CATALOGNO.6200.51O
Effective:
Replaces:
04-09-07
05-15-05
INSTALLATION
AND OPERATING
INSTRUCTIONS
TM
RAYTHERM
Models1287-1758
COMMMERCIAL
SWIMMING POOL
HEATER
Models
P-926 to P-1826
and
P-2100 to P-4001
Models2100-4001
WARNING: If the information in these instructions is 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 in the vicinity of
this or any other appliance.
— 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.
Thismanualshouldbemaintainedinlegibleconditionandkeptadjacenttothe
heater or in a safe place for future reference.
P/N240251Rev.16
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SECTION 1 / RECEIVING EQUIPMENT
IMPORTANTNOTICE
Onreceiptoftheequipment,visuallycheckforexternal
damage to the carton or the shipping crate. If the carton
or shipping crate is damaged, make a note on the Bill of
LadingandreportthedamagetotheCarrierimmediately.
Remove the boiler from the carton or shipping crate.
DoNOTusetheshippingbasecrateasaninstallation
base.
On occasion, we ship some items loose. Be sure that
you receive the number of packages indicated on the
Bill of Lading.
When ordering parts, you must specify Model and
Serial Number of boiler. When ordering under warranty
conditions, you must also specify date of installation.
Raypak recommends that this manual be reviewed
thoroughlybeforeinstallingyourRaypakPoolHeater. If
there are any questions which this manual does not
answer, please contact the factory or your local Raypak
representative.
Theseinstructionsareintendedfortheuseofqualified
personnel only, 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 li-
censed. If your state is such, be sure your contractor
bears the appropriate license. Persons not qualified
shall not attempt to fix this equipment nor attempt
repairs 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
Claims for shortages and damages must be filed with
carrier by consignee. Permission to return goods must
be factory authorized and are subject to a stocking
charge.
Purchased parts are subject to replacement only
underthemanufacturer'swarranty. Debitsfordefective
replacement parts will not be accepted and will be
replaced in kind only per our standard warranties.
NOTE: The heater should not be located in an area
where possible water leakage will result in damage to
the area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is recom-
mended that a suitable drain pan, adequately drained,
be installed under the appliance. The pan must not
restrict combustion air flow.
SECTION 2 / GENERAL SPECIFICATIONS
Installation must be in accordance with local codes,
or, in the absence of local codes, with the latest editions
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
and National Electrical Code, ANSI/NFPA 70.
Models 962, 1125, 1223, 1336, 1468, 1631, 1826 &
2100 through 4001 are specifically designed for indoor
installation only. Models 926, 1083, 1178, 1287, 1414,
1571&1758arespecificallydesignedforoutdoorinstal-
lation only. All heaters are standard with electronic
ignitionforbothnaturalandpropaneapplications.Heat-
ers require 115V power supply. Control circuits operate
at 24V, to be supplied by a 115V to 24V transformer.
BASEINSTALLATION
DoNOTusetheshippingbasecrateasaninstallation
base.
Heater must be mounted on a level base, such as
cement slab, cement blocks or other non-combustible
surface. An optional non-combustible base is available
for Indoor Heater 962 through 1826. An alternative
method for providing a base for combustible floors as
illustrated below. Heaters may not be installed on
carpeting.
Theseheatersaredesigncertifiedandtestedunderthe
requirements of ANSI Z21.56 / CSA 4.7 American Na-
tionalStandardforGas-FiredPoolHeaters.Ratedinputs
suitableforupto2000feetelevation.Forelevationsabove
2000feet,reduceinput4%foreach1000feetabovesea
level, as high elevation reduces combustion perfor-
mance.
12"
Minimum
12"
Minimum
TER
HEA
SECTION 3 / INSTALLATION
INSTRUCTIONS
Sheet Metal
24 Gauge
4"
Minimum
Fig. #8148
CALIFORNIA PROPOSITION 65 WARNING:
This product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive
harm.
Hollow concrete cinder block; align holes and leave
endsopen.Alternativemethodforprovidinganon-com-
bustible base.
3
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CLEARANCES
ALL HEATERS
For clearances from combustible surfaces, see chart
below. We require a minimal vertical clearance of three
feetbetweentheuppersurfaceoftheflueoutlettoanon-
combustiblematerial.
4
foot
Minimum
4
foot
Minimum
MINIMUM CLEARANCES FROM COMBUSTIBLE
CONSTRUCTION
4
foot
Minimum
3
foot
Minimum
INDOOR HEATERS
1
foot
Top - 24"
*Vent - 6"
10 foot
Minimum
Minimum
Back - 24"
Right Side - 24"
Left Side - 24"
Forced Air Inlet
Fig. #8245
OUTDOOR HEATERS (926-1758)
Top - unobstructed
Back - 24"
The point from where the flue products exit the heater
must be a minimum of four (4) feet below, four (4) feet
horizontallyfromorone(1)footaboveanydoor,window
orgravityinlettoabuilding. Thetopsurfaceoftheheater
shall be at least three (3) feet above any forced air inlet,
or intake ducts located within ten (10 ) feet horizontally.
Right side - 24"
Left Side - 24"
For servicing provide a front clearance as shown below
Model 926/962-758/1826 - 24"
Model 2100-4001 - 48"
HIGHWINDCONDITIONS(OUTDOORUNITSONLY)
In areas where high winds are frequent, it may be
necessary to locate the heater a minimum of 3' from
high vertical walls, or install a wind break so the heater
is not in direct wind current.
*Vent includes factory supplied drafthood and does not
include field supplied vent systems above the draft-
hood. On Models 2100-4001 drafthood is built into
boiler.
INDOOR HEATERS
For servicing, provide at least 24" in front of the heater
onModels926-1826&48"infrontoftheheateronModels
2100-4001forburnertrayremoval,andatleast18"onthe
right side of the heater to inspect and delime the heat
exchanger.
The design is also certified for indoor installation
whenequippedwithapproveddrafthood. Locateheater
as close as practical to a chimney or gas vent.
COMBUSTION AIR (INDOOR UNITS ONLY)
The heater must have both combustion and venti-
lation air. Openings must not be obstructed. Minimum
requirements are as follows:
OUTDOOR HEATERS (MODELS 926-1758)
These heaters are design certified for outdoor
installation,whenequippedwiththeapprovedtopdesig-
nated for outdoor use. Heaters must not be installed
underanoverhangoflessthanthree(3)feetfromthetop
of the heater. Three (3) sides must be open in the area
undertheoverhang. Roofwaterdrainagemustbediverted
awayfromtheheatersinstalledunderoverhangswiththe
use of gutters.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
1. Free combustion air 1 sq. in. per 1000 BTU
input within 12" of the floor.
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
andintotheheater. Thiscouldcauseheavyinternal
rusting or damage some electrical components,
and this would void the warranty.
