Raypak Raytherm 514-824 User's Manual
Contents
1. Check continuity of ignition cable and ground wire PILOTISLIT Clean flame rod YES Check electrical connections between flame rod and module Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adjust pilot flame If problem persists replace module Check for 24 Vac across MV MV PV terminals If no voltage replace module MAINBURNERLIGHTS NO Check electrical connections between module and gas control If okay replace YES gas valve or gas control operator i e pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system SYSTEMRUNS UNTIL NO CALL FOR HEAT ENDS Check continuity of ignition cable and ground wire YES NOTE If ground is poor or erratic shutdowns may occur occasionally even though operation is normal at the time of checkout Check that pilot flame covers flame rod and is steady and blue If checks are okay replace module CALL FOR HEAT ENDS Check for proper thermostat controller operation SYSTEMSHUTS OFF e Remove MV lead at module if valve closes recheck temperature controller and YES wiring if not replace gas valve TROUBLESHOOTING Repeat procedure until troublefree operation is obtained ENDS 29 SECTION 6 REPLAGEMENT PARTS LIST NOTE To supply the correct part itis important that you state the model number serial number and type of gas when applicable An2. Heater must be located so that any water leaks will not damage the structure of adjacent area Hightemperature plastic pipe CPVC may be connected directly into the heater if local codes permit and if controls operate the pump for at least fifteen minutes afterthe heateris turned off CAUTION NEVER install PVC directly into heater Four feet of copper or high temperature pipe and two elbows are required between the heater and the PVC connections Fig 8129 0 12 piping must be anchored copper or screwed into the flange metal if operating pressures above 30 PSI are encountered 2 Anyrestrictions between heater outlet and pool will void the warranty FLOW RATES MODEL PIPE SIZE MIN GPM MAX GPM COMPANION FLANGE CONNECTIONS DO NOT use petroleum base assembly fluids Such as Petroleum Jelly or lubricating oil If assembly tube is required use a silicone base such as Armoral etc The inlet outlet header flange accepts a 2 copper tube as a slip connection directly into the header The flange is also thread for a 2 copper male threaded adapter FLANGE GASKET INLET INLET OUTLET HEADER HEADER FLANGE OUTLET Fig 8221 0 AUTOMATIC CHLORINATORS AND CHEMICAL FEED ERS All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater Do not place chlorine tablets or bromine sticks in the skimmer High chemical concen trations will
3. GOVERNOR Fig 48224 0 U G GASKET Totestthe operation ofthe Unitherm Governor place in hot water over 100 F and watch formovement against spring If there is not movement replace unit SECTION 5 TROUBLESHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel 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 Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions MECHANICAL FOR QUALIFIED SERVICE PERSONNEL ONLY PROBLEM Harmonics or whining noise Heater going on and off continuously Liming or scale forming on heat exchanger Sooting Pilot outage Yellow lazy flame Outer jacket very hot paintblistered Takes long time to heat pool or spa CAUSE U G inoperative Debris or restriction in system LOW TOW nu sa DE enden Low water levelin pool External bypass setting out of Pressure switch out of Lave High
4. U G Inoperative Ailrstarvaflofi Improperventing Insects or debris clogging burner intake ports Restricted pilot Weakpilotgenerator Lowgaspressure Insects or debris clogging burner intake ports Broken refractory caused by shipping damage orimproper combustion Excessive sooting of heat epo P Calculate temperature in hr Filter notrunning long enough PE ne Gas line or meter undersized Usually occurs on initial start up 23 SOLUTION Check movement by putting in hot water 110 F or higher If no movement replace Locate the restriction and remove Flush system and clean Remove debris or blow out gas line Scale forming in heat exchanger clean heat exchanger and check pool pH and total alkalinity Backwash filter Raise water level Adjust bypass Adjust pressure switch See Water Chemistry page 2 Reduce by adding manual bypass valve and adjust by putting thermometer in header 1 4 NPT drain opening Set bypass so thermometer reads between 105 and 110 F Check movement by putting in hot wa
5. please contact the factory or your local Raypak representative SECTION 2 GENERAL SPECIFICATION These heaters are design certified and tested under the requirements of ANSI Z21 56 CSA 4 7 American National Standard CSA Standard for Gas Fired Pool Heaters All heaters are inter changeable and can be used either indoor or outdoors The appropriate top desig nated for that type of use is required If desired the top can be changed at a late date to change from outdoor to indoor or vice versa Rated inputs suitable for up to 2000 feet elevation For elevations above 2000 feet reduce input 4 for each 1000 feet above sea level as height elevation reduces combustion performance SECTION 3 INSTALLATION INSTRUCTIONS CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to State of California to cause cancer birth defects or other repro ductive harm IMPORTANT NOTICE These instructions are intended for the use of qualified personnel only specifically trained and expe rienced in the installation of this type of heating equip ment and related system components Installation and service personnel may be required by some states to be licensed If your state is such be sure your contractor bears the appropriate license Persons not qualified shall not attempt to fix this equipment nor attempt repair according to these instructions WARNING Improper installation adjustment alter ation service or maintenance
6. 001313F 001314F 001315F 001316F 001317F Refractory Retainer Kit 001627F 001627F 001627F 001627F 001627F 001627F SHEET METAL Jacket Top 002417F 002418F 002419F 002420F 002421F 002422F Flue Collector 002423F 002424F 002425F 002426F 002427F 002428F Door Assy 001834F 001835F 001836F 001837F 001838F 001839F Access Panel Group 001841F 001841F 001841F 001841F 001841F 001841F J Box Sheetmetal 002668F 002668F 002668F 002668F 002668F 002668F VENTING Stackless Top Kit Outdoor 001101F 001102F 001103 001104 001105 001106 Draft Hood Kit Indoor 001455F 001456F 001457 001458 001459 001460 30 LIMITED WARRANTY RAYTHERM TYPE P SIZES 0514 0824 SCOPE Raypak Inc Raypak warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty Labor charges and other costs for parts removal or reinstallation shipping and transportation are not covered by this Warranty but are the owner s responsibility HEAT EXCHANGER WARRANTY Five 5 years from date of boiler installation Includes only cupro nickel heat exchanger with bronze waterways ANY OTHER PART MANUFACTURED OR FURNISHED BY RAYPAK One 1 Year warranty from date of boiler installation or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PRO
