Raypak P-926, 1287-1758, P-1826, P-2100, P-4001 User Manual

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INSTALLATION AND OPERA TING INSTRUCTIONS

RAYTHERM

COMMMERCIAL SWIMMING POOL HEATER

Models

P-926 to P-1826

CATALOG NO. 6200.51O Effective: 04-09-07 Replaces: 05-15-05

Models 1287-1758

and P-2100 to P-4001

Models 2100-4001

WARNING: If the information in these instructions is 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 in a safe place for future reference.

P/N 240251 Rev. 16

Contents

SECTION 1: RECEIVING EQUIPMENT

SECTION 2: GENERAL SPECIFICATIONS

SECTION 3: INSTALLATION INSTRUCTIONS

Code Requirements

Base Installation

Clearances

Combustion Air

Venting Connections

Gas Supply Connections

Water connections

Controls

Wiring Diagrams

SECTION 4: SERVICING INSTRUCTIONS

General Location of Controls

Start-Up Procedures

Inspection Procedures

Servicing Procedures

Maintenance & Care

SECTION 5: TROUBLE SHOOTING

Mechanical

Electrical

SECTION 6: REPLACEMENT PARTS

WARRANTY

SECTION 1 / RECEIVING EQUIPMENT

On receipt of the equipment, visually check for external

IMPORTANT NOTICE

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 boiler 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

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.

Serial Number of boiler. 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

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.

representative.

Claims for shortages and damages must be filed with

CODE REQUIREMENTS

carrier by consignee. Permission to return goods must be factory authorized and are subject to a stocking charge.

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.

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.

SECTION 2 / GENERAL SPECIFICATIONS

Installation must be in accordance with local codes,

Models 962, 1125, 1223, 1336, 1468, 1631, 1826 & 2100 through 4001 are specifically designed for indoor

or, in the absence of local codes, with the latest editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and National Electrical Code, ANSI/NFPA 70.

installation only. Models 926, 1083, 1178, 1287, 1414, 1571 & 1758 are specifically designed for outdoor instal-

BASE INSTALLATION

lation only. All heaters are standard with electronic ignition for both natural and propane applications. Heaters require 115V power supply. Control circuits operate at 24V, to be supplied by a 115V to 24V transformer.

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

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 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.

surface. An optional non-combustible base is available for Indoor Heater 962 through 1826. An alternative method for providing a base for combustible floors as illustrated below. Heaters may not be installed on

carpeting.

12"

inimum

HEATER

Minimu

SECTION 3 / INSTALLATION INSTRUCTIONS

Sheet Metal

CALIFORNIA PROPOSITION 65 WARNING:

This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Hollow concrete cinder block; align holes and leave

ends open. Alternative method for providing a non-com-

Minimum

bustible base.

24 Gauge

Fig. #8148

CLEARANCES

ALL HEATERS For clearances from combustible surfaces, see chart below. We require a minimal vertical clearance of three feet between the upper surface of the flue outlet to a noncombustible material.

MINIMUM CLEARANCES FROM COMBUSTIBLE CONSTRUCTION

INDOOR HEATERS

Top - 24" *Vent - 6" Back - 24" Right Side - 24" Left Side - 24"

OUTDOOR HEATERS (926-1758)

Top - unobstructed Back - 24" Right side - 24" Left Side - 24"

For servicing provide a front clearance as shown below

Model 926/962-758/1826 - 24" Model 2100-4001 - 48"

*Vent includes factory supplied drafthood and does not include field supplied vent systems above the drafthood. On Models 2100-4001 drafthood is built into boiler.

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.

OUTDOOR HEATERS (MODELS 926-1758)

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 the heaters installed under overhangs with the use of gutters.

foot

Minimum

foot

Minimum

Forced Air Inlet

foot

Minimum

foot

Minimum

foot

Minimum

Fig. #8245

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 also certified for indoor installation when equipped with approved drafthood. Locate heater as close as practical to a chimney or gas vent.

COMBUSTION AIR (INDOOR UNITS ONLY)

The heater must have both combustion and ventilation air. Openings must not be obstructed. Minimum requirements are as follows:

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty.

1. Free combustion air 1 sq. in. per 1000 BTU

input within 12" of the floor.

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.

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

DRAFTHOOD (INDOOR) MODELS 962-1826

Locate and assemble as shown below. Secure with

screws supplied in envelope in carton.

Fig # 8165

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.

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 boiler drafthood. 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 construction.

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 Fuel Gas Code ANSI Z223.1/NFPA 54.

Models 2100-4001 have built-in drafthoods that must be properly vented to the outside.

VENT PIPING

WARNING:

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 draft hood 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 Chapter 10 of the National Fuel Gas Code, ANSI Z 223.1/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 should be supported at not more than five foot intervals. Plumbers' tape, criss-crossed, 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.

