WARNING: If these instructions are not followed exactly, a fire 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 another safe place for
future reference.
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.
Total Alkalinity (PPM)120 to 150120 to 15080 to 120
Calcium Hardness (PPM)200 to 300150 to 200200 to 400
Salt (PPM)6000 MAXIMUM6000 MAXIMUM6000 MAXIMUM
Free Chlorine (PPM)*2 to 32 to 32 to 3
Total Dissolved Solids
(PPM)
3000 MAXIMUM3000 MAXIMUM3000 MAXIMUM
* Free Chlorine MUST NOT EXCEED 5 PPM!
• Occasional chemical shock dosing of the pool or spa water should not damage the
heater providing the water is balanced.
• Automatic chemical dosing devices and salt chlorinators are usually more efficient
in heated water, unless controlled, they can lead to excessive chlorine level whichcan damage your heater, and which is not covered under warranty.
• Further advice should be obtained from your pool or spa builder, accredited pool
shop, or chemical supplier for the correct levels for your water.
Rev. 20 reflects the following:
Changes to: Wiring Diagram on page 23
Additions:
Deletions: Warranty on page 35
2
CONTENTS
WATER CHEMISTRY 2
WARNINGS 4
Pay Attention to These Terms4
RECEIVING EQUIPMENT 5
GENERAL
SPECIFICATIONS 5
INSTALLATION 5
Code Requirements5
Base Installation5
Clearances6
Combustion Air (Indoor Units Only)6
Venting Connections7
Gas Supply Connections8
Water Connections10
CONTROLS 10
Flow Switch10
Water Pressure Switch11
Automatic Chlorinators and Chemical
Feeders11
Unitherm Governor Operation11
Companion Flange Connections
(Models 926-1223)11
Mounting the Poolstat Control with FrontMounted Loop Using Mounting Slots12
Mounting Well into System Return Loop
Pipe - Front-Mounted Loop14
Piping Configurations for Raytherm
Commercial Pool Heaters (926-1223)15
Piping Configurations for Raytherm
Commercial Pool Heaters (1287-1826)16
Piping Configurations for Raytherm
Commercial Pool Heaters (2100-4001)17
Temperature Controls18
External Auxiliary Bypass Valve (Where
Required) Models 926-1223 Only18
Auxiliary Bypass Valve Adjustment18
Electrical Wiring19
Wiring Diagram—Models 926–1223
with UG20
Wiring Diagram—Models 926–1826
with H-Bypass21
Wiring Diagram—Models 2100–250022
Wiring Diagram—Models 3001–400123
SERVICING 24
General Location Of Controls24
Temperature Control24
Pressure Switch24
Pressure Switch Adjustment24
Two-Speed Pumps25
Pilot Safety25
START-UP PROCEDURES 25
Before Start-Up25
Start-Up25
After Start-Up26
INSPECTION PROCEDURES 26
Burners26
CONTROLS 26
SERVICING PROCEDURES 27
Tube Cleaning Procedure (Typical)27
Heat Exchanger Reassembly27
Burner Drawer Removal27
Gas Valve Removal27
Main Burner and Orifice Removal28
Pilot Removal and Cleaning28
Heat Exchanger Removal28
Combustion Chamber Removal29
Control Well Replacement29
Tube Replacement Procedure29
Procedure For Cleaning Flue Gas
Passageways29
Unitherm Governor Replacement30
MAINTENANCE AND CARE 30
Winterizing Your Heater31
TROUBLESHOOTING 32
3
WARNINGS
Pay Attention to These Terms
ndicates the presence of immediate hazards which will cause severe person-
DANGER:
I
al injury, death or substantial property damage if ignored.
WARNING:
CAUTION:
NOTE:
DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
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.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
CAUTION: Operation of this heater in lowtemperature systems requires special piping.
Harmful internal condensation will occur if the inlet
water temperature does not exceed 105°F. Warranty
claims will be denied when condensation occurs.
CAUTION: If this heater is to be installed above
radiation level, it must be provided with a low water
cut-off device at the time of heater installation.
CAUTION: If this heater is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
•Always keep the area around the heater free of
combustible materials, gasoline, and other flammable liquids and vapors.
•Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to deenergize the
equipment before servicing.