7. J00203 OMG SSF O D247TF B DQenB 29 DO2487F 002473 002481F 003182F 00238 001817F 001081F 5000565 DO02475F 007211F 300203 COGS F 002477 ADIADA DO4853F DO1BG5F DI2460F DOZAT3F GOS thar DOZ337F DO1818F DOOS IF BODO BSB DO2475F 500834 DOT 1 TF 300203 D069S4F BODOBOB FOR ALTIT UDES ABOVE 2 000 FEET ABOVE SEA LEVEL CONSULT THE OD LASSF OG 1667F O01878F DO1857F DO 18 53 Pasa pescnrmos sa su ou O01 BSF 301210138 201210044 301210050 003346F 007444F OG 202F D4B7TF D4B7 BF 02485F 002481F 03154F 02388F D1818F 001051F 8000855 02475F 5083 007211 00203 OO 994F 002477F 2853 002478 005345F BATE pO2470F DO2473F DOZz4B1F DO3185F DOz388F 18 DOT081F 000566 500834 007211 20 OD JEF OOF 144F OMG 20 AF 002471F 02473 00249 1F 3 186 D01524F D010654F Ra bea D02475F 500834 DOT 211F CALL nU DESCRIPTION MISCELLANEOUS COMPONENTS Pressure Switch 062237B 062237B 062237B 062237B 062237B 062237B Pressure Switch Tube Assy 003273F 003273F 003273F 003273F 003273F 003273F Thermostat Knob 006885F 006885F 006885F 006885F 006885F 006885F Knobstop 006886F 006886F 006886F 006886F 006886F 006886F Dial Plate 900536 900536 900536 900536 900536 900536 PRV 125 PSI 00722
8. agency 5 On indoor heater clean room intake openings to assure adequate flow of combustion and ventilation air CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty 6 Keep air around heater clear and free from com bustible materials gasoline and other flammable and corrosive vapors and liquids BASIC TIPS IF HEATER WILL NOT FIRE 1 If you have no electrical power it may be your circuit breakers have tripped Try re setting them 2 If you have electrical power but the heater will not fire check the following 3 The time clock must be moved to the ON position 4 Yourpump strainer basket may be full If so remove debris 5 Yourfilter may be dirty If so backwash or clean filter To tell if your filter is dirty the gauge pressure will be higher than usual 6 The pump may have lost it s prime It may be running dry check the pressure gauge on the filter If there is no pressure then you are not moving water or your gauge is broken Try to getthe pump to run at it s normal flow rate POOL amp SPA WATER CHEMISTRY 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 exchanger tubes reducing heater efficiency and also damaging the heater If
9. be flowing through Clean main burners and air louvers of dust lintand the heater during operation debris Keep heater area clear and free from com bustibles flammable liquids and chemicals Do not CAUTION Propane gas is heavier than air and will obstruct the flow of combustion and ventilating air settle on the ground Since propane can accumulate in confined areas extra care should be exercised when lighting propane heater OPERATING INSTRUCTIONS AND SHUT OFF PROCEDURES AUTOMATICALLY LIGHTED PILOTS ELECTRONIC IGNITIONS SYSTEMS A Thisappliance is equipped with an ignition device e f you cannot reach your gas supplier call the which automatically lights the pilot Do not try to fire department light the pilot by hand Use only your hand to push in or turn the gas control B BEFORE OPERATING smell all around the appli knob Never use tools If the knob will not push in ance area for gas Be sure to smell next to the floor or turn by hand do not try to repair it call a qualified because some gas is heavier than air and will settle service technician Force or attempted repair may on the floor result in fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been Do not try to light any appliance underwater Immediately call a qualified service Do nottouch any electric switch do not use any technician to inspect the appliance and to replace telephone in your building any part of the control syst
10. 0V DUAL VOLTAGE Lj TRANS 30VA AUTO AUTO MANUAL FIXED LIMIT PRESS FIXED LIMIT RESET LIMIT SEE KEY NC SWITCH NC NC eb Rl CAS IGNITION HICH TENSION TRANSFORMER WIRING INFO lt lt LOW WATER CUTOFF 120V ONLY GK M 240V HOT 24V m 120V MEC Wim 120V COMM L2 Se o 120V HOT 11 BLACK BROWN RED ORANGE GK mal 120V HOT C 120V COMM R GREEN BLUE VIOLET 4 CHECK CONTROLS PROVIDED WIRED AS SHOWN WHITE YELLOW PLUG ACTUAL REPLACE WIRING WITH 105 C WIRE ONLY WIRING DIAGRAM IID MODE ON OFF BOILER INPUTS 825 000BTUH INPUTS 825 000 BTUH FRONT VIEW BOILER SIZE BOILER TYPE 151965 8 16 SEE NOTE BELOW R 120 240V AUTO AUTO MANUAL FIXED LIMIT PRESS FIXED LIMIT RESET LIMIT SEE KEY NC SWITCH NC NC I IN NN SPASTAT REMOTE SPA SWITCH R le 9 O t t amp 0 0 8 R BL C INSTALLED C_ BL H POOL SPDT Y SIAT WIRING J Y V N ZN gt lt HIGH TENSION ES TRANSF ORMER WIRING INFO lt lt LOW WATER CUTOFF 120V ONLY GK m 240V HOT 24V y R 240V COMM W 120V COMM L2 Sk m 120V HOT L1 OD WIRE NU BLACK BROWN BK a 120V HOT H RED w s 120V COMM ORANGE YELLOW R C GREEN BLUE VIOLET CHECK CONTROLS PR
11. 4F 007224F 007224F 007224F 007224F 007224F Deliming Kit 052869F 052869F 052869F 052869F 052869F 052869F Power Vent Motor 951105F 951105F 951105F 951105F Power Vent Wheel 951106F 951106F 951106F 951106F Power Vent PC Board 005503F 005503F 005503F 005503F Power Vent Pressure Switch 601212 601212 601212 601212 Pilot Nat Standing 002480F 002480F Pilot Pro Standing 002481F 002481F Pilot Nat Standing Remote Spa 002412F 002412F Pilot Pro Standing Remote Spa 002413F 002413F Pilot Nat IID 002234F 002234F 002234F 002234F 002234F 002234F Pilot Pro IID 002235F 002235F 002235F 002235F Pilot Orifice Nat Standing 600552 600552 Pilot Orifice Pro Standing 600148 600148 Pilot Orifice Nat IID 600552 600552 600552 600552 600552 600552 Pilot Orifice Pro IID 600894 600894 600894 600894 Pilot Generator Standing 600019B 600019B Thermocouple Remote Spa 600003 600003 Ignitor Standing Piezo 001643F 001643F Ignition Control IID Nat 004817B 004817B 004817B 004817B 004817B 004817B Ignition Control IID Pro 004818B 004818B 004818B 004818B Mounting Bracket Standing 303612 303612 Mounting Bracket IID 304666 304666 304666 304666 304666 304666 Ignition Rod Standing 600502 600502 Ignition Rod IID 650554 650554 650554 650554 650554 650554 Pilot Tube Standing 004078F 004078F Pilot Tube IID Specify Length 400013 400013 400013 400013 400013 400013 High Tension Wire 002663B 002663B 002663B 002663B 002663B 002663B REFRACTORY Refractory Kit 001312F
12. CATALOG 6200 50 Effective 04 15 05 Replaces 06 01 00 INSTALLATION AND OPERATING INSTRUCTIONS COMMERCIAL SWIMMING POOL HEATERS Raytherm Models 514 824 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 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 qualified installer service agency or the gas supplier This manual should be maintained in legible condition and kept adjacent to the heater or kept in safe place for future reference P N 240499 WATER CHEMISTRY Corrosive water voids all warranties For your health and the protection of your pool equipment it is essential that your water chemically balanced The following levels must be used as a guide for balance water Recommended Level s Fiberglass Pools Fiberglass Spas Other Pool amp Spa Types Water Temp Deg F 68 to 88 89 to 104 68 to 104 H 7 3to 7 4 7 3to 7 4 7 6 to 7 8 Sat PPM Free Chlorine MUST NOT EXCEED 5 PPM e Occasional chemical shock dosing of the poolm or spa water should not damage the heater providing the water is balanced e Auto
