Raypak SR-410 Installation Manual

INSTALLATION & OPERATING

INSTRUCTIONS

X94
Professional
Gas-Fired
Pool & Spa
Heater

Low NOx Model

SR-410

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 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.

AVERTISSEMENT: Assurez-vous de bien suivre
les instructions données dans cette notice pour
réduire au minimum le risqué d’incendie ou
d’explosion ou pour éviter tout dommage matériel,
toute blessure ou la mort.

Ne pas entreposer ni utilizer d’essence ou ni
d’autres vapeurs ou liquids inflammables à proim­ité de cet appareil ou de tout autre appareil.

CE FAIRE SI VOUS SENTEZ UNE ODEUR
DE GAS:

Ne pas tenter d’allumer d’appareil. •
Ne touchez á aucun interrupteur; ne pas vous•
server des téléphones se trouvant dans la
bâtiment.
Appelez immédiatement votre fournisseur de•
gaz depuis un voisin. Suivre les instructions
du fournisseur.
Si vous ne pouvez rejoinder le fournisseur,•
appelez le service es incendies.

L’installation et l’entretien doivent être assurés par
un installeur qualifié ou par le fournisseur de gaz.

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

Catalog No. 6000.66 Effective: 10-15-14 Replaces: NEW P/N 241494 Rev. 1

WATER CHEMISTRY

(Corrosive water voids all warranties)

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.

Recommended Level(s) Fiberglass Pools Fiberglass Spas

Water Temp. Deg. F
(Deg. C)

68 to 88

(20 to 31)

89 to 104
(32 to 40)

Other Pool & Spa

Types

68 to 104
(20 to 40)

pH 7.3 to 7.4 7.3 to 7.4 7.6 to 7.8

Total Alkalinity (PPM) 120 to 150 120 to 150 80 to 120

Calcium Hardness (PPM) 200 to 300 150 to 200 200 to 400

Salt (PPM) 4500 MAXIMUM 4500 MAXIMUM 4500 MAXIMUM

Free Chlorine (PPM)* 2 to 3 2 to 3 2 to 3

Total Dissolved Solids (PPM) 3000 MAXIMUM** 3000 MAXIMUM** 3000 MAXIMUM**

* Free Chlorine MUST NOT EXCEED 5 PPM!

** In salt water chlorinated pools, the total TDS can be as high as 6000 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, and which is not covered under warranty. A check
valve should be installed between the heater outlet and a chlorinator or other chem­ical dosing device.

• 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. 1 reflects the following:
Changes to: None
Additions: None
Deletions: None

2

CONTENTS

2 Water Chemistry

4 WARNINGS

4 Pay Attention to These Terms

5 PART ONE

OWNER'S OPERATING INSTRUCTIONS

5 SECTION 1

START-UP PROCEDURES

6 SECTION 2

CAUTION

6 SECTION 3

MAINTENANCE & CARE PROCEDURES

7 Lighting & Shutdown Instructions
8 Pool & Spa Water Chemistry
8 Automatic Chlorinators & Chemical Feeders
8 Cold Weather Operation
8 Winterizing the Pool & Spa Heater

9 PART TWO

INSTALLATION & SERVICE INSTRUCTIONS

9 SECTION 1

RECEIVING EQUIPMENT

10 SECTION 2

GENERAL SPECIFICATIONS

10 SECTION 3

INSTALLATION INSTRUCTIONS

10 Code Requirements
11 Clearances
11 Outdoor Heater Installation
13 Florida Building Code
14 Indoor Heater Installation
14 Specifications and Dimensions
16 Combustion and Ventilation Air
16 Direct Vent
17 Venting
18 Support of Vent Stack
18 Vent Terminal Location
19 Venting Installation Tips
19 Condensate Management
20 Venting Configurations
20 Vertical Venting (Category IV)
22 Horizontal Through-the-Wall Venting

