Raypak 268A Installation And Operation Manual Download Page 42

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DESCRIPTION

268A

408A

BURNER TRAY

1-B

Burner Tray w/Burners (sea level)*

013796F

013797F

Burner Tray w/o Burners (sea level)*

013798F

013799F

Burner Tray w/Gas Valve Nat IID

013800F

013801F

Burner Tray w/Gas Valve Pro IID

013802F

013803F

2-B

Burner Spacer/Hold Down Kit

013804F

013805F

3-B

Burner

301210/18

301210/27

4-B

Burner Orifice

Natural Gas

Burner Orifice #50*

350079F/18

350079F/27

Burner Orifice #51*

350080F/18

350080F/27

Burner Orifice #52*

350081F/18

350081F/27

Propane Gas

Burner Orifice #57*

350083F/18

350083F/27

Burner Orifice #58*

350087F/18

350087F/27

Burner Orifice #59*

350350F/18

350350F/27

Burner Orifice #60*

350351F/18

350351F/27

5-B

Burner Tray w/o Manifold w/o burners

013806F

013807F

CONTROLS

1-C

Thermostat Auto Reset 135 Deg Surface Mount - Units manufactured from 12/2019

006725F

2-C

AGS 135° (Auto Gas Shutoff) - Red Epoxy - Units manufactured prior to 12/2019

600892B

3-C

High Limit 140° - Black Epoxy - Units manufactured prior to 12/2019

600893B

4-C

P.C. Board/Control

013464F

7-C

LCD Display

Units manufactured from 5/2011

013640F

8-C

Fuse 5 AMP

013733F

6-C

Temperature Sensor IID Units

009577F

9-C

Thermostat Reset Deg Surface Mount - Units manufactured from 12/2019

018304F

GAS VALVE

1-G

Combination Valve - Nat. IID

003900F

Combination Valve - Pro. IID

004306F

**WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and

Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause

premature failure of this replacement part.

*FOR INSTALLATION AT OVER 2,000 FEET ABOVE SEA LEVEL, DERATE 4% PER I,000 FEET ABOVE SEA LEVEL. Refer to the heater's

rating plate.

RELEASED

For Reference Only

Summary of Contents for 268A

Page 1: ...sonal 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 p...

Page 2: ...ns See page 14 WATER CHEMISTRY Water chemistry requirements See page 5 POWER Supply voltage See page 21 for acceptable input voltages VENTING Materials See pages 11 and 13 D 2 Power Vent Kit See page 13 Indoor Stack See page 11 CONTROLS INTERFACE Wiring diagrams See page 22 User interface See pages 23 Remote operation See page 27 QUICK START GUIDE Revision 7 reflects the following changes Figure 1...

Page 3: ...ve 17 Auxiliary Bypass Valve Adjustment 17 Pressure Relief Valve Installation 18 Heat Exchanger Reversal 18 Plumbing Diagrams 19 5 ELECTRICAL WIRING 20 Electrical Power Draw 20 Transformer Wiring 21 6 WIRING DIAGRAM 22 7 CONTROLS 23 Control Panel Removal 23 Control Adjustments 23 Operation 24 Status and Diagnostics 26 Remote Control Wiring 27 8 OPERATING INSTRUCTIONS 32 Before Start Up 32 Start Up...

Page 4: ...use severe personal injury death or substantial property damage if ignored ACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored CAUTION CAUTION used without the warning alert symbol indicates a potentially hazardous condition which could cause minor personal injury or product or property damage if ignored NO...

Page 5: ... CHEMISTRY Chemical imbalance can cause severe damage to your heater and associated equipment Maintain your water chemistry according to Table A If the mineral content and dissolved solids in the water become too high scale forms inside the heat exchanger tubes reducing heater efficiency and damaging the heater If the pH drops below 7 2 this will cause corrosion of the heat exchanger and severely ...

Page 6: ... 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 when appropriate venting is installed 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 All units have heat exchangers wit...

Page 7: ...alified shall not attempt to fix the equipment nor attempt repairs according to these instructions AWARNING Improper installation adjustment alteration service or maintenance may damage the equipment creating a hazard resulting in asphyxiation explosion or fire Such damage is not covered under warranty NOTE The heater should not be located in an area where possible water leakage will result in dam...

