Raypak 408, 268 Installation And Operation Manual

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Page 1

INSTALLATION AND OPERATION MANUAL

Gas-Fired Pool and Spa Heater

Atmospheric Models 268 and 408

WARNING: If these instructions are not followed exactly, a re or explosion may result causing property

damage, personal injury or death.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference.

Catalog No. 6000.64B Eective: 07-15-18 Replaces: 11-15-17 P/N 241452 Rev. 3

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Revision 3 reects the following changes:

Manual updated to the new format style. Removed California Proposition 65 warning.

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CONTENTS

1. WARNINGS ................................................................... 4

1.1. Pay Attention to These Terms ..............................4

2. WATER CHEMISTRY ................................................... 5

2.1. Automatic Chlorinators and Chemical

Feeders .......................................................................5

3. OPERATING INSTRUCTIONS .................................... 6

3.1. Start-Up Procedures ............................................... 6

3.2. Before Start-Up .........................................................6

3.3. Visual inspection ......................................................6

3.4. Caution ........................................................................6

3.5. Maintenance .............................................................8

3.6. Cold Weather Operation ........................................8

4. BEFORE INSTALLATION ............................................ 9

4.1. Receiving equipment .............................................. 9

4.2. Rating and certications .......................................9

4.3. Ambient Temperature Rating of Heater

Components .............................................................. 9

4.4. Atmospheric heaters ..............................................9

5. INSTALLATION ............................................................. 9

5.1. Installation Codes .................................................... 9

5.2. Clearances .............................................................. 10

5.3. Outdoor Heater Installation ............................... 11

5.4. Combustion and Ventilation Air ....................... 12

5.5. Vent Piping .............................................................. 15

5.6. Gas Supply Connections .................................... 16

5.7. Water Connection Installation .......................... 18

5.8. Unitherm Governor Operation .......................... 18

5.9. Internal Automatic Bypass Valve ..................... 18

5.10. External Auxiliary Bypass Valve ........................ 19

5.11. Auxiliary Bypass Valve Adjustment ................. 19

5.12. Pressure Relief Valve Installation .................... 19

5.13. Plumbing.................................................................. 19

6. ELECTRICAL WIRING ...............................................20

6.1. Electrical Power Draw ......................................... 20

6.2. Transformer Wiring .............................................. 21

7. WIRING DIAGRAM ....................................................23

8. CONTROLS..................................................................24

8.1. Control Panel Removal ........................................ 24

8.2. Control Adjustments ............................................ 24

8.3. Operation ................................................................. 24

8.4. Status and Diagnostics ....................................... 26

8.5. Remote Control Wiring ........................................ 28

9. REPLACEMENT PARTS ............................................32

10. TROUBLESHOOTING ...............................................33

10.1. Mechanical ............................................................. 33

10.2. Control Logic - Flow Chart ................................. 34

11. ILLUSTRATED PARTS LIST......................................35

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1. WARNINGS

1.1. Pay Attention to These Terms

DANGER

WARNING

CAUTION

NOTE

DANGER: Failure to install the drafthood on indoor

installation and properly vent the heater to the outdoors as outlined in the venting section of this manual can result in unsafe operation of the heater. To avoid the risk of re, explosion, or asphyxiation from carbon monoxide, never operate this heater unless it is properly vented and has an adequate air supply for proper operation. Be sure to inspect the vent system for proper installation at initial start-up, and at least annually thereafter. Refer to the venting section of this manual for more information regarding vent system inspections.

WARNING: To minimize the possibility of improper

operation, serious personal injury, re, or damage to the

heater:

• Always keep the area around the heater free of

combustible materials, gasoline, and other ammable liquids and vapors.

• Heater should never be covered or have any blockage to the ow of fresh air to the heater.

WARNING: This unit contains refractory ceramic

ber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high temperatures [>2192°F (1200°C)], the RCF can transform into crystalline silica (cristabolite). The International Agency for Research on Cancer (IARC) has classied the inhalation of crystalline silica (cristabolite) as carcinogenic to humans.

When removing the burners or heat exchangers, take precautions to avoid creating airborne dust and avoid inhaling airborne bers. When cleaning spills, use wet sweeping or High Eciency Particulate Air (HEPA) ltered vacuum to minimize airborne dust. Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment including gloves, safety glasses with side shields, and appropriate NIOSH certied respiratory protection, to avoid inhalation of airborne dust and airborne ber particles.

Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.

CAUTION used without the warning alert symbol indicates a potentially hazardous condition which could cause minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

WARNING: Improper installation, adjustment,

alteration, service, or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualied installer, service agency, or the gas supplier.

WARNING: Gasoline, as well as other ammable

materials and liquids (adhesives, solvents, etc.), and the vapors they produce, are extremely dangerous. Do not handle, use, or store gasoline or other ammable or combustible materials in the vicinity of a heater.

WARNING: Both natural gas and propane have an

odorant added to aid in detecting a gas leak. Some people may not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar with the smell of natural gas or propane, ask your local gas supplier.

Other conditions, such as “odorant fade,” which causes the odorant to diminish in intensity, can also hide,

camouage, or otherwise make detecting a gas leak by smell more dicult.

WARNING: UL-recognized fuel gas detectors are

recommended in all enclosed propane and natural gas applications wherein there is a potential for an explosive mixture of fuel gas to accumulate and their installation should be in accordance with the detector manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

WARNING: Do not install within 3 feet (0.9 m) of a heat

pump or an outdoor condensing unit. Strong air intake from this type of equipment can disturb the combustion process and cause damage or personal injury.

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 internal rusting or damage electrical components, and void the warranty.

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2. WATER CHEMISTRY

NOTE: Corrosive water voids all warranties.

Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water chemistry according to Table A. If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchanger tubes, reducing heater eciency and damaging the heater. If the pH drops below

7.2, this will cause corrosion of the heat exchanger and severely damage the heater. Heat exchanger damage

resulting from chemical imbalance is not covered by the warranty.

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 balanced water.

CAUTION: Free chlorine must not exceed 5 ppm which

can damage the heater and is not covered under warranty.

• 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.

• Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier for the correct levels for your water.

2.1. Automatic Chlorinators

and Chemical Feeders

All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place sanitizing chemicals in the skimmer. High chemical concentrations will result when the pump is not running (e.g. overnight).

Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the heater when the pump is shut o.

See plumbing diagrams on Figure 29 and Figure 30.

• Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is balanced.

Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool and Spa Types

Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)

pH 7.3-7.4 7.3-7.4 7.6-7.8

Total Alkalinity (ppm) 120-150 120-150 80-120

Calcium Hardness (ppm) 200-300 150-200 200-400

Salt (ppm) 4500 Maximum 4500 Maximum 4500 Maximum

Free Chlorine (ppm)* 2-3 2-3 2-3

Total Dissolved Solids (ppm) 3000 Maximum** 3000 Maximum** 3000 Maximum**

*Free Chlorine MUST NOT EXCEED 5 ppm! **In saltwater chlorinated pools, the total TDS can be as high as 6000 ppm.

Table A. Pool Water Chemistry

NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause rapid corrosion to the heat exchanger. Such damage is not covered under the warranty.

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3. OPERATING INSTRUCTIONS

3.3. Visual inspection

3.1. Start-Up Procedures

Your pool/spa heater has been designed for years of safe and reliable pool/spa water heating. It is available with electronic ignition. This manual provides installation, operation, maintenance, and service information for these heaters.

Temp Adjust Buttons

Mode Button

TEMP

LCD Display

Figure 1. Heater Control Toggle Switch

MODE

OFF

If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the heater contains the control center that allows you to turn the heater On or O and adjust the temperature settings for the pool or spa. The temperature range is factory set from 65°F (18°C) to 104°F (40°C). See Figure 1 for location of toggle switch to turn the heater On and O.

See Section 8 for additional details about the use of the controls in the Control Adjustments subsection.

3.2. Before Start-Up

3.2.1. Burners

Clean main burners and air louvers of dust, lint and debris. Keep heater area clear and free from combustibles, ammable liquids and chemicals. Do not obstruct the ow of combustion and ventilation air.

3.2.2. Water

Water must be owing through the heater during operation. Ensure that the system is lled with water and that the pump is operating.

3.3.1. Atmospheric Heaters

With the heater on, remove the door and make a visual check of the pilot and burner. The ame should be blue with a well-dened pattern.

A yellow or “oating” ame indicates restricted air openings or incorrect orice size. Should this occur, shut the heater o and contact your installer or gas supplier.

WARNING: Operation of the heater without water

circulation will cause rapid and severe damage to the heater, and will void the warranty.

3.4. Caution

Elevated water temperature can be hazardous. The U.S. Consumer Product Safety Commission has these guidelines:

1. Spa water temperatures should never exceed 104°F (40°C). A temperature of 100°F (38°C) 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°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 thermometer; spa or hot tub thermostats may err in regulating water temperatures by as much as 4°F (2.2°C).

5. Persons with a medical history of heart disease, circulatory problems, diabetes, or blood pressure problems should obtain a physician’s advice before using pools or hot tubs.

6. Persons taking medications which induce drowsiness, such as tranquilizers, antihistamines, or anticoagulants, should not use spas or hot tubs.

3.2.3. After Start-Up

Feel the 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 o, turn o the manual gas control to the appliance.

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CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in conned

areas, extra care should be exercised when lighting propane heaters.

OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES

ELECTRONIC IGNITION SYSTEM

(AUTOMATICALLY LIGHTED PILOT)

A. This appliance is equipped with an ignition

device which automatically lights the pilot. Do not try to light the pilot by hand.

B. BEFORE OPERATING, smell all around the

appliance area for gas. Be sure to smell near

the oor because some gas is heavier than air and will settle on the oor.

WHAT TO DO IF YOU SMELL GAS: *Do not try to light any appliance. *Do not touch any electric switch; do not use

any phone in your building.

*Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electrical power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

5. Remove heater door panel.

6. Turn gas control knob clockwise to “Off”. (Honeywell VR 8300 and Robertshaw

7000)

7. Wait 5 minutes to clear out any gas. If you then smell gas, STOP! Follow “B in the safety information above. If you don’t smell gas, go to the next step.

8. Turn gas control knob counter-clockwise to “On”. (Honeywell VR 8300 and Robertshaw

7000)

9. Replace heater door panel.

10. Turn on all electrical power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

*If you cannot reach your gas supplier, call the

re department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will not push in or turn by hand, do not try to

repair it. Call a qualied service technician. Force or attempted repair may result in a re

or explosion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualied

service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

HONEYWELL VR 8300 GAS VALVE IID

GAS

INLET

ROBERTSHAW 7000 GAS VALVE IID

1. Set the thermostat at the lowest setting.

2. Turn off all the electrical power to the appliance if service is to be performed.

3. Remove heater door panel.

SHUT-OFF PROCEDURES

4. For Honeywell VR 8300 and Robertshaw

7000 gas valve.

Turn gas control knob clockwise

to “Off”. Make sure knob rest against stop.

5. Replace heater door panel.

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3.5. Maintenance

DRAIN

WARNING: Check the heater for possible rodent nests

after long periods of non-use.

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. Any visible soot should be cleaned for proper operation.

CAUTION: Soot may be combustible. Wet sooted

surfaces completely prior to cleaning. Do not use steel wire brush.

2. Clean main burners and pilot burner of dust and lint.

3. Inspect and operate all controls, gas valve and pressure relief valve (if equipped).

4. Make visual check of the burner and pilot flames. Yellow flame means restriction of the air openings. Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure. Should the latter occur, shut the heater off and contact your gas supplier or qualified service agency.

5. On indoor heaters, clean room intake openings to ensure 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 area around heater clear and free from combustible materials, gasoline and other flammable and corrosive vapors and liquids.

If Heater Will Not Fire:

If you have no electrical power, it may be that your “circuit breaker” has tripped. Try re-setting it.

If you have electrical power but the heater will not re check the following or see Troubleshooting section:

1. The time clock must be in the “ON” position.

2. Your pump strainer basket may be full. If so remove debris.

3. Your filter may be dirty. If so, backwash or clean filter. (To tell if your filter is dirty, look to see if the filter pressure will be higher than usual).

4. The pump may have lost its prime and be running dry. Check the pressure on the filter. If there is no pressure; then you are not moving water (or your gauge is broken). Try to get the pump to run at its normal flow rate.

5. Check flow switch operation and paddles (“F” paddle on 268 or “A” paddle on 408).

3.6. Cold Weather Operation

3.6.1. Important Freeze Information

MODERATE CLIMATE: Heater operation can continue

during short-term cold spells. When temperatures are between 0° (-17°C) and 32°F (0°C), ow (continuous pump operation) must be maintained.

CAUTION: Do not use the heater to maintain water

temperatures just above freezing or for freeze protection. When heater is used during freezing weather, care must be taken to avoid freeze-ups. Continuous pump operation is a must. Additional protection may be required. The heater is not warranted against freeze-ups.

COLD CLIMATE: Prolonged operation with water

temperatures below 50°F (10°C) is not recommended. When starting the heater with water temperatures below 50°F (10°C), operate the heater continuously until higher temperatures are reached. Operating the heater for prolonged periods with pool water below 50°F (10°C) can seriously damage the heater, and is not covered by the warranty. For cold climate areas, please follow the winterizing procedures listed.

3.6.2. Winterizing the Pool and Spa

Heater

Heaters installed outdoors in freezing climate areas may be shut down for the winter. Observe the following procedure for winterizing the heater:

1. Turn off gas valve, manual gas valve, and electrical supply to the heater.

2. Open drain valve located on the inlet/outlet header, (under water pipes). Remove the heat exchanger inspection panel on the side opposite water piping to gain access to the drain plug on the return header. Open drain plug on return header.

Figure 2. Return Header Drain Valve

Page 9

4. BEFORE INSTALLATION

Rating Plate

4.1. Receiving equipment

The manufacturer recommends that this manual be reviewed thoroughly before installing the pool/spa heater. If there are any questions that this manual does not answer, please contact the factory or your local representative.

On receipt of your equipment it is 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 the equipment. Remove the heater from the carton. If it is damaged, report the damage to the carrier immediately. Save the carton.

These items are shipped inside a box in the carton with the heater:

1. “Pagoda” top

2. In/Out flanges (2)

3. 2" CPVC female tailpiece, ring nut and O-ring

4. 2" flange gaskets (2)

5. Flange bolts (4)

6. Pressure relief valve

7. 2" CPVC adapter

8. Plastic pipe finish flange for gas line

9. Bonding lug with mounting screw

10. 2" CPVC manifold adapter

11. Prewired 1" flow switch with outdoor cover

12. Temperature and pressure gauge

The Model and Serial No. can also be found inside the bezel above the display

Alternate

location

Be sure that you receive the number of packages indicated on the Bill of Lading.

When ordering parts, you must specify the model and serial numbers of the heater. See below for location of serial number. When ordering under warranty conditions, you must also specify date of installation.

4.2. Rating and certications

These heaters are design-certied and tested under the latest requirements of the ANSI Z21.56 / CSA 4.7 Standard for Gas-Fired Pool Heaters. All heaters can be used either indoor or outdoors. The appropriate top designated for each type of use is required. If necessary, the top can be changed at a later date to change from outdoor to indoor or vice versa.

All units have heat exchangers which are ASME-certied (BPV Section IV part HLW) and are registered with National Board.

4.3. Ambient Temperature Rating of Heater Components

Electronic Ignition Heater* -32°F to + 175°F (-36°C to 79°C)

*Requires 120 or 240VAC Power Supply

4.4. Atmospheric heaters

Rated inputs are suitable for up to 2,000 ft (610 m) elevation. For elevations above 2,000 ft (610 m), reduce input 4% for each 1,000 ft (305 m) above sea level, as high elevation reduces combustion performance.

5. INSTALLATION

5.1. Installation Codes

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/NFPA54 and National Electrical Code, ANSI/NFPA 70, and for Canada, the latest edition of CAN/CSA-B149 Installation Codes, and Canadian Electrical Code, CSA C22.1 Part 1 and Part2.

Model and Serial No. located on Rating Plate

Figure 3. Rating Plate Location

Page 10

5.2. Clearances

5.2.1. All Heaters

For indoor and outdoors clearances from combustible surfaces, see the chart below.

Location Indoor Installation

Top * 30" (762 mm) Drafthood

Front Alcove (Open)

Vent 6" (152 mm)

Floor ** 0"

Back 6" (152 mm)

Right Side 12" (305 mm) Water Side

Left Side 6" (152 mm) Opposite Water Side

Location Outdoor Installation

Top * Unobstructed (Outdoor Stack)

Top *** 36" (76 mm) (Stackless Top)

Right Side 12" (305 mm) Water Side

Left Side 6" (152 mm)

Floor 0"

Back 6" (152 mm)

* Clearance from top of vent terminal ** Do not install on carpeting *** Clearance from top of heater

Table B. Minimum Clearances from Combustible Installations

4' (1.2 m)

Minimum

4' (1.2 m) Minimum

3' (0.9 m) Minimum

10' (3 m) Minimum

Forced Air Inlet

Figure 4. Minimum Distances to Building Openings from

Where Flue Products Exit the Boiler

1' (0.3 m) Minimum

Description Location

Distance

in. (mm)

Back 9 (229)

a. 3-1/2" (89 mm) thick

masonry walls without ventilated air space

Right 9 (229) Left 9 (229) Vent 5 (127) Indoor Top 39 (991) Outdoor Top Unobstructed Back 6 (152)

b. 1/2" (13 mm)insulation

board over 1" (25 mm) glass ber or mineral wool batts

Right 6 (152) Left 6 (152) Vent 3 (76) Indoor Top 30 (762) Outdoor Top Unobstructed

c. 0.024 sheet metal over

1" (25 mm) glass ber or mineral wool batts reinforced with wire on rear face with ventilated air space

Back 4 (102) Right 4 (102) Left 4 (102) Vent 3 (76) Indoor Top 24 (610) Outdoor Top Unobstructed Back 6 (152)

d. 3-1/2" (89 mm) thick

masonry wall with ventilated air space

Right 6 (152) Left 6 (152) Vent 6 (152) Indoor Top 39 (991) Outdoor Top Unobstructed Back 4 (102) Right 4 (102)

e. 0.024 sheet metal with

ventilated air space

Left 4 (102) Vent 2 (51) Indoor Top 24 (610) Outdoor Top Unobstructed Back 4 (102)

f. 1/2" (13 mm) thick

insulation board with ventilated air space

Right 4 (102) Left 4 (102) Vent 3 (76) Indoor Top 24 (610) Outdoor Top Unobstructed Back 4 (102)

g. 0.024 sheet metal with

ventilated air space over

0.024 sheet metal with ventilated air space.