(Category IV)
23 Direct Vent - Horizontal
25 Direct Vent - Vertical
25 Outdoor Installation
26 Gas Supply Connections
26 Supply Pressures
26 Gas Pressure Adjustment Locations
26 Pipe Sizing For Gas Connections
26 Heat Exchanger Pressure Drop Tables
27 Flow Rates
27 External Automatic Bypass Valve
27 External Auxiliary Bypass Valve
27 Auxiliary Bypass Valve Adjustment
27 Pressure Relief Valve Piping
28 Electrical Wiring

28 Transformer Wiring
29 Plumbing—Water Connections
29 Loose Plumbing Parts Setup
30 Recommended Plumbing Setups
32 Wiring Diagram

33 SECTION 4

SERVICING INSTRUCTIONS

33 General Location of Controls
34 Control Adjustments
34 Control Panel Removal
35 Thermostat Operation - Direct Spark Board
36 Installer Setup Mode
38 Status and Diagnostics
40 Remote Control Installation and Operation
40 Remote Operation
40 Activating the Remote
41 Remote Control Wiring
41 2-Wire Remote Control
41 3-Wire Remote Control
42 Time Clock / Fireman’s Switch
42 High Limits
42 Flow Switch
42 Blocked Vent Switch
42 Adjusting Valve Manifold Pressure
43 Visual Inspection
43 Electrical
43 Orifice Removal
43 Combustion Settings
43 Igniter Removal

43 SECTION 5

TROUBLESHOOTING

44 Mechanical
45 Control Logic - Flow Chart

46 SECTION 6

REPLACEMENT PARTS

46 Illustrated Parts List
48 Part Numbers

50 Important Instructions for the

Commonwealth of Massachusetts

51 Installer Setup Record

3

WARNINGS—Pay Attention to These Terms

DANGER:

WARNING:

CAUTION:

NOTE:

DANGER: Failure to properly vent the heater to the

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

DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.

DANGER: When servicing or replacing components
that are in direct contact with the water, be certain
that:

• There is no pressure in the heater. (Pull the release
on the relief valve. Do not depend on the pressure
gauge reading).

• The heater water is not hot.

• The electrical power is off.

WARNING: All venting types must be of the same
material or product throughout the entire exhaust
installation to ensure proper securing and sealing.

WARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube
bundle headers, or any ASME parts not
manufactured and/or approved by Raypak will
instantly void the ASME and/or CSA ratings of the
vessel and any Raypak warranty on the vessel.
Altering the ASME and/or CSA ratings of the vessel
also violates national, state, and local approval
codes.

WARNING: This product must be installed by a
licensed plumber or gas fitter when installed within
the Commonwealth of Massachusetts.

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

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

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

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

WARNING: Both natural gas and propane have an
odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.

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

WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the

State of California to cause cancer, birth defects or
other reproductive harm.

WARNING: Do not install within 3 feet of a heat
pump or an outdoor condensing unit. Strong air
intake from this type of equipment can disturb the
combustion process and cause damage or personal
injury.

WARNING: 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.

AVERTISSEMENT: N’utilisez pas cet appareil s’il
a été plongé dans l’eau, même partiellement. Faites
inspecter l’appareil par un technicien qualifié et
remplacez toute partie du système de contrôle et
toute commande qui ont été plongés dans l’eau.

4

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 LOSS OF LIFE.

INTRODUCTION

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

With proper installation and setup, operation of the heater is straightforward. The upper front panel of the heater
contains the control center that allows you to turn the heater On or Off, select the mode of operation, and adjust
the temperature settings for the pool or spa. The temperature range is factory set from 50°F (18°C) to 104°F
(40°C). See figure above for location of toggle switch to turn the heater On and Off. Section 4 of this manual con­tains more details about the use of the controls in the Control Adjustments subsection (starting on page 34).

SECTION 1 - START-UP PROCEDURE

1. Clean air louvers of dust, lint and debris.

2. Keep heater area clear and free from com-

bustibles, flammable liquids and chemicals.