Page 8: ...et metal with ventilated air space over 0 024 sheet metal with ventilated air space Back 4 102 Right 4 102 Left 4 102 Vent 3 76 Indoor Top 24 610 Outdoor Top Unobstructed h 1 25 mm glass fiber or mineral wool batts sandwiched between two sheets 0 024 sheet metal with ventilated air space Back 4 102 Right 4 102 Left 4 102 Vent 3 76 Indoor Top 24 610 Outdoor Top Unobstructed Derived from National Fu...

Page 9: ...nside corner wall for proper outdoor venting Pagoda Top Installation 1 Insert tabs into keyhole 4 places See Figure 4 detail A 2 Snap tabs into keyholes so as not to pull out See Figure 4 detail B OUTDOOR TOP SHIPPED LOOSE WITH HEATER DETAIL A DETAIL B Figure 4 Outdoor Top Installation For installations in Florida and Texas that must comply withtheFloridaorTexasBuildingCode followthedirections sho...

Page 10: ... 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 and Washer Field Supplied NOTE Use hole closest to unit with washer overlapping edge of unit Min Edge Distance 6 152 mm Min Edge Distance 6 152 mm F10646 7 F10648 1 Model B in mm 268A 23 584 408A 29 737...

Page 11: ...e minimum requirements are listed in the latest edition of the National Fuel Gas Code U S ANSI Z223 1 or Canada CAN CSA B149 and any local codes that may have jurisdiction The most common approach is the 2 opening method with combustion air opening no more than 12 from the floor and the ventilation opening no more than 12 from the ceiling For opening sizes using this method see below All Air from ...

Page 12: ...hipping Weights lbs kg Heater Mode BTUH Input 000 kw A Cabinet Width in mm B Flue Dia in mm C Indoor Drafthood in mm D in mm J in mm Gas Conn in Water Conn in ASME Heater w Stackless Top Indoor Draft hood B _268A EN X 266 0 77 9 23 584 7 178 62 1575 11 5 292 11 279 3 4 2 229 104 16 7 3 B _408A EN X 399 116 9 29 737 9 229 64 9 16 1640 14 5 368 12 1 8 309 3 4 2 268 122 21 9 5 Table G Commercial Heat...

Page 13: ...the building within 8 2 4 m Vent stack shall be at least 5 1 5 m in vertical height above the drafthood outlet The vent cap location shall have a minimum clearance of 4 1 2 m horizontally from and in no case below unless a 4 1 2 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Theweightoftheventstackorchimneymustnotrestonthe heater drafthood Suppo...

Page 14: ...e Supply Pressure ACAUTION Do not use teflon tape on gas line pipe thread Only sealant tape or a pipe compound rated for use with natural and propane gases is recommended Apply sparingly only on male pipe ends leaving the two end threads bare A minimum of 6 in WC and a maximum of 10 5 in WC upstream pressure under load and no load conditions must be provided for natural gas A minimum of 12 in WC a...

Page 15: ...ure Drop Propane Gas 2500 BTU FT3 1 53 Specific Gravity 0 5 in WC Pressure Drop Model 3 4 1 1 1 4 1 1 2 N P N P N P N P 268A 15 4 6 35 10 7 50 15 2 125 38 1 210 64 0 480 146 3 445 135 6 408A 15 4 6 20 6 1 55 16 8 95 29 0 225 68 6 215 65 5 480 146 3 A 3 4 gas line can be used for up to 5 1 5 m maximum length from the gas valve in addition to the sediment trap Table I Gas Pipe Sizing Flow Rate Model...

Page 16: ...e ProTek Shield Adapter assembly shipped loose in the accessory carton for field installation on bronze ASME headers This component provides protection to the heat exchanger against galvanic corrosion when properly bonded to the heat exchanger It should be replaced when the weight of the ProTek Shield is reduced to about 40 of the original weight 1 46 F10715 Figure 17 ProTek Shield Assembly ACAUTI...

Page 17: ...PRING YELLOW COLOR 268A GREEN COLOR 408A Figure 19 Internal Automatic Bypass Valve Bronze NOTE The Unitherm Governor and Bypass Valve Assy are not individually replaced components onASME units If either needs to be replaced the entire UG Bypass assy must be replaced The yellow color spring is used on model 268A The green color spring is used on model 408A External Auxiliary Bypass Valve Where Requ...

Page 18: ...ed downstream of the discharge side of the filter pump See Figure 22 and Figure 23 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 heate...

Page 19: ...BY A PROFESSIONAL ENGINEER Figure 22 Single Pool Heater Installation THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER Figure 23 Multiple Pool Heater Installation ISOLATION VALVE PRESSURE RELIEF VALVE PUMP UNION CHECK VALVE BALL VALVE RELEASED For Reference Only ...