10' OR LESS

2' MIN

VENT PIPE

DRAFT HOOD

HEATER

VENT CAP

2' MIN

5' MIN

Fig. #8119

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.

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.

GAS SUPPLY CONNECTIONS

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 accordance with local codes.

MANUAL SHUT HEATER GAS VALVE

OFF VALVE JACKET

GAS INLET

UNION SEDIMENT TRAP

FIG. #8090.0

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.

(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 re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54.

For special venting applications that require reduced vent sizes and through the wall venting, the optional D Series Power Vent can be used. Consult the factory or your local Raypak representative.

NOTE: Do not use teflon tape on gas line pipe thread.

A flexible sealant is recommended.

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 counterclocwise , to decrease pressure.

GAS PRESSURE MANOMETER

TEST UPSTREAM MANUAL

SHUT-OFF

VALVE

GAS PRESSURE TEST

AT GAS VALVE GAS PRESSURE TEST

AT HEATER

PIPE SIZING FOR GAS CONNECTIONS

Fig. #8149.0

Bleed Line Connection

Fig. # 8185.2

WATER CONNECTIONS

LOCATION

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.

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 Models 926-1223, if local codes permit and if controls operate the pump for at least fifteen minutes after the heater is turned off.

VENTING OF DIAPHRAGM GAS COMPONENTS

Heaters have gas train 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 Gas Code. Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system.

CAUTION (Models 926-1223): NEVER install PVC directly into heater. Four feet of copper or high temperature pipe and two elbows are required between the heater and the PVC connections.

Fig. # 8129.0

When local codes permit the use of less than four feet high temperature piping or two elbows, provisions should be made to always shut the heater off a minimum of 15 minutes prior to pump shut down in order to carry away residual heat and prevent damage to the low temperature piping. A fireman switch included in the time clock may be used for this purpose with instructions not to override this sequence manually. See wiring diagram section for electrical hookup location of the fireman switch in the electrical circuit.

NOTE (Models 926-1223): 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.

CONTROLS

WATER PRESSURE SWITCH

A water pressure switch is provided in the heater to shut down the gas valves in the event the 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 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 in Section 4 of this manual).

WARNING: Operation of the heater without water circulation will cause rapid and severe damage to the heater.

AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS

UNITHERM GOVERNOR OPERATION

The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105° to 115°F despite continually changing flow rates from the filter 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. It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures.

The Unitherm Governor is built into the inlet/outlet header on models 926 through 1223. The larger sizes, models 1287 through 4001, have an externally mounted bypass pump that is designed to maintain the water entering the heater at the proper temperature that will prevent condensation and scale. Thermometers are provided on the inlet and outlet to the heater.

COMPANION FLANGE CONNECTIONS (Models 926-1223)

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.

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.

MODELS 926 - 1223

INLET/OUTLET HEADER

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).

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.

FLANGE GASKET

OUTLET

INLET HEADER FLANGE

Fig. #8221.0

MODELS 1287/1336 - 1758/1826

1-1/2" Slip Ball Valve

2-1/2" Outlet

2-1/2" Inlet

MODELS 2100-4001

2" Slip Ball Valve

3" Outlet

Inlet/Outlet Header

Pump

Inlet/Outlet Header

Fig. #9200

3" Inlet

2 H.P. Pump

FLOW RATES/WATER CONNECTIONS

MODEL CONNECTION SIZE MIN GPM MAX GPM

926-1223 * 60 120 1287-1826 2-1/2" FPT Refer to flow rate table 2100-4001 3" FPT

LOOP* HEATER

FLOW FLOW

RATES RATES

MODELS (GPM) (GPM)

1287/1336 30-50 85 1414/1468 35-55 85 1571/1631 40-65 85 1758/1826 45-70 85

2100 50-80 180 2500 60-95 180 3001 75-115 180 3500 90-135 180 4001 100-150 180

*Loop is secondary piping to heater from main system.

Fig. #9270

Raypak recommends the installation of an air bleed vent at a suitable location (usually the highest point) to remove air from the piping system. These units should be available at your local wholesale supplier. Raypak does not provide this item.

CAUTION:

Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation. Improper flow control can damage the heater. Uncontrolled flow (too high) or restricted flow (too low) can

seriously affect heater operation. Follow these instructions to make sure your heater is properly installed.

Models 1287 through 4001 are equipped with an external pump and bypass arrangement that blends outlet water with the inlet to increase the inlet water temperature, thereby reducing the likelihood of condensation forming on the heat exchanger. The pump also serves to circulate water through the heater from the main system piping.

To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return water line. This will ensure that the heater will be energized at the right time. If the main water line is too far away from the heater and the capillary bulb will not reach it, locate the pool thermostat adjacent to the main line and run wires back to the heater. Follow the instructions listed below to install the pool stat.

