INSTALLATION & OPERATING INSTRUCTIONS Raytherm™ Commercial Swimming Pool Heater Models 514–824 WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance.
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CONTENTS WARNINGS Pay Attention to These Terms WATER CHEMISTRY OWNER’S OPERATING INSTRUCTIONS Start-Up Procedures Operating Instructions and Shut-Off Procedures Automatically Lighted Pilots Electronic Ignitions Systems Caution Maintenance and Care Procedures INSTALLATION & SERVICE INSTRUCTIONS Receiving Equipment General Specifications Installation Instructions Wiring Diagram—Models 514–724 Wiring Diagram—Model 824 Wiring Diagram—Models 514–724 —Spa Wiring Diagram—Model 824—Spa Servicing Troubleshooting Re
WARNINGS Pay Attention to These Terms DANGER: WARNING: CAUTION: NOTE: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
WATER CHEMISTRY • NOTE: Heat exchanger damage resulting from chemical imbalance is not covered under the warranty. • 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 balanced water. • Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water, unless controlled, they can lead to excessive chlorine level which can damage your heater.
OWNER’S OPERATING INSTRUCTIONS WHAT TO DO IF YOU SMELL GAS: • • • FOR YOUR SAFETY - READ BEFORE OPERATING: WARNING: If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or death. • Do not try to light any appliance. Do not touch any electric switch; do not use any telephone in your building. Immediately call your gas supplier from a neighbor's telephone. Follow the gas supplier’s instructions.
OPERATING INSTRUCTIONS 1. STOP! Read the safety information on the preceeding page. 2. Set the thermostat on the lowest setting. 3. Turn off all electric power to the appliance. 4. Remove heater door panel. For Models 514-724 with Robertshaw Gas Valve. Turn Gas control knob clockwise to “OFF”. GAS CONTROL KNOB SHOWN IN “ON” POSITIONS GAS INLET 5. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. 6.
After Start-Up checked and adjusted for proper operation by a qualified service person at the time of installation and periodically checked thereafter. Refer to pressure switch servicing instruction in this manual). Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot. WARNING: Operation of the heater without water circulation will cause rapid and severe damage to the heater. Such damage is not covered under warranty.
Maintenance and Care Procedures 4. Your pump strainer basket may be full. If so remove debris. 1. Inspect top of heater and drafthood for soot, (a sticky black substance around finned tubes and “V” baffles), and open flue gas passageways. 6. The pump may have lost it's prime. It may be running dry, check the pressure gauge on the filter. If there is no pressure; then you are not moving water (or your gauge is broken). Try to get the pump to run at it's normal flow rate. 5. Your filter may be dirty.
INSTALLATION & SERVICE INSTRUCTIONS Installation Instructions NOTE: These instructions are intended for the use of qualified 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 licensed. If your state is such, be sure your contractor bears the appropriate license.
overhang. Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters. 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 heavy internal rusting or damage some electrical components, and this would void the warranty.
Combustion Air (Indoor Units Only) Venting Connections Air For Combustion and Ventilation (Indoor Units Only) Vent Terminal (Outdoor) 1. Lower outdoor “Stackless” top on to unit. Position top so it is centered on unit from side to side and front to rear. The heater must have both combustion and ventilation air. Minimum requirements for net free air supply openings, one 12 inches from ceiling for ventilation and one 12 inches from the floor for combustion air as outlined ANSI Z 223.
codes, to the latest edition of the National Fuel Gas Code, ANSI Z 223.1/NFPA 54. Vent Terminal (Indoor) Locate and assemble as shown below. Secure with screws supplied in envelope in carton. The discharge opening must be a minimum of two feet 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 draft hood outlet.
Gas Supply Connections 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 placed in operation, while the other appliances remaining connected to the common venting system are not in operation. Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut off valve located outside the heater jacket.