Page 20: ...ll P6 connector ground wires SPG transformer junction box front door and plug right side with the left side s grommet plug NOTE 7 8 diameter holes not utilized on jacket and control box can be used for fireman switch auxiliary control interface or power vent D 2 wiring Electrical Power Draw ACAUTION Heater must be electrically grounded and bonded Bonding lug is provided loose with the heater Insta...

Page 21: ...CK HOT HOT BLACK GREEN GREEN WHITE SUPPLY SIDE Figure 26 240 VAC Wire Connection 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 Canada Canadian Electrical Code CSA C22 1 Part 1 and Part 2 ACAUTION If the transformer s primary side is wired for 120 VAC and 240 VAC is...

Page 22: ...22 6 WIRING DIAGRAM RELEASED For Reference Only ...

Page 23: ...ad located on the upper front panel of the heater allows the user to select either POOL or SPA operation and to adjust the setpoint temperature The LCD display window indicates the mode OFF SPA POOL and the actual water temperature A manual power switch provided below the touchpad turns the control power ON or OFF See Figure 30 TEMP MODE ON OFF LCD DISPLAY TEMP ADJUST BUTTONS MODE BUTTON Figure 30...

Page 24: ...cator Press the DOWN button The Supply Voltage screen indicates the voltage supplied to the control board Normal readings range from 24 to 29 volts Figure 34 Supply Voltage Indicator Press the DOWN button The Run Time indicates the total hours of operation for the pool heater as measured by the amount of time that the main gas valve has been powered The Cycle count indicates the number of on off c...

Page 25: ... control can be set for a maximum of 107 F 42 C Pool Max Temp Pool Setpoint Maximum Adjustment Refer to step one above access into the program screen Press the MODE button until POOL MAX TEMP appears on the digital display Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value The control can be set for a maximum of 107 F 42 C Control Lockout The heater is ...

Page 26: ...lt replace board EEPROM Fault Memory fault reset setpoints 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 2 C Table M Heater Status Messages Active Faults The following conditions are displayed only while there is a demand for heat present Display Condition Water Sw Open Water pressure switch open Vent ...

Page 27: ...e Control Menu Remote Operation Activating the Remote To activate or deactivate the remote function 1 Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds The second line of the display will alternate even when the unit is off No Demand NOTE When in remote operation the keypad mode and temp buttons are disabled Figure 39 Remote Control Menu Activation Remote Control Wiring ATTENTION OBS...

Page 28: ... Pin Remote Interface Harness to the P8 connector and turn power ON to the heater See Figure 41 For activation of the remote control see section on page 27 3 Wire Remote Control Using Three Position Switch Pool Off Spa or Low Off High This application assumes that both heating functions pool and spa are required 1 Turn on power to the heater 2 Push the MODE button to the POOL or SPA mode and set t...

Page 29: ...o orange and orange black to orange black No further adjustment is needed Figure 43 Water Flow Switch Assembly NOTE The sheet metal cover should be in place at all times to protect the flow switch from rain and other environmental factors Flame Roll Out Safety Switch Heaters are equipped with a thermal cutoff device to prevent flame roll out in the event the heat exchanger becomes blocked This is ...

Page 30: ...ire brush 4 Orifices usually do not need to be replaced To clean run either copper wire or wood toothpick through orifice Do not enlarge hole To remove orifice use a socket wrench and remove from manifold DO NOT overtighten when reinstalling Pilot Removal And Cleaning 1 Disconnect pilot tubing and wires from gas valve 2 Remove pilot assembly from burner tray 3 Remove pilot from bracket 4 Remove pi...

Page 31: ...eat exchanger from the heater and wash with a garden hose making sure soot is removed from spaces between fins 6 Reverse above procedure to reinstall NOTE In extreme cases it may be necessary to do steam cleaning at the local car wash DO NOT WIRE BRUSH Combustion Chamber Removal To remove combustion chamber you must first have removed the heat exchanger F10723 Figure 49 Refractory Panels AWARNING ...

Page 32: ...ection 7 for additional details about the use of the controls in the Control Adjustments subsection After Start Up Feel the inlet and outlet pipes Outlet pipe should be only slightly warmer than the inlet It should not be hot AWARNING Should overheating occur or the gas supply fail to shut off turn off the manual gas control to the appliance Visual inspection With the heater on remove the door and...

Page 33: ...y 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 heater door panel 6 For Honeywell valve Turn gas control knob clockwise to OFF For Robertshaw valve Turn gas control knob clockwise to OFF 7 Wait 5 min...

Page 34: ...ook to see if the filter pressure is 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 Cold Weather Operation Important Freeze Information MODERATE CLIMATE Heater operation can continue during short term cold spells ...

Page 35: ...valve until heater outlet water temp is between 105 F and 110 F 40 C and 43 C U G inoperative Check movement by putting in hot water 110 F 43 C 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 Weak Flame signal Low gas pressure...

Page 36: ... pilot operator on gas control Check for 24 VAC across PV MV PV terminals on PC board If voltage is okay replace gas control if not replace PC board NOTE If PC board goes into lockout reset system Lockout is used on L P G models Check for 24 VAC across MV MV PV terminals If no voltage replace module Check electrical connections between PC board and gas control If okay replace gas valve or gas cont...

Page 37: ...8 41 Resistance k 261 1 199 0 153 1 118 8 93 0 73 3 58 3 51 0 If okay replace Circuit Board Sensor Failure Inspect thermistor wires and connector at Terminal P1 Check resistance value of the thermistor Reference to chart below Replace thermistor if not within 10 of values shown below If okay replace Circuit Board Sensor resistance at various temperatures Water Sw Open Pressure switch Verify water ...

Page 38: ...ndard 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 RELEASED For Re...

Page 39: ... 8 S 3 S 8 M 7 M 2 J 1 G 10 S 1 B 5 B 4 B 3 B 1 M 2 B 16 M 1 J 7 S 1 R 6 M 4 C 3 C 11 S 17 HM 4 S 1 V 4 V 2 V 3 V 1 S 12 S 2 S 5 HM 7 HM 2 H 3 R 6 HM 9 M 3 HM 14 M 2 R 5 S 6 S 4 HM 14 S 4 S 9 H 8 C 11 P 25 M RELEASED For Reference Only ...

Page 40: ... 7 HM 5 HM 20 M 21 M 19 M 2 HM FOR UNITS WITH ASME BRONZE HEADERS PRIOR TO 12 2019 16 HM 15 HM 12 HM 9 HM 10 HM 2 C 6 M 11 HM 8 HM 1 M 3 C 6 C 5 HM 17 HM 14 HM 13 HM 2 HM 4 HM 7 HM 3 HM 6 HM 2 S 9 S 4 S 18 HM 24 M 24 M 6 C 19 M 23 M OUTLET INLET 29 HM 23 M 24 M 6 M 28 HM 2 HM 1 C 20 M 21 M 27 HM 26 HM 9 C RELEASED For Reference Only ...

Page 41: ... P 7 P 9 P HONEYWELL IID ATMOSPHERIC PILOT PROTEK ADAPTER AND TEXAS CODE OPTION PRIOR TO 12 2019 19 M 20 M 22 M 24 M 23 M 21 M 22 M INLET OUTLET 24 M 29 HM 27 HM 26 HM 24 M 23 M RELEASED For Reference Only ...

Page 42: ...725F 2 C AGS 135 Auto Gas Shutoff Red Epoxy Units manufactured prior to 12 2019 600892B 600892B 3 C High Limit 140 Black Epoxy Units manufactured prior to 12 2019 600893B 600893B 4 C P C Board Control 013464F 013464F 7 C LCD Display Units manufactured from 5 2011 013640F 013640F 8 C Fuse 5 AMP 013733F 013733F 6 C Temperature Sensor IID Units 009577F 009577F 9 C Thermostat Reset Deg Surface Mount U...

Page 43: ... 17 HM Rear Drain Plug Cover 005264F 005264F 19 HM Adapter CPVC 2 005393F 005393F 20 HM Sensor Adapter Digital Electronic 006714F 006714F 26 HM Adapter ProTek Shield Includes 27 HM from end of Q3 2020 018006F 018006F 27 HM Nut ProTek Shield Adapter 2 Pc from end of Q3 2020 018007F 018007F 28 HM U G Bypass Assembly Units manufactured from 12 2019 017958F 017962F 29 HM ProTek Shield Assembly Units m...

Page 44: ... prior to 12 2019 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 010375F 8 S Poolstat Cover Lock 009505 009505 9 S High Limit Cover 010319F 010319F 10 S Base Heat Shield Units manufactured prior to 10 2019 010320F 010320F 11 S Up Front Control Panel 013822F 013823F 12 S High Limit Shield 010342F 010342F 13 ...

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Raypak 268A, Installation And Operation Manual

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