MOUNTING THE POOLSTAT CONTROL WITH FRONT-MOUNTED LOOP USING MOUNTING SLOTS

For heater models:

1287, 1336, 1414, 1468, 1571, 1631, 1758, 1826, 2100, 2500, 3001, 3500, 4001. Note: For more detail on piping, see figures 9268 and 9269.

1. Remove the poolstat control cover by removing the two cover screws at the top. See Figs. 1 & 2.

2. Lace metal strapping or clamps, (NOT PROVIDED) through the ¾” slots on the cover and fasten securely to pipe as shown in Figs. 3 & 4. NOTE: Do not over-tighten clamps.

3. Remove either the left or right “knock-out” for wiring on the poolstat control as shown in Fig. 5.

4. Attach appropriate conduit and connectors to the poolstat control.

5. Attach wires to the poolstat wire terminals. See Fig.6.

6. Install poolstat control to the cover and fasten cover screws.

7. Poolstat should be mounted level as shown in Fig. 7.

Fig. 3: Hose Clamp Slots

Fig. 4

Fig. 1: Poolstat Control

Fig. 2: Control Cover

Fig. 5 Fig. 6 Fig. 7

MOUNTING WELL INTO SYSTEM RETURN LOOP PIPE - FRONT-MOUNTED LOOP:

Note: For more detail on piping configurations for large systems, see figures 9268 and 9269.

1. Locate and mark an area on the main system return loop pipe where the well is always exposed to the water circulating back from the pool. See Fig. 8.

2. Shut off water and drain any water from the pipe as necessary.

3. Drill a 23/32" diameter hole (½” NPT) into the pipe as shown in Fig. 9.

4. Using a ½” NPT tap and appropriate handle, thread the tap into the pipe.

5. Apply pipe dope as necessary to male threads of well and insert into threaded hole.

Note: Do not over-tighten well.

Fig. 8

Fig. 10

Fig. 9

Note: The drawings and instructions above show only one of several acceptable ways of installing the dry well into main system loop. The use of saddle clamps and “Weld O Lets” (shown in Fig. 10) are acceptable. Follow clamp manufacturer’s instructions.

To adjust the temperature:

1. Both isolation valves must be fully open.

2. Adjust Bypass Valve "A" 1/2 open and Balancing Valve "B" fully open. (See piping configuration page 11)

3. Fire your Raypak pool heater and adjust Bypass Valve "A" to obtain a heater inlet temperature approximately 100°F-105°F. Turning Valve A in the open direction will raise the heater inlet temperature and closing Valve "A" will lower the heater inlet temperature.

4. If the heater inlet temperature remains less than 100°F and Valve "A" is fully open, leave Valve "A" fully open and throttle Valve "B" until the heater inlet temperature rises to within the range of 100°F-105°F.

5. The resultant heater outlet temperature should be in the range of 120-130°F.

6. As the pool temperature rises to the desired temperature as controlled by the Pool aquastat, small adjustments to valves "A" and "B" will be required for optimum performance. Heater temperatures should be checked regularly to prevent heater condensation. The heater inlet temperature can be higher than 100°F without heater damage but operating at less than 100°F inlet can cause damage from condensation.

Note: Consult factory if target temperatures cannot be achieved.

PIPING CONFIGURATIONS FOR RAYTHERM COMMERCIAL POOL HEATERS

Fig # 9268 Fig # 9269

Models 2100 thru 4001

To Tc

BLENDED WATER TEMPERATURE (THERMOMETER AT HEATER INLET)

HEATER OUTLET TEMPERATURE THERMOMETER

HEATER THERMOSTAT RECOMMENDED FIELD INSTALLED

ISOLATION VALVES FOR SERVICE

EXTERNAL AUXILIARY BYPASS VALVE (Where Required) 926-1223 Models only

An auxiliary bypass valve should be used when flow rates exceed 120 GPM (usually a high performance pump size larger than two HP will exceed this flow rate). This valve is required to complement the function of the automatic bypass valve, particularly when starting the heater in winter or early spring when the spa or pool temperature is below 55°F. It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the flow rate to the spa jets, etc.

FROM TO HEATER HEATER

BYPASS VALVE

INLET/OUTLET HEADER

Fig. #8223.0

OPEN POSITION CLOSED POSITION

MANUAL BYPASS ADJUSTMENT

Fig. #8222.0

TO POOL TO POOL

Fig. #8150

AUXILIARY BYPASS VALVE

(DO NOT USE GATE VALVE) AUXILIARY BYPASS VALVE ADJUSTMENT

To set bypass: With clean filter, 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.

NOTE: Do not use a gate valve as an auxiliary bypass valve on any heaters.

Models 926-1223 The heater is also equipped with a manual bypass built

into the header. This is in addition to the automatic bypass valve. This may be used with flow rates up to 120 GPM and adjusted as below.

NOTE: Sooting or liming caused by improper bypass adjustment voids the warranty.

