Raypak 207A manual

INST ALLA TION AND OPERA TING INSTRUCTIONS GAS-FIRED POOL AND SP A HEA TER CA T ALOG NO. 6000.59E Effective: 02-01-06 Replaces: 12-16-05 P/N 241236 WARNING: If these instructions are 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[...]

WA TER CHEMISTR Y (Corrosive water voids all warranties) For your health and the protection of your pool equipment, it is essential that your water be chemically balanced. The following levels must be used as a guide for bal- anced water . Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool & Spa T ypes W ater T emp. (Deg. F) 68 to[...]

4 P ART ONE OWNER'S OPERA TING INSTRUCTIONS 4 SECTION 1 ST ART -UP PROCEDURES 4 Before Start-Up 5 Lighting Instructions & Shut-Off Procedures - Manually Lighted Pilots MV 6 Operating Instruction & Shut-Off Procedures - Automatically Lighted Pilots IID 7 After Start-Up 7 SECTION 2 CAUTION 8 SECTION 3 MAINTENANCE & CARE PROCEDURES 8 [...]

4 P AR T ONE OWNER'S OPERA TING INSTRUCTIONS FOR YOUR SAFETY - READ BEFORE OPERA TING WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTL Y , A FIRE OR EXPLOSION MA Y RESUL T , CAUSING PROPERTY DAMAGE, PERSONAL INJUR Y OR LOSS OF LIFE. SECTION 1 - ST ART -UP PROCEDURES Y our pool/spa heater has been designed for years of safe and reliable [...]

5 CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters. LIGHTING INSTRUCTIONS AND SHUT -OFF PROCEDURES MILLIVOL T SYSTEM (MANUALL Y LIGHTED PILOT) A. This appliance has a pilot that must be lit by hand. When lighting the p[...]

6 CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters. OPERA TING INSTRUCTIONS AND SHUT -OFF PROCEDURES ELECTRONIC IGNITION SYSTEM (AUTOMA TICALL Y LIGHTED PILOT) A. This appliance is equipped with an ignition device whic[...]

7 AFTER ST ART -UP Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot. VISUAL INSPECTION - A TMOSPHERIC HEA TERS With the heater on, remove the door and make a visu- al check of the pilot and burner . The flame should be blue with a well-defined pattern. 4" MAX Fig. # 8205.2 MAIN BU[...]

8 SECTION 3 - MAINTENANCE AND CARE PROCEDURES T o be followed one month after start-up and then semi- annually . 1. Inspect top of heater and drafthood for soot, a sticky black substance around finned tubes and "V" baffles, and open flue gas passageways. Any visible soot should be cleaned for proper opera- tion. 2. Clean main burners and [...]

9 COLD WEA THER OPERA TION IMPORT ANT FREEZE INFORMA TION MODERA TE CLIMA TE: Heater operation can contin- ue during short-term cold spells. When temperatures are between 0° and 32°F , flow (continuous pump operation) must be maintained. CAUTION: Do not use the heater to maintain water temperatures just above freezing or for freeze protec- tion. [...]

10 P AR T TWO INST ALLA TION AND SERVICE INSTRUCTIONS SECTION 1 - RECEIVING EQUIPMENT The manufacturer recommends that this manual be reviewed thoroughly before installing your pool/spa heater . If there are any questions that this manual does not answer , please contact the factory or your local represen- tative. On receipt of your equipment it is[...]

11 SECTION 3 - INST ALLA TION INSTRUCTIONS CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer , birth defects or other reproductive harm. IMPORT ANT NOTICE These instructions are intended only for the use of qualified personnel, specifically trained and experienced in the installation[...]

12 OUTDOOR HEA TER INST ALLA TION These heaters are design-certified for outdoor installation, when equipped with the approved tops designated for outdoor use. WARNING: The heater shall not be located in an area where water sprinklers, or other devices, may cause water to spray through the cabinet louvers and into the heater . This could cause inte[...]

13 Heaters must not be installed under an overhang of less than three 3 ft from the top of the heater . Three sides must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters. For U.S. installations , the point from where the flue products exit the heater[...]