Model 514 624 724 824 N 1/2” P 10 N 15 10 1” P N 1-1/4” P N 1-1/2” P N 35 65 150 130 360 500 20 35 80 75 180 260 25 15 45 100 25 60 95 Natural gas, 1000 BTU/Ft .60 Specific Gravity @ 0.5 in. WC Pressure Drop Propane Gas, 2500 BTU/Ft 1.53 Specific Gravity @ 0.6 in. WC Pressure Drop 55 250 130 340 185 2” P 600 480 N 2-1/2” P 500 Table E: Pipe Sizing for Gas Connections Heater must be located so that any water leaks will not damage the structure of adjacent area.
Piping Diagram—Single Heater Piping Diagram—Two Heaters 16
NOTE: When 2” piping is used into the heater, this piping must be anchored (copper) or screwed into the flange (metal) if operating pressures above 30 PSI are encountered. Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the heater when the pump is shut off. NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid corrosion to the heat exchanger in the heaters.
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 comfortable to the touch. If pipe is hot, close bypass; if cold open bypass. PRESSURE RELIEF VALVE INLET/OUTLET HEADER 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.
For 120 V 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 “L2” or neutral leg of the power supply. Attach the wire nut to the red wire. There should be no connection to the red wire for 120V operation. Fig. 18: 240V Connections Heater must be electrically grounded and bonded in accordance with local codes, or, in the absence of local codes, with the latest edition of the National Electrical code, NFPA 70. Fig.
Wiring Diagram—Models 514–724 20
Wiring Diagram—Model 824 21
Wiring Diagram—Models 514–724—Spa 22
Wiring Diagram—Model 824—Spa 23
Servicing General Location of Controls Fig. 19: General Location of Controls Controls/Adjustments/Replacements TYPICAL COMFORTABLE SPA TEMPERATURE RANGE Thermostat The heater is built with a single mechanical thermostat, located in the front panel above the door. The thermostat maybe set for any desired pool or spa temperature TEMPERATURE SENSOR KNOBSTOP RING SET SCREW Fig. 21: Knobstop MECHANICAL THERMOSTAT Knobstop Adjustment Fig.
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. When the heater is located below the level 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 recommend the following procedure. 5’ Max 5’ Max Fig.
High Limit Removal Main Burner and Orifice Removal 1. Shut off main electrical power switch to heater. 1. Remove burner drawer. See burner drawer removal procedure. 2. Remove inspection panels. 2. Remove screws and burner hold down bracket. 3. Drain heater. NOTE: If the heat exchanger is sooted badly, the burner hold down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts. 4.
RAYPAK TUBE CLEANING KIT Extension Pieces (5) Auger with Carbide Tip Fig. 34: Tube Cleaning Kit 5. Remove heat exchanger corner brackets. Wire Brush F Shut gas and power off to the unit, close the system off and drain the heater. Remove the draft diverter. Remove the access panel and jacket top. Lift flue collector off. Remove “V” baffles over tube(s) to be replaced.
De-sooting Procedure Control Immersion Well Replacement Remove top, sensing bulb and clip. Collapse well tube at the open end with a chisel, push through into header and remove the header. Insert a new well and roll into place. If a roller is not available, solder or braze. CAUTION: Soot is combustible. exercise extreme care. Soot will clog areas between fins and cause eventual tube failure. Any sign of soot at the base of the burners or around the outer jacket indicates a need for cleaning. 1.
Troubleshooting 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.
Liming Bypassing too much water…………………… U. G. not functioning………………………… Inspect bypass for movement, if no movement, replace. Replace if no movement when heated. Leaking at well. Leaking at heat exchanger. Overacid……………………………………… Replace well and maintain water chemistry properly. Gasket brittle and leaking (overheated). Overacid……………………………………… Replace heat exchanger and maintain chemistry properly.
NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if the pilot fails to light. To reset, interrupt power to the heater. ELECTRICAL WARNING: HIGH VOLTAGE. technicians ONLY. For qualified Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START TURN GAS SUPPLY OFF.
Replacement Parts Replacement parts for the 514-824 Raytherm Swimming Pool Heaters may be found in Raypak’s Illustrated Parts List, Catalog No. 9100.60, which is available at the Raypak website: NOTE: To supply the correct part it is important that you state the model number, serial number and type of gas when applicable. http://www.raypak.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