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-off 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.

TEMPERATURE CONTROLS HIGH LIMITS

The pool heater is equipped with two high limits. Both high limits, the non-adjustable auto reset high limit and adjustable manual reset high limit are attached to the outlet side of the in/out header.

POOL STAT The pool heater is equipped with a pool thermostat that is attached to the inlet side of the in/out header to control the pool temperature.

LOW WATER CUT-OFF Automatically shuts down burner whenever water level drops below probe. 30 second time delay prevents premature lockout due to temporary conditions such as power failure or air pockets. Standard on Cal Code heaters.

Fig. #6043

HIGH & LOW GAS PRESSURE SWITCHES

Pressure switches sense either high or low gas pressure and automatically shut down burners if abnormal pressures exsist. Standard on Models 3001-4001.

PRESSURE SWITCH

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.

GAS MANIFOLD

Fig. #8236

ELECTRICAL WIRING

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

DANGER - SHOCK HAZARD - Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components.

NOTE: If it is necessary to replace any of the original wiring, it must be replaced with 105° C wire or its equivalent.

ELECTRONIC IGNITION

The intermittent ignition device conserves energy by automatically extinguishing the pilot when desired temperature is reached. When additional heat is needed, the pilot re-ignites electrically, eliminating the fuel costs of maintaining a constant pilot. To ensure safe operation, the gas valve cannot open until the pilot relights and is confirmed.

Fig. #8929.1

Model w/out lockout with lockout

926-1826 Natural Gas Standard Optional 926-1826 Propane N/A Standard 2100-4001 Natural Gas N/A Standard 2100-4001 Propane N/A Standard

WIRING DIAGRAM MODELS 926 - 1223

WIRING DIAGRAM MODELS 1287-1826

WIRING DIAGRAM MODELS 2100-2500

WIRING DIAGRAM MODELS 3001-4001

SECTION 4/ SERVICING INSTRUCTIONS

TEMPERATURE CONTROL

GENERAL LOCATION OF CONTROLS

MODELS 926-1826

Inlet/Outlet Pressure Header Switch

Unitherm Electrical Governor Conn.

Hi-limit control/ Temp. Control Main Burner Gas Valve

MODELS 2100-4001

Inlet/Outlet Header w/Bypass Pump

The pool water temperature is controlled by the pool

thermostat.

The heater water temperature high limit is controlled by

the manual reset high limit. PRESSURE SWITCH

The pressure switch, or heater actuator, ensures that the heater operates only when the filter pump is in operation. It is factory set at 1.75 PSI for deck level installations. When the heater is located below the level of the spa or pool, it may be necessary to reset the pressure switch to compensate for the no-flow static head. If it is necessary to reset the pressure switch, we recommend the following procedure:

PRESSURE SWITCH ADJUSTMENT:

1. Make sure the pool filter is clean before adjusting

the switch.

2. Set the heater control to the OFF mode.

3. Turn the filter pump on and confirm that the pressure

switch is closed (use a multimeter to check). If the pressure switch fails to close, either the switch setting is too high or the filter pump is not supplying enough pressure.

4. Turn the heater ON.

5. Manually turn the pressure adjustment knob clock-

wise until the heater shuts off. (A flat screw driver may be necessary if knob is too tight).

6. Slowly turn the adjustment knob counter-clockwise

until the heater calls for heat again.

7. Turn an additional 1/2 turn counter-clockwise.

8. While the heater is running, check the adjustment by

turning the pump off and on several times. The burners should shut off immediately when the pump is turned off. If it does not, repeat the above steps until proper operation is observed.

Main Burner

Gas ValveManual On/Off Valve

Electrical

Connection

Fig. #9261.1

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.

WATER

ADJUSTMENT KNOB

Fig. # 8069.1

PRESSURE SWITCH ADJUSTMENT RANGE

HEAT EXCHANGER HEIGHT 5' Max

5' Max

Fig. # 8152.0

NOTE: If heater is installed outside of the limits shown, a flow switch must be used in place of the pressure switch when mounted and wired adjacent to the heater.

TWO-SPEED PUMPS

In some cases, the flow on the low speed is insufficient to operate the heater. This is apparent when the pressure switch cannot be further adjusted or if the heater makes banging noises. In these cases, the pump must be run at high speed when heating the water.

Water must be flowing through the heater.

START-UP

CAUTION: Propane gas is heavier than air and sinks to the ground. Exercise extreme care in lighting heater in confined areas.

LIGHTING INSTRUCTIONS

1.Close all gas valves. Turn off electric power supply wait 5 minutes.

2.Open manual pilot valve. Turn on electric power, pilot is automatically lighted.

3.Open main gas valve.

4.Set temperature controls to desired temperature.

Fig. #8929.1

TO SHUT DOWN

CAUTION: Do not operate the heater without the function of a properly adjusted pressure switch.