13. L2 or second hot leg of the power supply Attach the wire nut to the white wire There should be no connection to the white wire for 240V operation hide vare with nut attached 240 volt LI Hol 240 volt L2 Hat Fig 9241 Heater must be electrically grounded and bonded in accordance with local codes or in the absence of local codes with the latest edition of the National Electrical code ANSI NFPA 70 NOTE Input power to the heater 120 240V should be supplied from the load Pump side of time clock or switch Connecting heater to continuous power source will allow Fail indications service and pressure switch when pump is not operating SEE NOTE BELOW R 120 240V DUAL VOLTAGE TRANS 30VA AUTO AUTO MANUAL FIXED LIMIT PRESS FIXED LIMIT RESET LIMIT SEE KEY NC SWITCH NC NC IGNITION HICH TENSION ES TRANSF ORMER WIRING INFO lt lt LOW WATER CUTOFF 120V ONLY GK m 240V HOT 24V y 120V Sk 120V HOT L1 S2 WIRE NU BLACK BROWN RED ORANGE GK mee 120V HOT medie 120V COMM R GREEN BLUE VIOLET 4 CHECK CONTROLS PROVIDED WIRED AS SHOWN WHITE YELLOW PLUG ACTUAL REPLACE WIRING WITH 105 C WIRE ONLY WIRING DIAGRAM IID uu ERI MODE ON OFF BOILER INPUTS 512 000 THRU 726 000 BTUH INPUTS 512 000 THRU 726 000 BTUH FRONT VIEW BOILER SIZE 514 724 151964 8 15 SEE NOTE BELOW R 120 24
14. OF OF INSTALLATION DATE SUCH AS INSTALLER INVOICE IS REQUIRED THIS WARRANTY WILL BE VOID IF THE BOILER RATING PLATE IS ALTERED OR REMOVED ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from 1 Failure to properly install operate or maintain the boiler in accordance with our printed instructions provided Abuse alteration accident fire flood and the like Sediment or lime buildup freezing or other conditions causing inadequate water circulation High velocity flow exceeding boiler design rates Failure of connected systems devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the boiler system Chemical contamination of combustion air or use of chemical additives to water Misuse or neglect including but not limited to freeze ups and operating the heater with cabinet door off having flow restrictions or obstructions between the heater outlet and pool spa or not maintaining proper thermal balance pH level must be between 7 4 and 7 8 and total alkalinity between 100 and 150 PPM Total Dissolved Solids TDS must be no greater 3000 PPM o gt WN PARTS REPLAGEMENT Under this Warranty Raypak will furnish replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The replace
15. OVIDED WIRED AS SHOWN REPLACE WIRING WITH 105 C WIRE ONLY WIRING DIAGRAM IID MODE ON OFF BOILER INPUTS 512 000 THRU 726 000 BTUH INPUTS 912 000 THRU 726 000 BTUH mm Tm BOILER SIZE 514 724 BOILER TYPE 152441 5 17 SEE NOTE BELOW R 120 240V AUTO AUTO MANUAL FIXED LIMIT PRESS FIXED LIMIT RESET LIMIT SEE KEY NC SWITCH NC NC EE Fe Y SPASTAT REMOTE SPA SWITCH SLOT 000 0 0 jon TT R BL J INSTALLED 4 BL H POOL SPDT Y STAT WIRING C Y I IN Nm Nr ZN HIGH TENSION TRANSFORMER WIRING INFO lt lt LOW WATER CUTOFF 120V ONLY GK M 240V HOT 24V w O ion R 240V COMM W n 120V COMM L2 Bk m 120V HOT 11 BLACK BROWN BK melee 120V HOT RED l 120V COMM ORANGE YELLOW R GREEN BLUE VIOLET CHECK CONTROLS PROVIDED WIRED AS SHOWN REPLACE WIRING WITH 105 C WIRE ONLY WIRING DIAGRAM IID a ee MODE ON OFF BOILER INPUTS 825 000BTUH INPUTS 825 000 BTUH E VE BOILER SIZE BOILER TYPE 1524142 6 18 SECTION 4 SERVICING INSRUCTIONS General Location of Controls UNITHERM GOVERNOR CONTROLS ADJUSTMENTS REPLACEMENTS THERMOSTAT The heater is built with a single mechanical thermo stat located in the front panel above the door The thermostat maybe set f
16. SHOWN IN POSITIONS GAS INLET For Models 824 Turn main gas shut off and pilot shut off valves counter clockwise to OFF TO PILOT PILOT SHUT OFF VALVE CONTROL SHOWN IN THE POSITION AIN GAS SHUT OFF VALVE SHOWN IN THE POSITION Fig 8220 0 9 Replace heater door panel 10 Turn on all electric power to the appliance 11 Set thermostat to desired setting 12 If the appliance will not operate follow the instruc tions To Turn Off Gas to Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Push in gas control knob slightly and turn clock wise N to OFF For Models 824 Turn main gas shut off and pilot shut off valves counter clockwise gt to OFF 5 Replace heater door panel AFTER START UP Feelthe inlet and outlet pipes Outlet pipe should be only slightly warmer than the inlet It should not be hot WARNING Should overheating occur or the gas supply fail to shut off turn off the manual gas control to the appliance VISUAL INSPECTION With the heater on remove the door and make a visual check of the pilot and burner The flame should be blue with a well defined pat tern MAIN BURNER FLAME Fig 8144 0 PILOT BURNER FLAME A yellow or floating flame indicates restricted air openings or incorrect orifice size Should this occur shut the heater off and contact your installe
17. afe place of discharge Drain pipe must be the same size as the valve discharge connection through out its entire length and must pitch downward from the valve No shutoff valve shall be installed betweenthe relief valve and the drain line Valve lever should be tripped at least once a year to ensure that waterways are clear ELECTRICAL WIRING NOTE If it is necessary to replace any of the original wiring it must be replaced with 105 wire or its equivalent except all black wires must be replaced with 150 C wire or its equivalent NOTE Heaters are factory wired for 240V power supply except Cal Code units wired for 120V Power Supply The Electronic Intermittent Ignition Device automati cally lights the pilot and main burners upon a call for the heat The heater is supplied with a dual voltage trans former for 120V or 240V input power hookup 8600 IGNITION CONTROL Fig 8929 1 14 For 120 V input power to the unit connect the black wire to the L1 or hot leg of the power supply Connect the white wire to the L2 or neutral leg of the power supply Attach the wire nut to the red wire There should be no connection to the red wire for 120V operation a d en Ih nui sEachail 21 voll neutral L7 Fig 49240 For 240 V input power to the unit connect the black wire to the L1 or hotleg of the power supply Connect the red wire to the