3. Remove the top panel by removing the two screws

at the rear of the heater and the knurled screw
above the control panel. Lift the top panel off and
set it aside. Visually verify that the filter box intake
is not obstructed and that the filter is clean.

4. Water must be flowing through the heater during

operation. Ensure that the system is filled with
water and the pump is operating. Double check
for any water leaks.

5. Purge air from the gas line. Insufficient purging

may keep the heater from lighting on the first try.

6. Double check gas connections, make sure no

leaks are present. Use soapy water to inspect.

7. Double check incoming electrical power, verify suf-

ficient supply of 120V/1ph/60Hz power to the
heater.

8. If installed indoors, make sure flue gases are vent-

ed properly, and that combustion and makeup air
openings are adequate and clear of obstruction.

9. Verify that the fuel type of the unit matches the

supply gas.

10. Locate and turn the manual gas valve ON.

11. Locate the plugged bleedle valve on the pipe

downstream of the gas valve.

12. Remove the bleedle plug and connect a manome-

ter capable of reading up to -24" WC (-6 kPa).

CAUTION: The X94 manifold and blower suction
pressures measured at this point are negative, and
can be as high as -19" WC (-4.73 kPa) when the
blower is at full speed and the gas valve is closed.
Verify that manometers are rated appropriately and
set up to take measurements of this magnitude.

13. Locate and flip the display lid upwards.

14. Turn the heater on, by pressing the ON/OFF tog­gle switch on the front display.

15. Set the mode to either SPA or POOL. For installa­tions utilizing the Raypak Expanded Function
Board refer to the installation and set up instruc­tions on page 36-37 to set up the pump, valve and
auxiliary functions prior to firing the heater.

16. If the set point is higher than the current tempera­ture, the heater will begin its startup sequence.

17. The ignition control will verify that the blower relay
is open before starting the blower. Once proven
open, the blower will be powered to start the igni­tion sequence.

18. Once the blower relay proves, a 45 second pre­purge period will begin to purge the combustion
chamber.

19. Once the pre-purge period ends, the igniter will
begin to spark just prior to the gas valve opening.
The gas valve will open for a 4 second trial for igni­tion. If flame is proven, the heater will operate to
meet heat demand. If flame is not proven, the

5

heater will enter a post-purge period and then retry
the ignition cycle or lockout, depending on the
heater configuration.

20. Once gas is flowing, the manometer reading will
drop to -0.2” +/- 0.1" WC (-0.05 +/- 0.02 kPa) at
ignition and will read -2.0" +/- 0.5" WC
(-0.5 +/- 0.12 kPa) at high fire (7500 +/- 50 RPM
fan speed). See the instructions on page 42 for
adjusting the valve manifold pressure if the read­ing is not within tolerance.

21. Visually check through the sight glass that the
heater is on and heating. An orange glow indi­cates that the heater is running. At high fire, the
flame should be visible. The flame should be blue
in color with some orange streaks when the
air/fuel ratio is correct. See the visual inspection
instructions on page 43 for additional information.

22. Remove the manometer and replace the bleedle
plug.

23. Reinstall top panel, install the two screws at the
rear and knurled screw above the control panel.

24. Feel the inlet and outlet pipes. Outlet pipe should
be 10ºF to 20ºF (6ºC to 11ºC) warmer than the
inlet. It should not be hot.

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

SECTION 3 - MAINTENANCE AND
CARE PROCEDURES

WARNING: Check the heater for possible rodent
nests after long periods of non-use.

To be followed one month after start-up and then semi­annually.

1. Inspect and operate all controls, gas valve and

pressure relief valve.

2. On indoor heaters, clean room intake openings to

ensure adequate flow of combustion and ventila­tion air.

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

SECTION 2 - CAUTION

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

1. Spa water temperatures should never exceed
104°F (40°C). A temperature of 100°F (38°C) is
considered safe for a healthy adult. Special caution
is suggested for young children.

2. Drinking of alcoholic beverages before or during
spa or hot tub use can cause drowsiness which
could lead to unconsciousness and subsequently
result in drowning.