PILOT SAFETY

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

Close all manual gas valves. Turn off electric power.

AFTER START-UP

INSPECTION PROCEDURES

Pilot System Checkout Procedure

1.Turn on power to the ignition systems and turn gas supply off.

2.Check ignition module as follows: a.Set the thermostat above pool water

temperature to turn heater on. b.Watch for continuous spark at the pilot burner. c.Time the spark operation. Time must be within

the lockout timing period (15 or 90 seconds). d.Turn thermostat down to turn off heater and

wait 60 seconds on lockout models before

beginning step 3.

3.Turn on gas supply.

4.Set thermostat above pool water temperature to turn on heater.

5.Systems should start as follows: a.Spark will turn on and pilot gas valve will open

at once. Pilot burner should ignite after gas reaches the pilot burner.

b.Spark ignition should cut off when pilot flame is

established.

c.Main gas valve should open and main burner

should ignite after gas reaches the burner port.

BURNERS

Clean main burners and air louvers of dust, lint and debris. Keep boiler area clear and free from combustibles and flammable liquids. Do not obstruct the flow of combustion and ventilating air. Make visual check of burner and pilot flame. Yellow flame indicates clogging of air openings. Lifting or blowing flame indicates high gas pressure. Low flame indicates low gas pressure.

4" Max

Fig. #8144

MAIN BURNER FLAME

PILOT BURNER FLAME

Feel inlet and outlet pipes. Outlet should be only slightly warmer than inlet. It should not be hot.

WARNING: Should overheating occur or the gas supply fails to shut off, turn off the manual gas control to the appliance.

CONTROLS

Check all controls to see that they are operational. To check electric safety turn off main burner. Observe pilot burner when shutting off pilot gas. Ignition spark should go on. Main gas valve will also drop out.

SERVICING PROCEDURES

TUBE CLEANING PROCEDURE (TYPICAL)

Establish a regular inspection schedule, the frequency depending on the local water condition and severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness.

Although the illustration shows the mechanical cleaning procedure of a small boiler, it is typical of all sizes. The boiler may be cleaned from the return header side as shown, without breaking pipe connections. It is preferable, however, to remove both headers for better

RAYPAK TUBE CLEANING KIT

Extension Pieces (5) Auger with Carbide Tip Wire Brush

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 pan or the heat

exchanger, generally.

After reaming, mount the wire brush in lieu of the

auger and clean out the 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.

Fig. #8154.0

Fig. #6049

BURNER DRAWER REMOVAL

1. Shut off power and gas supply to the pool heater. Disconnect union(s) and pilot tubing, then loosen and remove burner-hold down screws.

2. Disconnect wires at gas valve and slide burner drawer out.

GAS VALVE REMOVAL

1. Shut off gas supply to the pool heater. Remove gas piping to gas valve inlet.

2. Disconnect wires, pilot tubing and bleed line, if required.

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

4. Reverse above procedure to re-install.

MAIN BURNER AND ORIFICE REMOVAL

1. Remove screws and burner hold down bracket.

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

2. Lift burners from slotted spacer and slide from orifices. Clean with a wire brush.

3. Orifices usually do not need to be replaced. To clean, run either copper wire or wood through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove the manifold. DO NOT overtighten when reinstalling.

PILOT REMOVAL AND CLEANING

1. Disconnect pilot tubing at pilot and sensor/igniter wire. Remove screws holding pilot bracket to burner drawer.

2. Remove pilot and bracket, clean pilot of debris, small bugs, etc., with wire or small brush.

3. Replace pilot, pilot tubing, sensor ignition wires and check for leaks.

5. Remove heat exchanger corner brackets.

6. Remove combustion chamber clips at the four corners of the heat exchanger.

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

HEAT EXCHANGER REASSEMBLY

1. Heat exchanger header O-rings should be replaced with new ones.

2. Install inlet-outlet and return water headers and install header retainer nuts and torque nuts evenly.

3. Install the four (4) corner clips between tube sheets and refractory. Replace "V" baffles.

4. Install thermostat sensing bulbs in header wells and replace bulb retaining clips.

5. Install inlet and return pipes in water headers using pipe thread sealant.

6. Install water pressure relief valve, flow switch, and low water cutoff devices if so equipped.

7. Open water supply and return shutoff valves. Fill heater and water piping system with water. Check heater and piping system for leaks at full line pressure. Run system circulating pump for a minimum of 1/2 hour with heater shutoff.

8. Shut down entire system and vent all radiation units and high points in system piping. Check all strainers for debris.

9. Install fuel collector, jacket top and inspection panels. Install top holding screws. Install draft diverter and vent piping if so equipped.