2. Free ventilation air 1 sq. in. per 1000 BTU input
within 12" of the ceiling level.
NOTE: If the room the heater is installed in is located
against an outside wall and air openings communicate
directly with the outdoors, the openings may be 1/4 the
size specified above (ANSI Z223.1/NFPA 54, latest
edition)
4
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VENTINGCONNECTIONS
For protection against rain or blockage by snow, the
ventpipemustterminatewithaventcapwhichcomplies
with the local codes or, in the absence of such codes,
tothelatesteditionoftheNationalFuelGasCode,ANSI
Z223.1/NFPA54.
DRAFTHOOD(INDOOR)MODELS962-1826
Locate and assemble as shown below. Secure with
screws supplied in envelope in carton.
Thedischargeopeningmustbeaminimumoftwofeet
vertically from the roof surface and at least two feet
higher than any part of the building within ten feet. Vent
stack shall be at least five feet in vertical height above
the drafthood outlet. The vent cap location shall have a
minimumclearanceof4feethorizontallyfrom,andinno
case above or below, unless a 4-foot horizontal dis-
tance is maintained, from electric meters, gas meters
regulators and relief equipment.
The weight of the vent stack or chimney must not rest
onboilerdrafthood. Supportmustbeprovidedincompli-
ance with applicable codes. The heater top and draft
hood must be readily removable for maintenance and
inspection. Ventpipeshouldbeadequatelysupportedto
maintainproperclearancesfromcombustibleconstruc-
tion.
Type"B"doublewallorequivalentventpipeisrecom-
mended. However single wall metal vent pipe may be
used as specified in the latest edition of the National
Fuel Gas Code ANSI Z223.1/NFPA 54.
Fig # 8165
10' OR LESS
VENT CAP
Models2100-4001havebuilt-indrafthoodsthatmustbe
properly vented to the outside.
2' MIN
2' MIN
VENTPIPING
WARNING:
5' MIN
VENT PIPE
Indoor heater requires a drafthood that must be
connected to a vent pipe and properly vented to the
outside. Failure to follow this procedure can cause fire
or fatal carbon monoxide poisoning.
DRAFT HOOD
Ventpipingthesamesizeorlargerthanthedrafthood
outlet is recommended, however, when the total vent
heightisatleastten(10)feet(drafthoodreliefopeningto
vent terminal), the vent pipe size may be reduced as
specified in Chapter 10 of the National Fuel Gas Code,
ANSI Z 223.1/NFPA 54 - latest edition. Avoid long
horizontal runs of vent pipe and too many elbows. If
installation requires horizontal or non-vertical runs, the
vent pipe must have a minimum of 1/4 inch per foot rise
and should be supported at not more than five foot
intervals. Plumbers' tape, criss-crossed, will serve to
space both horizontal and vertical piping. Gas vents
supported only by the flashing and extending above the
roof more than five feet should be securely guyed or
braced to withstand snow and wind loads. We recom-
menduseofinsulatedventpipespacerthroughtheroofs
and walls.
HEATER
Fig. #8119
At the time of removal of an existing heater, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placedinoperation,whiletheotherappliancesremaining
connected to the common venting system are not in
operation.
5
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GASSUPPLYCONNECTIONS
(a) Seal any unused openings in the common
venting system.
Gas piping must have a sediment trap ahead of the
heatergascontrols,andamanualshut-offvalvelocated
(b) Visually inspect the venting system for proper
size and horizontal pitch and determine there is outside the heater jacket. All gas piping should be
no blockage or restriction, leakage, corrosion
and other deficiencies which could cause an
unsafe condition.
tested after installation in accordance with local codes.
MANUAL SHUT
OFF VALVE
HEATER
JACKET
GAS VALVE
(c) Insofar as is practical, close all building doors
and windows and all doors between the space
in which the appliances remaining connected
to the common venting system are located and
other spaces of the building. Turn on clothes
dryers and any appliance not connected to the
common venting system. Turn on any exhaust
fans, such as range hoods and bathroom
exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan.
Close fireplace dampers.
GA
SED
TRA
CAUTION:Theheateranditsmanualshut-offvalvemust
bedisconnectedfromthegassupplyduringanypressure
testing of that system at test pressures in excess of 1/
2 psig (3.45 KPA). Dissipate test pressure in the gas
supplylinebeforereconnectingtheheateranditsmanual
shut-offvalvetogassupplyline. FAILURETOFOLLOW
THISPROCEDUREMAYDAMAGETHEGASVALVE.
OVER PRESSURIZED GAS VALVES ARE NOT COV-
EREDBYWARRANTY. Theheateranditsgasconnec-
tionsshallbeleaktestedbeforeplacingtheappliancein
operation. Use soapy water for leak test. DO NOT use
openflame.
(d) Placeinoperationtheappliancebeinginspected.
Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
(e) Test for spillage at the drafthood relief opening
after 5 minutes of main burner operation. Use
the flame of a match or candle, or smoke from
a cigarette, cigar or pipe.
(f) After it has been determined that each
appliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans, fireplace dampers and any other gas
burning appliance to their previous conditions
of use.
NOTE: Do not use teflon tape on gas line pipe thread.
A flexible sealant is recommended.
Aminimumof7in. WCandamaximumof10.5in. WC
upstream pressure under load, and no load conditions
must be provided for natural gas or a minimum of 11 in.
WC and a maximum of 13 in. WC for propane gas.
(g) Any improper operation of the common venting
system should be corrected so the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54. When
re-sizing any portion of the common venting
system, the common venting system should be
re-sized to approach the minimum size as
determined using the appropriate tables in Part
11 of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54.
For special venting applications that require reduced
vent sizes and through the wall venting, the optional D
Series Power Vent can be used. Consult the factory or
yourlocalRaypakrepresentative.
6
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GAS PRESSURE REGULATOR
Thegaspressureregulatorispresetandsealedat4in.
WC for natural gas, and 11 in. WC for propane gas.
Betweenthegasvalveandtheburnersisa1/8"pipeplug.
The pressure at this point, taken with a manometer,
should be about 3.7 in. WC natural gas and 10.5 in. WC
propane gas. If an adjustment is needed, remove seal
and turn adjustment screw clockwise
increase pressure or counterclocwise
decreasepressure.
, to
, to
GAS PRES
TEST UPS
Bleed
Line Connection
Fig. # 8185.2
MANUAL
SHUT-OFF
VALVE
WATERCONNECTIONS
LOCATION
The heater requires water flow and positive pressure
to fire and operate properly. It must therefore be
installed downstream of the discharge side of the filter
pump. A typical installation is plumbed as follows:
GAS P
A
GAS PRESSURE TEST
AT HEATER
1.The inlet side of the filter is plumbed directly to the
discharge side of the filter pump;
Fig. #8149.0
2.The outlet side of the filter is then plumbed to the
inlet of the heater; and
PIPE SIZING FOR GAS CONNECTIONS
3.The outlet of the heater is plumbed to the return
line to the pool or spa. The pump, filter and heater
are thus plumbed in series.