18. ction in the flow rate to the spa jets etcetera FROM TO HEATER HEATER TO POOL im FROM POOL Fig 8150 0 AUXILIARY BYPASS VALVE ADJUSTMENT 13 To set bypass with clean filter adjustment is made by feeling the inlet and outlet pipes atthe heater Outlet pipes should be slightly warmerthan inletand comfortable to the touch If pipe is hot close bypass if cold open bypass The heater is also equipped with a manual bypass built into the header This is in addition to the automatic bypass valve This may be used with flow rates upto 120 GPM and adjusted as below NOTE Sooting or liming caused by improper bypass adjustment voids the warranty BYPASS VALVE INLET OUTLET HEADER Fig 8223 0 MANUAL BYPASS ADJUSTMENT OPEN POSITION CLOSED POSITION 8 27 O St Fig 8222 0 PRESSURE RELIEF VALVE INSTALLATION To conform to local building codes it may be necessary to install pressure relief valve 3 4 pressure relief valve having a capacity equal to BTU HR output of the model be installed is recommended for this appliance A 3 4 NPT connection is provided in the inlet outlet header for installation ofa pressure relief valve The valve shall be installed in a vertical position PRESSURE RELIEF VALVE INLET OUTLET HEADER INLET OUTLET Fig 8223 0 To avoid water damage or scalding due to valve operation drain pipe must be connected to valve outlet and run to a s
19. e foot intervals Plumbers tape crisscrossed will serve to space both horizontal and vertical piping Gas vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads Werecommend use of insulated vent pipe spacer through the roofs and walls For protection against rain or blockage by snow the ventpipe mustterminate with a vent cap which complies with the local codes or in the absence of such codes to the latest edition of the National Fuel Gas Code ANSI Z 223 1 The discharge opening must be a minimum of two feet vertically from the roof surface and at least two feet higher than any part of the building within ten feet Vent stack shall be atleastfive feetin vertical height above the draft hood outlet The vent cap location shall have a minimum clearance of 4 feet horizontally from and in no case above or below unless a 4 foot horizontal distance is maintained from electric meters gas meters regula tors and relief equipment The weight ofthe vent stack or chimney must notrest on heater draft hood Support must be provided in compliance with applicable codes The heater top and draft hood must be readily removable for maintenance and inspection Vent pipe should be adequately sup ported to maintain proper clearances from combustible constructions Type B double wall or equivalent vent pipe is recommended However single wall metal vent p
20. e the flame of a match or candle or smoke from a cigarette cigar or pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so the installation conforms with the latest edition of the National Fuel Gas Code ANSI Z 223 1 When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in part 11 of national Fuel Gas Code ANSI Z 223 1 N For special venting applications that require reduced vent sizes and through the wall venting the Type D Induced Draft Assembly can be used Consult the factory or your local Raypak representative GAS SUPPLY CONNECTIONS Gas piping must have sediment trap ahead of the heater gas controls and a manual shut off valve located outside the heater jacket All gas piping should be tested after installation in accordance with local codes MANUAL SHUT OFF VALVE GAS INLET gt _ HEATER JACKET BT SEDIMENT TRAP UNION VALVE 8090 0 Fig CAUTION the heater and its manual shut off valve must be disconnected from the gas supply during any pressure testing of that s
21. em and any gas control Immediately call your gas supplier from a neigh which has been underwater bor s telephone Follow the gas supplier s instructions OPERATING INSTRUCTIONS 1 STOP Read the safety information above 2 Set the thermostat on the lowest setting 3 Turn off all electric power to the appliance 4 Remove heater door panel 5 This appliance is equipped with an ignition device which automatically light the pilot Do nottry to light the pilot by hand 6 For Models 514 724 with Honeywell Gas Valve Push gas control knob slightly and turn clockwise NY to Knob cannot be turned to OFF unless knob is pushed in slightly Do not Force GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET Fig 8219 0 7 Wait fire 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 8 For Models 514 724 Turn gas control knob counter clockwise to On For Model 824 Turn main gas shut off and pilot shut off valves clockwise to on 1 Set the thermostat to the lowest setting 2 Turn off all the electric power to the appliance if service is to be performed 3 Remove heater door panel 4 For Models 514 724 For Models 514 724 with Robertshaw Gas Valve Turn Gas control knob clockwise to OFF GAS CONTROL KNOB
22. ght Side 6 Vent 6 Left Side Water Side 6 OUTDOORINSTALLATION Top Stackless Top Unobstructed Back 10 Side 6 Clearance from top of vent terminal For servicing provide at lease 24 in front of the heater for burnertray removal and atleast 18 on water connection side of the heater to inspect and delime the heat exchanger These heaters are design certified for outdoor installation when equipped with the approved tops designated for outdoor use Heaters must not be installed under an overhang of less than three 3 feet from the top of the heater Three 3 sides must be open inthe area under the overhang Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters WARNING The heater shall not be located in an area where water sprinklers or other devices may cause water to spray through the cabinet louvers and into the heater This could cause heavy internal rusting or damage some electrical components and this would void the warranty The point from where the flue products exit the heater must be a minimum of four 4 feet below four 4 feet horizontally from or one 1 foot above any door window or gravity inlet to a building The top surface of the heater shall be at least three 3 feet above any forced air inlet or intake ducts located within ten 10 feet horizontally 4 foot Minimum 4 foot Minimum 1 foot Minimum 4 foot M
23. hanger ream tubes and immerse heat exchanger in non inhibited de scale solvent for sever scale build up TUBEREPLACEMENT PROCEDURE On Raypak units tube replacement may be effected without rolling as a temporary means or repair providing there are two or more tubes rolled in to act as stays on the left andright side rings should provide a seal up to 120 PSI working pressure Use 3 8 heavy duty reversible drill motor or larger to power the tube roller If a reversible drill is not available after rolling the tube in remove the drill motor and wrench out the roller A tube roller is available from the factory RAYPAK TUBE CLEANING KIT MI TI os ES Me Extension Pieces 5 Auger with Carbide Tip Wire Brush Fig 8154 0 Shut gas and power off to the unit close the system off and drain the heater Remove the draft diverter Remove the access panel and jacket top Lift flue collector off Remove V baffles over tube s to be replaced If no pipe unions have been provided use the header as a union remove the flange nuts off the inlet outlet header break gas connection and slide heater away from piping to allow room to work Pull wedge clips out of control wells and remove sensing bulbs Remove flange nuts ofthe return header and remove header Lift heat exchanger straight up and out Inspect O ring seals atthis time Unless severed they are reusable The tube may be cut out with a hacksaw or hamme