Right 4 (102) Left 4 (102) Vent 3 (76) Indoor Top 24 (610) Outdoor Top Unobstructed

h. 1" (25 mm) glass ber

or mineral wool batts sandwiched between two sheets 0.024 sheet metal with ventilated air space

Derived from National Fuel Gas Code, Table 10.2.3

Back 4 (102) Right 4 (102) Left 4 (102) Vent 3 (76) Indoor Top 24 (610) Outdoor Top Unobstructed

Table C. Reduction of Clearances to Protected Surfaces

When installed according to the listed minimum clearances from combustible construction, the pool heater can still be serviced without removing permanent construction around the heater.

However for ease of servicing, we recommend a clearance of at least 24" (610 mm) in the front, and at least 18" (457 mm) on the water connection side.

Page 11

This will enable the heater to be serviced in its installed

PAGODA TOP

location, that is, without movement or removal of the heater. Clearances less than these (6" [152 mm] minimum), may require removal of the heater to service either the heat exchanger or the burner tray. In either case, the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater.

5.2.2. Flooring

This heater can be installed on combustible ooring. The combustible clearances listed can be reduced by protecting the exposed combustible surfaces as shown in

Table C.

5.3. Outdoor Heater Installation

These heaters are design-certied for outdoor installation, when equipped with the approved tops designated for outdoor use.

WARNING: The heater shall not be located in an area

For U.S. installations, the point from where the ue

products exit the heater must be a minimum of 4' (1.2m) below, 4' (1.2 m) horizontally from, or 1' (0.3 m) above any door, window or gravity inlet into any building. The top surface of the heater shall be at least 3' (0.9 m) above any forced air inlet, or intake ducts located within 10' (3 m) horizontally.

For installations in Canada, pool heaters shall not be installed with the top of the vent assembly within 10' (3 m) below, or to either side, of any opening into the building. Refer to the latest revisions of CAN/CSA-B149.

5.3.1. Pagoda Top Installation

1. Insert tabs into keyhole (4 places). See Figure 6, detail A.

2. Snap tabs into keyholes so as not to pull out. See Figure 6, detail B.

WARNING: Do not install within 3' (914 mm) of a heat

pump or an outdoor condensing unit. Strong air intake from this type of equipment can disturb the combustion process and cause damage or personal injury.

Figure 5. Heater with Outdoor Stackless Top

Heaters must not be installed under an overhang of less than three 3' (0.9 m) 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.

DETAIL A DETAIL B

OUTDOOR TOP

(SHIPPED LOOSE WITH HEATER)

Figure 6. Outdoor Top Installation

For installations in Florida and Texas, that must

comply with the Florida or Texas Building Code, follow the directions shown in Figure 9 for the installation of hurricane tie-down brackets for all models.

5.3.2. Indoor Heater Installation

The heater is also design-certied for indoor installation when equipped with the approved drafthood.

For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with an occupied area. Refer to the latest edition of CAN/ CSA-B149 for specic requirements. Locate heater as close as is practical to a chimney or gas vent. Heater must always be vented to the outside. See section "Vent Piping" on page 15 for details. Minimum allowable space is shown on the nameplate.

WARNING: Indoor heaters require a drafthood that

must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause re or fatal carbon monoxide poisoning.

Page 12

5.3.3. Outdoor and Indoor Stack

The outdoor and indoor stacks are optional equipment and do not come standard with the heater. Refer to installation instructions inside box for instructions on how to install outdoor/indoor stack.

Model Outdoor Stack Indoor Stack

268 009835 009839 408 009837 009841

Table D. Outdoor and Indoor Stack Kit Number

OUTDOOR STACK KIT

(1) Drafthood, painted

(1) Adapter plate

(3) Mounting brackets (clips)

(1) Top panel cover

(2) 1-foot sections of metal tape

(3) Screws

(1) Instructions

Clips

5.4. Combustion and Ventilation Air

5.4.1. Indoor Units Only

The heater must have both combustion and ventilation air. Minimum requirements for net free air supply openings are one opening that is 12" (305 mm) from the ceiling for ventilation, and one opening that is 12" (305 mm) from the oor for combustion air as outlined in the latest edition of the National Fuel Gas Code, ANSI Z223.1(Canada-CAN/ CSA-B149) and any local codes that may have jurisdiction.

All Air from Inside the Building:

Each opening shall have a minimum net free area as noted:

Model Square Inches Model Square Inches

268 266 408 399

Table E. Opening Minimum Net Free Requirements

All Air from Outdoors:

When air is supplied directly from outside the building, each opening shall have a minimum net free area as noted:

Model

Unrestricted

Opening

(sq. in.)

Typical Screened

or Louvered

Opening (sq. in.)

Typical Screened

and Louvered

Opening (sq. in.)

Figure 7. Outdoor Stack Kit Components

NOTE: The outdoor drafthood kit does not require any additional vent pipe for proper operation. This drafthood functions as the vent termination.

INDOOR STACK KIT

(1) Drafthood, unpainted

(1) Adapter plate

(3) Mounting brackets (clips)

(3) Screws

(1) Instructions

Clips

268 67 101 134

408 100 150 200

Table F. Opening Minimum Net Free Requirements

CAUTION: Combustion air must not be contaminated

by corrosive chemical fumes which can damage the heater and void the warranty.

Figure 8. Indoor Stack Kit Components

Page 13

FLORIDA AND TEXAS BUILDING CODES

WIND SPEED = 150 MPH, 3 SECOND GUST

Model B

268 23" (583 mm)

408 29" (735 mm)

2" x 6" x 1/8" Pallet Anchor Bracket (4 Total) (Kit# 011636)

EXPOSURE = C

268/408 ATMOSPHERIC

40"

(1 m)

28"

(709 mm)

3" (76 mm)

Min. Conc.

Pad by others

Min. Edge

Distance

(152 mm)

(1)–1/4" x 1-3/4" S.S. T apcon Bolt & Washer (Field Supplied) Ea. Pallet Anchor Bracket Use hole closest to unit (4 total)

1/4" x 1-3/4" S.S. Tapcon Bolt and Washer (Field Supplied) NOTE: Use hole closest to unit with washer overlapping edge of unit.

3" (76 mm) Min. Conc.

Pad by others

(1)–1/4" x 1-3/4" S.S. Tapcon Bolt & Washer (Field Supplied) Ea. Pallet Anchor Bracket Use hole closest to unit (4 total)

Min. Edge

Distance

(152 mm)

TOH

Figure 9. Florida And Texas Building Codes

Page 14

(709 mm)





FLUE

Amp Draw

120 Volt 240 Volt

4 2

10"

(253 mm)

INDOOR

DRAFTHOOD

(963 mm)

Heater

Model

BTUH

Input

(000)

38"

13-1/4"

(336 mm)

CONNECTION

GAS

(A)

Cabinet

Width

in. (mm)

(B)

Flue

Dia.

in.

(mm)

(C)

Indoor

Drafthood

in. (mm)

(D)

in. (mm)

28-5/8"

(725 mm)

(J)

Min.

in. (mm)

32-11/16"

(830 mm)

ELECTRICAL

CONNECTION

Gas

Conn.

Water

Conn.

3-3/8"

(85 mm)

28"

Shipping Weights - lbs (kg)

Standard

Heater

w/Stackless

ASME

Heater

w/Stackless

Top

6-5/8"

(167 mm)

40"

(1,016 mm)

ELECTRICAL

CONNECTION

Indoor

Draft-

hood

R268 266.0

R408 399.0

Designation for a heater using propane gas is “EP”; a heater using natural gas is “EN”.

Prex “B” is for brass (ASME) headers.

Sux “X” is for cupro-nickel tubing.

EXAMPLE: B-R408-EN-X = Brass headers, 408 model size, AFT, natural gas, cupro-nickel.

Reduce input 4% for each 1000 ft (305 m) above sea level when installed above 2000 ft (610 m) elevation.

For Canada, no de-rating is required for elevations up to 4500 ft (1,372 m)

*Note: For outdoor stack, use J dimension in the table above for appropriate size plus 6" (152 mm).

(584)

(737)

(178)

(229)

62 (1574)

64-9/16

(1640)

Figure 10. Heater Specication and Dimensions

11.5

(292)

14.5

(368)

(279)

12-1/8

(307)

3/4" 2"

210 (95)

249

(113)

229

(104)

268

(121)

16 (7)

21 (9)

Page 15

5.5. Vent Piping

WARNING: Indoor heaters require a drafthood that

must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause re or fatal carbon monoxide poisoning.

Vent piping the same size as the drafthood outlet is recommended, however, when the total vent height is at least 10 ft (drafthood relief opening to vent terminal), the vent pipe size may be reduced by no more than one (1) size as specied in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1 (Canada - CAN/CSA-B149). As much as possible, avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontal runs, the vent pipe must have a minimum of 1/4 in. per ft rise and should be supported at not more than ve foot intervals. Plumbers tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the ashing and extending above the roof more than ve feet should be securely guyed or braced to withstand snow and wind loads. We recommend use of insulated vent pipe spacers through the roofs and walls. Another option for installation that requires horizontal runs is using the D-2 power vent kit option.

Model 120 VAC P/N 240 VAC P/N

268 010744 009832

408 010745 009833

Table G. Power Vent Kit Part Number

For protection against rain or blockage by snow, the vent pipe must terminate 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 Z223.1 (Canada - CAN/CSA-B149).

The discharge opening must be a minimum of 2' (0.6 M) vertically from the roof surface and at least 2' (0.6 m) higher than any part of the building within 8' (2.4 m). Vent stack shall be at least 5' (1.5 m) in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4' (1.2 m) horizontally from, and in no case below, unless a 4' (1.2 m) horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.

The weight of the vent stack or chimney must not rest on heater drafthood. Support must be provided in compliance with applicable codes. The heater top and drafthood must be readily removable for maintenance and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible construction. This unit operates under venting Category I conditions, with natural draft.

Type “B” double-wall or equivalent vent pipe is recommended. However single-wall metal vent pipe may be used as specied in the latest edition of the National Flue Gas Code ANSI Z223.1 (Canada - CAN/CSA-B149).

8' (2.4 m) OR LESS

2' MIN

(610 mm)

VENT CAP

NOTE: The D-2 Power Vent operates with a positve vent static pressure and with a vent gas temperature that prevents excessive condensate production in the vent, and as such, is a CATEGORY III appliance. For more information consult the D-2 Power Vent manual

6000.57.1.

Figure 11. Optional Raypak D-2 Power Vent

The unit, when installed as directed, is capable of operating in applications such as through-the-wall venting and reduced horizontal and vertical vent pipe sizes in new and current installations. The unit is factory-wired for 240 VAC, with capability of rewiring for 120 VAC.

2' MIN

(610 mm)

5' MIN

(1.5 m)

VENT PIPE

DRAFT HOOD

HEATER

Figure 12. Venting Clearances

NOTE: With venting application of two or more heaters, contact the factory.

Page 16

5.5.1. Appliance Categories

HEATER JACKET

MANOMETER

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-positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category II – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

Category III – A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category IV – A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

5.6. Gas Supply Connections

5.6.1. Supply Pressure

CAUTION: Only sealant tape or a pipe compound rated

for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.

A minimum of 6 in. WC and a maximum of 14 in. WC upstream pressure under load and no-load conditions must be provided for natural gas. A minimum of 12 in. WC and a maximum of 14 in. WC are required for propane gas under load and no-load conditions.

5.6.2. Gas Pressure Regulator

The gas pressure regulator is preset at 4.0 in. WC throughout for natural gas, and 10.5 in. WC. for propane gas. The pressure at the gas valve, taken with a manometer, should be about 4.0 in. WC natural gas and 10.5 in. WC propane gas. If an adjustment is needed, remove seal and turn adjustment screw clockwise to increase pressure or counter-clockwise to decrease pressure.

GAS INLET

Figure 13. Gas Supply Plumbing

MANUAL SHUT-OFF VALVE

(Field supplied)

GAS VALVE

FINISH FLANGE

UNION

(Field supplied)

SEDIMENT TRAP

(Field supplied)

Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-o valve located outside the heater jacket. All gas piping should be tested after installation in accordance with local codes.

CAUTION: The heater and its manual shut-o valve

must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1/2 psi (3.45 kPa). Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut o valve to gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE 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 ame.

MANUAL

SHUT-OFF

VALV E

UNION

Figure 14. Manual Shut-O Valve Installation

5.6.3. Gas Pressure Adjustment Locations

Gas Pressure Adjustment

Figure 15. Robertshaw 7000 BDER (Heater Model 268)

Page 17

Gas Pressure Adjustment

Figure 16. Robertshaw 7000 DERHC (Heater Model 408)

Gas Pressure Adjustment

Model Pipe Size

Min. GPM

(lpm)

Max. GPM*

(lpm)

268 1-1/4"–1-1/2" - 2" 25 (95) 125 (473) 408 1-1/4"–1-1/2" - 2" 40 (151) 125 (473)

* When ow rates exceed maximum GPM (lpm) an external auxiliary bypass valve is required. See external bypass valve section for details.

Table I. Flow Rates

Figure 17. Honeywell VR8304 (Heater Models 268 and 408)

5.6.4. Pipe Sizing for Gas Connection

These capacities shown below based on using SCH 40 black iron pipe. For capacities using other materials, consult local code.

Input 3/4" 1" 1-1/4" 1-1/2"

Model

(KBTU) N P N P N P N P

268 266.0

408 399.0 *

Natural Gas 1000 BTU/FT3 0.60 specic Gravity @ 0.5 in. WC Pressure Drop Propane Gas 2500 BTU/FT * 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.

15 (5)35(11)50(15)

15 (5)20(6)55(17)95(29)

1.53 specic Gravity @ 0.5 in. WC Pressure Drop

Table H. Maximum Equivalent Pipe Length (ft/m)Flow

Rates

125 (38)

210 (64)

480

(146)

225 (69)

445

(136)

215 (66)

480

(146)

Figure 18. External Bypass Valve

Flow

GPM (lpm)

Pressure Drop (Ft of Head)

268 408

30 (114) 8.0

40 (151) 9.0 9.0

50 (189) 9.8 9.8

60 (227) 10.5 10.5

70 (265) 11.0 11.0

80 (302) 11.5 11.5

90 (341) 14.0 14.0

100 (378) 17.0 17.0

Table J. Heat Exchanger Pressure Drop

Page 18

5.7. Water Connection Installation

UG SPRING

Gather the loose items that were shipped with the heater.

Figure 19. Water Connection Components

The components should be assembled onto the inlet and outlet header of the unit as shown below.

The heater must be located so that any water leaks will not damage the structure of adjacent area. High temperature 2" plastic pipe (CPVC) may be threaded directly into the header anges. This is not the same as the Schedule 80 PVC pipe which is also gray. PVC may be used immediately after the supplied CPVC adapters.

DO NOT use petroleum-based assembly uids (such as petroleum jelly or lubricating oil). If assembly lube is required, use a silicon base such as AquaLube etc.

5.8. Unitherm Governor Operation

CAUTION: The patented Unitherm Governor is a

thermostatic mixing valve specically designed to maintain constant heater internal temperature between 105° (41°C) and 115°F (46°C) despite continually changing ow rates from the lter and changing pool temperatures. This narrow range is needed to prevent damaging condensation on the burners which will occur if the heater runs for any length of time below 100°F (38°C). It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures.

Figure 20. Water Connection Assembly

Once all components are in place and installed properly, the water connections will appear as shown below:

Figure 21. Water Connection Installation

GASKET (BEHIND UG)

UNITHERM

UG PLUG

Figure 22. Unitherm Governor Valve

GOVERNOR

5.9. Internal Automatic Bypass Valve

In addition to the Unitherm Governor, a built-in automatic bypass valve is provided in the in/out header. While the Unitherm Governor responds to the changes in water temperature in the heater, the internal bypass valve automatically responds to changes in water pressure in the piping system. Proper amount of water ow is maintained through the heater under varying pressures dictated by the conditions of the pump and lter.

Page 19

BYPASS VALVE

BYPASS SPRING

Figure 23. Internal Automatic Bypass Valve

BYPASS PLUG & SHAF

5.10. External Auxiliary Bypass Valve

Where Required - An auxiliary bypass valve should

be used when ow rates exceed 125 GPM (473 lpm). Usually a high-performance pump size larger than two horsepower will exceed this ow 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 below 50°F (10°C). It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the ow rate to the spa jets, etc.

FROM HEATER

FULL PORT

BALL VALVE

OR GLOBE

TO HEATER

VALVE

5.12. Pressure Relief Valve

Installation

To conform to local building codes, it may be necessary to install a pressure relief valve. A 3/4" pressure relief valve, having a capacity equal to the BTUH output of the model to be installed, is recommended for this heater. The maximum acceptable pressure relief valve setting is 125 psi.

PRV

Figure 25. Pressure Relief Valve

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 connection throughout its entire length and must pitch downward from the valve. No shut-o valve shall be installed between the relief valve and the drain line. Valve lever should be tripped at least once a year to ensure that waterways are clear.

TO POOL/SPA

BYPASS VALVE

Figure 24. Auxiliary Bypass Valve

5.11. Auxiliary Bypass Valve Adjustment

To set bypass - With clean lter, adjustment is made by

feeling the inlet and outlet pipes at the heater. Outlet pipes should be slightly warmer than inlet and comfortable to the touch. If pipe is hot, close bypass; if cold, open bypass.

FROM POOL/SPA

5.13. Plumbing

5.13.1. Water Connection

The heater requires water ow and positive pressure to re and operate properly. It must therefore be installed downstream of the discharge side of the lter pump. SeeFigure 29 and Figure 30.

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. The outlet of the heater is plumbed to the return line to the pool or spa. The pump, filter and heater are thus plumbed in series (Salt generators and chemical feeders must be down stream of the pool heater).

Page 20

Plumbing from the heater back to the pool or spa must

SWAY BRACE

not have any valves or restriction that could prevent ow when the pump is operating.

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 provides adequate heat to maintain set-point, the heater will not re. Be advised

that the control panel will then display sensed water

temperatures downstream of the primary heating system, rather than the temperature of the water exiting the pool.

Heater must be located so that any water leaks will not damage the structure of adjacent area.

6.1. Electrical Power Draw

CAUTION: Heater must be electrically grounded and

bonded. Bonding lug is provided loose with the heater. Install bonding lug on lower right or left side of jacket as necessary for bonding the heater. Mounting hole is provided on the jacket.

NOTE: Failure to ground the heater electrically could aect the heater’s electronics.

NOTE: See "Time Clock/Fireman’s Switch" on page 29 for further instructions if using a time clock/reman’s switch.

6. ELECTRICAL WIRING

NOTE: If it is necessary to replace any of the original

wiring, use 105°C wire or its equivalent, and/or 150°C wire or its equivalent, like the original wiring.

WARNING: Heaters are factory-wired for 240 VAC

power supply. DO NOT attempt to operate at 208 VAC.

The standard eld-wiring connection is on the right side of the heater.

To wire the heater from the left side, follow these steps:

1. Remove the two (2) screws that hold the front door to the heater. Remove and set aside door for better access to wiring.

2. Remove the four (4) screws that hold down the junction box to the sway brace.

3. Remove the transformer cover located on the far right by removing one (1) screw.

4. Remove the two (2) screws that hold down the transformer.

5. Remove the one (1) screw that holds down the ground wires.

6. Disconnect P6 connector from PC board.

7. Remove transformer from its current location and relocate it on the far left side of the heater.

8. Re-route all high-voltage wires and ground wires through the left jacket side of heater.

9. Re-install P6 connector, ground wires (SPG), transformer, junction box, front door, and plug right side with the left side’s grommet plug.

The Electronic Intermittent Ignition Device automatically lights the pilot and main burners upon a call for heat. The heater is supplied with a dual-voltage transformer for 120 VAC or 240 VAC input power hookup.

4 amps at 120VAC

2 amps at 240VAC

OPTION LOCATION LEFT SIDE FIELD WIRING

CONTROL BOX

(FACTORY MOUNTED

LOCATION)

NOTE: 7/8" diameter holes not utilized on jacket and control box can be used for reman switch, auxiliary control interface or power vent (D-2) wiring.

Figure 26. Heater Wiring Locations

Page 21

6.2. Transformer Wiring

RED

HOT

WHITE

6.2.1. 120 VAC Wiring

For 120 VAC 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 “Ret” 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 120 VAC operation.

BLACK

RETURN

SUPPLY

NEUTRAL

SIDE

GROUND

Figure 27. 120 VAC Wire Connection

6.2.2. 240 VAC Wiring

For 240 VAC input power to the unit, connect the black wire to the “L1” or hot leg of the power supply. Connect the red wire to the “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 240 VAC operation.

BLACK

WHITEWHITE

GREENGREEN

HEATER 4 WIRES

NOTE: If the transformer’s primary side is wired for 120 VAC and 240 VAC is applied, damage to the transformer and PC board may result. Such damages are not covered under manufacturer’s limited warranty.

Input power to the heater (120 or 240 VAC) can be supplied from the load (pump) side of time clock or directly from the GFCI power source. It is preferred that full-time power

be supplied to the heater from the GFCI power source, and that the heater be controlled by the reman’s switch connection or using a two or three-wire remote.

If using a switched GFCI power source, the heater could display false service indicators on the display panel if the pump is turned o.

WARNING: DO NOT attempt to operate the heater at

208 VAC.

BLACK

SUPPLY

HOT

RED RED

SIDE

Figure 28. 240 VAC Wire Connection

BLACK

HEATER

4 WIRES

GREENGREEN

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. (Canada - Canadian Electrical Code, CSA C22.1, Part 1 and Part 2.)

Page 22

THIS DIAGRAM IS RAYPAK’S RECOMMENDATION

THIS DIAGRAM IS RA AND IS NO PIPING S

AND IS NOT INTENDED TO REPLACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER.

Figure 29. Single Pool Heater Installation

YPAK’S RECOMMENDATION

T INTENDED TO REPLACE AN ENGINEERED

YSTEM BY A PROFESSIONAL ENGINEER.

Figure 30. Multiple Pool Heater Installation

Page 23

7. WIRING DIAGRAM

Page 24

8. CONTROLS

MOUNTED ON RETURN

HEADER

HL2 - HIGH LIMIT

DRAIN PLUG

AFT THERMOSTAT

CIRCUIT BOARD

ROLL-OUT

SWITCH

GAS VALVE

PILOT

MOUNTED ON IN/OUT

HL1 - HIGH LIMIT

TEMP SENSOR/WELL

TRANSFORMER

(BEHIND PANEL)

HEADER

UNITHERM GOVERNOR

DRAIN VALVE

8.2. Control Adjustments

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 temperature. A manual power switch provided below the touchpad turns the control power ON or OFF.

Temp Adjust Buttons

Mode Button

TEMP

MODE

Figure 31. General Location of Controls

8.1. Control Panel Removal

1. Remove screw from front door. Set aside door for serviceability.

2. Remove (4) screws from sides of control panel.

3. Rotate control panel down until panel stops. Do not force.

NOTE: Caution must be used to not damage controls or wiring.

KNURLED SCREW

LCD Display

Figure 33. Digital Control Adjustment

OFF

8.2.1. MENU/SET Button

The MENU/SET button is used to select POOL or SPA operation. It allows the user to turn the heater o electronically. The LCD remains energized and displays OFF, while continues to show the actual water temperature.

8.2.2. Temp Buttons

If the heater is in POOL or SPA mode, the desired water temperature (SETPOINT) will be displayed and may be adjusted using the UP or DOWN buttons.

8.3. Operation

In the POOL or SPA modes, the actual water temperature is displayed along with the desired water temperature (SETPOINT). When the water temperature is above the setpoint, “Water Temp” will alternate with “No Demand.” When the water temperature is below the setpoint and the heater is ring, “Water Temp” will alternate with “Heating.”

To adjust the setpoint temperature, make sure the control is in the appropriate mode (POOL or SPA) and push the UP or DOWN buttons.

Figure 32. Knurled Screw Location

Page 25

Figure 34. Alternating Display During Heating

Program Mode Button (SW1)

Figure 38. Run Time Indicator

Press the DOWN button. The Fault History displays up to ten faults in memory. The order of the faults begins with “Fault Last,” which is the most recent fault, and proceeds through ten most recent messages in chronological order. The second line of the display shows the fault message. If there are no faults in the history buer, the second line reads “All Faults Clear.”

Figure 39. Fault History Indicator

Figure 35. Thermostat Program Button (SW1)

8.3.1. Service Menu and Fault History

To access the Service Menu and fault history, press the MENU/SET and UP buttons simultaneously for 3 to 5 seconds. The heater will continue to operate while in the Service Menu. The rst screen displayed is the Flame Strength indicator, which indicates the pilot ame current using a bar graph and numerical display. A signal of less than 4 bars indicates a weak ame signal and may require service. Refer to the Troubleshooting section for possible causes and corrections.

Figure 36. Flame Strength Indicator

Press the DOWN button. The Supply Voltage screen indicates the voltage supplied to the control board. Normal readings range from 24 to 29 volts.

8.3.2. Program Button

1. Remove the two screws holding the control cover, and swing the panel down so the back side of the board is visible. Locate the Program Mode button (SW1) as shown in Figure 35. Press and hold the button for 5-7 seconds until Set Factory Defaults appears on the display. Release the program button.

2. Press the MENU/SET button sequentially until the desired program event is reached. There are 5 different events that can be programmed. They appear in the sequence listed in Figure 40:

Resets board to factory default settings.

Resets faults in the History File.

Change from Fahrenheit to Celsius.

Figure 37. Supply Voltage Indicator

Press the DOWN button. The Run Time indicates the total hours of operation for the pool heater, as measured by the amount of time that the main gas valve has been powered. The Cycle count indicates the number of on/o cycles of the heater, as measured by the number of times the pilot valve has been powered.

SPA setpoint maximum adjustment.

POOL setpoint maximum adjustment.

Figure 40. Programmable Events

Page 26

Set Factory Defaults

Refer to step one above to access the program screen. Set Factory Defaults should appear on the screen. If it does not, press the MENU/SET button until it appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Defaults Set appears. This operation resets the operating program to its factory default values.

Both the POOL and SPA setpoints will revert to 65°F (18°C) and both POOL and SPA maximum temperature settings will be 104°F (40°C). The Control Lockout PIN will be cleared and the control will resume normal operation.

Clear Faults

Refer to step one above to access the program screen. Press the MENU/SET button until Clear Faults appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Faults Cleared appears. This operation resets the Fault History le to “0” and clears all the stored faults.

Fahrenheit or Celsius

Refer to step one above to access the program screen. Press the MENU/SET button until Fahrenheit or Celsius appears on the digital display. The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display. Choose the desired temperature scale.

Cleared.” Failure to enter the correct PIN will display “Invalid PIN.”

In the event that the user-selected PIN is lost or does not clear the Control Lockout, use the Program Button to Set Factory Defaults. This will clear the PIN and allow normal operation and selection of a new PIN if desired.

NOTE: Both the POOL and SPA setpoints will revert back to 65°F (18°C) and the POOL and SPA maximum temperature settings will be 104°F (40°C). These setpoints will need to be readjusted to desired settings.

NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa thermometer. The heater reads the water temperature at the inlet. Due

to the circulation characteristics of any pool or spa, the

water temperature at the inlet to the heater may dier from that observed at a given location in the pool or spa.

