Instruction/ maintenance manual of the product 267A Raypak
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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.
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.
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 Instruct.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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).
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.
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.
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 Heade.
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.
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 .
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.
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.
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).
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.
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.
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.
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.
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.
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 .
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.
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.
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? .
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 s.
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.
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 .
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-.
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.
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 Bu.
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 .
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 .
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.
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.
An important point after buying a device Raypak 267A (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Raypak 267A yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Raypak 267A - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Raypak 267A you will learn all the available features of the product, as well as information on its operation. The information that you get Raypak 267A will certainly help you make a decision on the purchase.
If you already are a holder of Raypak 267A, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Raypak 267A.
However, one of the most important roles played by the user manual is to help in solving problems with Raypak 267A. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Raypak 267A along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
