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DANGER: 

Failure to install the drafthood on indoor 

installation and 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 venting section of this manual for more information 

regarding vent system inspections.

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WARNING:

  Gasoline,  as  well  as  other  flammable 

materials  and  liquids  (adhesives,  solvents,  etc.),  and 

the  vapors  they  produce,  are  extremely  dangerous.  Do 

not handle, use, or store gasoline or other flammable or 

combustible materials in the vicinity of a heater.

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WARNING:

  Improper  installation,  adjustment, 

alteration,  service,  or  maintenance  can  cause  property 

damage,  personal  injury  or  loss  of  life.  Installation  and 

service must be performed by a qualified installer, service 

agency, or the gas supplier.

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WARNING:

 Do not install within 3 feet (0.9 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.

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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.

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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.

1.  WARNINGS

1.1.  Pay Attention to These Terms

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DANGER

Indicates the presence of immediate hazards which will cause severe personal injury, death or 

substantial property damage if ignored.

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WARNING 

Indicates the presence of hazards or unsafe practices which could cause severe personal injury, 

death or substantial property damage if ignored.

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CAUTION

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.

NOTE

Indicates special instructions on installation, operation, or maintenance which are important but 

not related to personal injury hazards.

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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.

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WARNING:

  To  minimize  the  possibility  of  improper 

operation, serious personal injury, fire, or damage to the 

heater:
• 

Always  keep  the  area  around  the  heater  free  of 

combustible materials, gasoline, and other flammable 

liquids and vapors.

• 

Heater should never be covered or have any blockage 

to the flow of fresh air to the heater.

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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  (1200°C)],  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  burners  or  heat  exchangers,  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.

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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