4
RECEIVING EQUIPMENT
INSTALLATION
On receipt of the equipment, visually check for external damage to the carton or the shipping crate. If the
carton or shipping crate is damaged, make a note on
the Bill of Lading and report the damage to the Carrier
immediately. Remove the heater from the carton or
shipping crate. Do NOT use the shipping base crate as
an installation base.
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 Heater.
If there are any questions which this manual does not
answer, please contact the factory or your local
Raypak representative.
Claims for shortages and damages must be filed with
carrier by consignee. Permission to return goods must
be factory authorized and are subject to a stocking
charge.
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
repairs 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 Requirements
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.
Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defective replacement parts will not be accepted and will be
replaced in kind only per our standard warranties.
GENERAL
SPECIFICATIONS
Models 962, 1125, 1223, 1336, 1468, 1631, 1826 &
2100 through 4001 are specifically designed for indoor
installation ONLY
1414, 1571 & 1758 are specifically designed for outdoor installation ONLY. All heaters are standard with
electronic ignition for both natural and propane applications. Heaters require 120V power supply. Control
circuits operate at 24V, supplied by an internal 120V to
24V transformer.
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. Rated
inputs are suitable for up to 2000 feet elevation. For
elevations above 2000 feet, reduce input 4% for each
1000 feet above sea level, as high elevation reduces
combustion performance.
. Models 926, 1083, 1178, 1287,
Installation must be in accordance with local codes, or,
in the absence of local codes, with the latest editions
of the National Fuel Gas Code (NFGC), ANSI
Z223.1/NFPA 54, and National Electrical Code (NEC),
ANSI/NFPA 70.
Base Installation
Do NOT use the shipping base crate as an installation
base. Heater must be mounted on a level base, such
as cement slab, cement blocks or other non-combustible surface. An optional non-combustible base is
available for Indoor Models 962 through 1826. An
alternative method for providing a base for combustible floors as illustrated below. Heaters may not be
installed on carpeting.
Fig. 1: Alternate Mounting Base
5
Clearances
All Heaters
or clearances from combustible surfaces, see
F
Table A below. A minimal vertical clearance of three
feet between the upper surface of the flue outlet to a
noncombustible material is required.
Indoor Heaters
Heater
Side
Top24Top24
Back24Back24
Right Side24Right Side24
Left Side24Left Side24
Vent*6
*Vent includes factory supplied drafthood and does not include field
supplied vent systems above the drafthood. On Models 2100-4001
drafthood is built into heater.
For servicing provide a front clearance as shown below:
Model 926/962-758/1826 - 24"
Model 2100-4001 - 48"
Table A: Minimum Clearances from Combustible
For servicing, provide at least 24" in front of the heater
on Models 926-1826 & 48" in front of the heater on
Models 2100-4001 for burner tray removal, and at
least 18" on the right side of the heater to inspect and
delime the heat exchanger.
Clearance
(Inches)
Construction
Outdoor Heaters
(926–1758)
Heater
Side
Clearance
(Inches)
Outdoor Heaters (Models 926-1758)
Fig. 2: Minimum Distance from Openings
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.
High Wind Conditions
(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 Heaters
The design is certified for indoor installation when
equipped with approved drafthood. Locate the heater
as close as practical to a chimney or gas vent.
These heaters are design-certified for outdoor installation, when equipped with the approved top 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 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.
Combustion Air
(Indoor Units Only)
The heater must have both combustion and ventilation
air. Openings must not be obstructed. Minimum
requirements are from the National Fuel Gas Code
(ANSI Z223.1/NFPA 54).
CAUTION:Combustion air must not be
contaminated by corrosive chemical fumes which
can cause unwarrantable damage to the heater.
6
he “two-opening” method requires:
5' MIN
2' MIN
10' OR LESS
2' MIN
VENT CAP
VENT PIPE
DRAFT HOOD
HEATER
T
1. Free combustion air 1 sq. in. per 1000 BTU input
within 12" of the floor.
2. Free ventilation air 1 sq. in. per 1000 BTU input
within 12" of the ceiling level.
NOTE: If the room the heater is installed in is
located against an outside wall and air openings
communicate directly with the outdoors, the
openings may be 1/4 the size specified above (ANSI
Z223.1/NFPA 54, latest edition)
Venting Connections
hould be supported at not more than five foot inter-
s
vals. Plumber’s tape, criss-crossed, will serve to
space both horizontal and vertical piping.
as vents supported only by the flashing and extend-
G
ing 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 Z223.1/NFPA 54.