Heatermustbelocatedsothatanywaterleakswillnot
damage the structure of adjacent area. High tempera-
ture plastic pipe (CPVC) may be connected directly into
the heater Models 926-1223, if local codes permit and
if controls operate the pump for at least fifteen minutes
after the heater is turned off.
CAUTION (Models 926-1223): NEVER install PVC
directlyintoheater. Fourfeetofcopperorhightempera-
ture pipe and two elbows are required between the
heater and the PVC connections.
VENTINGOFDIAPHRAGMGASCOMPONENTS
Heaters have gas train components that have dia-
phragms in their construction are supplied with a bleed
line connection that must be connected to the outside
atmosphereasrequiredbytheNationalFuelGasCode.
Under NO circumstances shall bleed lines terminate in
the gas utilization equipment flue or exhaust system.
Fig. # 8129.0
7
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When local codes permit the use of less than four feet UNITHERM GOVERNOR OPERATION
high temperature piping or two elbows, provisions
The patented Unitherm Governor is a thermostatic
shouldbemadetoalwaysshuttheheateroffaminimum
of 15 minutes prior to pump shut down in order to carry mixing valve specifically designed to maintain constant
away residual heat and prevent damage to the low heater internal temperature between 105° to 115°F
temperature piping. A fireman switch included in the despite continually changing flow rates from the filter
time clock may be used for this purpose with instruc- and changing pool temperatures. This narrow range is
tions not to override this sequence manually. See neededtopreventdamagingcondensationontheburn-
wiring diagram section for electrical hookup location of ers which will occur if the heater runs for any length of
the fireman switch in the electrical circuit.
time below 100°F. It is also needed to inhibit scale
formationinthetubesbymaintainingtemperatureswell
NOTE (Models 926-1223): If piping is used into the below accelerated scaling temperatures.
heater,thispiping(copper)mustbeanchoredorscrewed
into the flange (metal) if operating pressures above 30
PSIareencountered.
The Unitherm Governor is built into the inlet/outlet
header on models 926 through 1223. The larger sizes,
models1287through4001,haveanexternallymounted
bypass pump that is designed to maintain the water
entering the heater at the proper temperature that will
prevent condensation and scale. Thermometers are
CONTROLS
WATER PRESSURE SWITCH
A water pressure switch is provided in the heater to provided on the inlet and outlet to the heater.
shutdownthegasvalvesintheeventthewatersupplyto
theheaterisinterrupted. Itisveryimportanttoverifythat
the switch electrically opens and shuts off the gas valve
whenwaterflowtotheheaterisinterrupted. Otherwise,
rapid and severe damage to the heater will likely occur.
(The water pressure switch should be checked and
adjustedforproperoperationbyaqualifiedserviceperson
at the time of installation and periodically checked
thereafter. Refer to pressure switch servicing instruc-
tions in Section 4 of this manual).
COMPANION FLANGE CONNECTIONS
(Models 926-1223)
DO NOT use petroleum base assembly fluids (such
as Petroleum Jelly or Lubricating Oil). If assembly lube
is required use a silicone base such as Armoral etc.
The inlet/outlet header flange accepts a 2" copper
tube as a slip connection directly into the header. The
flangeisalsothreadedfora2"NPTcoppermaleadapter.
WARNING:
Operation of the heater without water
circulation will cause rapid and severe damage to the MODELS 926 - 1223
heater.
INLET/OUTLET HEADER
AUTOMATIC CHLORINATORS AND CHEMICAL
FEEDERS
All chemicals must be introduced and completely
dilutedintothepoolorspawaterbeforebeingcirculated
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer. High chemical concen-
trations will result when the pump is not running (eg,
O
INLET
overnight).
Chlorinatorsmustfeeddownstreamoftheheaterand
have an anti-siphoning device to prevent chemical
backup into the heater when the pump is shut off.
HEADER FLANGE
Fig. #8221.0
NOTE: High chemical concentrates from feeders and
chlorinators that are out of adjustment will cause very
rapid corrosion to the heat exchanger in the heater.
Such damage is not covered under the warranty.
8
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MODELS 1287/1336 - 1758/1826
1-1/2" Slip Ball Valve
Pump
2-1/2" Outlet
2-1/2" Inlet
Fig.#9200
MODELS2100-4001
3" Outlet
3" Inlet
2 H.P. Pump
2" Slip
Ball Valve
Inlet/Outlet
Header
Fig.#9270
FLOWRATES/WATERCONNECTIONS
MODEL
926-1223
1287-1826
2100-4001
CONNECTIONSIZE
MIN GPM
MAX GPM
*
60
120
2-1/2"FPT
3" FPT
Refer to flow rate table
LOOP*
FLOW
RATES
(GPM)
30-50
35-55
40-65
45-70
50-80
HEATER
FLOW
RATES
(GPM)
85
MODELS
1287/1336
1414/1468
1571/1631
1758/1826
2100
85
85
85
180
2500
60-95
180
3001
3500
4001
75-115
90-135
100-150
180
180
180
*Loop is secondary piping to
heater from main system.
9
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Raypakrecommendstheinstallationofanairbleedventatasuitablelocation(usuallythehighestpoint)toremove
airfromthepipingsystem. Theseunitsshouldbeavailableatyourlocalwholesalesupplier. Raypakdoesnotprovide
this item.
CAUTION:
Power to the heater should be interlocked with the main system pump to make sure the heater does not
fire without the main system pump in operation.
Improper flow control can damage the heater. Uncontrolled flow (toohigh) or restricted flow (too low)can
seriouslyaffectheateroperation. Followtheseinstructionstomakesureyourheaterisproperlyinstalled.
Models1287through4001areequippedwithanexternalpumpandbypassarrangementthatblendsoutletwaterwith
theinlettoincreasetheinletwatertemperature,therebyreducingthelikelihoodofcondensationformingontheheat
exchanger. The pump also serves to circulate water through the heater from the main system piping.
Tocompletetheinstallationofthepoolheater,thepoolthermostatneedstobeinstalledinthemainreturnwaterline.
Thiswillensurethattheheaterwillbeenergizedattherighttime. Ifthemainwaterlineistoofarawayfromtheheater
and the capillary bulb will not reach it, locate the pool thermostat adjacent to the main line and run wires back to the
heater. Follow the instructions listed below to install the pool stat.
MOUNTING THE POOLSTAT CONTROL WITH FRONT-MOUNTED
LOOP USING MOUNTING SLOTS
For heater models:
1287, 1336, 1414, 1468, 1571, 1631, 1758, 1826, 2100, 2500, 3001,
3500, 4001.
Note: For more detail on piping, see figures 9268 and 9269.
