From Inside Building Ver...

Page 18: ... can freeze causing ice formations 11 Locate or guard vent to prevent condensate from NOTE During winter months check the vent cap and make sure no blockage occurs from build up of snow or ice damaging exterior finishes Use a rust resistant sheet metal backing plate against brick or mason ry surfaces 12 DO NOT extend exposed vent pipe outside of building beyond the minimum distance required for th...

Page 19: ...UTION In general the condensate piping from the appliance must have a downward slope of 1 4 per horizontal foot Condensate drain traps must be primed with water to prevent gas flue leaks Neutralizers should be checked at least once per year and the chips should be replenished as neces sary When replacing the chips they should be no smaller than 3 4 to avoid blockage in the condensate piping Fig 6 ...

Page 20: ...o allow annual inspection of the venting system Fig 7 Vertical Venting CAUTION A listed vent cap terminal adequately sized must be used to evacuate the flue products from the building NOTE If installing multiple heaters with common vent contact the factory Venting Configurations For heaters connected to gas vents or chimneys vent installations shall be in accordance with the NFGC U S or B149 Canad...

Page 21: ...LC S636 Vent and Intake Air Size Vent Length Combustion Air Intake Pipe Material Intake Air Max Length Min Max 410 Stainless Steel AL29 4C ANSI ASTM D1785 Sch 40 PVC ANSI ASTM F441 Sch 40 CPVC DuraVent Polypropylene 4 5 1 52 m 65 19 81 m Galvanized Steel PVC ABS CPVC 65 19 81 m The maximum and minimum venting length for this Category IV appliance shall be determined per the NFGC U S or B149 Canada...

Page 22: ...straight pipe and three elbows 25 7 62 m of straight pipe and four elbows The vent cap is not considered in the overall length of the venting system Model No Vent Size Maximum Horizontal Vent Length 410 4 65 19 81 m Subtract 10 3 05 m per elbow maximum 4 elbows The vent must be installed to prevent flue gas leakage Care must be taken during assembly to ensure that all joints are sealed properly an...

Page 23: ...mbustion air inlet directly above a direct vent cap This vertical spacing would allow the flue products from the direct vent cap to be pulled into the combus tion air intake installed above This type of installation can cause non warrantable problems with components and poor operation of the heater due to the recirculation of flue products Multi ple direct vent caps should be installed in the same...

Page 24: ...24 Fig 10 Outdoor Venting Fig 11 3 in 1 Multi Vent Adapter ...

Page 25: ... to adjacent structures or building finish For maximum efficiency and safety the precautions on page 25 must be observed 1 Periodically check venting system The heater s venting areas must never be obstructed in any way and minimum clearances must be observed NOTE Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition NOTE Remove the unused g...

Page 26: ...ipate test pressure in the gas supply line before reconnecting the heater and its manual shut off valve to gas supply line FAIL URE TO FOLLOW THIS PROCEDURE MAY DAM AGE THE GAS VALVE OVER PRESSURIZED GAS VALVES ARE NOT COVERED BY WARRANTY The heater and its gas connections shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use open flame A minimum o...

Page 27: ... in the flow rate to the spa jets etc EXTERNAL AUXILIARY BYPASS VALVE Where Required From Heater To Heater From Pool Spa To Pool Spa AUXILIARY BYPASS VALVE DO NOT USE GATE VALVE PRESSURE RELIEF VALVE PIPING The heater is supplied with a pressure relief valve sized for the maximum output of the heater and set at 125 psig The pressure relief valve outlet must be plumbed to a safe point of discharge ...

Page 28: ...ck or directly from the GFCI power source It is required that full time power be supplied to the heater from the GFCI power source and that the heater be controlled by the fireman s switch connection or using a two or three wire remote See pages 40 42 If using a switched GFCI power source the heater post purge function will be bypassed adversely affecting heater operation and life Fig 19 120 VAC W...

Page 29: ...o connect your plumbing to the heater see page 9 for list Two options are recommended for the installer as shown in the following images LOOSE PLUMBING PARTS SETUP NOTE Use appropriate CPVC or CPVC to PVC transition primer and glue for attachments STANDARD RIGHT HAND CONNECTIONS LEFT HAND CONNECTIONS LEFT IN RIGHT OUT CONNECTIONS RIGHT IN LEFT OUT CONNECTIONS Fig 20 Water Connection Configurations...

Page 30: ...eders must be down stream of the pool heater Heater must be located so that any water leaks will not damage the structure of adjacent area PVC pipe may be glued directly into the bypass connections CAUTION An additional source of heated water e g a solar system must be connected to the main line ahead of the heater inlet pipe in order for it to act as the primary heat source If the primary system ...

Page 31: ...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: ...32 WIRING DIAGRAM Fig 26 Wiring Diagram ...

Page 33: ...33 SECTION 4 SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS Fig 27 Location of Controls ...

Page 34: ... the PC board carefully remove all connectors and wires from the PC board and ON OFF toggle switch 4 Lift the front bezel lid and remove the two lower Phillips screws 5 Carefully lift the control panel upwards and pull away from the heater 6 The control panel can now be flipped around to remove or inspect the PC board 7 Reverse procedure for re installation Fig 28 Control Adjustments Fig 29 Contro...

Page 35: ...lame signal strength when the heater is firing A signal of less than 4 indicates a weak flame signal and may require 35 Controls Operation The pool heater touchpad located on the upper por tion of the angled corner panel of the heater allows the user to select the mode of operation adjust the set point temperature configure the heater controls and access diagnostic information The LCD display win ...

