Page 3 - PART ONE - OWNER'S OPERATING INSTRUCTIONS; FOR YOUR SAFETY - READ BEFORE OPERATING; BURNERS
3 PART ONE - OWNER'S OPERATING INSTRUCTIONS FOR YOUR SAFETY - READ BEFORE OPERATING WARNING: IF YOU DO NOT FOLLOW THESEINSTRUCTIONS EXACTLY, A FIRE OREXPLOSION MAY RESULT, CAUSINGPROPERTY DAMAGE, PERSONAL INJURY ORLOSS OF LIFE. SECTION 1 / START-UP PROCEDURES BEFORE START-UP BURNERS Clean main burne...
Page 4 - MILLIVOLT SYSTEM
4 TO TURN OFF GAS TO APPLIANCE LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES MANUALLY LIGHTED PILOTS MILLIVOLT SYSTEM A. This appliance has a pilot that must be lighted by hand. When lighting the pilot, follow theseinstructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas....
Page 5 - ELECTRONIC IGNITION SYSTEMS; GAS INLET
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES AUTOMATICALLY LIGHTED PILOTS ELECTRONIC IGNITION SYSTEMS A. This appliance is equipped with an ignition device which automatically lights the pilot. Donot try to light the pilot by hand. B. BEFORE OPERATING, smell all around the appli- ance area for gas...
Page 6 - MAIN BURNER FLAME; Operation of the heater without water
6 SECTION 2 / CAUTION Elevated water temperature can be hazardous, and theU.S. Consumer Product Safety Commission recom-mends the following guidelines: 1. Spa or hot tub water temperatures should never exceed 104°F (40°C). A temperatureof 100°F(38°C) is considered safe for ahealthy adult. Special ca...
Page 7 - SECTION 3 / MAINTENANCE AND CARE PROCEDURES; SPA WATER CHEMISTRY; High chemical concentrates from feeders and
7 SECTION 3 / MAINTENANCE AND CARE PROCEDURES 4. Your pump strainer basket may be full. If so remove debris. 5. Your filter may be dirty. If so, backwash or clean filter. (To tell if your filter is dirty, thegauge pressure will be higher than usual). 6. The pump may have lost it's prime. It may be r...
Page 8 - COLD WEATHER OPERATION; Heater operation can con-; WINTERIZING THE POOL & SPA HEATER; When heaters installed outdoors in freezing climate
COLD WEATHER OPERATION MODERATE CLIMATE: Heater operation can con- tinue during short term cold spells. When temperaturesare below freezing 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...
Page 9 - PART 2 - INSTALLATION / SERVICE INSTRUCTIONS; SECTION 1 / RECEIVING EQUIPMENT; IMPORTANT NOTICE; The heater should not be located in an area; BASE INSTALLATION
9 PART 2 - INSTALLATION / SERVICE INSTRUCTIONS SECTION 1 / RECEIVING EQUIPMENT On receipt of your equipment it is suggested that you visually check for external damage to the carton. Ifthe carton is damaged, a note should be made on the Billof Lading when signing for equipment. Remove theheater from...
Page 10 - CLEARANCES; ALL HEATERS
10 CLEARANCES 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 someelectrical components, and this would void the warranty. ALL HEA...
Page 12 - COMBUSTION AIR; and void the warranty.; VENTING CONNECTIONS
INDOOR DRAFT HOOD INDOOR HEATERS The design is also certified for indoor installation when equipped with the approved draft hood. Locate heater as close as practical to a chimney or gas vent. Heater must always be vented to the outside. See Vent Piping Sectionfor venting details. Minimum allowable s...
Page 13 - Indoor boilers require a drafthood that; ANSI
DRAFT HOOD MOUNTINGSCREWS (8) VENT TERMINAL (Outdoor) OUTDOOR STACK STEP 1 Line up (8) holes in jacket top with (8)holes in adapter assembly. STEP 2 Lower entire outdoor stack assemblyon to jacket top. STEP 3 Secure with fasteners provided. VENT TERMINAL (Indoor) Locate and assemble as shown. Secure...
Page 14 - GAS SUPPLY CONNECTIONS; The heater and its manual shut off valve; PIPE SIZING FOR GAS CONNECTIONS
GAS SUPPLY CONNECTIONS Gas piping must have a sediment trap ahead of theheater gas controls, and a manual shut-off valve lo-cated outside the heater jacket. All gas piping shouldbe tested after installation in accordance with localcode s. Gas Inlet Gas Valve Heater Jacket Union Sediment Trap CAUTION...