14 FLORIDA BUILDING CODE 2001 WIND SPEED = 150 MPH, 3 SECOND GUST EXPOSURE = C T O H B 28” 40” 3 ” Min. Conc. Pad by others 3 ” Min. Conc. Pad by others Min. Edge Distance Min. Edge Distance (1)–1/4” x 1- 3 /4” S . S . T apcon Bolt & W asher Ea. Raypak Pallet Anchor Bracket Use hole closest to unit (4 total) (1)–1/4” x 1- 3 /4[...]

15 W ARNING: Indoor heaters require 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. INDOOR HEA TER INST ALLA TION The heater is also design-certified for indoor installation when equipped with the approved drafthood. For Canada [...]

16 SPECIFICA TIONS AND DIMENSIONS Heater Model BTUH Input (000) (A) Cabinet Width (B) Flue Dia. (C) Indoor Drafthood (J) Min. Gas Conn. W ater Conn. Shipping W eights (lbs) Standard Heater w/Stackless To p ASME Heater w/Stackless To p Indoor Draft- hood R206A 199.5 20” 6” 61-5/8” 1 1-3/4” 3/4” 2” 187 206 12 R266A 266.0 23” 7” 62” [...]

17 Lo w NO x UNITS Heater Model BTUH Input (000) (A) Cabinet Width (B) Flue Dia. (C) Indoor Drafthood (J) Min. Gas Conn. W ater Conn. Shipping W eights (lbs) Standard Heater w/Stackless To p ASME Heater w/Stackless To p Indoor Draft- hood R207A 199.5 20” 6” 55-5/8” 1 1-3/4” 3/4” 2” 174 193 12 R267A 266.0 23” 7” 56” 11 ” 3/4” 2[...]

18 B. All Air From Outdoors: When air is supplied directly from outside of build- ing, each opening shall have a minimum net free area as noted: COMBUSTION AND VENTILA TION AIR (Indoor Units Only) The heater must have both combustion and ventilation air . Minimum requirements for net free air supply open- ings are one opening that is 12 inches from[...]

19 The discharge opening must be a minimum of 2 ft ver- tically from the roof surface and at least 2 ft higher than any part of the building within 10 ft. V ent stack shall be at least 5 ft in vertical height above the drafthood out- let. The vent cap location shall have a minimum clear- ance of 4 ft horizontally from, and in no case below , unless[...]

20 GAS PRESSURE REGULA TOR The gas pressure regulator is preset at 4.0 in. WC throughout for natural gas, and 10.5 in. WC. for propane gas. The pressure at the gas valve, taken with a manometer , should be about 4.0 in. WC natural gas (3.0 in. WC for Low NOx) and 10.5 in. WC propane gas. If an adjustment is needed, remove seal and turn adjustment s[...]

21 PLUMBING FOR WA TER CONNECTIONS 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: 1. The inlet side of the filter is plumbed directly to the discharge side of the filter pump; 2. The [...]

22 CAST IRON HEADERS (ASME MODELS) Heater must be located so that any water leaks will not damage the structure of adjacent area. High tempera- ture 2" plastic pipe (CPVC) may be threaded directly into the header flanges. This is not the same as the Schedule 80 PVC pipe which is also gray . PVC may be used immediately after the supplied CPVC a[...]

23 INTERNAL AUTOMA TIC BYP ASS V AL VE In addition to the Unitherm Governor , a built-in auto- matic bypass valve is provided in the in/out header . While the Unitherm Governor responds to the changes in water temperature in the heater , the internal bypass valve automatically responds to changes in water pressure in the piping system. Proper amoun[...]

24 HEA T EXCHANGER PRESSURE DROP T ABLES POL YMER HEADER (ST ANDARD MODELS) FLOW GPM PRESSURE DROP (FT OF HEAD) 206/207 266/267 336/337 406/407 20 1.5 2.8 4.1 4.1 30 1.7 4.6 5.8 5.8 40 2.1 5.2 6.5 6.5 50 2.4 5.6 7.2 7.2 60 2.8 6.1 7.7 7.7 70 3.7 6.5 8.2 8.2 80 4.6 7.3 8.7 8.7 90 5.7 8.8 10.2 10.2 100 6.8 10.0 13.0 13.0 CAST IRON HEADER (ASME MODELS[...]