1. Remove the poolstat control cover by removing the two cover
screws at the top. See Figs. 1 & 2.
2. Lace metal strapping or clamps, (NOT PROVIDED) through the ¾”
slots on the cover and fasten securely to pipe as shown in Figs. 3
& 4. NOTE: Do not over-tighten clamps.
Fig. 1: Poolstat Control
3. Remove either the left or right “knock-out” for wiring on the poolstat
control as shown in Fig. 5.
4. Attach appropriate conduit and connectors to the poolstat control.
5. Attach wires to the poolstat wire terminals. See Fig.6.
6. Install poolstat control to the cover and fasten cover screws.
7. Poolstat should be mounted level as shown in Fig. 7.
Fig. 2: Control Cover
Fig. 3: Hose Clamp Slots
Fig. 4
Fig. 5
Fig. 6
Fig. 7
10
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MOUNTING WELL INTO SYSTEM RETURN LOOP PIPE - FRONT-MOUNTED LOOP:
Note: For more detail on piping configurations for large systems, see figures 9268 and 9269.
1. Locate and mark an area on the main system return loop pipe where the well is always exposed to the water
circulating back from the pool. See Fig. 8.
2. Shut off water and drain any water from the pipe as necessary.
3. Drill a 23/32" diameter hole (½” NPT) into the pipe as shown in Fig. 9.
4. Using a ½” NPT tap and appropriate handle, thread the tap into the pipe.
5. Apply pipe dope as necessary to male threads of well and insert into threaded hole.
Note: Do not over-tighten well.
Fig. 9
Fig. 8
Fig. 10
Note: The drawings and instructions above show only one of several acceptable ways of installing the
dry well into main system loop. The use of saddle clamps and “Weld O Lets” (shown in Fig. 10) are
acceptable. Follow clamp manufacturer’s instructions.
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To adjust the temperature:
1. Both isolation valves must be fully open.
2. Adjust Bypass Valve "A" 1/2 open and Balancing Valve "B" fully open. (See piping configuration page 11)
3. Fire your Raypak pool heater and adjust Bypass Valve "A" to obtain a heater inlet temperature approximately
100°F-105°F. TurningValveAintheopendirectionwillraisetheheaterinlettemperatureandclosingValve"A"
will lower the heater inlet temperature.
4. Iftheheaterinlettemperatureremainslessthan100°FandValve"A"isfullyopen,leaveValve"A"fullyopenand
throttle Valve "B" until the heater inlet temperature rises to within the range of 100°F-105°F.
5. The resultant heater outlet temperature should be in the range of 120-130°F.
6. As the pool temperature rises to the desired temperature as controlled by the Pool aquastat, small adjustments
tovalves"A"and"B"willberequiredforoptimumperformance. Heatertemperaturesshouldbecheckedregularly
topreventheatercondensation. Theheaterinlettemperaturecanbehigherthan100°Fwithoutheaterdamage
but operating at less than 100°F inlet can cause damage from condensation.
Note: Consult factory if target temperatures cannot be achieved.
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PIPINGCONFIGURATIONSFORRAYTHERMCOMMERCIALPOOLHEATERS
Fig#9268
Fig#9269
Models 2100 thru 4001
BLENDEDWATERTEMPERATURE
(THERMOMETERATHEATERINLET)
T
I
HEATEROUTLETTEMPERATURE
THERMOMETER
To
HEATERTHERMOSTAT
T
c
RECOMMENDED FIELD INSTALLED
ISOLATIONVALVESFORSERVICE
13
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BYPASSVALVE
EXTERNALAUXILIARYBYPASSVALVE
(WhereRequired) 926-1223Modelsonly
LET
An auxiliary bypass valve should be used when flow
rates exceed 120 GPM (usually a high performance
pump size larger than two HP will exceed this flow rate).
This valve is required to complement the function of the
automatic bypass valve, particularly when starting the
heater in winter or early spring when the spa or pool
temperature is below 55°F. It also serves to eliminate
needlesspressuredropthroughtheheaterandaccompa-
nying reduction in the flow rate to the spa jets, etc.
Fig. #8223.0
OPEN POSITION
CLOSED POSITION
MANUAL BYPASS ADJUSTMENT
H
g. #8222.0
NOTE:To avoidwaterdamageorscaldingduetovalve
operation, drain pipe must be connected to valve outlet
andruntoasafeplaceofdischarge. Drainpipemustbe
the same size as the valve discharge connection
throughout its entire length and must pitch downward
from the valve. No shut-off valve shall be installed
between the relief valve and the drain line. Valve lever
should be tripped at least once a year to ensure that
waterways are clear.
TO POOL
TO POOL
Fig. #8150
AUXILIARY BYPASS VALVE
(DO NOT USE GATE VALVE)
AUXILIARY BYPASS VALVE ADJUSTMENT
To set bypass: With clean filter, adjustment is made
by feeling the inlet and outlet pipes at the heater. Outlet
pipes should be slightly warmer than inlet and comfort-
able to the touch. If pipe is hot, close bypass; if cold,
open bypass.
TEMPERATURECONTROLS
HIGHLIMITS
Thepoolheaterisequippedwithtwohighlimits.Bothhigh
limits, the non-adjustable auto reset high limit and
adjustable manual reset high limit are attached to the
outlet side of the in/out header.
NOTE: Do not use a gate valve as an auxiliary bypass
valve on any heaters.
Models 926-1223
POOLSTAT
The heater is also equipped with a manual bypass built
into the header. This is in addition to the automatic
bypass valve. This may be used with flow rates up to
120 GPM and adjusted as below.
The pool heater is equipped with a pool thermostat that
isattachedtotheinletsideofthein/outheadertocontrol
thepooltemperature.
LOWWATERCUT-OFF
NOTE: Sooting or liming caused by improper bypass
Automatically shuts down burner whenever water level
drops below probe. 30 second time delay prevents
premature lockout due to temporary conditions such as
power failure or air pockets. Standard on Cal Code
heaters.
adjustmentvoidsthewarranty.
Fig.#6043
14
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HIGH & LOW GAS PRESSURE SWITCHES
Heater must be electrically grounded and bonded in
Pressure switches sense either high or low gas accordance with local codes, or, in the absence of local
pressure and automatically shut down burners if abnor- codes, with the latest edition of the National Electrical
mal pressures exsist. Standard on Models 3001-4001. Code, ANSI/NFPA 70.
PRESSURE
SWITCH
Fig. #8929.1
GAS MANIFOLD
Fig. #8236
ELECTRICAL WIRING
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after
servicing.
DANGER - SHOCK HAZARD - Make sure electrical
power to the heater is disconnected to avoid potential
serious injury or damage to components.
NOTE: If it is necessary to replace any of the original
wiring, it must be replaced with 105° C wire or its
equivalent.