Drafthood (Indoor) Models 962-1826
Locate and assemble as shown in Fig. 3. Secure with
screws supplied in envelope in carton. Do not modify
the drafthood. The height of the relief openings above
the cabinet is critical to proper operation.
Fig. 3: Indoor Drafthood
Models 2100-4001 have built-in drafthoods that must
be properly vented to the outside.
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 drafthood 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 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.
Type "B" double-wall or equivalent vent pipe, certified
for Category I conditions, is recommended. However,
single-wall metal vent pipe may be used as specified
in the latest edition of the National Fuel Gas Code
ANSI Z223.1/NFPA 54.
Vent Piping
WARNING: An indoor heater requires a drafthood
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 drafthood
outlet is recommended, however, when the total vent
height is at least ten (10) feet (drafthood relief opening
to vent terminal), the vent pipe size may be reduced
as specified in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 - latest edition. Avoid long horizontal
runs of vent pipe and too many elbows. If installation
requires horizontal or non-vertical runs, the vent pipe
must have a minimum of 1/4 inch per foot rise and
Fig. 4: Venting Clearances
7
S
EDIMENT
T
RAP
MANUAL
SHUT-OFF
VALV E
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 appliances 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 fireplace 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 drafthood 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 Z223.1/NFPA 54. When resizing any portion of the common venting system,
the common venting system should be re-sized to
approach the minimum size as determined using
the appropriate tables in the National Fuel Gas
Code, ANSI Z223.1/NFPA 54.
For special venting applications that require reduced
vent sizes or through-the-wall venting, the optional D
Series Power Vent can be used. Consult the factory or
your local Raypak representative.
Gas Supply Connections
Per NFGC requirements, gas piping must have a sediment trap ahead of the heater gas controls, and a
manual shut-off valve located outside the heater jacket. All gas piping should be tested after installation in
ccordance with local codes.
a
Fig. 5: Gas Piping
CAUTION: The heater and its manual shut-off
valve must be disconnected from the gas supply
during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.45 KPA).
Dissipate test pressure in the gas supply line before
reconnecting the heater and its manual shut-off
valve to gas supply line. FAILURE TO FOLLOW
THIS PROCEDURE MAY DAMAGE THE GAS
VALVE. OVER PRESSURIZED GAS VALVES ARE
NOT COVERED BY WARRANTY. The heater and its
gas connections shall be leak tested before placing
the appliance in operation. Use soapy water for leak
test. DO NOT use open flame.
CAUTION: Do not use Teflon tape on gas line pipe
thread. 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 7 in. WC and a maximum of 10.5 in. WC
upstream pressure under load, and no load conditions
must be provided for natural gas or a minimum of 11
in. WC and a maximum of 13 in. WC for propane gas.
Gas Pressure Regulator
The gas pressure regulator is preset and sealed at 4
in. WC for natural gas, and 11 in. WC for propane gas.
Between the gas valve and the burners is a 1/8" pipe
plug. The pressure at this point, taken with a manometer, should be about 3.7 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.
8
MANOMETER
GAS PRESSURE
T
ES T AT G AS
V
ALVE
GAS PRESSURE TEST
AT HEATER
M
ANUAL
SHUTOFF
V
ALVE
G
AS PRESSURE
TEST UPSTREAM
Fig. 6: Gas Pressure Test Points
Venting of Diaphragm Gas
Components
Gas Code. Under NO circumstances shall bleed lines
terminate in the gas utilization equipment flue or
exhaust system.
Heaters with gastrain components that have
diaphragms in their construction are supplied with a
bleed line connection that must be connected to the
outside atmosphere as required by the National Fuel
Model
No.