25 HEA T EXCHANGER REVERSAL PROCEDURE - ST ANDARD MODELS 1. Remove right and left side access panels (Figure 1). 2. Disconnect wires at high limit, AGS (automatic gas shut-off), and pressure switch on the in/out header (Figure 2). 3. Digital Models: Remove the thermostat tempera- ture sensor by loosening the compression fitting nut (Figure 3). Re-r[...]

26 A TMOSPHERIC Wiring locations LOW NOx Wiring locations ELECTRICAL WIRING NOTE: If it is necessary to replace any of the original wiring, use 105°C wire or its equivalent, and/or 150°C wire or its equivalent, like the original wiring. MILLIVOL T MODELS The Millivolt models are equipped with a self-generat- ing electrical system in which the ele[...]

27 TRANSFORMER WIRING 120 V AC WIRING For 120 V AC input power to the unit, connect the black wire to the “L1” or hot leg of the power supply . Connect the white wire to the “Ret” or neutral leg of the power supply . Attach the wire nut to the red wire. There should be no connection to the red wir e for 120 V AC operation. For Low NOx pool [...]

28 WIRING DIAGRAM - MILLIVOL T (MECHANICAL THERMOST A T)[...]

29 WIRING DIAGRAM - DIGIT AL MODELS - A TMOSPHERIC[...]

30 WIRING DIAGRAM - DIGIT AL MODELS - LOW NOx[...]

31 SECTION 4 - SERVICING INSTRUCTIONS GENERAL LOCA TION OF CONTROLS A TMOSPHERIC LOW NOx Digital Thermostat Circuit Board Drain Plug (Located in rear header) Unitherm Governor Mounted On T op Of Header HL1 - High Limit HL2 - High Limit Pressure Switch T emp Sensor/Well Pilot Roll-Out Switch Gas V alve T ransformer Draw Plug Digital Thermostat Circu[...]

32 CONTROL P ANEL REMOV AL 1. Remove (2) screws from front door . Set aside door for serviceability . CONTROL ADJUSTMENTS - MILLIVOL T MODELS The water temperature is controlled by the heater ther- mostat on the upper front panel of the heater . The control center contains an On/Off switch and one ther- mostat. The thermostat is fitted with a means[...]

33 THERMOST A T CONTROL OPERA TION The pool heater thermostat, located on the upper front panel of the heater , controls the pool/spa water tem- perature. This control center contains a mode button, up and down temperature adjustment buttons, and an LCD display . Mode Button The MODE button functions as a means to turn the heater off or on in eithe[...]

34 set Resets board to factory default settings. Resets faults in the History File. Change from Fahrenheit to Celsius. SP A setpoint maximum adjustment. POOL setpoint maximum adjustment. SETdef – Default Settings Refer to step one above to access the program screen. SETdef should appear on the screen. If not, press the Mode button until SETdef ap[...]

35 If the PRS fault code is displayed, it indicates that there is insufficient water flow through the heater . Make sure the pool filter and pump strainer are clean before calling a service representative. DIAGNOSTICS The digital thermostat models are equipped with on- board diagnostic controls. If there is a safety fault, a fault code will be disp[...]

36 REMOTE CONTROL INST ALLA TION AND OPERA TION CAUTION: Before installing r emote controls to the digital thermostat model heaters r ead the following: The digital thermostat model is remote-ready in most cases. The digital liquid crystal display (LCD) shows the actual pool temperature, operating status, and service codes (See examples below). The[...]

37 REMOTE CONTROL WIRING Important Installation Notes for Remote or External Wiring Configuration • Remote wiring must be run in a separate conduit. • Remote wiring must not be run parallel to high voltage lines. • For runs of under 30 feet, remote wiring should have stranded conductors with a minimum of 22 A WG, 600V , cable twisting 1.5 to [...]

