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36

CALL

OUT

DESCRIPTION

268A

408A

B

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 

013800F

013801F

Burner Tray w/Gas Valve Pro 

013802F

013803F

    2-B

Burner Spacer/Hold Down Kit

013804F

013805F

    3-B

Burner

301210/18

301210/27

    4-B

Burner Orifice Nat. #50 (Sea Level)*

350079F/18

350079F/27

Burner Orifice Pro. #57 (Sea Level)*

350083F/18

350083F/27

5-B

Burner Tray w/o Manifold w/o burners 

013806F

013807F

C

CONTROLS

1-C

AGS 135° (Auto Gas Shut-Off) - Red Epoxy

600892B

600892B

2-C

High Limit 140° - Black Epoxy

600893B

600893B

3-C

P. C. Board/Control 

013464F

013464F

    4-C

LCD Display

013640F

013640F

    5-C

Fuse 5 AMP

013733F

013733F

6-C

Temperature Sensor IID Units

009577F

009577F

7-C

Flow Switch 

007142F

007142F

    8-C

Flow Switch Paddle

010026F

010026F

G

GAS VALVE

1-G

Combination Valve - Nat. 

003900F

003900F

Combination Valve - Pro. 

004306F

004306F

H

HEAT EXCHANGER 

1-H

Heat Exchange Assy Cupro-Nickel ASME BR

013808F

013809F

   2-H

Inlet/Outlet Header ASME BR Complete

013810F

013810F

Inlet/Outlet Header ASME BR 

013811F

013811F

   3-H

Inlet or Outlet Flange BR (1 only)

013812F

013812F

        4-H

Flange Gasket (3)

016732F

016732F

        23-H

Flange Bolts

016159F

016159F

   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 Valve Assembly

016194F

016194F

       14-H

Bypass Spring

Units with Brass Bypass Valve (Units manufactured to 3/5/17)

013794F

013794F

Units with Plastic Bypass Valve (Units manufactured from 3/5/17)

016196F

016196F

   15-H

Drain Valve

013793F

013793F

   16-H

Sensor Well

003765F

003765F

   17-H

Well Retaining Clip

300203

300203

18-H

Rear Drain Plug & Cover

005264F

005264F

19-H

2" CPVC Adapter NPT (Inlet Plumbing)

005393F

005393F

20-H

2" CPVC Connector (Outlet Plumbing)

NPT Connection

013795F

013795F

Flange Connection

015883F

015883F

   24-H

Flange Bolts & Washers

016162F

016162F

   21-H

2" CPVC Connector & Nut 

006723F

006723F

   22-H

O Ring 

006724F

006724F

25-H

Pipe Plug Brass 1/4"

016163F

016163F

J

CONTROL BOX

1-J

Transformer 120/240/24V

006736F

006736F

2-J

Rocker Switch 

009493F

009493F

*FOR INSTALLATION AT OVER 2,000 FEET ABOVE SEA LEVEL, DERATE 4% PER I,000 FEET ABOVE SEA LEVEL.

**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.

Summary of Contents for 408

Page 1: ...injury or death FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other com bustible materials in the vicinity of this or any other appliance To do so may result in...

Page 2: ...2 Revision 3 reflects the following changes Manual updated to the new format style Removed California Proposition 65 warning...

Page 3: ...r Installation 11 5 4 Combustion and Ventilation Air 12 5 5 Vent Piping 15 5 6 Gas Supply Connections 16 5 7 Water Connection Installation 18 5 8 Unitherm Governor Operation 18 5 9 Internal Automatic...

Page 4: ...could cause severe personal injury death or substantial property damage if ignored A ACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product...

Page 5: ...should be obtained from your pool or spa builder accredited pool shop or chemical supplier for the correct levels for your water 2 1 Automatic Chlorinators and Chemical Feeders All chemicals must be...

Page 6: ...ce 3 3 Visual inspection 3 3 1 Atmospheric Heaters With the heater on remove the door and make a visual check of the pilot and burner The flame should be blue with a well defined pattern A yellow or f...

Page 7: ...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 l...

Page 8: ...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 wate...

Page 9: ...ing 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 instal...

Page 10: ...r mineral wool batts reinforced with wire on rear face with ventilated air space Back 4 102 Right 4 102 Left 4 102 Vent 3 76 Indoor Top 24 610 Outdoor Top Unobstructed d 3 1 2 89 mm thick masonry wall...

Page 11: ...tions the point from where the flue products exit the heater must be a minimum of 4 1 2 m below 4 1 2 m horizontally from or 1 0 3 m above any door window or gravity inlet into any building The top su...

Page 12: ...5 4 1 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 12 305 mm from the ceiling for ventilati...

Page 13: ...her 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 P...

Page 14: ...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 305 m above sea level when...

Page 15: ...ypak D 2 Power Vent The unit when installed as directed is capable of operatinginapplicationssuchasthrough the wallventing and reduced horizontal and vertical vent pipe sizes in new and current instal...

Page 16: ...pply 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 va...

Page 17: ...Drop Propane Gas 2500 BTU FT3 1 53 specific Gravity 0 5 in WC Pressure Drop 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 H Maxi...

Page 18: ...r Operation A ACAUTION The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105 41 C and 115 F 46 C despite cont...

Page 19: ...ll a pressure relief valve A 3 4 pressure relief valve having a capacity equal to the BTUH output of the model to be installed is recommended for this heater The maximum acceptable pressure relief val...

Page 20: ...rmer cover located on the far right by removing one 1 screw 4 Remove the two 2 screws that hold down the transformer 5 Remove the one 1 screw that holds down the ground wires 6 Disconnect P6 connector...

Page 21: ...ER 4 WIRES L1 L2 RED RED BLACK HOT HOT BLACK GREEN GREEN WHITE SUPPLY SIDE Figure 28 240 VAC Wire Connection Heater must be electrically grounded and bonded in accordance with local codes or in the ab...

Page 22: ...ACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER THIS DIAGRAM IS RAYPAK S RECOMMENDATION AND IS NOT INTENDED TO REPLACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER Figure 30 Multi...

Page 23: ...23 7 WIRING DIAGRAM...

Page 24: ...temperature A manual power switch provided below the touchpad turns the control power ON or OFF TEMP MODE ON OFF LCD Display Temp Adjust Buttons Mode Button Figure 33 Digital Control Adjustment 8 2 1...

Page 25: ...er of on off cycles of the heater as measured by the number of times the pilot valve has been powered Figure 38 Run Time Indicator Press the DOWN button The Fault History displays up to ten faults in...

Page 26: ...esired value The control can be set for a maximum of 107 F 42 C 8 3 3 Control Lockout The heater is equipped with a Control Lockout feature to prevent unauthorized tampering or adjustment of the contr...

Page 27: ...en Alternating with Main Ign Failure Pilot flame lost 4 times within the 8 second trial to ignite the main burner Heater will lockout for 6 minutes before retrying Table M Heat Status Messages Demand...

Page 28: ...ector must be utilized NOTE The remote wires must be connected to the 7 pin connector before the connector is plugged into the board 8 5 1 2 Wire Remote Control On Off This application assumes that on...

Page 29: ...ital control board Splice into the red wire jumper tagged Where necessary add Fireman s switch circuit here to connect the time clock The fireman s switch connection on both heaters must be a dry cont...

Page 30: ...GAS VALVE PILOT BURNER BURNER HOLD DOWN BRACKET Figure 49 Burner Tray Assembly 8 5 5 Flame Roll Out Safety Switch The heater is equipped with a thermal cutoff device to prevent flame roll out in the e...

Page 31: ...thickness The heater may be cleaned from the return header side without breaking pipe connections It is preferable however to remove both headers for better visibility through the tubes and to be sure...

Page 32: ...itherm Governor place in hot water over 110 F 43 C and watch for movement against spring If there is no movement replace unit 9 REPLACEMENT PARTS NOTE To supply you with the correct part it is importa...

Page 33: ...until heater outlet water temp is between 105 F and 110 F 40 5 C and 43 3 C If no movement replace Unitherm governor inoperative Check movement by putting in hot water 110 F 40 C or higher If no move...

Page 34: ...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 Resis...

Page 35: ...4 H 23 H 25 H HONEYWELL IID ATMOSPHERIC PILOT 12 M 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 11 M 1 J 9 S 4 S 7 S 1 R 6 M 4 C 3 C 11 S 9 M 2 R 5 S 6 S 6 P 13 S 18 H 4 S 1 V 4 V 2 V 3 V 1 S...

Page 36: ...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 062234...

Page 37: ...Right 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 01...

Page 38: ...38 NOTES...

Page 39: ...39 NOTES...

Page 40: ...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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