3. Pregnant Women Beware! Soaking in water over
102°F (39°C) can cause fetal damage during the
first three months of pregnancy resulting in the birth
of a brain-damaged or deformed child. Pregnant
women should stick to the 100°F (38°C) maximum
rule.

4. Before entering the spa or hot tub, users should
check the water temperature with an accurate ther­mometer; spa or hot tub thermostats may err in reg­ulating water temperatures by as much as 4°F
(2.2°C).

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

3. Keep area around heater clear and free from com­bustible materials, gasoline and other flammable
and corrosive vapors and liquids.

4. Visually inspect the intake air filter for damage or
obstruction. If the filter is visually good, test the fil­ter. If the intake suction reading when operating at
7500 RPM is more negative than -0.5" WC
(-0.1 kPa) replace the filter.

Fig. 1: Air Intake Pressure Measurement Location

IF HEATER WILL NOT FIRE:

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

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

6

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

AVERTISSEMENT: En cas de surchauffe ou si l’alimentation en gaz ne s’arrête pas, fermez manuellement
le robinet d’arrêt de l’admission de gaz.

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.

7

1. The time clock must be in the "ON" position.

COLD WEATHER OPERATION

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

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

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

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 tube, reducing heater efficiency and damaging the
heater. If the pH drops below 7.2, this will cause cor­rosion of the heat exchanger and severely damage the
heater. Heat exchanger damage resulting from

chemical imbalance is not covered by the warran­ty.

AUTOMATIC CHLORINATORS AND
CHEMICAL FEEDERS

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

Chlorinators must feed downstream of the heater and
have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off. A
check valve should be installed between the heater
outlet and the chlorinator.

See plumbing diagrams on page 30 and 31.

IMPORTANT FREEZE INFORMATION

MODERATE CLIMATE: Heater operation can con­tinue during short-term cold spells. When tempera­tures are between 0°F (-17ºC) and 32°F (0ºC), flow
(continuous pump operation) must be maintained.

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

COLD CLIMATE: Prolonged operation with water
temperatures below 50°F (10ºC) is not recommend­ed. When starting the heater with water temperatures
below 50°F (10ºC), operate the heater continuously
until higher temperatures are reached. Operating the
heater for prolonged periods with pool water below
50°F (10ºC) can seriously damage the heater, and is
not covered by the warranty.

For cold climate areas, please follow the winterizing
procedures listed.

WINTERIZING THE POOL & SPA HEATER

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

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

2. Disconnect the field supplied condensate drain line
from the condensate trap located below the
inlet/outlet water connections.

3. Remove the access panel below the inlet/outlet
water connections and connect a hose to the drain
valve. Direct the hose discharge to a safe drainage
location.

NOTE: High chemical concentrates from feeders and
chlorinators that are out of adjustment will cause rapid
corrosion of the heat exchanger. Such damage is

not covered under the warranty.

4. Open the drain valve and pull the PRV handle or
open the union at the water outlet connection to
allow the heater to drain.

5. Close the drain valve and disconnect the hose.

6. Remove the cap from the condensate trap.
Disconnect, remove and drain the condensate trap
and then re-intstall it.

7. Re-install the lower access panel and re-attach the
condensate drain line to the trap.

8

PART TWO
INSTALLATION AND SERVICE INSTRUCTIONS

SECTION 1 - RECEIVING EQUIPMENT

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

On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the
carton is damaged, a note should be made on the Bill of Lading when signing for the equipment. Remove the
heater from the carton. If it is damaged, report the damage to the carrier immediately. Save the carton.