24. inimum HIGH WIND CONDITIONS OUTDOOR UNITS ONLY In areas where high winds are fre quent it may be necessary to locate the heater a minimum of 3 from high vertical walls or install a wind break so the heater is not in direct wind current 3 foot Minimum 10 foot Minimum Forced Air Inlet Fig 8245 0 INDOOR HEATER The design is also certified for indoor installation when equipped with the approved draft hood Locate heater as close as practical to chimney or gas vent Heater must always be vented to the outside See Vent Piping Section for venting details Minimum allowable space is shown on the nameplate COMBUSTION AIR Indoor Units Only Air For Combustion And Ventilation Indoor Units Only The heater musthave both combustion and ventila tion air Minimum requirements for net free air supply openings one 12 inches from ceiling for ventilation and one 12inches from the floor for combustion air as outlined ANSI Z223 1 and any local codes that may have jurisdic tion CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty a Al air from inside the building Each opening shall have a minimum net free square inches as noted Model Square Inches Model Square Inches 514 512 724 726 624 627 824 825 b All air f
25. ipe may be usedas specified in the latest edition of the National Flue Gas Code ANSI Z 223 1 10 OR LESS Pan CAP VENT PIPE DRAFT gt HEATER Fig 48119 10 At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remain ing connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and deter mine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliance remaining connected to the common venting system are located and other spaces of the build ing Turn on clothes dryers and any appli ance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fire place dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Us
26. lbows provisions should be made to always shut the heater off a minimum of 15 minutes prior to pump shut down in order to carry away residual heat and prevent damage to the low temperature piping A fireman switch included in the time clock may be used for this purpose with instruction not to override this sequence manually See wiring diagram section for electrical hookup location of the fireman switch in the electrical circuit MAXIMUM EQUIVALENT PIPELENGTH Natural gas 1000 BTU Ft 60 Specific Gravity 0 5 W C Pressure Drop Propane Gas 2500 BTU Ft 1 53 Specific Gravity 0 6 W C Pressure Drop IN PN P N PIN P NDP NIP 514 10 15 35 65 150 130 360 500 624 10 25 45 100 95 250 340 724 20 35 80 75 180 260600 fos Jen v es onn PLUMBING FOR WATER CONNECTIONS NOTE 1 When 2 piping is used into the heater this LOCATION The heater requires water flow and positive pressure to fire and operate properly It musttherefore 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 filter pump 2 The outlet side of the filter is then plumbed to the inlet of the heater and 3 Theoutletofthe heater is plumbed to the return line to the pool or spa The pump filter and heater are thus plumbed in series
27. lve 5 Remove 2 screws that mount burner tray to unit and 2 screws that secure gas valve to jacket Disconnect wires that terminate at gas valve Slide out burner tray Reverse above procedure to reinstall pe GAS VALVE REMOVAL 1 Shut off gas supply to the heater Remove gas piping to gas valve inlet 2 Disconnect wires pilot tubing and bleed line if required 3 Turn vertical gas pipe from manifold slightly and unscrew gas valve 4 Reverse above procedure to re install MAIN BURNER AND ORIFICE REMOVAL 1 Remove burner drawer See burner drawer removal procedure 2 Remove screws and burner hold down bracket NOTE fthe heatexchangeris sooted badly the burner hold down bracket and spacer can become distorted from direct flame impingement and this usually neces sitates replacement of these parts 3 Liftburners from slotted spacers and slide from orifices Clean with a wire brush 4 Orifices usually do not need to be replaced To clean run either copper wire or wood toothpick through orifice Do not enlarge hole To remove orifice use a socket wrench and re move from manifold DO NOT over tighten whenreinstalling PILOTREMOVAL AND CLEANING 1 Remove burner drawer See burner drawer removal procedure 2 Disconnect pilot tubing disconnect wires from gas valve Disconnect pilot bracket from burner shield Remove pilot form bracket Remove pilot orifice and air opening and clean with wire o
28. matic 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 e Further advice should obtained from your pool or spa builder accredited pool shop or chemical supplier for the correct levels for your water CONTENTS PART ONE OWNER S OPERATING INSTRUCTIONS SECTION 1 START UP PROCEDURES Before Start Up Operating Instructions After Start up SECTION 2 CAUTION SECTION 3 MAINTENANCE AND CARE PROCEDURES Pool amp Spa Water Chemistry PART TWO INSTALLATION SERVICE INSTRUCTIONS SECTION 1 RECEIVING EQUIPMENT SECTION 2 GENERAL SPECIFICATION SECTION 3 INSTALLATION INSTRUCTIONS Base Installation Clearances Combustion Air Venting Connections Outdoor Gas Supply Connections Plumbing for Water Connections Electrical Wiring Wiring Diagrams SECTION 4 SERVICING INSTRUCTIONS General Location of Controls Controls Adjustments Replacements SECTION 5 TROUBLESHOOTING GUIDE Electrical SECTION 6 REPLACEMENT PARTS LIST WARRANTY 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 ORDEATH SECTION 1 START UP PROCEDURES BEFORE START UP WATER Firstthing insure that systemis filled with water and BURNERS have pump operating Water must
29. may damage the equip ment create a hazard resulting in asphyxiation explo sion or fire and will void the warranty CODE REQUIREMENT NOTE The heater should not be located in an area where possible water leakage will result in damage to the area adjacent to the appliance or to the structure When such locations cannot be avoided it is recom mended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Installation must be in accordance with local codes or in the absence of local codes with the latest edition of the National Fuel Gas Code ANSI Z223 1 and National Electrical Code ANSI NFPA 70 BASE INSTALLATION Heater must be mounted on a level base such as cement slab cement blocks or other non combustible surface An optional non combustible surface An optional non combustible base is available for all models An alternative method for providing a base for combus tible floors is illustrated Heater must not be installed on carpeting 12 Minimum Sheet Metal 24 Gauge Fig 8148 0 Tes SF v Hollow Concrete Cinder Block Align Holes And Leave Ends Open Alternative Method For Providing A Non Combustible Base OUTDOORHEATERS CLEARANCES ALL HEATERS For clearances from combustible surfaces see the chart below CLEARANCE FROM COMBUSTIBLE CONSTRUCTION INDOORINSTALLATIONS Top Drafthood 36 Back 10 Front Alcove Ri
30. ment part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts not manufactured by it but Raypak will apply any such warranty as may be provided to it by the parts manufacturer TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of installation and description of the problem The installer must then notify his Raypak distributor for instructions regarding the claim If either is not available contact Service Manager Raypak Inc 2151 Eastman Ave Oxnard CA 93030 or call 818 889 1500 In all cases proper authorization must first be received from Raypak before replacement of any part EXCLUSIVE WARRANTY LIMITATION OF LIABILITY This is the only warranty given by Raypak No one is authorized to make any other warranties on Raypak s behalf THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPEC TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS WARRANTY OR IN CONTRACT TORT NEGLIGENCE OR OTHERWISE FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGE INCLUDING DAMAGE FROM WATER LEAKAGE Some states do not allow limitations on how long an implied warrant
31. must be used in place of the pressure switch when mounted and wired adjacent to the heater 20 TWO SPEED PUMPS In some cases the flow on the low speed is insuffi cient to operate the heater This is apparent when the pressure switch cannot be further adjusted of ifthe heater makes banging noises In these cases the pump must be run at high speed when heating the water CAUTION Do not operate the heater without the function of a properly adjusted pressure switch HIGHLIMITS Theheateris equipped with two automatic high limits Set to operate at 135 F and 140 F NOTE erratic high limit is often characteristic of internal heat exchanger problem i e scale build up U G operation Refer to troubleshooting sections Fig 9275 HIGH LIMIT REMOVAL 1 Shut off main electrical power switch to heater 2 Remove inspection panels 3 Drain heater 4 Remove defective high limit and replace with a new high limit 5 Reverse above procedure to re install PILOT SAFETY The heater employs a pilot safety which closes the main gas valve within 8 10ths of asecond whenever the pilot flame is interrupted Pilot flame is automatically lit when the device is powered Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit BURNERDRAWER REMOVAL 1 Shut off main electrical power switch to heater 2 Shut off gas upstream of heater 3 Remove front door 4 Disconnect gas line from gas va
32. nt women should stick to the 100 F 38 maximum rule 4 Before entering the spa or hot tub users should check the water temperature with an accurate thermometer spa or hot tub thermostats may err in regulating water temperatures by as much as 4 F 2 2 5 Persons with medical history of heat disease circulatory problems diabetes or blood pressure problems should obtain physician s advice before using pools or hot tubs 6 Persons taking medications which induce drowsi ness such as tranquilizers antihistamines or anti coagulants should not use spas or hot tubs SECTION 3 MAINTENANCE AND CARE PROCEDURES To be followed one month after start up and then semiannually 1 Inspect top of heater and drafthood for soot a sticky black substance around finned tubes and V baffles and open flue gas passageways CAUTION Soot may be combustible Wet sooted surfaces completely prior to cleaning Do not use steel wire brush 2 Cleanmain burners and pilotburner of dust and lint 3 Inspect and operate all controls gas valve and pressure relief valve 4 Make visual check of the burner and pilot flame Flame pattern on the main burner and pilot is indicated in the previous illustration Yellow flame means restriction of the air openings Lifting or blowing flame indicates high gas pressure Low flame means low gas pressure Should this occur shut the heater off and contact your gas supplier or qualified service
33. or any desired pool or spa temperature TEMPERATURE MECHANICAL THERMOSTAT Fig 8060 1 19 PRESSURE SWITCH TYPICAL COMFORTABLE SPATEMPERATURE RANGE N PA F KNOBSTOP RING SET SCREW TYPICAL COMFORTABLE POOL TEMPERATURE RANGE Fig 8104 0 KNOBSTOP ADJUSTMENT If desired a higher setting of the thermostat can be obtained by adjusting the knobstop ring on the dial plate Loosen the set screw adjust the knobstop for the higher desired temperature setting and retighten the set screw PRESSURE SWITCH The pressure switch or heater actuator insures that the heater operates only when the filter pump is in operation It is factory set at 1 75 PSI for deck level installations When the heater is located below the level of the spa or pool it may be necessary to reset the pressure switch to compensate for the no flow static head If itis necessary to resetthe pressure switch we recommend the following procedure PRESSURE SWITCH ADJUSTMENT 1 With pump and heater on turn adjustment knob clockwise until a click is heard from the gas valve 2 Turnadjustment knob counter clockwise 1 4 turn 3 Turn pump off and on several times Heater should shut off immediately If it does not repeat steps above until proper adjustment is made ADJUSTMENT KNOB Fig 8069 1 PRESSURE SWITCH ADJUSTMENT RANGE Fig 8152 0 NOTE If heater is installed outside of the limits shown a flow switch
34. ound the outer jacket indicates a need for cleaning 1 Remove top and flue collector from cabinet 2 Remove V baffles from heat exchanger 3 Remove burner drawer See burner tray removal 4 Take garden hose and wash heat exchanger making sure soot is removed from between fins Avoid excessive water against refractory 5 Reassemble When heateris fired some steam will form from wet refractory This is normal 22 NOTE In extreme cases it may be necessary to remove the heat exchanger completely for cleaning The simplest method is steam cleaning at the local car wash DO NOT WIREBRUSH COMBUSTION CHAMBER REMOVAL Toremove combustion chamber you mustfirst have removed the heat exchanger Unbolt metal combination chamber retainer from top and remove combustion chamber panels individually REFACTORY PANELS TOP VIEW CONTROLIMMERSION WELL REPLACEMENT Remove top sensing bulb and clip Collapse welltube atthe open end with a chisel push through into header and remove the header Insert a new well and roll into place If a roller is not available solder IMMERSION WELL Fig 8126 0 UNITHERM GOVERNOR U G REPLACEMENT 1 Shutwater gas and electricity off close valves and relieve pressure 2 Drain heat exchanger 3 Loosen and remove 2 bolts that secure U G Assembly to header 4 Remove U G Assembly with gasket 5 Reverse above procedure to re install HEADER V7 UNITHERM
35. pped with j an ignition module that shuts off pilot gas if pilot fails to light To reset interrupt power to heater AMAA AMAA AMAA AA AAA AA MA AM AA MAA MA AAA AA AAA AMAA AMMA AAA ESSE ESSE EE EEE EE EE Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START NOTE Before troubleshooting familiarize yourself with the startup and checkout TURN GAS SUPPLY OFF procedure TURN THERMOSTAT CONTROLLER TO CALL Check line voltage power low voltage transformer limit controller thermostat control FORHEAT NOI ler and wiring POWER TO MODULE 24V NOMINAL YES Pull ignition lead and check spark at module SPARK ACROSS NO IGNITER SENSOR GAP Spark Okav YES YES Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or buckling Take protective action to shield cable and boot from excessive temperatures TURNGASSUPPLYON Check that all manual gas valves are open supply tubing and pressures are good and pilot burner orifice is not blocked YES Check electrical connections between module and pilot operator on gas control Check for 24 Vac across PV MV PV terminals on module If voltage is okay replace gas control if not replace module NOTE If S8600H goes into lockout reset system Lockout is used on L P G models SPARK STOPS WHEN
36. r and chisel adjacent to both tube sheets leaving studs in the tube sheets Then proceed to collapse studs in the tube sheets with a chisel or screwdriver Use caution not to cut into the tube sheet Replacement tubes will have the fins stripped off longer on one end The long end is inserted into the opening of the tube sheet first then the short end is fitted through the opposite tube sheet Ifthe tube ends become dented or bent straighten atleast 4 inches back from the tube and by means of a tapered punch Insert tube roller into tube opening up to stop against tube then push center rod in until rolleristight Be careful to keep replacement tube squared up 1 8 outside each tube sheet Aloose tube will sometimes pull toward the roller Attach drill motor to tube roller holding it straight andlevel Proceedto expand tube until the tool begins to grab Atthis point 1 2 to 1 should be expose on the tool shank Reverse drill motor or wrench out by hand Care should be exercised to avoid applying excessive torque during rolling operation and to avoid thinning out any part of the tube wall excessively over 015 Use same procedure at the opposite end of the tube Apply line pressure test and re roll if necessary before reassembly of the heater DESOOTING PROCEDURE CAUTION SOOT IS COMBUSTIBLE EXERCISE EXTREME CARE Soot will clog areas between fins and cause eventual tube failure Any sign of soot atthe base of the burners or ar
37. r or gas supplier WATER PRESSURE SWITCH A water pressure switch is provided in the heater to shut off the burners in the event that water supply to the heater is interrupted It is very important to verify that the switch electrically opens and shuts off the gas valve when water flow to the heater is interrupted Otherwise rapid and severe damage will likely occur to the heater The water pressure switch should be checked and adjusted for proper operation by qualified service person at the time of installation and periodically checked thereafter Refer to pressure switch servicing instruc tion in Section 4 of this manual WARNING Operation ofthe heater without water circu lation will cause rapid and severe damage to the heater SECTION 2 CAUTION Elevated water temperature can be hazardous and the U S consumer Product Safety Commission recom mends the following guidelines 1 Spa or hot tub water temperatures should never exceed 104 F 40 Atemperature of 100 F 38 is considered safe for a healthy adult Special caution is suggested for young children 2 Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning 3 Pregnant Women Beware Soaking in water over 102 F 39 can cause fetal damage during the first three months of pregnancy resulting in the birth of a braindamaged or deformed child Preg na
38. r small brush CAUTION DO NOT enlarge hole in pilot orifice 6 Reverse above procedure to re install aa HEAT EXCHANGER REMOVAL 1 Shutwater gas and electricity off close valves and relieve pressure remove relief valve Remove side inspections panels 2 Removetop holding screws 3 Remove draft diverter lift and remove top and flue collector Remove inspection panels 4 Loosen bolts and disconnect flange nuts on inlet outlet header loosen union s at gas pipe and slide boiler away from piping until stud clear the header o Remove heat exchanger corner brackets 6 Remove combustion chamber slips at the four corners of the heat exchanger 7 Lift heat exchanger straight up using caution not to damage refractory 8 Reverse above procedure to reinstall TUBECLEANING PROCEDURE Establish a regular inspection schedule frequency depending on local water condition and severity of service Do not let the tubes clog up solidly Clean out deposits over 1 16 in thickness The heater may be cleaned from the right side without breaking pipe connections If is preferable however to remove both headers for better visibility through the tubes and to be sure the ground up lime dust does not get into the system Note that you do notremove the top panel orthe heat exchanger generally After reaming mount the wire brush in place of the auger and clean out debris remaining in the tubes Another method is to remove the heat exc
39. result when the pump is not running i e overnight Chlorinators mustfeed downstream ofthe heater and haveananti siphoning device to prevent chemical back up into the heater when the pump is shut off NOTE High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid corrosion to the heat exchanger in the heaters Such damage is not covered under the warranty UNITHERM GOVERNOR OPERATION The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105 F to 115 F despite continually changing flow rated from the filter and changing pool temperatures This narrow range is needed to prevent damaging condensation on the burn ers which will occur if the heater runs for any length of time below 100 F It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures EXTERNAL AUXILIARY BYPASS VALVE Where Required An auxiliary bypass valve should be used when flow rates exceed 115 GPM usually a high performance pump size larger than two HP will exceed this flow rate This valve is required to complement the function of the automatic bypass valve particularly when starting the heater in winter or early spring when the spa or pool temperature is down below 55 F It also serves to eliminate needless pressure drop through the heat and accompanying redu
40. rom outdoors When air is supplied directly from outside of build ing each opening shall valve a minimum net free square inches as noted Model Square Inches 624 157 724 182 824 207 VENTING CONNECTIONS VENT TERMINAL Outdoor STEP 1 Lower outdoor Stackless top onto unit Position top so it is centered on unit from side to side and front to rear AN M Fig 8166 STEP 2 Tighten the 4 screws Shown below until they come in contactwith the unitjackettop then evenly tighten all 4 screws to secure to unit Fig 8233 VENT TERMINAL Indoor Locate and assemble as shown below Secure with screws supplied in envelope in carton Fig 8167 VENT PIPING WARNING Indoor heaters require a draft hood that must be connected to a vent pipe and properly vented to the outside Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning Vent piping the same size or large than the draft hood outlet is recommended however when the total vent height is at least ten 10 feet draft hood relief opening to vent terminal the vent pipe size may be reduced as specified in Chapter 10 ofthe latest edition ofthe National Fuel Gas Code ANSI Z 223 1 As much as possible avoid long horizontal runs of vent pipe and too many elbows If installation requires horizontal non vertical runs the vent pipe must have a minimum of 1 4 inch per foot rise and should be supported at not less than fiv
41. ter 110 or higher If no movement replace Refer to installation instructions Follow recommended installation instructions Clean burners Adjust gas pressure Clean pilot Replace pilot Adjust gas pressure Clean burners Replace refractory panels Determine cause of sooting amp correct Heat rise hr Heater output Pool gallonage x 8 33 or refer to heater sizing chart This does not take into account heat loss due to weather Reset time clock Clean filter Refer to installation instructions Liming Bypassing too much water Inspect bypass for movement if no movement replace U G notfunctioning Replace if no movement when heated Leaking at well Q Replace well and maintain water Leaking at heat exchanger chemistry properly Gasket brittle and leaking overheated eri TE Replace heat exchanger and maintain chemistry properly Heater running after pump shuts off See pressure switch adjustment Refractory damage Replace refractory Sooted heater Determine cause of sooting and correct 24 MV MV MV MV MV AV AV AV AV AV AV AV AV 11 1 1 WARNING HIGH VOLTAGE For qualified Technicians ONLY gt vr ELECTRICAL NOTE Some heaters may be equi
42. the pH drops below 7 2 the heater will be severely damaged This will result in corrosion of the heat exchanger Heat exchanger damage resulting from chemical imbalance is not covered by the warranty When heaters installed outdoors in freezing climate areas are to be shut down for the winter observe the following step by step procedure 1 Turnoffgas valve manual gas valve and electrical supply to the heater 2 Opendrain cock located on the inlet outlet header under water pipes 3 Disconnect compression fittings from the pressure switch and return header that connect to the 1 4 copper tube and allow the tube to drain PART TWO INSTALLATION SERVICE INSTRUCTIONS SECTION 1 RECEIVING EQUIPMENT Onreceiptof your equipmentitis suggested that you visually check for external damage to the carton If the carton is damaged a note should be made on the Bill of Lading when signing for equipment Remove the heater from the carton and if itis damaged report the damage to the carrier immediately On occasion we ship some items loose Be sure that you receive the number of packages indicated on the Bill of Lading When ordering parts you must specify model and serial number of heater When ordering under warranty conditions you must also specify date of installation Raypak recommends that this manual be reviewed thoroughly before installing your Raypak pool spa heater If there are any questions that this manual does not answer
43. y lasts or for the exclusion of incidental or consequential damages So the above limitation or exclusion may not apply to you This Limited Warranty gives you specific legal rights You may also have other rights which may vary from state to state We suggest that you complete the information below and retain this certificate in the event warranty service is needed Reasonable proof of the effective date of the warranty date of installation must be presented otherwise the effective date will be based on the rate of manufacture plus thirty 30 days E T w T B W P lI gt Registered Quality Management System www raypak com RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 FAX 800 872 9725 Litho in U S A
44. y part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag completely filled in with the heater serial number model number etc and shipped to the Com pany freight prepaid 26 If determined defective by the Company and within warranty the part will be returned in kind or equal substitution freight collect Credit will not be issued Raypak Inc 31111 Agoura Road Westlake Village CA 91361 this page is empty Fy 8283535 Fig 9293 He Fig 9294 PILOT ASSEMBLY ELECTRONIC IGNITION PILOT ASSEMBLY STANDING PILOT 28 emis ge ao ergo Saa Laval Burner Tray wa Bumers Sea Burner Spacer Hold Dean Bracket Kit Burar Burner Orfice Nar Sea Level TUE Lima 135 F High Limit 140 F Thermostat Control Manual Hi Lima Control Cal Code Combinalion Valve Nar MV Comibina amp oan Valve Pro Mv Valve Mar Remate Sp Combination Valve Pro Remote Spa Combination Valve Nat 110 Camrbralion Valve Pro 10 Pitot Gas Valve Nat ID Only Pilot Regulator Mat IC Crib Manual Valve Nat ID n Ii Ont ven Exchange ney Complete Header J Bax Mato Complete Transformer 120 2424 V O01 BS iF DDTBS3F QOO18B4F 04876F 301210 2D 301210 24 301210 31 O02466F 00249 1F 00316 1F 002 37 SF ODTETEF 00105 1F BUDUBSB DD2475F 500834 11
45. ystem at test pressures in excess of 1 2 Psig 3 45 KPA Dissipate test pressure inthe gas supply line before reconnecting the heater and its manual shut off valve to gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVERPRESSURED 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 NOTE Do not use teflon tape on gas line pipe thread A flexible sealant is recommended A minimum of 7 W C and a maximum of 14 W C upstream pressure under load and no load conditions must be provided for natural gas or a minimum of 12 W C and a maximum of 14 for propane gas 11 GAS PRESSURE REGULATOR Thegas pressure regulator is preset and sealed at 4 W C for natural gas and 11 W C for propane gas Between the gas valve and the burners is a 1 8 pipe plug The pressure at this point taken with a manometer should be about 3 7 W C natural gas and 10 5 W C propane gas If an adjustment is needed remove seal and turn adjustment screw clockwise to in crease pressure or counter clockwise to decrease pressure GAS PRESSURE MANOMETER TEST UPSTREAM MANUAL SHUT OFF VALVE GAS PRESSURE TEST AT GAS VALVE GAS PRESSURE TEST AT HEATER Fig 8149 0 PIPE SIZING FOR GAS CONNECTIONS When local codes permit the use of less than four feet high temperature piping or two e
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