38 WA TER PRESSURE SWITCH The water pressure switch, or heater actuator , ensures that the heater operates only when the filter pump is in operation. It is located on the inlet/outlet header . It is factory set at 1.75 PSI for deck-level installations. When the heater is located below the level of the spa or pool, it may be necessary to adjust the [...]

39 PILOT REMOV AL AND CLEANING 1. Disconnect pilot tubing and wires from gas valve. 2. Remove pilot assembly from burner tray . 3. Remove pilot from bracket. 4. Remove pilot orifice and air opening (Honeywell MV unit only), and clean with wire or small brush. CAUTION! Do not enlarge hole in pilot orifice. 5. Reverse above procedure to reinstall. Pi[...]

40 TUBE CLEANING PROCEDURE Establish a regular inspection schedule, the frequency depending on the local water conditions and the sever- ity of service. Do not let the tubes clog up solidly . Clean out deposits over 1/16" in thickness. The heater may be cleaned from the return header side, without breaking pipe connections. It is prefer- able,[...]

41 The Low NOx pool heaters are certified and tested under the ANSI Z21.56/CSA 4.7 Standard for Gas- Fired Pool Heaters. The heater should be installed to meet all local codes, and the latest editions of the National Fuel Gas Code Z223.1 and the National Electrical Code, ANSI/NFP A 70. OPERA TION On call for heat, the ignition system, consisting of[...]

42 LOW NOx HEA TERS (CONTINUED) BURNER TRA Y REMOV AL 1. Shut off main electrical power switch to heater . 2. Shut off gas upstream of heater . 3. Remove front door . 4. Disconnect gas line from gas valve. 5. Remove (2) screws that mount burner tray to the base of the unit, and (2) screws that mount the blower box to the burner tray , and (1) screw[...]

43 MECHANICAL IMPOR T ANT NOTICE These instructions are intended for the use of qualified personnel who are specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be require d by some states to be licensed. Persons not qualified shall not attem[...]

44 ELECTRICAL - ST ANDING PILOT MILLIVOL T POOL OR SP A HEA TER ELECTRICAL CHECK WITH MILLIVOL T GAS V AL VE CAUTION: For qualified service personnel only . 1. Filter must be on with adequate water flow through heater . 2. Gas valve must be in "ON" position. Thermostat set higher than pool water temperature. 3. Jumpers are for temporary c[...]

45 ST ART TURN GAS SUPPL Y OFF . TURN THERMOST A T (CONTROLLER) TO CALL FOR HEA T POWER T O PC BOARD? (24 V NOMINAL) YES SP ARK ACROSS IGNITER/SENSOR GAP? YES TURN GAS SUPPL Y ON PILOT BURNER LIGHTS? YES MAIN BURNER LIGHTS? YES SYSTEM RUNS UNTIL CALL FOR HEA T ENDS? YES CALL FOR HEA T ENDS SYSTEM SHUTS OFF? YES TROUBLESHOOTING ENDS NOTE: Before tro[...]

46 Power On Is the water temperature displayed? NO YES Push MODE switch to select " Pool " or " SP A " Push T emp arrow to scroll to desired temperature NO W ater temperature and set temperature displayed? YES CFH (call for heat) will display briefly SPK (spark) will display until pilot is lit up to 2 minutes maximum NO NO YES Y[...]

47 SECTION 6 - REPLACEMENT P ARTS NOTE: T o supply you with the correct part, it is impor- tant that you supply the heater model number , serial number and type of gas when applicable. Any part returned for replacement under standard company warranties must be properly tagged with a return parts tag, completely filled in with the heater serial numb[...]

48 10-M 14-M 9-M 9-M 5-C 4-C 11-S 4-S 5-S 3-B 4-B 5-B 1-B 6-S 7-S 4-S 2-R 1-R 1-J 16-M 3-R 2-V 4-V 1-V 3-V 1-S 13-S 2-S 12-S 4-HP 5-HP 7-HP 6-HP 6-HP 3-HP 12-HM 17-HM 14-M 8-S 2-J 2-B 1-G 4-M 2-M 5-M 12-M 11-M 13-M 3-S 10-S 16-M A TMOSPHERIC HEA TERS[...]

49 8-S 3-S 11-S 4-S 6-S 7-S 4-S 5-S 1-R 1-J 2-S 3-R 9-M 1-V 2-V 3-V 1-S 2-S 12-S 13-S 9-M 17-HM 12-HM 4-HP 3-HP 6-HP 5-HP 7-HP 6-HP 2-J 1-G 4-B 3-B 6-B 5-B 1-B 10-S 3-J 2-B 2-M 10-M 4-C 6-C 6-M 8-M 7-M 7-B 12-M 13-M 12-M 4-V LOW NOx HEA TERS[...]

50 16-HM 15-HM 12-HM 9-HM 10-HM 2-C 3-M 11-HM 8-HM (OPTIONAL) 3-M 5-C 19-HP 11-HP 16-HP 10-HP 13-HP 14-HP 17-HP 18-HP 8-HP 15-HP 12-HP 2-HP 1-M (OPTIONAL) 1-C POL YMER IN/OUT HEADER AND A CCESSORIES 1-M 3-C 5-C 5-HM 17-HM 14-HM 13-HM 2-HM 4-HM 7-HM 3-HM 6-HM 2-S 9-S 4-S HONEYWELL IID A TMOSPHERIC PILO T 2-P 7-P 9-P 8-P 1-P 5-P 6-P 3-P 9-P HONEYWELL[...]

51 CALL OUT DESCRIPTION 206A 266A 336A 406A B BURNER TRAY 1-B Burner Tray w/Burners (sea level)* 010391F 010392F 010393F 010394F Burner Tray w/o Burners (sea level)* 010395F 010396F 010397F 010398F Burner Tray w/Gas Valve Nat Millivolt 010399F 010400F 010401F 010402F Burner Tray w/Gas Valve Pro Millivolt 010403F 010404F 010405F 010406F Burner Tray [...]

52 CALL OUT DESCRIPTION 206A 266A 336A 406A HM HEA T EXCHANGER - MET AL 1-HM Heat Exchange Assy .Copper ASME CI 010051F 006727F 010053F 010054F Heat Exchange Assy .Cupro Nickel ASME CI 010360F 010361F 010362F 010363F 2-HM Inlet/Outlet Header ASME CI 006730F 006730F 006730F 006730F 15-HM Inlet & Outlet Flange 003766F 003766F 003766F 003766F 16-H[...]

53 CALL OUT DESCRIPTION 206A 266A 336A 406A S SHEETMET AL 1-S Jacket T op (Louvered) 010047F 010048F 010049F 010050F 2-S Flue Collector (Units with Polymer Header) 010071F 010072F 010073F 010074F Flue Collector (Units with Metal Header) 010075F 010076F 010077F 010078F 3-S Door Assy . Raypak 010378F 010379F 010380F 010381F Rheem 010382F 010383F 0103[...]

54 CALL OUT DESCRIPTION 207A 267A 337A 407A BB BURNER TRA Y 1-B Burner T ray w/Burners (0-5000) 010343F 010344F 010345F 010346F Burner T ray w/o Burner (0-5000) 010084F 010085F 010086F 010087F 2-B Burner Hold Down Kit 010254F 010255F 010256F 010257F 3-B Burner 310732/3 310732/4 310732/5 310732/6 4-B Burner Orifice Nat. #26 (0-5000)* 351510/3 351510[...]

55 CALL OUT DESCRIPTION 207A 267A 337A 407A J CONTROL BOX 1-J Transformer 120/240/24V 006736F 006736F 006736F 006736F 2-J Rocker Switch 009493F 009493F 009493F 009493F 3-J Relay Low Nox 008784F 008784F 008784F 008784F M MISCELLANEOUS COMPONENTS 1-M Pressure Switch 1.75 PSI 006737F 006737F 006737F 006737F Pressure Switch 1 1 PSI S p ecial-See Water [...]