Raypak AVIA 264 User manual

AVIA Pool & Spa Heater
Tool Box Quick Reference Guide

Water Chemistry
GENERAL
Recommended Levels Fiberglass Pools Fiberglass Spas Other Pool & Spa Types
Water Temp. 68 to 88°F (20 to 31°C) 89 to 104°F (31 to 40°C) 68 to 104°F (20 to 40°C)
pH 7.3 to 7.4 7.3 to 7.4 7.6 to 7.8
Total Alkalinity (PPM) 120 to 150 120 to 150 80 to 120
Calcium Hardness (PPM) 200 to 300 150 to 200 200 to 400
Salt (PPM) 4500 MAXIMUM 4500 MAXIMUM 4500 MAXIMUM
Free Chlorine (PPM)22 to 3 2 to 3 2 to 3
Total Dissolved Solids (PPM) 3000 MAXIMUM33000 MAXIMUM33000 MAXIMUM3
For your health and the protection of your pool equipment, it is essential that your water be chemically balanced1.
The following levels must be used as a guide for balanced water.
1 Damage from corrosive water is not covered under warranty. Consult your product manual for more information.
2 Free Chlorine MUST NOT EXCEED 5PPM.
3 In salt water chlorinated pools, the total TDS can be as high as 6000PPM.
• 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ecientinheatedwater,unlesscontrolled,
they can lead to excessive chlorine level which can damage your heater.
• Check valve should be installed between the heater outlet and a chlorinator or other chemical dosing device.
• Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier for the
correct levels for your water.
• Warning: Electrolytic Corrosion and pH instability may be present with salt chlorinated pools.
2

Model Number and Serial Number Location
Before you call Raypak service, make sure you have the MODEL NUMBER and SERIAL NUMBER.
Model & Serial
number can also
be found inside the
bezel above digital
display.
Model & Serial
number located
on rating plate.
Model & Serial number located on
carton label.
GENERAL
3

Minimum Clearances
CLEARANCES
FLOORING: THIS UNIT CAN BE INSTALLED ON COMBUSTIBLE FLOORING.
4
See product manual for more information.
Location Indoor Installation
Top 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
Top Unobstructed
Front 0”
Floor 0”
Back 0”
Right Side 3” (76 mm) from Panel - Water Side
Left Side 6” (152 mm) from Vent Cap

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denedbyNFGC
(National Fuel Gas Code).
CLEARANCES
5

Minimum Clearances – Indoor
CLEARANCES
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oor
All air from outdoors, each opening shall have a
net free area as shown in table.
Check state and local codes before proceeding. Some states do not recognize the NFGC and require larger openings.
6
Model
Unrestricted
Opening
Sq. In. (m2)
Typical
Screened or
Louvered
opening
Sq. In. (m2)
Typical
Screened and
Louvered
opening
Sq. In. (m2)
264 66 (0.04) 99 (0.06) 132 (0.09)
404 100 (0.06) 150 (0.1) 200 (0.13)

Gas Line Sizing
Maximum Equivalent Pipe Length ft (m)
Natural Gas 1000 BTU/FT3
0.60SpecicGravity@0.5in.WCPressureDrop
Propane Gas 2500 BTU/FT3
1.53SpecicGravity@0.5in.WCPressureDrop
Model No.
Size 3/4” Size 1” Size 1-1/4” Size 1-1/2”
NAT PRO NAT PRO NAT PRO NAT PRO
264 15
(4.6)
35
(10.7)
50
(12.2)
125
(38.1)
210
(64.0)
480
(146.3)
445
(135.6)
404 *15
(4.6)
20
(8.8)
55
(16.8)
95
(29.0)
225
(68.6)
215
(65.5)
280
(85.3)
GAS SUPPLY
EFFECTS OF LOW GAS PRESSURE
• Pulsatingburnerame/Flamelost
• DelayedIgnition/Hardlighto
• Exposure to condensation
• Emissions not at compliance levels
• Damage burner
• Sooting
• Ignition failure
7
*A3/4”gaslinecanbeusedforupto5’(1.5m)maximumlengthfromthegasvalveinadditiontothesedimenttrap.