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

STANDARD UNIT

1. Bypass assembly P/N 077087 6. (4) Mounting screws and (4) washers

2. Bonding lug with mounting screw 7. (2) Bird screens (not shown)

3. 4" Intake air adapter (not shown) 8. 4" Sch 40 PVC Tee and

4. PVC/Polypropylene/Stainless Steel 5" (127 mm) L x 4" diameter Sch 40
vent adapter P/N 502117 PVC vent pipe P/N 077450

5. (2) 2" CPVC Plugs (not shown) 9. (2) 2” CPVC Swivel Unions P/N 502142

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

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

9

SECTION 2 - GENERAL SPECIFICATIONS

These heaters are design-certified and tested under the latest requirements of the ANSI Z21.56 / CSA 4.7
Standard for Gas-Fired Pool Heaters. All heaters can be used either indoor or outdoors.

Ambient Temperature Rating of Heater Components

Electronics and controls -32°F to +175°F (-35.5ºC to +79.5ºC)
Condensate drains and trap* +32ºF to 175ºF (0ºC to 79ºC)

*The heater must be in a non-freezing environment to operate properly. Frozen condensate may damage com­ponents. Winterize the heater prior to prolonged exposure to freezing temperatures.

Rated inputs are suitable for up to 4,500’ (1,371 m) elevation. At elevations above 4500 feet (1,371 m) the input
will be reduced by approximately 4% for each 1,000’ (304.8 m) above sea level as high elevation reduces gas
and air density.

SECTION 3 - INSTALLATION INSTRUCTIONS

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.

WARNING: This unit contains refractory ceramic fiber (RCF) insulation in the combustion chamber. RCF, as
manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very
high temperatures (>2192°F), the RCF can transform into crystalline silica (cristabolite). The International
Agency for Research on Cancer (IARC) has classified the inhalation of crystalline silica (cristabolite) as car­cinogenic to humans.

When removing the burner or heat exchanger, take precautions to avoid creating airborne dust and avoid
inhaling airborne fibers. When cleaning spills, use wet sweeping or High Efficiency Particulate Air (HEPA)
filtered vacuum to minimize airborne dust. Use feasible engineering controls such as local exhaust ventilation
or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment
including gloves, safety glasses with side shields, and appropriate NIOSH certified respiratory protection, to
avoid inhalation of airborne dust and airborne fiber particles.

IMPORTANT NOTICE

These instructions are intended only for the use by 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. If your state is such, be sure your con­tractor bears the appropriate license. Persons not qualified shall not attempt to repair this equipment 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

NOTE: The heater should not be located in an area where possible water leakage will result in damage to the
area adjacent to the heater or to the structure. When such locations cannot be avoided, it is recommended
that a suitable drain pan, with adequate drainage, be installed under the heater. The pan must not restrict com­bustion air flow.

Installation must be in accordance with local codes, or, in the absence of local codes, with the latest edition of
the National Fuel Gas Code, ANSI Z223.1/NFPA54 and National Electrical Code, ANSI/NFPA 70, and for
Canada, the latest edition of CAN/CSA-B149 Installation Codes, and Canadian Electrical Code, CSA C22.1
Part1 and Part 2.

10

CLEARANCES

ALL HEATERS
For clearances from combustible surfaces, see the
chart below.

CLEARANCE FROM
COMBUSTIBLE CONSTRUCTION

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

INDOOR INSTALLATIONS:

Top - 24” (609.6 mm) Back - 1” (25.4 mm)
Front - Alcove (Open) Right Side - 1” (25.4 mm)
Vent - 1” (25.4 mm) Left Side - 1” (25.4 mm)
Floor* - 0” (0 mm)

OUTDOOR INSTALLATION

Top - Unobstructed (Outdoor Stack)
Floor - 0” (0 mm) Right Side - 1” (25.4 mm)
Back - 12” (304.8 mm) Left Side - 1” (25.4 mm)

*Do not install on carpeting.

OUTDOOR HEATER INSTALLATION

X94 Professional heaters are design-certified for outdoor installation, when equipped with the approved vent ter­minals designated for outdoor use. The heaters are designed for outdoor operation in non-freezing conditions
only. Freezing conditions may cause condensate to freeze in the condensate drain line and trap causing the unit
to shut down from a blocked condensate drain. Additionally, components of the condensate management sys­tem may be damaged by the ice formation. Units installed in freezing climates for seasonal use must be winter­ized to avoid freeze damage to the heater. See Winterizing Instructions on page 8.

However, for ease of servicing, Raypak recom-

mends a clearance of at least 24” (609.6 mm) in the
front and back. This will enable the heater to be serv-

iced in its installed location, without movement or
removal of the heater.

NOTE: The heater must be installed in a manner
that will enable the heater to be serviced without
removing any structure around the heater.

FLOORING: This heater can be installed on com­bustible flooring.

WARNING: The heater shall not be located in an area where water sprinklers, or other devices, may cause
water to spray through the cabinet louvers and into the heater. This could cause internal rusting or damage
electrical components, and void the warranty.

WARNING: Do not install within 3’ (0.91 m) of a heat pump or an outdoor condensing unit. Strong air intake
from this type of equipment can disturb the combustion process and cause damage or personal injury.

11

Heaters must not be installed under an overhang of less than five 5’ (1.52 m) from the top of the heater, and the

4’ (1.22 m)

Minimum

4’ (1.22 m)

Minimum

3’ (0.91 m)

Minimum

10’ (3.05 m)

Minimum

1’ (0.3 m)
Minimum

4’ (1.22 m)

Minimum

vent terminal must be a minimum of 5’ (1.52 m) from any overhang. See Page 18 for vent terminal location
requirements. Three sides must be open in the area under the overhang. Roof water drainage must be divert­ed away from the heaters installed under overhangs with the use of gutters.

For U.S. installations, the point from where the flue products exit the heater must be a minimum of 4’ (1.22 m)
below, 4’ (1.22 m) horizontally from, or 1’ (0.3 m) above any door, window or gravity inlet into any building. The
vent discharge of the heater shall be at least 3’ (0.91 m) above any forced air inlet, or intake ducts located with­in 10’ (3.05 m) horizontally.

For installations in Canada, pool heaters shall not be installed with the top of the vent assembly within 10’
(3.05 m) below, or to either side, of any opening into the building. Refer to the latest revisions of CAN/CSA­B149.

Fig. 2: Clearances

For installations in Florida and Texas that must comply with the Florida or Texas Building Code, follow the
directions on page 13 for the installation of hurricane tie-down method for all models.

12

FLORIDA BUILDING CODE 2010

ULTIMATE WIND SPEED = 170 MPH, 3 SECOND GUST

NOMINAL WIND SPEED = 132 MPH

EXPOSURE = C

Gas Heater Model No. 410

Fig. 3: Hurricane Tie Down Instructions

13

INDOOR HEATER INSTALLATION

The heater must always be vented to the outside. See the Venting section (beginning on page 17) for details.

Minimum allowable space is shown on the nameplate.

SPECIFICATIONS AND DIMENSIONS

Electrical Requirements:
120V/1ph/60Hz 5A

*Dimensions are in inches and [millimeters]

Fig. 4: Specifications and Dimensions

Dimensions

Heater

Model

SR-410 399.0 4” 4”

Notes:

1. The model number prefix indicates: (S=Stainless Steel Heat Exchanger), (R=Raypak) Model number suf­fix indicates: pilot type (E = Digital) and fuel type (P = Propane, N = Natural Gas). Example: Model number
SR-410-EN indicates a unit with digital (IID) ignition using natural gas with a stainless steel heat exchang­er.

2. Heaters are rated for natural gas and propane up to 4,500 feet (1,371.6 m). For elevations over 4,500’
(1,371.6 m), consult the factory.

3. Flue gases must be properly vented with CAT III for horizontal and CAT IV for vertical venting. Inlet air can
be ducted with 4” (101.6 mm) metal or PVC pipe. See the venting section of this manual for complete vent­ing details.

MBTU

Input

Flue

Diameter

(B)

Table 1: Specifications and Dimensions

Air Inlet

(C)

Minimum

Flow

40 GPM

(151 LPM)

Maximum

(473 LPM)

Flow

125 GPM

Shipping

Weight

300 (136 kg)

14

U.S. Installations

1

Canadian Installations

2

A

Clearance above grade, veranda, porch,
deck, or balcony

1 ft (30 cm) 1 ft (30 cm)

B

Clearance to window or door that may be
opened

4 ft (1.2m) below or to side

of opening; 1 foot (30 cm)

above opening

3 ft (91 cm)

C Clearance to permanently closed window * *

D

Vertical clearance to ventilated soffit located
above the terminal within a horizontal dis­tance of 2 ft (61cm) from the centerline of the
terminal

5 ft (1.5m) *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner 6 ft (1.83m) *

H

Clearance to each side of center line ex­tended above meter/regulator assembly

*

I Clearance to service regulator vent outlet * 3 ft (91cm)

J

Clearance to non-mechanical air supply inlet
to building or the combustion air inlet to any
other appliance

4 ft (1.2m) below or to side

of opening; 1 ft (30 cm)

above opening

3 ft (91 cm)

K Clearance to mechanical air supply inlet

3 ft (91 cm) above if within

10 ft (3m) horizontally

6 ft (1.83m)

L

Clearance above paved sidewalk or paved
driveway located on public property

7 ft (2.13m) 7 ft (2.13m) t

M

Clearance under veranda, porch, deck or
balcony

* 12 in. (30 cm) TT

1

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code

2

In accordance with the current CAN/CSA-B149 Installation Codes

t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that se rves

both dwellings

TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of term inal and

underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)

* Clearances in accordance with local installation codes and the requirements of the gas supplier

3 ft (91 cm) within a

height 15 ft above the

meter/regulator assembly

Fig. 5: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table 2: Vent/Air Inlet Termination Clearances

15

COMBUSTION AND VENTILATION AIR (Indoor Units Only)

The heater must have both combustion and ventilation air. Minimum requirements for net free air supply open­ings are one opening that is 12” (304.8 mm) from the ceiling for ventilation, and one opening that is 12”
(304.8 mm) from the floor for combustion air as outlined in the latest edition of the National Fuel Gas Code, ANSI
Z223.1(Canada-CAN/CSA-B149) and any local codes that may have jurisdiction.

A. All Air From Inside The Building:

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

Model Square Inches

SR-410 399 (0.26 m2)

B. All Air From Outdoors:

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

Model

Unrestricted Opening (sq. in.)

Typical Screened or

Louvered Opening (sq. in.)

Typical Screened and

Louvered Opening (sq. in.)

SR-410 100 (0.06 m2) 150 (0.1 m2) 200 (0.13 m2)

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

Table 3: Combustion Air Requirements

Direct Vent and Ducted Combustion Air Systems

If outside air is drawn through the intake pipe directly to the unit for combustion:

1. Install combustion air direct vent as instructed on page 22 (horizontal) or page 23 (vertical) of this manual.

2. Provide adequate ventilation of the space occupied by the heater(s) by an opening(s) for ventilation air at

the highest practical point communicating with the outdoors.

2

a) In the US, the total cross-sectional area shall be at least 1 in.

per kW) of total input rating of all equipment in the room when the opening is communicating directly
with the outdoors or through vertical duct(s). The total cross-sectional area shall be at least 1 in.

2

area per 10,000 BTUH (222 mm

per kW) of total input rating of all equipment in the room when the

opening is communicating with the outdoors through horizontal duct(s).

b) In Canada, there shall be permanent air supply opening(s) having a total cross-sectional area of not less

2

than 1 in.

of free area per 30,000 BTUH (70 mm2per kW) of the total rated input. The location of the

opening(s) shall not interfere with the intended purpose of the opening(s) for the ventilation air.

of free area per 20,000 BTUH (111 mm

2

of free

2

3. In cold climates, and to mitigate potential freeze-up, Raypak highly recommends the installation of a motor-

ized sealed damper to prevent the circulation of cold air through the heater during the non-operating hours.

16