8.4. Status and Diagnostics

The digital thermostat models are programmed to display a variety of status and diagnostic messages, depending on the operating conditions.

The following heat status messages are displayed in Pool, Spa, and Remote modes when there are no active fault conditions.

Display Condition

Spa Max Temp – Spa Set Point Maximum Adjustment

Refer to step one above to access the program screen. Press the MENU/SET button until Spa Max Temp appears on the digital display. Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value. The control can be set for a maximum of 107°F (42°C).

Pool Max Temp – Pool Set Point Maximum Adjustment

Refer to step one above access into the program screen. Press the MENU/SET button until Pool Max Temp appears on the digital display. Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value. The control can be set for a maximum of 107°F (42°C).

8.3.3. Control Lockout

The heater is equipped with a Control Lockout feature to prevent unauthorized tampering or adjustment of the control settings. To lock out the controls, press the DOWN button and MENU/SET button for 5 seconds. Choose a three digit PIN, using the UP and DOWN buttons to select the digits and the MENU/SET button to lock in selections. Conrm your selection and record your PIN.

To unlock the controls, press any button to bring up the Enter PIN menu. Enter the PIN that was used to lock the control. Note that power cycling will not clear the lockout. Successfully unlocking the control will display “Lockout

Heating Call for heat established, ame present.

Spark Spark operating.

No Demand Heat demand is satised.

Table K. Heat Status Messages - No Active Faults

Page 27

The following conditions are displayed in Pool, Spa and Remote modes.

Display Condition

Sensor Failure

Sensor Open

Sensor Short

Flame w/o CFH

PV Output Fault

MV Output Fault

Internal Fault Board fault, replace board.

EEPROM Fault

Clock/Fireman Sw

Low Temp

Lockout

Table L. Heat Status Messages - Active Faults

Thermistor temperatures disagree by more than 2°F (1°C)

Thermistor sensor failed open. Below

-20°F (-29°C).

Thermistor sensor failed short. Above 217°F (103°C).

Board is sensing ame when both main and pilot valves are commanded shut.

Pilot gas valve output is not in commanded state.

Main gas valve output is not in commanded state.

Memory fault, reset set points, replace board if fault does not clear.

Time clock/reman switch circuit is open.

Water temperature below 36°F (2°C).

The following conditions are displayed only while there is a demand for heat present.

Display Condition

8.4.1. 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 Figure 41. The

touch pad on the control panel allows you to select the

desired pool or spa temperature. It also indicates when a remote system is controlling the heater by displaying Remote in the display. When connecting the heater to a

remote system, identify whether it is a two- or three-wire

remote system. Select the appropriate instruction listed below to properly install the remote to the heater.

8.4.2. Remote Operation

The heaters are equipped with the ability to work with external remote controls. The supplied 7-pin remote wiring connector supplies power out to either a toggle switch or the switch contacts of a third party remote. The remote works by either making or breaking the circuit created by 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 O. 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 thermostatic controls with a time clock. See "Time Clock/Fireman’s

Switch" on page 29.

Water Sw Open Water pressure switch open.

Vent/Field Sw #1

Hi Limit 1 Fault High limit 1 open.

Hi Limit 2 Fault High limit 2 open.

Rollout Sw Open Rollout switch open.

Flow/Field SW #2

Ignition Lockout (Propane Tab Broken)

Ignition Failure (Propane Tab Not Broken)

Ign 6min Delay (Propane Tab Not Broken)

Table M. Heat Status Messages - Demand for Heat

Vent spill switch/eld switch #1 open.

Field-supplied ow switch/eld switch #2 open.

Alternating with “No pilot sensed” Pilot ame not established within the required time (15 sec or 90 sec).

Alternating with “Main Ign Failure”

- Pilot ame lost during the 8 second trial to ignite the main burner.

Alternating with “No pilot sensed” Pilot ame not established within 90 seconds.

Alternating with “Main Ign Failure”

- Pilot ame lost 4 times within the 8 second trial to ignite the main burner. Heater will lockout for 6 minutes before retrying.

OFF Mode

Heating in the POOL Mode

Heating in the SPA Mode

Remote Mode

Figure 41. Remote Control Menu - Remote Operation

Page 28

8.4.3. Activating the Remote

To activate or deactivate the remote function, follow these steps:

1. Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds.

2. The second line of the display will alternate even when the unit is off (“No Demand”).

NOTE: When in remote operation, the keypad mode and temp buttons are disabled.

Figure 42. Remote Control Menu - Activation

8.5. Remote Control Wiring

ATTENTION

OBSERVE PRECAUTIONS

ELECTROSTATIC

SENSITIVES DEVICES

NOTE: The remote wires must be connected to the 7-pin connector before the connector is plugged into the board.

8.5.1. 2-Wire Remote Control (On-O)

This application assumes that only one heating function (pool or spa) is required.

1. Turn on power to the heater.

2. For a 2-Wire Remote Control from a remote without its own sensor, push the MENU/SET button to the “POOL” or “SPA” mode and set the desired setpoint (eg. 102 °F (39°C) for Spa).

3. For a 2-Wire Remote Control from a remote with its own sensor, push the MENU/SET button “POOL” or “SPA” mode and set the temperature to the highest setting available on the control. The actual setpoint will be controlled by the remote control.

4. Turn the MENU/SET 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 connect the other side to either the ORANGE/BLACK wire for “SPA” operation or the BLACK/ORANGE wire for “POOL” operation. See Figure 43.

Pool Common (BLK/ORN)

Spa Common (ORN/BLK)

CAUTION: Electrostatic Discharge (ESD) damage can

be caused by direct or indirect contact with the wiring or circuit board. When one walks to the heater area, an electrostatic charge accumulates on the body. Contact of a nger allows the body to discharge, possibly causing device damage. This damage can be limited if the service person discharges himself, following ESD preventive/ removal practices, and holds on to the heater enclosure for 5 seconds before proceeding.

Important Installation Notes for Remote or External Wiring Conguration:

• 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' (9.1 m), remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, cable twisting 1.5" to 2.5" (3.8 to 6.4 cm) lay and jacketed.

• For runs over 30' (9.1 m), the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5" to 2.5" (3.8 to 6.4 cm) lay that is shielded and jacketed.

• Maximum cable length is 200' (61 m).

• For both two- and three-wire remote systems, the

provided 7-pin wiring connector must be utilized.

24VAC HOT (BLU)

Figure 43. 7-Pin Remote Interface Harness

6. Attach wire nut on unused wire to the “Remote Interface Harness.”

7. Install the “7-Pin Remote Interface Harness” to the P8 connector and turn power “On” to the heater. SeeFigure 44.

8. For activation of the remote control, see section 8.4.3

on page 28.

8.5.2. 3-Wire Remote Control Using

Three-Position Switch (Pool-OSpa, or Low-O-High)

1. This application assumes that both heating functions (pool and spa) are required.

1. Turn on power to the heater.

2. Push the menu/set button to the “POOL” or “SPA” mode and set the desired temperature for each (eg. 80°F (27°C) for Pool and 102°F (39°C) for Spa).

3. Turn the MENU/SET button to “OFF” and remove power from the heater.

Page 29

BLU - 24VAC

ORN/BLK - To Spa (COMM)

Wire Nut BLK/ORN - To Pool (COMM)

Figure 44. 2-Wire Remote Harness Installation on the P8

Connector of the ATF Board

On heaters, splice into the red/white wire to connect the time clock. For heaters the reman’s switch connection is located on the 14-pin header connected to the digital control board. Splice into the red wire jumper tagged “Where necessary add “Fireman’s” switch circuit here” to connect the time clock.

The reman’s switch connection on both heaters must be a dry contact and must not supply power to the heater. Powering the reman’s switch connection externally may damage the heater, and is not covered by warranty.

Do not exceed 50' (15.2 m) of total wiring using 18 AWG stranded copper wire rated for 221°F (105°C) minimum.

NOTE: When using a time clock, the heater will display “Clock/Fireman Sw” when the reman’s switch is open, indicating that the time clock has shut o the call for heat.

8.5.4. Water Flow Switch

The water ow switch ensures that the heater operates only when the lter pump is in operation. It is located on the outlet side of the In/Out header. It is factory pre-wired and pre-set with a minimum water ow paddle. Install conduit to the upper jacket hole. Connect two wires from the conduit to the appropriate terminal wires behind the transformer cover (i.e. orange to orange and orange/black to orange/black). No further adjustment is needed.

BLU - 24VAC

ORN/BLK - To Spa (COMM)

BLK/ORN - To Pool (COMM)

Figure 45. 3-Wire Remote Harness Installation on the P8

Connector of the ATF Board

4. On the “Remote Interface Harness” connect the BLUE wire to one side of the “REMOTE” switch and connect the ORANGE/BLACK wire for “SPA” operation and the BLACK/ORANGE wire for the “POOL” operation. See Figure 43.

5. Install the “Remote Interface Harness” to the P8 connector and turn power “ON” to the heater. SeeFigure 45.

6. For activation of the remote control, see section 8.4.3 on page 28.

8.5.3. Time Clock/Fireman’s Switch

To operate the heater with a time clock, connect the timer to the reman’s switch connection in the heater’s wiring. The time clock should be of the dual switch type and set to shut o the call for heat to the pool heater (chaue-piscine) 15 to 20 minutes prior to shutting down the pool pump.

