Raypak 514-824 User Manual
INSTALLATION
AND OPERA TING
INSTRUCTIONS
COMMERCIAL
SWIMMING POOL
HEATERS
Raytherm
Models 514-824
CATALOG NO: 6200.50N
Effective: 04-09-07
Replaces: 04-15-05
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
— 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 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 kept in a safe place for future reference.
P/N 240499 Rev. 15
WATER CHEMISTRY
(Corrosive water voids all warranties)
For your health and the protection of your pool equipment it is essential that your water is chemically
balanced. The following levels must be used as a guide for balanced water.
Free Chlorine MUST NOT EXCEED 5 PPM!
• Occasional chemical shock dosing of the pool or spa water should not damage
the heater providing the water is balanced.
• Automatic chemical dosing devices and salt chlorinators are usually more efficient
in heated water, unless controlled, they can lead to excessive chlorine level which
can damage your heater.
• Further advice should obtained from your pool or spa builder, accredited pool shop,
or chemical supplier for the correct levels for your water.
CONTENTS
4 PART ONE - OWNER’S OPERATING INSTRUCTIONS
4 SECTION 1/START-UP PROCEDURES
4 Before Start-Up
5 Operating Instructions
6 After Start-up
6 SECTION 2/CAUTION
6 SECTION 3/MAINTENANCE AND CARE PROCEDURES
Pool & Spa Water Chemistry
7 PART TWO - INSTALLATION/SERVICE INSTRUCTIONS
7 SECTION 1/RECEIVING EQUIPMENT
7 SECTION 2/GENERAL SPECIFICATION
7 SECTION 3/INSTALLATION INSTRUCTIONS
8 Base Installation
8 Clearances
9 Combustion Air
9 Venting Connections (Outdoor)
11 Gas Supply Connections
12 Plumbing for Water Connections
14 Electrical Wiring
15 Wiring Diagrams
19 SECTION 4/SERVICING INSTRUCTIONS
19 General Location of Controls
19 Controls/Adjustments/Replacements
23 SECTION 5/TROUBLESHOOTING GUIDE
25 Electrical
26 SECTION 6/REPLACEMENT PARTS LIST
31 WARRANTY
3
PART ONE - OWNER’S OPERATING INSTRUCTIONS
FOR YOUR SAFETY - READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY
RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
SECTION 1/START-UP PROCEDURES
BEFORE START-UP
BURNERS
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from combustibles, flammable liquids and chemicals. Do not
obstruct the flow of combustion and ventilating air.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
AUTOMATICALLY LIGHTED PILOTS
ELECTRONIC IGNITIONS SYSTEMS
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 appli-
ance area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle
on the floor.
WATER
First thing, ensure that system is filled with water and
have pump operating. Water must be flowing through
the heater during operation.
CAUTION: Propane gas is heavier than air and will
settle on the ground. Since propane can accumulate in
confined areas, extra care should be exercised when
lighting propane heaters.
• If you cannot reach your gas supplier, call the
fire 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 qualified
service technician. Force or attempted repair may
result in fire or explosion.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
telephone in your building.
• Immediately call your gas supplier from a neighbor's telephone. Follow the gas supplier’s
instructions.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
4
OPERATING INSTRUCTIONS
1. STOP! Read the safety information on the preceeding
page.
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 lights the pilot. Do not try to light
the pilot by hand.
6. For Models 514-724 with Honeywell Gas Valve.
Push in gas control knob slightly and turn clockwise
to “OFF”. Knob cannot be turned to “OFF”
unless knob is pushed in slightly. Do not Force.
GAS CONTROL KNOB
SHOWN IN “ON”
POSITION
GAS INLET
For Models 514-724 with Robertshaw Gas Valve.
Turn Gas control knob clockwise to “OFF”.
GAS CONTROL
KNOB SHOWN
IN “ON” POSITIONS
GAS INLET
Fig. # 8080.0
For Models 824
Turn main gas shut-off and pilot shut-off valves counter
clockwise to “OFF”.
TO PILOT
PILOT SHUT-OFF
VALVE CONTROL MAIN GAS SHUT-OFF
SHOWN IN THE VALVE SHOWN IN
“ON” POSITION THE “ON” POSITION
Fig. #8219.0
7. Wait five (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
located on page 4. 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".
TO TURN OFF GAS TO APPLIANCE
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
GAS
INLET
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 instructions “To Turn Off Gas to Appliance” and call your
service technician or gas supplier.
Push in gas control knob slightly and turn clockwise to “OFF”.
For Models 824
Turn main gas shut-off and pilot shut-off valves
counter clockwise to “OFF”.
5. Replace heater door panel.
5
AFTER START-UP
SECTION 2/CAUTION
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 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.
4" Max.
Fig. # 8144.0
MAIN BURNER FLAME
Elevated water temperature can be hazardous, and
the U.S. Consumer Product Safety Commission recommends the following guidelines:
1. Spa or hot tub 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. Preg-
nant 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 heat 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 drowsi-
ness, such as tranquilizers, antihistamines, or anti-
coagulants, should not use spas or hot tubs.
