Raypak Swimming Pool Heater P926, P1826, P2100, P4001 User Guide

CATALOGNO.6200.51O

Effective:

Replaces:

04-09-07

05-15-05

INSTALLATION

AND OPERATING

INSTRUCTIONS

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

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.

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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.

foot

Minimum

foot

Minimum

MINIMUM CLEARANCES FROM COMBUSTIBLE

CONSTRUCTION

foot

Minimum

foot

Minimum

INDOOR HEATERS

foot

Top - 24"

*Vent - 6"

10 foot

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)

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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

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.

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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

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.

GAS INLET

UNION

SEDIMENT

TRAP

FIG. #8090.0

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.

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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

GAS PRESSURE

TEST UPSTREAM

MANOMETER

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 PRESSURE TEST

AT GAS VALVE

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

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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,

FLANGE GASKET

OUTLET

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.

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MODELS 1287/1336 - 1758/1826

1-1/2" Slip Ball Valve

Pump

Inlet/Outlet

Header

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

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)

MODELS

1287/1336

1414/1468

1571/1631

1758/1826

2100

180

2500

60-95

180

3001

3500

4001

75-115

90-135

100-150

180

*Loop is secondary piping to

heater from main system.

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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

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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)

HEATEROUTLETTEMPERATURE

THERMOMETER

HEATERTHERMOSTAT

RECOMMENDED FIELD INSTALLED

ISOLATIONVALVESFORSERVICE

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BYPASSVALVE

EXTERNALAUXILIARYBYPASSVALVE

(WhereRequired) 926-1223Modelsonly

INLET/OUTLET

HEADER

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

FROM

HEATER

Fig. #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

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

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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

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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

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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

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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.

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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.

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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

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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.

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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

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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.

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.

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.

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.

TROUBLESHOOTING

ENDS

Repeat procedure until trouble free operation is obtained.

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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.

Download from Www.Somanuals.com. All Manuals Search And Download.

www.raypak.com

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

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