1”1-1/4”1-1/2”2”2-1/2”3”4”
NPNPNPNPNPNPNP
Bleed Line
Connection
Fig. 7: Bleed Line Connection
926/96215204545110150360400
1083/11251015353580120300300
1178/122325256085220200
1287/133625205575180170325560
1414/146820154565150165300500
1571/16311515355020125250400
1758/182615103040100100225340
2100101025308075175260
250015205555135160400600
30011015354085120250500
35001030304580200400600
4001520253565160300400
Natural Gas, 1000 BTU/FT3.60 Specific Gravity @ 0.5 in. WC Pressure Drop
Propane Gas, 2500 BTU/FT31.53 Specific Gravity @ 0.6 in. WC Pressure Drop
Table B: Maximum Equivalent Pipe Length
9
Water Connections
Location
Models 926-1223 With UG
The heater requires water flow and positive pressure
to fire and operate properly. It must therefore be
installed downstream of the discharge side of the filter
pump. A typical installation is plumbed as follows:
1. The inlet side of the filter is plumbed directly to the
discharge side of the filter pump;
2. The outlet side of the filter is then plumbed to the
inlet of the heater; and
3. 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.
low temperature piping. A fireman switch included in
the time clock may be used for this purpose with
instructions not to override this sequence manually.
See wiring diagram section for electrical hookup location of the fireman switch in the electrical circuit.
NOTE: If piping is used into the heater, this piping
(copper) must be anchored or screwed into the
flange (metal) if operating pressures above 30 PSI
are encountered.
All Models With H-Bypass or CWR
These heaters must be installed using primary/secondary piping. For multiple-heater installations, use
reverse-return logic to ensure equal duty cycles. Flow
in the main line must be at least 120% of the heater
flow. See pages 16-17.
CONTROLS
Heater must be located so that any water leaks will not
damage the structure of adjacent area. High-temperature plastic pipe (CPVC) may be connected directly
into the heater, if local codes permit and if controls
operate the pump for at least fifteen minutes after the
heater is turned off.
CAUTION: NEVER install PVC directly into heater.
Four feet of copper or high temperature pipe and two
elbows are required between the heater and the
PVC connections. See Fig. 8 below.
Flow Switch
This dual purpose control shuts off the boiler in the
case of a pump failure or low water condition. It is
mounted and wired in series to the main gas valve.
Standard on all units except on UG models.
NOTE: Flow switch will not operate if flow is less
than:
When local codes permit the use of less than four feet
of high-temperature piping or two elbows, provisions
should be made to always shut the heater off a minimum of 15 minutes prior to pump shutdown in order to
carry away residual heat and prevent damage to the
Fig. 9: Flow Switch
10
Water Pressure Switch
Unitherm Governor Operation
On Models 926-1223 built with a Unitherm Governor
(UG), a water pressure switch is provided in the heater
instead of a flow switch, to shut down the gas valves
in the event the water supply to the heater is interrupt-
d. It is very important to verify that the switch
e
electrically opens and shuts off the gas valve when
water flow to the heater is interrupted.
Otherwise, rapid and severe damage to the heater will
likely occur. (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 instructions on page 24).
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to
the heater.
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 chlorine tablets or
bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (eg,
overnight).
The patented Unitherm Governor (UG) is a thermostatic mixing valve specifically designed to maintain
constant heater internal temperature between 105°
and 115°F despite continually changing flow rates from
he filter and changing pool temperatures. This narrow
t
range is needed to prevent damaging condensation on
the burners which will occur if the heater runs for any
length of time with an inlet temperature below 105°F. It
is also needed to inhibit scale formation in the tubes by
maintaining temperatures well below accelerated scaling temperatures.
The Unitherm Governor is the default configuration on
models 926 through 1223. Where installed, it is built
into the inlet/outlet header. The larger sizes, models
1287 through 4001, do not have a UG option. Instead,
they have an externally-mounted bypass pump that is
designed to maintain the water entering the heater at
the proper temperature to prevent condensation and
scale. Thermometers are provided on the inlet and
outlet to the heater.
Companion Flange
Connections
(Models 926-1223 with UG)
DO NOT use petroleum base assembly fluids (such as
Petroleum Jelly or Lubricating Oil). If assembly lube is
required use a silicone base such as Armoral etc.
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 off.
NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will cause
very rapid corrosion to the heat exchanger in the
heater. Such damage is not covered under the
warranty.
The inlet/outlet header flange accepts a 2" copper tube
as a slip connection directly into the header. The
flange is also threaded for a 2 NPT copper male
adapter.
Fig. 10: Companion Flange Connections
(Models 926–1223 with UG)
11
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