ELECTRONIC IGNITION
The intermittent ignition device conserves energy by
automatically extinguishing the pilot when desired tem-
peratureisreached. Whenadditionalheatisneeded,the
pilot re-ignites electrically, eliminating the fuel costs of
maintaining a constant pilot. To ensure safe operation,
the gas valve cannot open until the pilot relights and is
confirmed.
Model
w/out lockout with lockout
926-1826NaturalGas
926-1826Propane
2100-4001 Natural Gas N/A
2100-4001Propane N/A
Standard
N/A
Optional
Standard
Standard
Standard
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WIRING DIAGRAM
MODELS 926 - 1223
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WIRING DIAGRAM
MODELS1287-1826
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WIRING DIAGRAM
MODELS 2100-2500
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WIRING DIAGRAM
MODELS 3001-4001
19
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TEMPERATURECONTROL
SECTION 4/ SERVICING INSTRUCTIONS
GENERAL LOCATION OF CONTROLS
MODELS 926-1826
The pool water temperature is controlled by the pool
thermostat.
Theheaterwatertemperaturehighlimitiscontrolledby
the manual reset high limit.
PRESSURESWITCH
Inlet/Outlet
Header
Pressure
Switch
The pressure switch, or heater actuator, ensures that
the heater operates only when the filter pump is in
operation. It is factory set at 1.75 PSI for deck level
installations. Whentheheaterislocatedbelowthelevel
of the spa or pool, it may be necessary to reset the
pressure switch to compensate for the no-flow static
head. If it is necessary to reset the pressure switch, we
recommendthefollowingprocedure:
Unitherm
Governor
Electrical
Conn.
Hi-limit
control/
Temp. Control
Main Burner Gas Valve
PRESSURE SWITCH ADJUSTMENT:
1. Make sure the pool filter is clean before adjusting
the switch.
2. Set the heater control to the OFF mode.
3. Turnthefilterpumponandconfirmthatthepressure
switch is closed (use a multimeter to check). If the
pressure switch fails to close, either the switch
setting is too high or the filter pump is not supplying
enoughpressure.
MODELS2100-4001
4. TurntheheaterON.
5. Manually turn the pressure adjustment knob clock-
wiseuntiltheheatershutsoff.(Aflatscrewdrivermay
be necessary if knob is too tight).
6. Slowly turn the adjustment knob counter-clockwise
until the heater calls for heat again.
Inlet/Outlet
Header w/Bypass
Pump
7. Turn an additional 1/2 turn counter-clockwise.
8. Whiletheheaterisrunning,checktheadjustmentby
turning the pump off and on several times. The
burnersshouldshutoffimmediatelywhenthepump
isturnedoff.Ifitdoesnot,repeattheabovestepsuntil
properoperationisobserved.
Electrical
Connection
Fig.#9261.1
Main Burner
Gas Valve
Manual On/Off Valve
20
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START-UPPROCEDURES
BEFORE START-UP
BURNERS
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from com-
bustibles, flammable liquids, and chemicals. Do not
obstruct the flow of combustion and ventilating air.
WATER
Water must be flowing through the heater.
START-UP
ADJUSTMENT KNOB
Fig. # 8069.1
CAUTION: Propane gas is heavier than air and sinks to
the ground. Exercise extreme care in lighting heater in
confined areas.
PRESSURE SWITCH ADJUSTMENT RANGE
LIGHTING INSTRUCTIONS
HEAT EXCHANGER HEIGHT
5' Max
1.Close all gas valves. Turn off electric power supply
wait 5 minutes.
2.Open manual pilot valve. Turn on electric power,
pilot is automatically lighted.
5' Max
3.Open main gas valve.
4.Set temperature controls to desired temperature.
Fig. # 8152.0
NOTE: If heater is installed outside of the limits shown,
a flow switch must be used in place of the pressure
switch when mounted and wired adjacent to the heater.
TWO-SPEEDPUMPS
In some cases, the flow on the low speed is insuffi-
cient to operate the heater. This is apparent when the
pressure switch cannot be further adjusted or if the
heater makes banging noises. In these cases, the
pump must be run at high speed when heating the
water.
Fig. #8929.1
TO SHUT DOWN
CAUTION: Do not operate the heater without the
function of a properly adjusted pressure switch.
Close all manual gas valves. Turn off electric power.
PILOT SAFETY
The heater employs a pilot safety which closes the
maingasvalvewithin8/10thsofasecondwheneverthe
pilot flame is interrupted. Pilot flame is automatically lit
when the device is powered. Unit performs its own
safety check and opens the main valve only after the
pilot is proven to be lit.
21
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INSPECTIONPROCEDURES
AFTER START-UP
BURNERS
Pilot System Checkout Procedure
Clean main burners and air louvers of dust, lint and
debris. Keep boiler area clear and free from com-
bustibles and flammable liquids. Do not obstruct the
flow of combustion and ventilating air. Make visual
check of burner and pilot flame. Yellow flame indicates
clogging of air openings. Lifting or blowing flame
indicates high gas pressure. Low flame indicates low
gas pressure.
1.Turn on power to the ignition systems and turn
gas supply off.
2.Check ignition module as follows:
a.Set the thermostat above pool water
temperature to turn heater on.
b.Watch for continuous spark at the pilot burner.
c.Time the spark operation. Time must be within
the lockout timing period (15 or 90 seconds).
d.Turn thermostat down to turn off heater and
wait 60 seconds on lockout models before
beginning step 3.
4" Max
3.Turn on gas supply.
4.Set thermostat above pool water temperature to
turn on heater.
5.Systems should start as follows:
a.Spark will turn on and pilot gas valve will open
at once. Pilot burner should ignite after gas
reaches the pilot burner.
Fig. #8144
b.Spark ignition should cut off when pilot flame is
established.
MAIN BURNER FLAME
c.Main gas valve should open and main burner
should ignite after gas reaches the burner port.
PILOT BURNER FLAME
Feel inlet and outlet pipes. Outlet should be only
slightly warmer than inlet. It should not be hot.
WARNING: Should overheating occur or the gas
supply fails to shut off, turn off the manual gas control
to the appliance.
CONTROLS
Check all controls to see that they are operational.
To check electric safety turn off main burner. Observe
pilot burner when shutting off pilot gas. Ignition spark
should go on. Main gas valve will also drop out.
22
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SERVICING PROCEDURES
TUBE CLEANING PROCEDURE (TYPICAL)
visibility through the tubes and to be sure the ground up
lime dust does not get into the system.
Note that you do not remove the top pan or the heat
exchanger, generally.
Establish a regular inspection schedule, the fre-
quency depending on the local water condition and
severity of service. Do not let the tubes clog up solidly.
Clean out deposits over 1/16" in thickness.
After reaming, mount the wire brush in lieu of the
auger and clean out the debris remaining in the tubes.