Gas Pressure Test
Gas Required Pressure Manifold
Pressure
Min. Max.
Natural Gas 3.5”
(Dynamic)
10.5”
(Static) -0.3”
Propane Gas 8.0”
(Dynamic)
13.0”
(Static) -0.3”
GAS SUPPLY
• Propane requires an external “pounds
to inches” regulator
8
Inlet Gas Pressure
Gas Valve
Manifold
Gas Pressure
Gas Valve

Gas Line Sediment Trap
GAS SUPPLY
Check state and local codes before proceeding. Some states do not recognize the NFGC.
Sediment Trap should be located as close
to the inlet of the appliance as practical.
9

ELECTRICAL
10
Model 264
Model 404
Printed circuit board. Boards cannot be
interchanged.
Circuit Board

ELECTRICAL
Wiring Diagram – Common Wiring
11

ELECTRICAL
12
Power Connections
*NOTE: Heater will not work properly if wired to a 208VAC power source.
Supply side Supply side
Heater
6 wires
Heater
6 wires
120VAC 240VAC

13
Wiring Diagram – 240V
ELECTRICAL
240V Blower Jumper
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.

Wiring Diagram – 120V
14
ELECTRICAL
120V Blower Jumper
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.

AUXILIARY CONTROL
15
Auxiliary Output
Auxiliary Terminal
TheAVIAheateroers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.
Route Communication Harness
Route harness from
knockout to control
board
To auxiliary device
Terminal Wire AC Rating DC Rating
Common Black
250V Max,
3A
30V Max,
3A
Normally Open Black and Red
Normally Closed Black and White
CAUTION: Do not exceed Auxiliary relay rating. Check power
requirements of any electric component connected to this device,
following the applicable installation norms and requirements.

AUXILIARY CONTROL
Auxiliary Output - Wiring
16
1. P9 Auxiliary is a dry contact output: It requires external
power supply to energize connected devices.
2. Load on P9 must not exceed 3 Amps. If the load is
larger than 3 Amps, use P9 auxiliary output to drive a
eld-installedcontactor.Forpumps,blowers,andother
applicationsratedabove3Amps,useeld-supplied
relay (Raypak kit# 008784F).
3. Use the Normally Closed (NC) and Normally Open (NC)
terminalstodrivea3-wayvalve.Thisconguration
typically uses an external 24VAC supply.
12
3
Raymote
Scheduling AUX
Outputs Control
OMRON LY2F 24AC

OPERATION & CONTROLS
17
Start-Up Operating Displays
1 2 3a 3b
4 5a 5b 6
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.
5. Blower “Pre-Purge” for 45 seconds, Spark and Ignite.
6. Heater temperature setpoint, water temperature and “Heating” is displayed.

OPERATION & CONTROLS
Operating Displays
1. UnitHeatinguntildemandissatised,water
temperature reached.
2. Blower “Post-Purge” for 3 minutes.
3. WhenPool/SpaSETtemperatureissatised
“No Demand” will display.
7 8 9a
18
9b
7.
8.
9.

OPERATION & CONTROLS
Sequence of Operation
SUPPLY (Power to Heater)
HEATING (Spark and 24 VAC to Gas Valve)
APPLY 24 VAC to Ignition/Gas Control
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.
1. Control Board produces SPARK and Gas Valve energized.
2. Sparkstops,andFLAMESENSING(Rectication)OCCURS.
3. “Heating” Displayed with steady Flame Sensing.
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. Control board initiates pre-purge sequence. “Pre-purge” displayed.
19

OPERATION & CONTROLS
Remote Wiring Connections and Setup
Part Number 652187
Pool
Spa
24V Hot
Wire Harness Connection
Aremotemaybewiredtoprovidean“On-O”switchingfunction(twowire)orasathree-way
“Pool-O-Spa”selectorswitch(threewire).
Modern automation systemsuseatwo-wireconguration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.
20
Remote Wire