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 installer 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 a qualified service
person at the time of installation and periodically checked
thereafter. Refer to pressure switch servicing instruction in Section 4 of this manual).
WARNING: Operation of the heater without water circulation will cause rapid and severe damage to the heater.
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. Clean main burners and pilot burner 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 agency.
6
5. On indoor heater, clean room air 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 air around heater clear and free from combustible 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 that 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. Your pump strainer basket may be full. If so remove
debris.
5. Your filter 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
water (or your gauge is broken). Try to get the pump
to run at it's normal flow rate.
no pressure; then you are not moving
POOL & 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 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. Turn off gas valve, manual gas valve, and electrical
supply to the heater.
2. Open drain 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 - INSTALLA TION/SER VICE INSTRUCTIONS
SECTION 1/RECEIVING EQUIPMENT
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 equipment. Remove the heater
from the carton and if it is 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, 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 for Gas-Fired Pool Heaters.
All heaters are inter-changeable and can be used
either indoor or outdoors. The appropriate top designated for that type of use is required. If desired, the top
can be changed at a later date 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 reproductive harm.
IMPORTANT NOTICE
These instructions are intended for the use of
qualified personnel only, 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. 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, alteration, service or maintenance may damage the equipment, create a hazard resulting in asphyxiation, explosion 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 recommended that a suitable drain pan, adequately drained,
be installed under the appliance. The pan must not
restrict combustion air flow.
7
m
M
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/NFPA 54
and National Electrical Code, ANSI/NFPA 70.
CLEARANCES
ALL HEATERS
For clearances from combustible surfaces, see the
chart below
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 combustible floors is illustrated. Heater must not be installed on
carpeting.
CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION
INDOOR INSTALLATIONS:
Top* (Drafthood) - 36" Back - 10"
Front - Alcove Right Side 6"
Vent - 6" Left Side (Water Side) 6"
OUTDOOR INSTALLATION:
Top* (Stackless Top) - Unobstructed
Back - 10" Side - 6"
12"
inimum
12"
Minimu
HEATER
*Clearance from top of vent terminal.
*For servicing, provide at lease 24" in front of the
heater for burner tray removal, and at least 18" on water
Sheet Metal
4"
Minimum
24 Gauge
Fig. # 8148.0
Hollow Concrete Cinder Block, Align Holes And Leave
Ends Open. Alternative Method For Providing A Non-
Combustible Base.
connection side of the heater to inspect and delime the
heat exchanger.
OUTDOOR HEATERS
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 in the 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
4
foot
Minimum
HIGH WIND CONDITIONS
3
foot
Minimum
1
10
foot
Minimum
Forced Air Inlet
Fig. # 8245.0
foot
Minimum
8
(OUTDOOR UNITS ONLY)
In areas where high winds are frequent, 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.
INDOOR HEATER
The design is also certified for indoor installation
when equipped with the approved draft hood. Locate
heater as close as practical to a 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 must have both combustion and ventilation air. Minimum requirements for net free air supply
openings, one 12 inches from ceiling for ventilation and
one 12 inches from the floor for combustion air as outlined
ANSI Z 223.1/NFPA 54 and any local codes that may
have jurisdiction.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
a. All 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
STEP #2
Tighten the (4) screws (Shown below) until they come in
contact with the unit jacket top, 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.
b. All air from 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
514 128
624 157
724 182
824 207
VENTING CONNECTIONS
VENT TERMINAL (Outdoor)
STEP #1
Lower outdoor “Stackless” top on to unit. Position top so
it is centered on unit from side to side and front to rear.
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 larger 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 of the latest edition of
the National Fuel Gas Code, ANSI Z 223.1/NFPA 54.
Fig. # 8166
9
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 five 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. We recommend use of insulated vent pipe spacer
through the roofs and walls.
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
Z 223.1/NFPA 54.
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 at least five feet in 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, regulators and relief equipment.
The weight of the vent stack or chimney must not rest
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 supported to maintain proper clearances from combustible
constructions.
Type “B” double wall or equivalent vent pipe is
recommended. However single wall metal vent pipe may
be used as specified in the latest edition of the National
Flue Gas Code ANSI Z 223.1/NFPA 54.
10' OR LESS
2' MIN
VENT PIPE
DRAFT HOOD
VENT CAP
2' MIN
5' MIN
At the time of removal of an existing heater, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remaining
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 determine there is no blockage or restriction,
leakage, corrosion and other deficiencies
which could cause an unsafe condition.
(c) 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 building. Turn on clothes dryers and any appliance 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.
(d) Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
(e) Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Use the flame of a match or
candle, or smoke from a cigarette, cigar or
pipe.
(f) 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/
NFPA 54. When re-sizing any portion of the
common venting system, the common venting
system should be re-sized to match the
minimum size as determined using the appropriate tables in part 11 of national Fuel Gas
Code, ANSI Z 223.1/NFPA 54.
HEATER
Fig. #8119
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.
10
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