Another method is to remove the heat exchanger,
ream tubes and immerse heat exchanger in non-inhib-
ited de-scale solvent.
Althoughtheillustrationshowsthemechanicalclean-
ing procedure of a small boiler, it is typical of all sizes.
The boiler may be cleaned from the return header side
as shown, without breaking pipe connections. It is
preferable, however, to remove both headers for better
RAYPAK TUBE CLEANING KIT
Extension Pieces (5)
Auger with Carbide Tip
Wire Brush
Fig. #8154.0
Fig. #6049
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BURNER DRAWER REMOVAL
5. Remove heat exchanger corner brackets.
6. Remove combustion chamber clips at the four
corners of the heat exchanger.
7. Lift heat exchanger straight up using caution
not to damage refractory.
1. Shutoffpowerandgassupplytothepoolheater.Dis-
connect union(s) and pilot tubing, then loosen and
removeburner-holddownscrews.
2. Disconnect wires at gas valve and slide burner
drawer out.
HEATEXCHANGERREASSEMBLY
GAS VALVE REMOVAL
1. HeatexchangerheaderO-ringsshouldbereplaced
with new ones.
2. Install inlet-outlet and return water headers and
install header retainer nuts and torque nuts evenly.
3. Install the four (4) corner clips between tube sheets
and refractory. Replace "V" baffles.
4. Install thermostat sensing bulbs in header wells
and replace bulb retaining clips.
5. Install inlet and return pipes in water headers
using pipe thread sealant.
1. Shutoffgassupplytothepoolheater. Removegas
piping to gas valve inlet.
2. Disconnect wires, pilot tubing and bleed line, if
required.
3. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.
4. Reverse above procedure to re-install.
MAIN BURNER AND ORIFICE REMOVAL
6. Install water pressure relief valve, flow switch, and
low water cutoff devices if so equipped.
7. Open water supply and return shutoff valves.
Fill heater and water piping system with water.
Check heater and piping system for leaks at full
line pressure. Run system circulating pump for
a minimum of 1/2 hour with heater shutoff.
8. Shut down entire system and vent all radiation
units and high points in system piping. Check all
strainers for debris.
1. Remove screws and burner hold down bracket.
NOTE: Iftheheatexchangerissootedbadly,theburner
hold-down bracket and spacer can become distorted
fromdirectflameimpingementandthisusuallynecessi-
tates replacement of these parts.
2. Lift burners from slotted spacer and slide from
orifices. Clean with a wire brush.
9. Install fuel collector, jacket top and inspection
panels. Install top holding screws. Install draft
diverter and vent piping if so equipped.
10. If gas piping was disconnected, reconnect gas
piping system and check for leakage using a
soap solution.
3. Orifices usually do not need to be replaced. To
clean, run either copper wire or wood through
orifice. Do not enlarge hole. To remove orifice,
use a socket wrench and remove the manifold.
DO NOT overtighten when reinstalling.
11. Double check electrical circuits, grounding con-
nections and pump with wiring diagram supplied
withheater.
12. Check for correct water pressure and water level
in the system. Make sure that system pump
operates immediately on the call for heat.
The system is ready for operation.
PILOT REMOVAL AND CLEANING
1. Disconnect pilot tubing at pilot and sensor/igniter
wire. Remove screws holding pilot bracket to
burner drawer.
2. Remove pilot and bracket, clean pilot of debris,
small bugs, etc., with wire or small brush.
3. Replace pilot, pilot tubing, sensor ignition wires
and check for leaks.
COMBUSTION CHAMBER REMOVAL
To remove the combustion chamber you must first
haveremovedtheheatexchanger. Unboltmetalcombus-
tion chamber retainer from top and remove combustion
chamberpanelsindividually.
HEAT EXCHANGER REMOVAL
1. Shut water, gas and electricity off, close valves,
relievepressureandremovereliefvalve. Remove
side inspection panels.
2. Removetopholdingscrews.
3. Remove draft diverter, lift and remove top and
flue collector on stack type models. Remove
inspectionpanels.
4. Loosen bolts and disconnect flange nuts on inlet-
outletheader,loosenunion(s)atgaspipe,andslide
boiler away from piping until studs clear the heater.
REFRACTORY PANELS TOP VIEW
Fig. #8155.0
24
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Insert tube roller into tube opening up to stop against
tube, then push center rod in until roller is tight. Be
careful to keep replacement tube squared up 1/8"
outside each tube sheet. A loose tube will sometimes
pull toward the roller. Attach drill motor to tube roller,
holding it straight and level. Proceed to expand tube
until the tool begins to grab. At this point, 1/2" to 1"
should be exposed on the tool shank. Reverse drill
motororwrenchoutbyhand. Careshouldbeexercised
to avoid applying excessive torque during rolling opera-
tion and to avoid thinning out any part of the tube wall
excessively over .015". Use same procedure at the
opposite end of the tube.
CONTROL WELL REPLACEMENT
Remove top, sensing bulb and clip. Collapse well
tubeattheopenendandwithachisel,pushthroughinto
the header, and remove the well through header. Insert
a new well and roll into place. If a roller is not available,
solder the well in place with silver solder.
Apply line pressure test, and re-roll, if necessary,
before replacing canopy.
IMMERSION WELL
PROCEDURE FOR CLEANING FLUE GAS
PASSAGEWAYS
Fig. #8126.0
Soot can clog areas behind fins and cause eventual
tube failure. Any sign of soot at base of burners or
around outer jacket indicates a need for cleaning.
TUBEREPLACEMENTPROCEDURE
On Raypaktubereplacementmaybeaffectedwithout
rolling,asatemporarymeansofrepair,providedthereare
twoormoretubesrolledintoactasstaysonleftandright
1.Lift off draft hood and flue collector by removing
bolts and screws.
2.Remove "V" baffles from heat exchanger.
sides. The"O"ringsshouldprovideasealupto125PSI 3.Removeburnertray.
working pressure. Use a 3/8" heavy duty reversible drill
motororlarger,topowerthetuberoller. Ifareversibledrill
is not available, after rolling the tube in, remove the drill
motorandwrenchouttheroller. Atuberollerisavailable
from the factory.
4.Take garden hose and wash heat exchanger,
making sure soot is removed from between fins.
(Avoid excessive water against refractory).
5.Reassemble; when boiler is fired, some steam
will form from wet refractory. This is normal.
Shut gas and power off to the unit, close the system
off and drain the pool heater. Remove draft diverter.
Remove the access panels and jacket top. Lift the
canopy and flue collector off (on models 926-1826,
remove the canopy hold-down brackets). Remove "V"
bafflesovertube(s)tobereplaced. Ifnopipeunionshave
been provided, use the header as a union, remove the
flangenutsofftheinlet-outletheader,breakgasconnec-
tion and slide boiler away from piping, allowing room to
work. Pull wedge slips out of control wells and remove
sensing bulbs. Remove flange nuts from the return
headerandremoveheader. Liftheatexchangerstraight
up and out.
NOTE: In extreme cases it may be necessary to
remove the heat exchanger completely for cleaning.
The simplest method is steam cleaning at a local car
wash. DO NOT WIRE BRUSH!
CAUTION: Soot is combustible, so exercise extreme
care.
UNITHERM GOVERNOR REPLACEMENT
1.Shut off water, gas and electricity, close valves,
relieve pressure.
Heatexchangerheadero-ringsmustbereplacedwith
new ones. The tube may be cut out with a hack-saw or
hammerandchiseladjacentto bothtubesheets,leaving
stubs in the tube sheets. Then proceed to collapse
stubsinthetubesheetswithachiselorscrewdriver. Use
caution not to cut into the tube sheet. Replacement
tubeswillhavethefinsstrippedofflongerononeend. The
long end is inserted into the opening of the tube sheet
first;thentheshortendisfittedthroughtheopposite tube
sheet. Ifthetubeendsbecomedentedorbent,straighten
at least four(4)inchesbackfromthetubeendby means
of a tapered punch.
2.Drain heat exchanger.
3.RemoveUnithermGovernor.
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MODELS926-1223
UNITHERM GOVERNOR
3.Inspect and operate all controls and gas valve.
4.Make visual check of burner and pilot flame. Flame
pattern on main burner and pilot is indicated above.
Yellow flame means restriction of air openings.
Lifting or blowing flame indicates high gas pressure.
Low flame means low gas pressure.
INLET/OUTLET HEADER
5.Clean room air intake openings to ensure adequate
flow of combustion and ventilation air.
OUTLET
INLET
6.Removeheaderoppositeinletpipeswhencleaning
and inspect internal tubes for scale deposits. If
scale does not form within first quarterly inspection,
theninspectannuallythereafter.
Fig. #8224.0
GASKET
UNITHERM GOVERNOR
WITH POWER ELEMENT
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
MODELS 1287-1826 (Models prior to Jan. '95)
DOUBLE EXTERNAL U.G.
7.Keep heater air clear and free from combustible
materials and other flammable and corrosive vapors
and liquids.
8.Keepmovingpartslubricated.
9.Manualoperationofpressure/temperaturerelief
valve at least once a year.
SPA WATER CHEMISTRY
NOTE: Chemical imbalance can cause severe damage
to your heater and associated equipment. Maintain
your water pH between 7.2 and 7.8, and total alkalinity
between 100 and 150 ppm. If the mineral content and
dissolved solids in the water become too high, scale
forms inside the heat exchanger tubes, reducing heater
efficiencyandalsodamagingtheheater. IfthepHdrops
below 7.2, the heater will be severely damaged.
MODELS 2100-4001 (Models prior to Jan. '95)
EXTERNAL U.G.
NOTE: Heat exchanger damage resulting from chemi-
cal imbalance is not covered under the warranty.
WINTERIZATION
WINTERIZING YOUR HEATER
TotestoperationofUnithermGovernor,placeinhotwater
andwatchformovementagainstspring. Ifnomovement,
replace.
When heaters installed outdoors in freezing climate
areasaretobeshutdownforthewinter,pleaseobserve
the following step-by-step procedure:
MAINTENANCEANDCARE
To be followed one month after initial start-up and
then quarterly.
1.Remove the drain plug or open the drain cock located
on the inlet-outlet header. On larger heaters with
external Unitherm Governor(s) and piping, locate
plug at low point of Governor piping, or break connec-
tions and rotate inlet fittings 180° to face downward.
Turn off manual main gas and main gas shut off.
2.Disconnect compression fittings on both ends of the
1/8" copper tube and allow the tube to drain. Remove
the "heat exchanger inspection panels" on the right
side of the heater to gain access to the fitting on the
return header. Remove return header.
1.Inspect top of heater and draft-hood for soot, and
open fuel gas passageways.
CAUTION: Soot may be combustible. Wet completely
when cleaning.
2.Clean main burners and pilot burner of dust and lint.
26
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SECTION 5 / TROUBLESHOOTING GUIDE
IMPORTANT NOTICE
These instructions are primarily intended for the use of 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. Persons not qualified shall not attempt to install this
equipment nor attempt repairs according to these instructions.
MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY)
PROBLEM
CAUSE
SOLUTION
Harmonics, or whining noise
U.G. Inoperative……………………
Check movement by putting in hot
water (110°F or higher). If no move-
ment, replace.
Locate the restriction and remove.
Flush system and clean.
Remove debris or blow out gas line.
Scale forming in heat exchanger -
clean heat exchanger and check
pool pH and total alkalinity.
*Debris or restriction in system……
*Debris in gas line…………………..
Lowflow……………………………...
Heatergoingonandoff
continously
Dirty filter……………………………
Lowwaterevelinpool………………
External bypass setting out of
adjustment…………………………..
*Pressure switch out of
Backwash filter.
Raise water level.
Adjust bypass
adjustment…………………………..
Adjust pressure switch
Liming or scale forming on
heatexchanger
Poolwater…………………………....
Highflowrates…………………….....
U.G.Inoperative……………………..
Recommended pH should be be-
tween7.2and7.8totalalkalinity100-
150PPMmaximum. Hardness-150-
400 PPM maximum.
Sooting
Reduce by adding manual bypass
valve and adjust by putting ther-
mometer in header (1/4" NPT) drain
opening. Set bypass so thermome-
ter reads between 105° and 110°F.
Check movement by putting in hot
water (110°F or higher). If no move-
ment, replace.
*Airstarvation………………………..
*Improperventing…………………....
Refer to installation instructions.
Follow recommended installation
instructions.
*Insects or debris clogging
burnerintakeports…………………..
Clean burners
Pilot outage
Lowgaspressure…………………....
Restrictedpilot……………………....
Weakpilotgenerator………………..
Adjust gas pressure.
Clean pilot.
Replace pilot.
Yellow lazy flame
Lowgaspressure…………………....
*Insects or debris clogging
burnerintakeports…………………..
Adjust gas pressure.
Clean burners.
*Usually occurs on initial start-up
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*Broken refractory caused by
shippingdamageorimproper
combustion…………………………..
Excessive sooting of heat
Outer jacket very hot
(paint blistered)
Replace refractory panels.
exchanger…………………………...
Determine cause of sooting &
correct.
Calculatetemperaturein°F/hr……... Heat rise (°F/hr.) = Htr.output
Pool gallonage x 8.33
Takes long time to heat pool
or spa
or refer to heater sizing chart.
This does not take into account heat
loss due to weather.
Filternotrunninglongenough……....
Reset time clock.
Dirtyfilter…………………………….. Cleanfilter.
Gas line or meter under-
sized……….................................. Refer to installation instructions.
Liming
Bypassingtoomuchwater……….... Inspect bypass for movement, if no
movement, replace.
U/Gnotfunctioning……………….....
Overacid…………………………......
Overacid……………………………...
Replace if no movement when
heated.
Replace well and maintain water
chemistry properly.
Replace heat exchanger and main-
tain chemistry properly.
Leaking at well.
Leaking at heat exchanger.
Gasket brittle and leaking-
(overheated).
Heaterrunningafterpump
shutsoff……………………………...
Refractorydamage………………….
Sootedheater………………………..
See pressure switch adjustment.
Replace refractory.
Determine cause of sooting and cor-
rect.
*Usually occurs on initial start-up
28
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WARNING
HIGH VOLTAGE
ELECTRICAL (ELECTRONIC IGNITION IID) IID
For qualified Technicians ONLY
Intermittent Pilot System
TROUBLESHOOTING HONEYWELL S8600
NOTE: Some heaters may be equipped with
an ignition module that shuts off pilot gas if
pilot fails to light. To reset, interrupt power to
heater.
START
TURN GAS SUPPLY OFF.
TURN THERMOSTAT
(CONTROLLER) TO CALL
FOR HEAT
POWER TO MODULE
(24 V NOMINAL)
YES
NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout
procedure.
Check line voltage power, low voltage transformer, limit controller, thermostat
(controller) and wiring.
NO
NO
Pull ignition lead and check spark at module.
SPARK ACROSS
IGNITER/SENSOR GAP
YES
Spark Okay?
YES
• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
• Check boot of the ignition cable for signs of melting or buckling. Take protective
action to shield cable and boot from excessive temperatures.
TURN GAS SUPPLY ON
PILOT BURNER LIGHTS?
YES
• Check that all manual gas valves are open, supply tubing and pressures are
good, and pilot burner orifice is not blocked.
• Check electrical connections between module and pilot operator on gas control.
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,
replace gas control; if not, replace module.
NO
NO
NOTE: If S8600H goes into lockout, reset system. Lockout is used on Pro. models.
SPARK STOPS WHEN
PILOT IS LIT?
YES
• Check continuity of ignition cable and ground wire.
• Clean flame rod.
• Check electrical connections between flame rod and module.
• Check for cracked ceramic flame rod insulator.
• Check that pilot flame covers flame rod and is steady and blue.
• Adjust pilot flame.
• If problem persists, replace module.
• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.
• Check electrical connections between module and gas control. If okay, replace
gas valve or gas control operator, i.e. pilot gas valve, flow switch etc.
NO
NO
MAIN BURNER LIGHTS?
YES
NOTE: IF S8600H goes into lockout, reset system.
• Check continuity of ignition cable and ground wire.
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though
operation is normal at the time of checkout.
• Check that pilot flame covers flame rod and is steady and blue.
• If checks are okay, replace module.
CALL FOR HEAT ENDS
SYSTEM SHUTS OFF?
YES
• Check for proper thermostat (controller) operation.
• Remove MV lead at module; if valve closes, recheck temperature controller and
wiring; if not, replace gas valve.
NO
TROUBLESHOOTING
ENDS
Repeat procedure until trouble free operation is obtained.
29
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SECTION 6 / REPLACEMENT PARTS LIST
NOTE: Tosupplythecorrectpartitisimportantthatyou
state the model number, serial number and type of gas
when applicable.
If determined defective by the Company and within
warranty, the part will be returned in kind or equal
substitution, freight collect. Credit will not be issued.
Any part returned for replacement under standard
company warranties must be properly tagged with
RAYPAK return parts tag, completely filled in with the
heater serial number, model number, etc., and shipped
to the Company freight prepaid.
Raypak, Inc.
2151 Eastman Avenue
Oxnard, CA 93030
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MODELS: 926/962, 1083/1125, 1178/1223, 1287/1336, 1414/1468, 1571/1631, 1758/1826
2-C
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MODELS: 2100, 2500, 3001, 3500, 4001
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LIMITED WARRANTY
RAYTHERM TYPE P
SIZES 0926-4001
SCOPE:
Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater which are actually manufactured
by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to
the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping
and transportation are not covered by this Warranty but are the owner’s responsibility.
HEAT EXCHANGER WARRANTY:
Five (5) years from date of heater installation. Includes only cupro nickel heat exchanger with bronze waterways.
ANY OTHER PART MANUFACTURED OR FURNISHED BY RAYPAK:
One (1) Year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based
on Raypak’s records, whichever comes first.
SATISFACTORY PROOF OF INSTALLATION DATE, SUCHAS INSTALLER INVOICE, IS REQUIRED. THIS WAR-
RANTY WILL BE VOID IF THE HEATER RATING PLATE ISALTERED OR REMOVED.
ADDITIONAL WARRANTY EXCLUSIONS:
This warranty does not cover failures or malfunctions resulting from:
1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided;
2. Abuse, alteration, accident, fire, flood and the like;
3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;
4. High velocity flow exceeding heater design rates;
5. Failure of connected systems devices, such as pump or controller;
6. Use of non-factory authorized accessories or other components in conjunction with the heater system;
7. Chemical contamination of combustion air or use of chemical additives to water.
8. Misuse or neglect, including but not limited to freeze ups, and operating the heater with cabinet door off, having
flow restrictions or obstructions between the heater outlet and pool/spa or not maintaining proper thermal balance
(pH level must be between 7.2 and 7.8 and total alkalinity between 100 and 150 PPM. Total Dissolved Solids (TDS)
must be no greater than 3000 PPM)
PARTS REPLACEMENT:
Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to
Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied.
The replacement part will be warranted for only the unexpired portion of the original warranty. Raypak makes no
warranty whatsoever on parts not manufactured by it, but Raypak will apply any such warranty as may be provided
to it by the parts manufacturer.
TO MAKE WARRANTY CLAIM:
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and
description of the problem. The installer must then notify his Raypak distributor for instructions regarding the claim.
If either is not available, contact Service Manager, Raypak, Inc., 2151 EastmanAve, Oxnard, CA93030 or call (818)
889-1500. In all cases proper authorization must first be received from Raypak before replacement of any part.
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY:
This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak’s behalf.
THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FORAPARTICULAR PURPOSE.
RAYPAK’S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE
PARTS SHALLBEAS PROVIDED IN THIS WARRANTY. IT ISAGREED THAT RAYPAK SHALLHAVE NO LIABIL-
ITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FOR
ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAK-
AGE. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental
or consequential damages. So the above limitation or exclusion may not apply to you.
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to
state. We suggest that you complete the information below and retain this certificate in the event warranty service
is needed. Reasonable proof of the effective date of the warranty (date of installation) must be presented, otherwise,
the effective date will be based on the date of manufacture plus thirty (30) days.
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Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 913030 (805) 278-5300 FAX (800) 872-9725
Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036
Litho in U.S.A.
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