Page 15 - NEVER install PVC directly into header
FLOW RATES MIN GPM 20MAX GPM 115**When flow rates exceed 115 GPM an external auxil-iary bypass valve is required. See external auxiliarybypass valve section for details. COMPANION FLANGE CONNECTIONS DO NOT use petroleum base assembly fluids (such as Petroleum Jelly or lubricating oil). If assemblylu...
Page 17 - To avoid water damage or scalding due to valve; ELECTRICAL WIRING
NOTE: To avoid water damage or scalding due to valve operation, drain pipe must be connected to valve outletand run to a safe place of discharge. Drain pipe mustbe the same size as the valve discharge connectionthroughout its entire length and must pitch downwardfrom the valve. No shut-off valve sha...
Page 18 - WIRING DIAGRAM KEY
WIRING DIAGRAM KEY 18 Fig. # 8096.0 For 120 V input power to the unit, connect the black wireto the “L1” or hot leg of the power supply. Connect thewhite wire to the “L2” or neutral leg of the power supply.Attach the wire nut to the red wire. There should be noconnection to the red wire for 120V ope...
Page 19 - WIRING DIAGRAM MILLIVOLT UNITS
Page 21 - SECTION 4 / SERVICING INSTRUCTIONS; GENERAL LOCATION OF CONTROLS
VIEW OF HEATER FROM FRONT VIEW OF HEATER FROM BACK SECTION 4 / SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS 21 CONTROL PANEL REMOVAL 1. Remove lower door.2. Remove (2) screws from bottom flange of control panel. 3. Slide down control panel to clear jacket top panel. 4. Rotate control panel do...
Page 23 - If the heat exchanger is sooted badly, the; DO NOT
PILOT SAFETY (Millivolt System) The heaters equipped with the standing pilot (millivolt system), have pilot generators which act as asafety device to shut off the flow of gas to the mainburners and the pilot burner in case the pilot flame isextinguished. The pilot burner must be manually re-lighted ...
Page 25 - roller; RAYPAK TUBE CLEANING KIT; Wire Brush
DESOOTING PROCEDURE CAUTION: SOOT IS COMBUSTIBLE. EXERCISE EXTREME CARE. Soot can clog areas between fins and cause even- tual tube failure. Any sign of soot at the base of theburners or around the outer jacket indicates a need forcleaning. 1. Remove top and flue collector from cabinet.2. Remove ...
Page 26 - SECTION 5 / TROUBLE SHOOTING GUIDE; MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY)
SECTION 5 / TROUBLE SHOOTING GUIDE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installationof this type of heating equipment and related system components. Installation and service personnel may be required by somestates to...
Page 27 - only
If pilot burner remains lit. Jump across pressure switch terminals If main burner does not fire, remove jumper Check for adequate water flow from filter Replace pressure switch Jump across thermostat If main burner fires, remove jumper If main burner does NOT fire... Jump across each high limit and ...
Page 28 - WARNING; HIGH VOLTAGE; Intermittent Pilot System; TROUBLESHOOTING HONEYWELL S8600; START
ELECTRICAL (ELECTRONIC IGNITION IID) 28 1234567890123456789012345678901212345678901234567890123456789012 1234567890123456789012345678901212345678901234567890123456789012 1234567890123456789012345678901212345678901234567890123456789012 1234567890123456789012345678901212345678901234567890123456789012 ...
Page 29 - SENSOR RESISTANCE AT VARIOUS TEMPERATURES; Check voltage at 24 V terminals.
ELECTRICAL (SOLID STATE THERMOSTAT IID) If the pool/spa/hot tub water is too cold, troubleshoot the system as follows: Check voltage at 24 V terminals. VOLTAGE BETWEEN 21.5-28.5 V.Set control to max. temperature. After 2-3cycles, check water temperature. TEMPERATURE BELOW 105°FDisconnect sensor lead...
Page 30 - SECTION 6/REPLACEMENT PARTS LIST; To supply the correct part it is important that
30 SECTION 6/REPLACEMENT PARTS LIST NOTE: To supply the correct part it is important that you state the model number, serial number and typeof gas when applicable. Any part returned for replacement under standardcompany warranties must be properly tagged withRAYPAK return parts tag, completely fille...