10. If gas piping was disconnected, reconnect gas piping system and check for leakage using a soap solution.

11. Double check electrical circuits, grounding connections and pump with wiring diagram supplied with heater.

12. Check for correct water pressure and water level in the system. Make sure that system pump operates immediately on the call for heat. The system is ready for operation.

COMBUSTION CHAMBER REMOVAL

HEAT EXCHANGER REMOVAL

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

2. Remove top holding screws.

3. Remove draft diverter, lift and remove top and flue collector on stack type models. Remove inspection panels.

4. Loosen bolts and disconnect flange nuts on inletoutlet header, loosen union(s) at gas pipe, and slide boiler away from piping until studs clear the heater.

To remove the combustion chamber you must first have removed the heat exchanger. Unbolt metal combustion chamber retainer from top and remove combustion chamber panels individually.

REFRACTORY PANELS TOP VIEW

Fig. #8155.0

CONTROL WELL REPLACEMENT

Remove top, sensing bulb and clip. Collapse well tube at the open end and with a chisel, push through into the header, and remove the well through header. Insert a new well and roll into place. If a roller is not available, solder the well in place with silver solder.

Insert tube roller into tube opening up to stop against tube, then push center rod in until roller is tight. Be careful to keep replacement tube squared up 1/8" outside each tube sheet. A loose tube will sometimes pull toward the roller. Attach drill motor to tube roller, holding it straight and level. Proceed to expand tube until the tool begins to grab. At this point, 1/2" to 1" should be exposed on the tool shank. Reverse drill motor or wrench out by hand. Care should be exercised to avoid applying excessive torque during rolling operation and to avoid thinning out any part of the tube wall excessively over .015". Use same procedure at the opposite end of the tube.

Apply line pressure test, and re-roll, if necessary, before replacing canopy.

IMMERSION WELL

Fig. #8126.0

TUBE REPLACEMENT PROCEDURE

On Raypak tube replacement may be affected without rolling, as a temporary means of repair, provided there are two or more tubes rolled into act as stays on left and right sides. The "O" rings should provide a seal up to 125 PSI working pressure. Use a 3/8" heavy duty reversible drill motor or larger, to power the tube roller. If a reversible drill is not available, after rolling the tube in, remove the drill motor and wrench out the roller. A tube roller is available from the factory.

Shut gas and power off to the unit, close the system off and drain the pool heater. Remove draft diverter. Remove the access panels and jacket top. Lift the canopy and flue collector off (on models 926-1826, remove the canopy hold-down brackets). Remove "V" baffles over tube(s) to be replaced. If no pipe unions have been provided, use the header as a union, remove the flange nuts off the inlet-outlet header, break gas connection and slide boiler away from piping, allowing room to work. Pull wedge slips out of control wells and remove sensing bulbs. Remove flange nuts from the return header and remove header. Lift heat exchanger straight up and out.

Heat exchanger header o-rings must be replaced with new ones. The tube may be cut out with a hack-saw or hammer and chisel adjacent to both tube sheets, leaving stubs in the tube sheets. Then proceed to collapse stubs in the tube sheets with a chisel or screwdriver. Use caution not to cut into the tube sheet. Replacement tubes will have the fins stripped off longer on one end. The long end is inserted into the opening of the tube sheet first; then the short end is fitted through the opposite tube sheet. If the tube ends become dented or bent, straighten at least four (4) inches back from the tube end by means of a tapered punch.

PROCEDURE FOR CLEANING FLUE GAS PASSAGEWAYS

Soot can clog areas behind fins and cause eventual tube failure. Any sign of soot at base of burners or around outer jacket indicates a need for cleaning.

1.Lift off draft hood and flue collector by removing

bolts and screws.

2.Remove "V" baffles from heat exchanger.

3.Remove burner tray.

4.Take garden hose and wash heat exchanger,

making sure soot is removed from between fins.

(Avoid excessive water against refractory).

5.Reassemble; when boiler is fired, some steam

will form from wet refractory. This is normal.

NOTE: In extreme cases it may be necessary to remove the heat exchanger completely for cleaning. The simplest method is steam cleaning at a local car wash. DO NOT WIRE BRUSH!

CAUTION: Soot is combustible, so exercise extreme care.

UNITHERM GOVERNOR REPLACEMENT

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

2.Drain heat exchanger.

3.Remove Unitherm Governor.

MODELS 926-1223

UNITHERM GOVERNOR

INLET/OUTLET HEADER

OUTLET

INLET GASKET

UNITHERM GOVERNOR WITH POWER ELEMENT

MODELS 1287-1826 (Models prior to Jan. '95) DOUBLE EXTERNAL U.G.

Fig. #8224.0

3.Inspect and operate all controls and gas valve.

4.Make visual check of burner and pilot flame. Flame pattern on main burner and pilot is indicated above. Yellow flame means restriction of air openings. Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure.

5.Clean room air intake openings to ensure adequate flow of combustion and ventilation air.