Figure 46. Water Flow Switch Assembly

NOTE: The sheet metal cover should be in place at all times to protect the ow switch from rain and other environmental factors.

CAUTION: Do not operate the heater without the

function of a properly adjusted ow switch.

Page 30

GAS VALVE

8.5.5. Flame Roll-Out Safety Switch

The heater is equipped with a thermal cuto device to prevent ame roll-out in the event the heat exchanger becomes blocked. This is a “single-use” type fusible link or thermal fuse, that must be replaced when disabled by an over-temperature condition, caused by excessive restriction in the heat exchanger ue passage.

Figure 47. Flame Roll-Out Safety Switch

8.5.6. High Limits

The heater is equipped with two automatic high limits. One is located in the inlet/outlet header, and the other is located in the return header. Both are set to open at 135°F (57°C).

NOTE: An erratic high limit is often characteristic of an internal heat exchanger problem, e.g. scale build-up, defective bypass. Refer to Troubleshooting section.

2. Shut off gas upstream of heater.

3. Remove front door.

4. Disconnect gas line from gas valve.

5. Remove (2) screws that mount burner tray to unit, and (2) screws that secure gas valve to jacket.

6. Disconnect wires that terminate at gas valve.

7. Disconnect hi-tension wire from PC board.

8. Slide out burner tray.

9. Reverse above procedure to reinstall.

8.5.9. 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. Remove burner tray from heater.

4. Turn vertical gas pipe from manifold slightly and unscrew gas valve.

5. Reverse above procedure to reinstall.

8.5.10. Main Burner And Orice Removal

1. Remove burner tray.

2. Remove screws and burner hold-down bracket.

Figure 48. High Limit Switch

High Limit Removal

1. Shut off main electrical power switch to heater.

2. Remove inlet/outlet and/or return inspection panel.

3. Remove defective high limit and replace with a new high limit.

4. Replace inspection panel.

8.5.7. Pilot Safety

The heater employs a pilot safety which closes the main gas valve within 8/10ths of a second whenever the pilot ame is interrupted. The pilot ame is automatically lit when the device is powered. The heater performs its own safety check and opens the main valve only after the pilot is proven to be lit.

NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become distorted from direct-ame impingement and this usually necessitates replacement of these parts.

3. Lift burners 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 remove from manifold. DO NOT overtighten when reinstalling.

BURNER

HOLD-DOWN

BRACKET

PILOT

GAS

ORIFICE

8.5.8. Burner Tray Removal

1. Shut off main electrical power switch to heater.

Figure 49. Burner Tray Assembly

Page 31

8.5.11. Pilot Removal And Cleaning

1. Disconnect pilot tubing and wires from gas valve.

2. Remove pilot assembly from burner tray.

3. Remove pilot from bracket.

4. Remove pilot orice and air opening, and clean with

wire or small brush.

CAUTION! Do not enlarge hole in pilot orice.

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 exchanger, ream tubes and immerse heat exchanger in non-inhibited de-scale solvent for severe scale build-up.

8.5.14. Desooting Procedure

WARNING: Soot Is Combustible. Exercise Extreme

Care.

5. Reverse above procedure to reinstall.

Extension Pieces (2)

Figure 50. Tube Cleaning Kit

Auger

with Carbide Tip

Wire Brush

8.5.12. Heat Exchanger Removal

1. Shut water, gas and electricity off, close valves and relieve pressure, then remove relief valve. Remove side inspection panels.

2. Remove top jacket holding screws.

3. Remove rear top panel.

4. Remove screws mounting the rain shield to the rear panel. Also remove the screws that mount the rain shield to the sway brace. Remove rain shield.

5. Remove the four (4) screws holding down the flue collector. Remove the flue collector.

6. Disconnect flange nuts on Inlet/Outlet header, loosen union(s) at gas pipe and slide heater away from piping.

7. Lift heat exchanger straight up using caution not to damage refractory.

8. Reverse above procedure to reinstall. Make sure the insulation strips are properly replaced on top of the refractory retainer.

Soot will clog areas between ns and cause eventual tube failure. Any sign of soot at the base of the burners or around 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 tray.

4. Remove heat exchanger from the heater and wash with a garden hose, making sure soot is removed from spaces between fins.

5. Reverse above procedure to reinstall.

NOTE: In extreme cases it may be necessary to do steam cleaning at the local car wash. DO NOT WIRE BRUSH.

8.5.15. Combustion Chamber Removal

To remove combustion chamber, you must rst have removed the heat exchanger.

Figure 51. Atmospheric Heaters

8.5.13. Tube Cleaning Procedure

Establish a regular inspection schedule, the frequency depending on the local water conditions and the 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 return header side, without breaking pipe connections. It 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 not remove the top panel or the heater exchanger, generally.

8.5.16. Immersion Well Replacement

1. Shut off water to heater and drain heat exchanger.

2. Remove access panel on water connection side.

3. Remove old immersion well with bushing and sleeve.

4. Install replacement well in header.

Figure 52. Well Assembly

Page 32

8.5.17. Unitherm Governor Replacement

1. Shut water, gas and electricity off, close valves and relieve pressure.

2. Drain heat exchanger.

3. Remove retainer plug located next to the outlet pipe connection.

4. Unsnap old unitherm governor to remove from retainer plug. Snap in new unitherm governor.

5. Reinstall retainer plug, taking care to lubricate gasket with a non-petroleum based grease such as AquaLube.

9. REPLACEMENT PARTS

NOTE: To supply you with the correct part, it is important

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 lled in with the heater serial number, model number, etc., and shipped to the Company freight prepaid. If determined defective by the Company and within warranty, a like part or equal substitution will be returned, freight collect. Credit will not be issued.

MANUFACTURER:

2151 Eastman Avenue

Oxnard, Ca 93030

GASKET (BEHIND UG)

UNITHERM

UG PLUG

Figure 53. Unitherm Governor Valve

UG SPRING

GOVERNOR

To test the operation of the Unitherm Governor, place in hot water (over 110°F [43°C]) and watch for movement against spring. If there is no movement, replace unit.

Page 33

10. TROUBLESHOOTING

10.1. Mechanical

IMPORTANT NOTICE: These instructions are intended for the use of qualied personnel who are specically 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 qualied shall not attempt to install this equipment nor attempt repairs according to these instructions.

Problem Possible Cause Corrective Action

Harmonics, or whining noise Unitherm governor inoperative ................... Check movement by putting in hot water (110°F [40°C] or

*Debris or restriction in system .................. Locate the restriction and remove. Flush system and clean

*Debris in gas line ........................................... Remove debris or blow out gas line

Low ow ............................................................. Scale forming in heat exchanger - clean heat exchanger and

Heater going on and o

continuously

Liming or scale forming in exchanger

Sooting High ow rates ................................................. Reduce by adding manual bypass valve

Pilot outage or “Weak Flame” signal

Yellow lazy ame Low gas pressure ............................................ Adjust gas pressure

Outer jacket very hot (paint blistered)

Takes too long to heat pool or

spa

Leaking at well Overacid ............................................................. Replace well and maintain proper water chemistry

Leaking at heat exchanger Overacid ............................................................. Replace heat exchanger and maintain proper water chemistry

Gasket brittle and leaking (overheated)

* Indicates symptom which usually occurs on initial start-up.

Dirty lter ........................................................... Clean or replace lter

Low water level in pool .................................. Raise water level

External bypass setting out of

adjustment ........................................................ Adjust bypass

Marginal ow .................................................... Check pump. Check ow switch

Pool water .......................................................... See Water Chemistry on page 5

Bypassing too much water ........................... Inspect bypass for movement, if no movement, replace

Unitherm governor not functioning .......... Replace if no movement when heated

Unitherm governor inoperative .................. Check movement by putting in hot water (110°F [40°C] or

*Air starvation ................................................... Refer to installation instructions

*Improper venting ........................................... Follow recommended installation instructions

Insects or debris clogging burner intake

ports .................................................................... Clean burners

Low gas pressure ............................................ Adjust gas pressure

Restricted/dirty pilot ...................................... Clean pilot and/or electrode

Weak pilot generator ...................................... Replace pilot

*Insects or debris clogging burner intake

ports .................................................................... Clean burners

*Broken refractory caused by shipping

damage or improper combustion .............. Replace refractory panels

Excessive sooting of heat exchanger ....... Determine cause of sooting and correct

Under-sized heater .........................................

Filter not running long enough ................... Reset time clock

Dirty lter ........................................................... Clean lter

Gas line or meter undersized ...................... Refer to installation instructions

Refractory damage ......................................... Replace refractory

Sooted heater ................................................... Determine cause of sooting and correct

higher)

check pool pH and total alkalinity

Adjust manual bypass valve until heater outlet water temp is between 105°F and 110°F (40.5°C and 43.3°C) If no movement, replace

higher). If no movement, replace

Calculate heating capacity of heater Htr. output (BTUH) Pool gallonage x 8.33 or refer to heater sizing chart This does not take into account heat loss due to weather

Page 34

10.2. Control Logic - Flow Chart

Power On

Is the water

temperature displayed?

YES

• Check On/Off switch (under lid on control panel)

• Check for 120/240 volts to the transformer (time clock, circuit breaker, wire connections)

• Check for 24 volts to Circuit Board (P6 connector)

Push MODE

switch to select

"Pool" or "Spa"

Push Temp

arrow to scroll to

desired temperature

Water temperature

and set

temperature

displayed?

YES

“Heating” will display briefly

“Spark”

Flame icon displayed

and flashing?

Water temp displayed?

(pilot lit and rectified)

YES

“Remote” and Water Temperature displayed

(a remote control is controlling the heater)

Note: Disconnect the remote by turning the

remote function off. See page 30 for instructions.

Is a fault code displayed and flashing?

YES

Diagnostic Readouts

“Sensor Failure,” “Sensor Open” or “Sensor Short” -

Temperature sensor out of range (replace sensor)

Sensor Failure

Inspect thermister, wires, and connector at Terminal P1 Check resistance value of the thermister. Reference to chart below. Replace thermister if not within 10% of values shown below. If okay, replace Circuit Board.

Sensor resistance at various temperatures

Temp Degrees F 40 50 60 70 80 90 100 106 Resistance (k)

If okay, replace Circuit Board

“Water Sw Open” Water flow switch. Verify water flow and pressure CLEAN FILTER / STRAINER - backwash if neccessary.

“Hi Limit 1 Fault” High limit switch. Verify water flow. Inspect internal “Hi Limit 2 Fault” Thermostat (Unitherm Governor) and bypass valve.

“Rollout Sw Open” Rollout Sensor - Check for blocked heat exchanger and soot. Atmospheric Units - Replace fusible link. Lo NOx Units - Press manual reset button.

“Clock/Fireman Sw” Fireman or Remote switch connected to safety loop is in the OFF mode.

“Vent/Field Sw #1” Vent switch open. Check connections to the board. If extractor installed, troubleshoot extractor.

“Ignition Lockout” Ignition lockout. Check power at pilot valve. Check spark (bad

ignition circuit or hi-tension wire). Verify clean pilot orifice and clearance from igniter to ground hood.

“Ignition Failure” Ignition failure. Verify gas to the heater. Verify valve operation (gas present at tube fitting).

261.1 199.0 153.1 118.8 93.0 73.3 58.3 51.0

Heater Fired?

YES

END

Verify power at MV on P-4 Terminal on digital circuit board.

Verify power to valve MV voltage. (Replace valve.)

Page 35

2-M

11. ILLUSTRATED PARTS LIST

13-H

14-H

3-V

4-H

3-H

9-M

1-S

12-S

23-H

15-H

3-H

4-H

10-H

11-H

12-H

20-H

4-H

22-H

21-H

1-C

23-H

7-C

19-H

8-C

20-H

24-H

21-H

22-H

25-H

4-M

2-S

5-C

1-P

3-P

4-P

5-P

HONEYWELL IID ATMOSPHERIC PILOT

8-S

3-S

13-S

8-M

6-M

2-C

4-V

18-H

1-V

5-H

2-V

9-H

6-H

4-S

18-H

3-R

9-M

7-H

8-H

6-C

17-H

16-H

2-H

9-H

7-S

11-S

3-C

4-C

2-R

4-S

2-J

6-S

9-S

1-M

2-B

7-M

12-M

1-J

1-G

11-M

1-R

5-S

3-B

4-B

10-S

1-B

5-B

6-P

Page 36

CALL

OUT DESCRIPTION 268A 408A

2" CPVC Adapter NPT (Inlet Plumbing) 005393F 005393F

inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part.

B BURNER TRAY

1-B Burner Tray w/Burners (sea level)* 013796F 013797F

Burner Tray w/o Burners (sea level)* 013798F 013799F Burner Tray w/Gas Valve Nat 013800F 013801F

Burner Tray w/Gas Valve Pro 013802F 013803F 2-B Burner Spacer/Hold Down Kit 013804F 013805F 3-B Burner 301210/18 301210/27 4-B Burner Orifice Nat. #50 (Sea Level)* 350079F/18 350079F/27

Burner Orifice Pro. #57 (Sea Level)* 350083F/18 350083F/27 5-B Burner Tray w/o Manifold w/o burners 013806F 013807F

C CONTROLS

1-C AGS 135° (Auto Gas Shut-Off) - Red Epoxy 600892B 600892B 2-C High Limit 140° - Black Epoxy 600893B 600893B 3-C P. C. Board/Control 013464F 013464F 4-C LCD Display 013640F 013640F 5-C Fuse 5 AMP 013733F 013733F 6-C Temperature Sensor IID Units 009577F 009577F 7-C Flow Switch 007142F 007142F 8-C Flow Switch Paddle 010026F 010026F

G GAS VALVE

1-G Combination Valve - Nat. 003900F 003900F

Combination Valve - Pro. 004306F 004306F

H HEAT EXCHANGER

1-H Heat Exchange Assy Cupro-Nickel ASME BR 013808F 013809F 2-H Inlet/Outlet Header ASME BR Complete 013810F 013810F

Inlet/Outlet Header ASME BR 013811F 013811F 3-H Inlet or Outlet Flange BR (1 only) 013812F 013812F 4-H Flange Gasket (3) 016732F 016732F 23-H Flange Bolts 016159F 016159F 5-H Return Header ASME BR 002451F 002451F 6-H Tube Bundle Cupro-Nickel ASME ** 013813F 013814F 7-H Baffle 013815F 013816F 8-H Stud Bolt Kit 007870F 007870F 9-H Header Gasket (9) 800014B 800014B 10-H Unitherm Governor 062234B 062234B 11-H U.G. Retainer Spring 013792F 013792F 12-H U.G. Plug 013738F 013738F 13-H Bypass Valve Assembly 016194F 016194F 14-H Bypass Spring

Units with Brass Bypass Valve (Units manufactured to 3/5/17) 013794F 013794F

Units with Plastic Bypass Valve (Units manufactured from 3/5/17) 016196F 016196F 15-H Drain Valve 013793F 013793F 16-H Sensor Well 003765F 003765F 17-H Well Retaining Clip 300203 300203 18-H Rear Drain Plug & Cover 005264F 005264F 19-H 20-H 2" CPVC Connector (Outlet Plumbing)

NPT Connection 013795F 013795F

Flange Connection 015883F 015883F 24-H Flange Bolts & Washers 016162F 016162F 21-H 2" CPVC Connector & Nut 006723F 006723F 22-H O Ring 006724F 006724F 25-H Pipe Plug Brass 1/4" 016163F 016163F

J CONTROL BOX

1-J Transformer 120/240/24V 006736F 006736F 2-J Rocker Switch 009493F 009493F

*FOR INSTALLATION AT OVER 2,000 FEET ABOVE SEA LEVEL, DERATE 4% PER I,000 FEET ABOVE SEA LEVEL. **WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and

Page 37

CALL

** Conversion must be made with complete burner tray with gas valve (see item 1-B).

* Gas conversions are to be done only by a qualified agency.

OUT DESCRIPTION 268A 408A

M MISCELLANEOUS COMPONENTS

1-M Thermal Fuse 005899F 005899F 2-M PRV 125 PSI 011912F 011912F 3-M Deliming Kit 052871F 052871F 4-M T & P Gauge 014647F 014647F 5-M Wire/Harness 013817F 013817F 6-M Control Bezel (Includes Switch Decal) 013491F 013491F 7-M Switch/Decal-Membrane 013492F 013492F 8-M Control Bezel Cover 009487F 009487F 9-M Gasket Insulation (Swaybrace & Jacket Top) 010350F 010350F 10-M Touch-up Paint (Cool Dark Gray) 750256 750256 11-M Tie Down Bracket (Optional) 011636 011636 12-M PC Board Shield (Optional) 015557F 015557F

P PILOT

1-P

Pilot Nat & Pro 002003F 002003F

2-P Pilot Orifice Nat .020 003903F 003903F

Pilot Orifice Pro .012 004308F 004308F 3-P Pilot Mounting Bracket 013791F 013791F 4-P Pilot Tube 004078F 004078F 5-P Hi Tension Wire with Pilot Electrode N/A N/A 6-P Pilot Shield 010351F 010351F

R REFRACTORY

1-R Refractory Common (Left & Right) 010088F 010088F 2-R Refractory Uncommon (Front & Rear) 010090F 010092F 3-R Refractory Retainer Kit 010388F 010390F

S SHEETMETAL

1-S Jacket Top (Louvered) 010048F 010050F 2-S Flue Collector 013818F 013819F 3-S Door Assy 013820F 013821F

13-S Screw & Retainer 006744F 006744F 4-S Access Panel Set (3 Pcs) 010312F 010312F 5-S Jacket Side Panel Right 010376F 010376F 6-S Jacket Side Panel Left 010377F 010377F 7-S Jacket Rear Panel (2 Pcs.) 010373F 010375F 8-S Control Cover/Lock Box 009505 009505 9-S High Limit Cover 010319F 010319F 10-S Base Heat Shield 010320F 010320F 11-S Up Front Control Panel 013822F 013823F 12-S Weather Shield 013824F 013825F

V VENTING

1-V Indoor Stack Kit (Includes inner adapter panel) 009839 009841

Outdoor Stack Kit (Includes inner adapter panel) 009835 009837 2-V Stack Adapter 010331F 010333F 4-V Outer Stack Adapter 011462F 011464F 3-V "Pagoda" Top 010335 010337

Atmospheric CONVERSION KITS* 268A 408A

Nat. to Pro. ** **

Pro. to Nat. ** **

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NOTES

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NOTES

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Raypak 408, 268 Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual