Raypak 268 Installation & Operating Instructions Manual Download Page 3

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PART ONE
OWNER'S OPERATING INSTRUCTIONS

SECTION 1
START-UP PROCEDURES

Before Start-Up

Operating Instruction & Shut-Off Procedures -
Automatically Lighted Pilots IID

After Start-Up

SECTION 2
CAUTION

SECTION 3
MAINTENANCE & CARE PROCEDURES

Pool & Spa Water Chemistry

Automatic Chlorinators & Chemical Feeders

Cold Weather Operation

Winterizing the Pool & Spa Heater

PART TWO
INSTALLATION & SERVICE INSTRUCTIONS

SECTION 1
RECEIVING EQUIPMENT

SECTION 2
GENERAL SPECIFICATIONS

SECTION 3
INSTALLATION INSTRUCTIONS

Code Requirements

Clearances

Outdoor Heater Installation

Florida and Texas Building Codes

Indoor Heater Installation

Outdoor Stack/Indoor Stack

Specifications and Dimensions

Combustion and Ventilation Air

Vent Piping

Gas Supply Connections

Gas Pressure Regulator

Gas Pressure Adjustment Locations

Pipe Sizing For Gas Connections

Flow Rates

Heat Exchanger Pressure Drop

Water Connection Installation

Unitherm Governor Operation

Internal Automatic Bypass Valve

External Auxiliary Bypass Valve

Auxiliary Bypass Valve Adjustment

Pressure Relief Valve Installation

Plumbing—Water Connections

Electrical Wiring

Transformer Wiring

Wiring Diagram

SECTION 4
SERVICING INSTRUCTIONS

General Location of Controls

Control Panel Removal

Control Adjustments

Thermostat Operation

Status and Diagnostics

Remote Control Installation and Operation

Remote Operation

Activating the Remote

Remote Control Wiring

2-Wire Remote Control

3-Wire Remote Control

Time Clock / Fireman’s Switch

Water Flow Switch

Flame Roll-Out Safety Switch

High Limits

Pilot Safety

Burner Tray Removal

Gas Valve Removal

Main Burner and Orifice Removal

Pilot Removal and Cleaning

Heat Exchanger Removal

Tube Cleaning Procedure

Desooting Procedure

Combustion Chamber Removal

Immersion Well Replacement

Unitherm Governor (U.G.) Replacement

SECTION 5
TROUBLESHOOTING

Mechanical

Control Logic - Flow Chart

SECTION 6
REPLACEMENT PARTS

Illustrated Parts List

Part Numbers

CONTENTS

Summary of Contents for 268

Page 1: ...ot use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas sup plier 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 pl...

Page 2: ...XIMUM 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 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...

Page 3: ...Installation 20 Unitherm Governor Operation 21 Internal Automatic Bypass Valve 21 External Auxiliary Bypass Valve 21 Auxiliary Bypass Valve Adjustment 21 Pressure Relief Valve Installation 22 Plumbing Water Connections 23 Electrical Wiring 24 Transformer Wiring 25 Wiring Diagram 26 SECTION 4 SERVICING INSTRUCTIONS 26 General Location of Controls 26 Control Panel Removal 26 Control Adjustments 27 T...

Page 4: ...anel of the heater contains the control center that allows you to turn the heater On or Off and adjust the temperature set tings for the pool or spa The temperature range is factory set from 65 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 subs...

Page 5: ...technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water 1 STOP Read the safety information above 2 Set the thermostat to the lowest setting 3 Turn off all electrical power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand 5 Remove h...

Page 6: ...gested 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 ...

Page 7: ...4 The pump may have lost its prime and be running dry Check the pressure on the filter If there is no pressure then you are not moving water or your gauge is broken Try to get the pump to run at its normal flow rate 5 Check flow switch operation and paddles F pad dle on 268 or A paddle on 408 CAUTION Combustion air must not be contaminat ed by corrosive chemical fumes which can damage the heater a...

Page 8: ...arting the heater with water temperatures below 50 F operate the heater continuously until higher temperatures are reached Operating the heater for prolonged periods with pool water below 50 F can seriously damage the heater and is not cov ered by the warranty For cold climate areas please follow the winterizing procedures listed WINTERIZING THE POOL SPA HEATER Heaters installed outdoors in freezi...

Page 9: ...ese items are shipped inside a box in the carton with the heater 1 Pagoda top 2 In Out flanges 2 3 2 CPVC female tailpiece ring nut and o ring 4 2 flange gaskets 2 5 Flange bolts 4 6 Pressure relief valve 7 2 CPVC adapter 8 Plastic pipe finish flange for gas line 9 Bonding lug with mounting screw 10 2 CPVC manifold adapter 11 Prewired 1 flow switch with outdoor cover 12 Temperature pressure gauge ...

Page 10: ...2 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 The appropriate top designated for each type of use is required If necessary the top can be changed at a later date to change from outdoor to indoor or vice versa Ambient Tempe...

Page 11: ... Top 30 Drafthood Back 6 Front Alcove Open Right Side 12 Water Side Vent 6 Left Side 6 Floor 0 Opposite Water Side OUTDOOR INSTALLATION Top Unobstructed Outdoor Stack Top 36 Stackless Top Floor 0 Right Side 12 Water Side Back 6 Left Side 6 Opposite Water Side Clearance from top of vent terminal Do not install on carpeting Clearance from top of heater When installed according to the listed minimum ...

Page 12: ...ny building The top surface of the heater shall be at least 3 ft above any forced air inlet or intake ducts located within 10 ft horizontally For installations in Canada pool heaters shall not be installed with the top of the vent assembly within 10 ft below or to either side of any opening into the building Refer to the latest revisions of CAN CSA B149 4 ft Minimum 4 ft Minimum 1 ft Minimum 4 ft ...

Page 13: ...Washer Field Supplied Ea Pallet Anchor Bracket Use hole closest to unit 4 total 1 1 4 x 1 3 4 S S Tapcon Bolt Washer Field Supplied Ea Pallet Anchor Bracket Use hole closest to unit 4 total 2 x 6 x 1 8 Pallet Anchor Bracket 4 Total Kit 011636 1 4 x 1 3 4 S S Tapcon Bolt Washer Field Supplied NOTE Use hole closest to unit with washer overlapping edge of unit 6 6 268 408 Atmospheric MODEL B 268 23 4...

Page 14: ...e See Vent Piping section pg 16 17 for details Minimum allowable space is shown on the nameplate OUTDOOR STACK INDOOR STACK NOTE The outdoor and indoor stacks are optional equipment and do not come standard with the heater OUTDOOR STACK KIT INCLUDES 1 Drafthood painted 1 Adapter plate 3 Mounting brackets clips 1 Top panel cover 2 1 foot sections of metal tape 3 Screws 1 Instructions Clips INDOOR S...

Page 15: ... natural gas is EN Prefix B is for brass ASME headers Suffix X is for cupro nickel tubing EXAMPLE B R408 EN X Brass headers 408 model size AFT natural gas cupro nickel Reduce input 4 for each 1000 ft above sea level when installed above 2000 ft elevation For Canada no de rating is required for elevations up to 4500 ft Note For outdoor stack use J dimension in the table above for appropriate size P...

Page 16: ... Code ANSI Z223 1 Canada CAN CSA B149 COMBUSTION AND VENTILATION AIR Indoor Units Only The heater must have both combustion and ventilation air Minimum requirements for net free air supply open ings are one opening that is 12 inches from the ceiling for ventilation and one opening that is 12 inches from the floor for combustion air as outlined in the latest edition of the National Fuel Gas Code AN...

Page 17: ... locat ed outside the heater jacket All gas piping should be tested after installation in accordance with local codes 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 psi 3 45 kPa Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut off...

Page 18: ... Honeywell VR8304 Heater Models 268 and 408 Gas Pressure Adjustment Robertshaw 7000 BDER Heater Model 268 Gas Pressure Adjustment Robertshaw 7000 DERHC Heater Model 408 PIPE SIZING FOR GAS CONNECTIONS Maximum Equivalent Pipe Length ft Natural Gas 1000 BTU FT3 0 60 Specific Gravity 0 5 in WC Pressure Drop Propane Gas 2500 BTU FT3 1 53 Specific Gravity 0 5 in WC Pressure Drop Input 3 4 1 1 1 4 1 1 2...

Page 19: ...tes exceed maximum GPM an external auxil iary bypass valve is required See external bypass valve section for details FLOW RATES HEAT EXCHANGER PRESSURE DROP FLOW GPM PRESSURE DROP FT OF HEAD 268 408 30 8 0 40 9 0 9 0 50 9 8 9 8 60 10 5 10 5 70 11 0 11 0 80 11 5 11 5 90 14 0 14 0 100 17 0 17 0 19 ...

Page 20: ...he 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 temper atures UNITHERM GOVERNOR UG SPRING UG PLUG GASKET BEHIND UG The heater must be located so that any water leaks will not damage the structure of adjacent area High tem perature 2 plastic pipe CPVC may be threaded directly into ...

Page 21: ... the heater the internal bypass valve automatically responds to changes in water pres sure in the piping system Proper amount of water flow is maintained through the heater under varying pres sures dictated by the conditions of the pump and filter EXTERNAL AUXILIARY BYPASS VALVE Where Required An auxiliary bypass valve should be used when flow rates exceed 125 GPM Usually a high performance pump s...

Page 22: ...ater Heater must be located so that any water leaks will not damage the structure of adjacent area CAUTION An additional source of heated water e g a solar system must be connected to the main line ahead of the heater inlet pipe in order for it to act as the primary heat source If the primary system provides adequate heat to maintain set point the heater will not fire Be advised that the control p...

Page 23: ...ough the left jacket side of heater 9 Re install P6 connector ground wires SPG transformer junction box front door and plug right side with the left side s grommet plug NOTE 7 8 dia holes not utilized on jacket and control box can be used for fireman switch auxiliary control interface or power vent D 2 wiring The Electronic Intermittent Ignition Device automati cally lights the pilot and main burn...

Page 24: ...al Code CSA C22 1 Part 1 and Part 2 120V ATMOSPHERIC HEATER SUPPLY SIDE RETURN or NEUTRAL HEATER 4 WIRES GROUND L1 RED BLACK HOT BLACK GREEN GREEN WHITE WHITE 240V ATMOSPHERIC HEATER HEATER 4 WIRES L1 L2 RED RED BLACK HOT HOT BLACK GREEN GREEN WHITE SUPPLY SIDE NOTE Input power to the heater 120 or 240 VAC can be supplied from the load pump side of time clock or directly from the GFCI power source...

Page 25: ...25 WIRING DIAGRAM ...

Page 26: ...rol panel down until panel stops Do not force NOTE Caution must be used to not damage controls or wiring CONTROL ADJUSTMENTS SECTION 4 SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS Roll Out Switch Gas Valve Pilot AFT Thermostat Circuit Board Transformer behind panel Unitherm Governor Drain Valve Mounted on In Out Header HL1 High Limit Temp Sensor Well Mounted on Return Header HL2 High Limit ...

Page 27: ...ory press the MODE and UP buttons simultaneously for 3 to 5 seconds The heater will continue to operate normal ly while in the Service Menu The first screen dis played is the Flame Strength indicator which indicates LCD Display Temp Buttons Mode Button Program button ALTERNATING DISPLAYS DURING HEATING FLAME STRENGTH INDICATOR SUPPLY VOLTAGE INDICATOR RUN TIME INDICATOR Press the DOWN button The S...

Page 28: ...f displaying Celsius as well as Fahrenheit temperatures The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display Choose the desired temperature scale Spa Max Temp Spa Set Point Maximum Adjustment Refer to step one above to access the program screen Press the Mode button until Spa Max Temp appears on the digital display Using the UP and DOWN buttons will change the Maximu...

Page 29: ...m manded state Internal Fault Board fault replace board EEPROM Fault Memory fault reset set points replace board if fault does not clear Clock Fireman Sw Time clock fireman switch circuit is open Low Temp Lockout Water temperature below 36 F The following heat status messages are displayed in Pool Spa and Remote modes when there are no active fault conditions The following conditions are displayed...

Page 30: ...by the remote wiring Typically a remote does not supply power to the heater it only provides a switching function to turn the heater On or Off If your remote is supplying its own voltage to the heater it will not work with this heater and may damage the digital circuit board For operation of the heater using the onboard thermo static controls with a time clock see the Time Clock Fireman s Switch s...

Page 31: ...e actual setpoint will be con trolled by the remote control 4 Turn the mode button to OFF and remove power from the heater 5 On the Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and con nect the other side to either the ORANGE BLACK wire for SPA operation or the BLACK ORANGE wire for POOL operation 6 Attach wire nut on unused wire to the Remote Interface Harness 7...

Page 32: ...ype and set to shut off the call for heat to the pool heater 15 to 20 minutes prior to shutting down the pool pump The fireman s switch connection is located on the 14 pin header connected to the digital control board Splice into the red wire jumper tagged Where necessary add Fireman s switch circuit here to con nect the time clock The fireman s switch connec tion must be a dry contact and must no...

Page 33: ...secure gas valve to jacket 6 Disconnect wires that terminate at gas valve 7 Disconnect hi tension wire from PC board 8 Slide out burner tray 9 Reverse above procedure to reinstall GAS VALVE REMOVAL 1 Shut off gas supply to the heater Remove gas piping to gas valve inlet 2 Disconnect wires pilot tubing and bleed line if required 3 Remove burner tray from heater 4 Turn vertical gas pipe from manifol...

Page 34: ...the refractory retainer TUBE CLEANING PROCEDURE Establish a regular inspection schedule the frequency depending on the local water conditions and the sever ity of service Do not let the tubes clog up solidly Clean out deposits over 1 16 in thickness The heater may be cleaned from the return header side without breaking pipe connections It is prefer able however to remove both headers for better vi...

Page 35: ...vement replace unit UNITHERM GOVERNOR U G REPLACEMENT 1 Shut water gas and electricity off close valves and relieve pressure 2 Drain heat exchanger 3 Remove retainer plug located next to the outlet pipe connection 4 Unsnap old U G to remove from retainer plug Snap in new U G 5 Reinstall retainer plug taking care to lubricate gasket with a non petroleum based grease such as AquaLube 35 ...

Page 36: ...r outlet water temperature is between 105 F and 110 F U G Inoperative Check movement by putting in hot water 110 F or higher If no movement replace Air starvation Refer to installation instructions Improper venting Follow recommended installation instructions Insects or debris clogging burner intake ports Clean burners Pilot outage or Low gas pressure Adjust gas pressure Weak Flame signal Restrict...

Page 37: ...Check resistance value of the thermister Reference to chart below Replace thermister if not within 10 of values shown below If okay replace Circuit Board Temp Degrees F 40 50 60 70 80 90 100 106 Resistance k 261 1 199 0 153 1 118 8 93 0 73 3 58 3 51 0 If okay replace Circuit Board Sensor resistance at various temperatures Water Sw Open Water flow switch Verify water flow and pressure CLEAN FILTER ...

Page 38: ...ement under standard company warranties must be properly tagged with a 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 a like part or equal substitution will be returned freight collect Credit will not be issued MANUFACTURER 2151 EASTMAN AVENUE OXNARD CA 93030 ...

Page 39: ...39 ...

Page 40: ...811F 013811F 3 H Inlet Outlet Flange BR 013812F 013812F 4 H Flange Gasket 800080B 800080B 5 H Return Header ASME BR 002451F 002451F 6 H Tube Bundle Cupro Nickel ASME 013813F 013814F 7 H Baffle 013815F 013816F 8 H Stud Bolt Kit 007870F 007870F 9 H Header Gasket 9 800014B 800014B 10 H Unitherm Governor 062234B 062234B 11 H U G Retainer Spring 013792F 013792F 12 H U G Plug 013738F 013738F 13 H Bypass...

Page 41: ...ght 010088F 010088F 2 R Refractory Uncommon Front Rear 010090F 010092F 3 R Refractory Retainer Kit 010388F 010390F S SHEETMETAL 1 S Jacket Top Louvered 010048F 010050F 2 S Flue Collector 013818F 013819F 3 S Door Assy 013820F 013821F 4 S Access Panel Set 3 Pcs 010312F 010312F 5 S Jacket Side Panel Right 010376F 010376F 6 S Jacket Side Panel Left 010377F 010377F 7 S Jacket Rear Panel 2 Pcs 010373F 0...

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Page 44: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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