Page 36: ...t input for the shortest heat up times Spa Fan Mode Eco Efficiency Turbo Rapid Heat or Comfort Modulate Selection Use the UP and DOWN buttons to select Eco Efficiency Turbo Rapid Heat or Comfort Modulate mode of operation Eco mode offers increased effi ciency and reduced operating sound levels by reduc ing the operating fan speed and gas input rate by 30 Turbo mode operates to provide maximum heat...

Page 37: ...ration Selection available only with Pump Operation enabled Use the UP and DOWN buttons to enable or disable operation of motorized three way valves Return Valve Selection available only with Valve Operation enabled Use the UP and DOWN buttons to define the valve positions for the Return Valve Valve Position 1 can be set to Pool or Spa Suction Valve Selection available only with Valve Operation en...

Page 38: ...gram Button to access the Installer Setup Mode to Set Factory Defaults This will clear the PIN and allow normal operation and selection of a new PIN if desired See the Installer Setup Mode directions on page 36 for details The digital thermostat models are programmed to dis play a variety of status and diagnostic messages depending on the operating conditions The following heat status and error co...

Page 39: ... Switch open with inducer on Air Flow Sw Closed Air Pressure Switch closed with inducer off 5 Min Ind Off Inducer off for 5 minutes because the inducer s interlock didn t close Fan Lockout 3 fan switch faults within same heat demand cycle Ignition Failure No flame detected within 4 seconds Natural gas only not stored in EEPROM Ign 60 min Delay Ignition trial failed 3 times in single call for heat ...

Page 40: ... the remote wiring Typically a remote does not supply power to the heater it only provides a switching function to turn the heater On or Off If your remote is supplying its own voltage to the heater it will not work with this heater and may damage the digital circuit board For operation of the heater using the onboard thermo static controls with a time clock see the Time Clock Fireman s Switch sec...

Page 41: ...setting available on the control The actual setpoint will be con trolled by the remote control 4 Press the mode button to OFF and remove power from the heater 5 On the Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and con nect the other side to either the ORANGE BLACK wire for SPA operation or the BLACK ORANGE wire for POOL operation 6 Attach wire nut on unused wi...

Page 42: ...failure or low water flow Fig 31 Flow Switch FLOW SWITCH BLOCKED VENT SWITCH This heater is equipped with a blocked vent pressure switch to prevent the operation of the heater when the vent is blocked Fig 32 Blocked Vent Switch ADJUSTING VALVE MANIFOLD PRESSURE 1 Gas manifold pressure is measured at the pres sure tap between the gas valve and gas orifice See Fig 32 2 To increase the manifold press...

Page 43: ...ts for CO ppm Follow the instructions from the Adjusting Valve Manifold Pressure section to make adjustments Desired CO2 and max CO ppm apply to all firing rates but firing rate must be stable for a good reading fan RPM should not change more than 50 RPM while taking a sample Fuel Type CO2 Range CO Max PPM Natural Gas 8 6 9 2 100 Propane 9 5 10 1 100 IGNITER REMOVAL NOTE Orifices for propane gas h...

Page 44: ...ication Burned motor Motor control failure Heater turns on for less Wiring than 4 seconds Incorrect supply wiring no display error PC Board short Ignition not sensed Clean igniter with wire brush Replace board if no strength signal is being detected Replace fan relay Loose connection or failed motor Incorrect wiring replace blower Replace blower Check for loose or broken verify continuity wiring g...

Page 45: ...P1 Check resistance value of the thermistor Reference to chart below Replace thermistor if not within 10 of values shown below If okay replace Circuit Board Temp Degrees F 40 50 60 70 80 90 100 106 Temp Degrees C 4 4 10 15 6 21 1 26 7 32 2 37 8 41 1 Resistance k 261 1 199 0 153 1 118 8 93 0 73 3 58 3 51 0 If okay replace Circuit Board Sensor resistance at various temperatures Water Sw Open Water f...

Page 46: ...46 SECTION 6 REPLACEMENT PARTS ...

Page 47: ...47 ...

Page 48: ... 013733F 5 C Seal Gasket 014866F 6 C P C Board Digital Control 015454F 7 C Temperature Sensor Water Flue 009577F 8 C Water Flow Switch 015115F 9 C Flow Switch Paddle 010026F 10 C Switch Air Pressure Vent Field 010354F 11 C Rocker Switch 009493F 12 C Vent Temp Limit Switch 013428F F FAN 1 F Blower 015455F 2 F Blower Gasket 015456F 3 F Combustion Air Venturi Adapter 015457F 4 F Hose Duct 4 Plastic 0...

Page 49: ...R Refractory Front Rear 015479F 4 R Refractory Top 015480F S SHEET METAL CABINET 1 S Jacket Top 015481F 2 S Upper Cabinet Supports 015482F 3 S Vertical Supports 015483F 4 S Heat Transfer Vertical Supports 015484F 5 S Vertical Cabinet Supports 015485F 6 S Flue Collector 015486F 7 S Flue Collector Seal Gasket 015487F 8 S Flue Collector Outlet Gasket 015488F 9 S Flue Exhaust Inlet Collar 015489F 10 S...

Page 50: ...e wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbo...

Page 51: ...hrenheit Spa Max Temp 104 F Pool Max Temp 104 F Pool Fan Mode Eco Turbo Turbo Spa Fan Mode Eco Turbo Comfort Turbo Flue Monitor PVC CPVC PP OFF PVC Max Fan RPM 7500 RPM Pump Operation Disabled 1 Speed 2 Speed 4 Speed Variable Disabled Spa Heat Speed Disabled Pool Heat Speed Disabled Filter Speed Disabled Freeze Protect Enabled with Pump Operation Valve Operation Disabled only available with pump o...

Page 52: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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