6.Remove header opposite inlet pipes when cleaning and inspect internal tubes for scale deposits. If scale does not form within first quarterly inspection, then inspect annually thereafter.

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty.

7.Keep heater air clear and free from combustible materials and other flammable and corrosive vapors and liquids.

8.Keep moving parts lubricated.

9.Manual operation of pressure/temperature relief valve at least once a year.

SPA WATER CHEMISTRY

MODELS 2100-4001 (Models prior to Jan. '95) EXTERNAL U.G.

To test operation of Unitherm Governor, place in hot water and watch for movement against spring. If no movement, replace.

MAINTENANCE AND CARE

To be followed one month after initial start-up and

then quarterly.

1.Inspect top of heater and draft-hood for soot, and open fuel gas passageways.

CAUTION: Soot may be combustible. Wet completely when cleaning.

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

NOTE: Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water pH between 7.2 and 7.8, and total alkalinity between 100 and 150 ppm. 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.

NOTE: Heat exchanger damage resulting from chemical imbalance is not covered under the warranty.

WINTERIZATION

WINTERIZING YOUR HEATER

When heaters installed outdoors in freezing climate areas are to be shut down for the winter, please observe the following step-by-step procedure:

1.Remove the drain plug or open the drain cock located

on the inlet-outlet header. On larger heaters with

external Unitherm Governor(s) and piping, locate

plug at low point of Governor piping, or break connec-

tions and rotate inlet fittings 180° to face downward.

Turn off manual main gas and main gas shut off.

2.Disconnect compression fittings on both ends of the

1/8" copper tube and allow the tube to drain. Remove

the "heat exchanger inspection panels" on the right

side of the heater to gain access to the fitting on the

return header. Remove return header.

SECTION 5 / TROUBLESHOOTING GUIDE

IMPORTANT NOTICE

These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.

MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY)

PROBLEM Harmonics, or whining noise

Heater going on and off continously

Liming or scale forming on heat exchanger

Sooting

CAUSE U.G. Inoperative……………………

*Debris or restriction in system…… *Debris in gas line…………………..

Low flow……………………………...

Dirty filter…………………………… Low water evel in pool……………… External bypass setting out of adjustment………………………….. *Pressure switch out of adjustment…………………………..

Pool water…………………………....

High flow rates…………………….....

U.G. Inoperative……………………..

*Air starvation………………………..

*Improper venting…………………....

*Insects or debris clogging burner intake ports…………………..

SOLUTION Check movement by putting in hot

water (110°F or higher). If no movement, replace. Locate the restriction and remove. Flush system and clean. Remove debris or blow out gas line. Scale forming in heat exchanger clean heat exchanger and check pool pH and total alkalinity.

Backwash filter. Raise water level.

Adjust bypass Adjust pressure switch Recommended pH should be be-

tween 7.2 and 7.8 total alkalinity 100150 PPM maximum. Hardness -150400 PPM maximum.

Reduce by adding manual bypass valve and adjust by putting thermometer in header (1/4" NPT) drain opening. Set bypass so thermometer reads between 105° and 110°F. Check movement by putting in hot water (110°F or higher). If no movement, replace. Refer to installation instructions. Follow recommended installation instructions.

Clean burners

Pilot outage

Yellow lazy flame

Low gas pressure…………………....

Restricted pilot……………………....

Weak pilot generator………………..

Low gas pressure…………………....

*Insects or debris clogging burner intake ports…………………..

Adjust gas pressure. Clean pilot. Replace pilot.

Adjust gas pressure. Clean burners.

*Usually occurs on initial start-up

Outer jacket very hot (paint blistered)

Takes long time to heat pool or spa

Liming

Leaking at well. Leaking at heat exchanger. Gasket brittle and leaking-

(overheated).

*Broken refractory caused by shipping damage or improper combustion………………………….. Excessive sooting of heat exchanger…………………………...

Calculate temperature in °F/hr……...

Filter not running long enough……....

Dirty filter…………………………….. Gas line or meter under-

sized………..................................

Bypassing too much water………....

U/G not functioning……………….....

Overacid…………………………......

Overacid……………………………... Heater running after pump

shuts off……………………………... Refractory damage…………………. Sooted heater………………………..

Replace refractory panels. Determine cause of sooting &

correct. Heat rise (°F/hr.) = Htr.output

Pool gallonage x 8.33 or refer to heater sizing chart. This does not take into account heat loss due to weather. Reset time clock. Clean filter.

Refer to installation instructions.

Inspect bypass for movement, if no movement, replace. Replace if no movement when heated. Replace well and maintain water chemistry properly. Replace heat exchanger and maintain chemistry properly.

See pressure switch adjustment. Replace refractory. Determine cause of sooting and correct.

*Usually occurs on initial start-up

ELECTRICAL (ELECTRONIC IGNITION IID) IID

Intermittent Pilot System

TROUBLESHOOTING HONEYWELL S8600

234567890123456789012345678901212345678901234567890123456789012

For qualified Technicians ONLY

NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. To reset, interrupt power to heater.

WARNING

HIGH VOLTAGE

START

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

POWER TO MODULE

(24 V NOMINAL)

YES

SPARK ACROSS

IGNITER/SENSOR GAP

YES

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

SPARK STOPS WHEN

PILOT IS LIT?

YES

NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout procedure.

Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring.

Pull ignition lead and check spark at module. Spark Okay?

YES

• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.

• Check boot of the ignition cable for signs of melting or buckling. Take protective action to shield cable and boot from excessive temperatures.

• Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice is not blocked.

• Check electrical connections between module and pilot operator on gas control.

• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay, replace gas control; if not, replace module.

NOTE: If S8600H goes into lockout, reset system. Lockout is used on Pro. models.

• Check continuity of ignition cable and ground wire.

• Clean flame rod.

• Check electrical connections between flame rod and module.

• Check for cracked ceramic flame rod insulator.

• Check that pilot flame covers flame rod and is steady and blue.

• Adjust pilot flame.

• If problem persists, replace module.

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

TROUBLESHOOTING

ENDS

• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.

• Check electrical connections between module and gas control. If okay, replace gas valve or gas control operator, i.e. pilot gas valve, flow switch etc.

NOTE: IF S8600H goes into lockout, reset system.

• Check continuity of ignition cable and ground wire. NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though

operation is normal at the time of checkout.

• Check that pilot flame covers flame rod and is steady and blue.

• If checks are okay, replace module.

• Check for proper thermostat (controller) operation.

• Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas valve.

Repeat procedure until trouble free operation is obtained.

SECTION 6 / REPLACEMENT PARTS LIST

NOTE: To supply the correct part it is important that you

state the model number, serial number and type of gas when applicable.

Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to the Company freight prepaid.

If determined defective by the Company and within warranty, the part will be returned in kind or equal substitution, freight collect. Credit will not be issued.

Raypak, Inc.

2151 Eastman Avenue

Oxnard, CA 93030

MODELS: 926/962, 1083/1125, 1178/1223, 1287/1336, 1414/1468, 1571/1631, 1758/1826

2-C

MODELS: 2100, 2500, 3001, 3500, 4001

343536

LIMITED WARRANTY

RA YTHERM TYPE P

SIZES 0926-4001

SCOPE: Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty . Labor charges and other costs for part s removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility .

HEAT EXCHANGER WARRANTY : Five (5) years from date of heater installation. Includes only cupro nickel heat exchanger with bronze waterways.

ANY OTHER P ART MANUF ACTURED OR FURNISHED BY RA YP AK: One (1) Y ear warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak’s records, whichever comes first. SA TISFACT ORY PROOF OF INST ALLA TION DA TE, SUCH AS INST ALLER INVOICE, IS REQUIRED. THIS W ARRANTY WILL BE VOID IF THE HEA TER RA TING PLA TE IS AL TERED OR REMOVED.

ADDITIONAL WARRANTY EXCLUSIONS: This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;

2. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding heater design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the heater system;

7. Chemical contamination of combustion air or use of chemical additives to water.

8. Misuse or neglect, including but not limited to freeze ups, and operating the heater with cabinet door off, having flow restrictions or obstructions between the heater outlet and pool/spa or not maintaining proper thermal balance (pH level must be between 7.2 and 7.8 and total alkalinity between 100 and 150 PPM. T ot al Dissolved Solids (TDS) must be no greater than 3000 PPM)

P ARTS REPLACEMENT : Under this Warranty , Raypak will furnish a replacement for any failed p art. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty . Raypak makes no warranty whatsoever on parts not manufactured by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer .

TO MAKE WARRANTY CLAIM: Promptly notify the original installer , supplying the model and serial numbers of the unit, date of inst allation and description of the problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service Manager, Rayp ak, Inc., 2151 Eastman A ve, Oxnard, CA 93030 or call (818) 889-1500. In all cases proper authorization must first be received from Raypak before replacement of any part.

EXCLUSIVE WARRANTY - LIMIT A TION OF LIABILITY : This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf. THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P ARTICULAR PURPOSE. RAYP AK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE P ARTS SHALL BE AS PROVIDED IN THIS W ARRANTY . IT IS AGREED THAT RA YP AK SHALL HA VE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT , TOR T, NEGLIGENCE OR OTHERWISE, FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENT AL DAMAGE, INCLUDING DAMAGE FROM WA TER LEAKAGE. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not apply to you. This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the date of manufacture plus thirty (30) days.

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 913030 (805) 278-5300 FAX (800) 872-9725

Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036

Litho in U.S.A.

Raypak P-926, 1287-1758, P-1826, P-2100, P-4001 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual