Raypak 268 Manual

INSTALLATION & OPERATING
INSTRUCTIONS
Gas-Fired
P l & Spa
Heater
Catalog No. 6000.64 Effective: 08-18-11 Replaces: NEW P/N 241452 Rev. 1
WARNING: If these instructions are not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
W AT 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 sup-
plier'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.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
Atm spheric M dels
268 & 408
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
TM

WATER C EMISTRY
(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
Types
Water Temp. (Deg. ) 68 to 88 89 to 104 68 to 104
pH 7.3 to 7.4 7.3 to 7.4 7.6 to 7.8
Total Alkalinity (PPM) 120 to 150 120 to 150 80 to 120
Calcium Hardness (PPM) 200 to 300 150 to 200 200 to 400
Salt (PPM) 4500 MAXIMUM 4500 MAXIMUM 4500 MAXIMUM
ree Chlorine (PPM)* 2 to 3 2 to 3 2 to 3
Total Dissolved Solids (PPM) 3000 MAXIMUM** 3000 MAXIMUM** 3000 MAXIMUM**
* Free Chlorine MUST NOT EXCEED 5 PPM!
• Occasional chemical shock dosing of the pool or spa water should not damage the
heater providing the water is balanced.
• 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, and which is not covered under warranty.
• urther advice should be obtained from your pool or spa builder, accredited pool
shop, or chemical supplier for the correct levels for your water.
2
** In salt water chlorinated pools, the total TDS can be as high as 6000 ppm.

4 PART ONE
OWNER'S OPERATING INSTRUCTIONS
4 SECTION 1
START-UP PROCEDURES
4 Before Start-Up
5 Operating Instruction & Shut-Off Procedures -
Automatically Lighted Pilots IID
6After Start-Up
6 SECTION 2
CAUTION
7 SECTION 3
MAINTENANCE & CARE PROCEDURES
7 Pool & Spa Water Chemistry
7 Automatic Chlorinators & Chemical eeders
8 Cold Weather Operation
8 Winterizing the Pool & Spa Heater
9 PART TWO
INSTALLATION & SERVICE INSTRUCTIONS
9 SECTION 1
RECEIVING EQUIPMENT
10 SECTION 2
GENERAL SPECIFICATIONS
10 SECTION 3
INSTALLATION INSTRUCTIONS
10 Code Requirements
11 Clearances
11 Outdoor Heater Installation
13 lorida and Texas Building Codes
14 Indoor Heater Installation
14 Outdoor Stack/Indoor Stack
15 Specifications and Dimensions
16 Combustion and Ventilation Air
16 Vent Piping
17 Gas Supply Connections
18 Gas Pressure Regulator
18 Gas Pressure Adjustment Locations
18 Pipe Sizing or Gas Connections
19 low Rates
19 Heat Exchanger Pressure Drop
20 Water Connection Installation
20 Unitherm Governor Operation
21 Internal Automatic Bypass Valve
21 External Auxiliary Bypass Valve
21 Auxiliary Bypass Valve Adjustment
21 Pressure Relief Valve Installation
22 Plumbing—Water Connections
23 Electrical Wiring
24 Transformer Wiring
25 Wiring Diagram
26 SECTION 4
SERVICING INSTRUCTIONS
26 General Location of Controls
26 Control Panel Removal
26 Control Adjustments
27 Thermostat Operation
29 Status and Diagnostics
30 Remote Control Installation and Operation
30 Remote Operation
30 Activating the Remote
31 Remote Control Wiring
31 2-Wire Remote Control
31 3-Wire Remote Control
32 Time Clock / ireman’s Switch
32 Water low Switch
32 lame Roll-Out Safety Switch
32 High Limits
33 Pilot Safety
33 Burner Tray Removal
33 Gas Valve Removal
33 Main Burner and Orifice Removal
33 Pilot Removal and Cleaning
34 Heat Exchanger Removal
34 Tube Cleaning Procedure
34 Desooting Procedure
34 Combustion Chamber Removal
34 Immersion Well Replacement
35 Unitherm Governor (U.G.) Replacement
36 SECTION 5
TROUBLES OOTING
36 Mechanical
37 Control Logic - low Chart
38 SECTION 6
REPLACEMENT PARTS
39 Illustrated Parts List
40 Part Numbers
3
CONTENTS

4
PART ONE
OWNER'S OPERATING INSTRUCTIONS
FOR YOUR SAFETY - READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW T ESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY
RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
SECTION 1 - START-UP PROCEDURES
Your pool/spa heater has been designed for years of safe and reliable pool/spa water heating. It is available with
electronic ignition. This manual provides installation, operation, maintenance, and service information for these
heaters.
If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the
heater contains the control center that allows you to turn the heater On or Off and adjust the temperature set-
tings for the pool or spa. The temperature range is factory set from 65° (18°C) to 104° (40°C). See figure
above for location of toggle switch to turn the heater On and Off. Section 4 of this manual contains more details
about the use of the controls in the Control Adjustments subsection (page 26).
ON
O
BEFORE START-UP
BURNERS
Clean main burners and air louvers of dust, lint
and debris. Keep heater area clear and free from
combustibles, flammable liquids and chemicals. Do
not obstruct the flow of combustion and ventilation air.
WATER
Water must be flowing through the heater during oper-
ation. Ensure that the system is filled with water and
that the pump is operating.

5
CAUTION: ropane 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.
OPERATING INSTRUCTIONS AND S UT-OFF PROCEDURES
ELECTRONIC IGNITION SYSTEM
(AUTOMATICALLY LIG TED PILOT)
A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
B. BE ORE OPERATING, smell all around the
appliance area for gas. Be sure to smell near
the floor because some gas is heavier than air
and will settle on the floor.
WHAT TO DO I YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. ollow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, do not try to repair
it. Call a qualified service technician. orce or
attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
service technician to inspect the appliance and
to replace any part of the control system and
any gas control which has been under water.
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
5. Remove heater door panel.
6. Turn gas control knob clockwise to
"Off". (Honeywell VR 8300 and Robertshaw
7000)
7. Wait 5 minutes to clear out any gas. If you
then smell gas, STOP! ollow "B" in the safe-
ty information above. If you don't smell gas, go
to the next step.
8. Turn gas control knob counter-clockwise
to "On". (Honeywell VR 8300 and
Robertshaw 7000)
9. Replace heater door panel.
10. Turn on all electrical power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance"
and call your service technician or gas
supplier.
OPERATING INSTRUCTIONS
1. Set the thermostat at the lowest setting.
2. Turn off all the electrical power to the appli-
ance if service is to be performed.
3. Remove heater door panel.
4. For oneywell VR 8300 and Robertshaw
7000 gas valve.
Turn gas control knob clockwise
to "Off". Make sure knob rest against stop.
5. Replace heater door panel.
S UT-OFF PROCEDURES
ROBERTS AW 7000
GAS VALVE IID
ONEYWELL
VR 8300 GAS
VALVE IID
GAS
INLET

AFTER START-UP
eel the inlet and outlet pipes. Outlet pipe should be
only slightly warmer than the inlet. It should not be hot.
VISUAL INSPECTION - ATMOSP ERIC EATERS
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.
A yellow or "floating" flame indicates restricted air
openings or incorrect orifice size. Should this occur,
shut the heater off and contact your installer or gas
supplier.
WARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
to the appliance.
4” MAX
MAIN BURNER FLAME
SECTION 2 - CAUTION
Elevated water temperature can be hazardous. The
U.S. Consumer Product Safety Commission has these
guidelines:
1. Spa water temperatures should never exceed
104° (40°C). A temperature of 100° (38°C) is
considered safe for a healthy adult. Special caution
is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use can cause drowsiness which
could lead to unconsciousness and subsequently
result in drowning.
3. regnant Women Beware! Soaking in water over
102° (39°C) can cause fetal damage during the
first three months of pregnancy resulting in the birth
of a brain-damaged or deformed child. Pregnant
women should stick to the 100° (38°C) maximum
rule.
4. Before entering the spa or hot tub, users should
check the water temperature with an accurate ther-
mometer; spa or hot tub thermostats may err in reg-
ulating water temperatures by as much as 4°
(2.2°C).
5. Persons with a medical history of heart disease, cir-
culatory problems, diabetes, or blood pressure
problems should obtain a physician's advice before
using pools or hot tubs.
6. Persons taking medications which induce drowsi-
ness, such as tranquilizers, antihistamines, or anti-
coagulants, should not use spas or hot tubs.
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to
the heater, and will void the warranty.
6

SECTION 3 - MAINTENANCE AND
CARE PROCEDURES
To 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 pilot burner of dust and
lint.
3. Inspect and operate all controls, gas valve and
pressure relief valve (if equipped).
4. Make visual check of the burner and pilot flames.
lame pattern on the main burner and pilot is illus-
trated on page 6. Yellow flame means restriction
of the air openings. Lifting or blowing flame indi-
cates high gas pressure. Low flame means low
gas pressure. Should the latter occur, shut the
heater off and contact your gas supplier or quali-
fied service agency.
5. On indoor heaters, clean room intake openings to
ensure adequate flow of combustion and ventila-
tion air.
6. Keep area around heater clear and free from com-
bustible materials, gasoline and other flammable
and corrosive vapors and liquids.
I HEATER WILL NOT IRE:
If you have no electrical power, it may be that your
"circuit breaker" has tripped. Try re-setting it.
If you have electrical power but the heater will not fire
check the following or see Troubleshooting section:
1. The time clock must be in the "ON" position.
CAUTION: Soot may be combustible. Wet sooted
surfaces completely prior to cleaning. Do not use
steel wire brush.
3. Your filter may be dirty. If so, backwash or clean
filter. (To tell if your filter is dirty, look to see if the
filter pressure will be higher than usual).
4. The pump may have lost its prime and be running
dry. Check the pressure 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 its
normal flow rate.
5. Check flow switch operation and paddles (“ ” pad-
dle on 268 or “A” paddle on 408).
CAUTION: Combustion air must not be contaminat-
ed by corrosive chemical fumes which can damage
the heater and void the warranty.
WARNING: Check the heater for possible rodent
nests after long periods of non-use.
2. Your pump strainer basket may be full. If so
remove debris.
POOL & SPA WATER C EMISTRY
Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain
your water chemistry according to the chart on page 2.
If the mineral content and dissolved solids in the water
become too high, scale forms inside the heat exchang-
er tubes, reducing heater efficiency and damaging the
heater. If the pH drops below 7.2, this will cause cor-
rosion of the heat exchanger and severely damage the
heater. eat exchanger damage resulting from
chemical imbalance is not covered by the warran-
ty.
AUTOMATIC C LORINATORS AND
C EMICAL FEEDERS
All chemicals must be introduced and completely dilut-
ed into the pool or spa water before being circulated
through the heater. Do not place sanitizing chemicals
in the skimmer. High chemical concentrations will
result when the pump is not running (e.g. overnight).
Chlorinators must feed downstream of the heater and
have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off.
See plumbing diagrams on page 22.
NOTE: High chemical concentrates from feeders and
chlorinators that are out of adjustment will cause rapid
corrosion to the heat exchanger. Such damage is not
covered under the warranty.
7

COLD WEAT ER OPERATION
IMPORTANT FREEZE INFORMATION
MODERATE CLIMATE: Heater operation can contin-
ue during short-term cold spells. When temperatures
are between 0° and 32° , 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. When heater is used during freezing weather,
care must be taken to avoid freeze-ups. Continuous
pump operation is a must. Additional protection may
be required. The heater is not warranted against
freeze-ups.
COLD CLIMATE: Prolonged operation with water
temperatures below 50° is not recommended.
When starting the heater with water temperatures
below 50° , operate the heater continuously until
higher temperatures are reached. Operating the
heater for prolonged periods with pool water below
50° can seriously damage the heater, and is not cov-
ered by the warranty.
or cold climate areas, please follow the winterizing
procedures listed.
WINTERIZING T E POOL & SPA EATER
Heaters installed outdoors in freezing climate areas
may be shut down for the winter. Observe the follow-
ing procedure for winterizing the heater:
1. Turn off gas valve, manual gas valve, and electri-
cal supply to the heater.
2. Open drain valve located on the inlet/outlet head-
er, (under water pipes). Remove the heat
exchanger inspection panel on the side opposite
water piping to gain access to the drain plug on the
return header. Open drain plug on return header.
DRAIN
8

PART TWO
INSTALLATION AND SERVICE INSTRUCTIONS
SECTION 1 - RECEIVING EQUIPMENT
INSTALLERS - The manufacturer recommends that this manual be reviewed thoroughly before installing the
pool/spa heater. If there are any questions that this manual does not answer, please contact the factory or your
local representative.
On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the
carton is damaged, a note should be made on the Bill of Lading when signing for the equipment. Remove the
heater from the carton. If it is damaged, report the damage to the carrier immediately. Save the carton.
These items are shipped inside a box in the carton with the heater:
1. "Pagoda" top
2. In/Out flanges (2)
3. 2" CPVC female tailpiece, ring nut and o-ring
4. 2" flange gaskets (2)
5. lange bolts (4)
6. Pressure relief valve
7. 2" CPVC adapter
8. Plastic pipe finish flange for gas line.
9. Bonding lug with mounting screw.
10. 2” CPVC manifold adapter
11. Prewired 1” flow switch with outdoor cover
12. Temperature & pressure gauge.
Be sure that you receive the number of packages indicated on the Bill of Lading.
When ordering parts, you must specify the model and serial numbers of the heater. See below for location of
serial number. When ordering under warranty conditions, you must also specify date of installation.
The Model & Serial No.
can also be found inside
the bezel above the display
Model & Serial No.
located on
Rating Plate
Alternate
Rating Plate
location
9

SECTION 3 - INSTALLATION INSTRUCTIONS
CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California
to cause cancer, birth defects or other reproductive harm.
IMPORTANT NOTICE
These instructions are intended only for the use by qualified personnel, specifically trained and experi-
enced 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 con-
tractor 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 equip-
ment, create a hazard resulting in asphyxiation, explosion or fire, and will void the warranty.
CODE REQUIREMENTS
NOTE: The heater should not be located in an area where possible water leakage will result in damage to the
area adjacent to the heater or to the structure. When such locations cannot be avoided, it is recommended that
a suitable drain pan, with adequate drainage, be installed under the heater. The pan must not restrict combus-
tion air flow.
Installation must be in accordance with local codes, or, in the absence of local codes, with the latest edition of
the National uel Gas Code, ANSI Z223.1/N PA54 and National Electrical Code, ANSI/N PA 70, and for
Canada, the latest edition of CAN/CSA-B149 Installation Codes, and Canadian Electrical Code, CSA C22.1 Part
1 and Part 2.
SECTION 2 - GENERAL SPECIFICATIONS
These heaters are design-certified and tested under the latest requirements of the ANSI Z21.56 / CSA 4.7
Standard for Gas- ired Pool Heaters. All heaters can be used either indoor or outdoors. The appropriate top
designated for each type of use is required. If necessary, the top can be changed at a later date to change from
outdoor to indoor or vice versa.
Ambient Temperature Rating of eater Components
Electronic Ignition Heater* -32° to + 175°
*Requires 120 or 240VAC Power Supply
Atmospheric heaters:
Rated inputs are suitable for up to 2,000 feet elevation. or elevations above 2000 feet, reduce input 4% for
each 1,000 feet above sea level, as high elevation reduces combustion performance.
WARNING: This unit cont ins refr ctory cer mic fiber (RCF) insul tion in the combustion ch mber. RCF, s
m nuf ctured, does not cont in respir ble cryst lline silic . However, following sust ined exposure to very
high temper tures (>2192F), the RCF c n tr nsform into cryst lline silic (crist bolite). The Intern tion l
Agency for Rese rch on C ncer (IARC) h s cl ssified the inh l tion of cryst lline silic (crist bolite) s c r-
cinogenic to hum ns.
When removing the burners or he t exch ngers, t ke prec utions to void cre ting irborne dust nd void
inh ling irborne fibers. When cle ning spills, use wet sweeping or High Efficiency P rticul te Air (HEPA)
filtered v cuum to minimize irborne dust. Use fe sible engineering controls such s loc l exh ust ventil tion
or dust collecting systems to minimize irborne dust. We r ppropri te person l protective equipment
including gloves, s fety gl sses with side shields, nd ppropri te NIOSH certified respir tory protection, to
void inh l tion of irborne dust nd irborne fiber p rticles.
10

OUTDOOR EATER INSTALLATION
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 internal rusting or damage
electrical components, and void the warranty.
WARNING: Do not install within 3 feet of a heat pump or an outdoor condensing unit. Strong air intake from
this type of equipment can disturb the combustion process and cause damage or personal injury.
HEATER WITH OUTDOOR STACKLESS TOP Pagoda Top Installation
1. Insert tabs into keyhole (4 places).
Pagoda Top
(Shipped inside
box in heater
carton)
2. Snap tabs into keyholes so as not to pull out.
CLEARANCES
ALL HEATERS
or clearances from combustible surfaces, see the
chart below.
CLEARANCE FROM
COMBUSTIBLE CONSTRUCTION
INDOOR INSTALLATIONS:
Top* - 30” (Drafthood) Back - 6”
ront - Alcove (Open) Right Side - 12” (Water Side)
Vent - 6” Left Side - 6”
loor** - 0” (Opposite Water Side)
OUTDOOR INSTALLATION:
Top* - Unobstructed (Outdoor Stack)
Top*** - 36” (Stackless Top)
loor - 0” Right Side - 12” (Water Side)
Back - 6” Left Side - 6”
(Opposite Water Side)
*Clearance from top of vent terminal.
**Do not install on carpeting.
***Clearance from top of heater.
When installed according to the listed minimum clear-
ances from combustible construction, the pool heater
can still be serviced without removing permanent
construction around the heater.
However for ease of servicing, we recommend a clear-
ance of at least 24” in the front, and at least 18" on the
water connection side. This will enable the heater to
be serviced in its installed location, that is, without
movement or removal of the heater.
Clearances less than these (6” minimum), may require
removal of the heater to service either the heat
exchanger or the burner tray. In either case, the
heater must be installed in a manner that will enable
the heater to be serviced without removing any struc-
ture around the heater.
FLOORING: This heater can be installed on com-
bustible flooring.
PAGODA TOP
11

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 must be a minimum of 4 ft below,
4 ft horizontally from, or 1 ft above any door, window or gravity inlet into any building. The top surface of the
heater shall be at least 3 ft above any forced air inlet, or intake ducts located within 10 ft horizontally.
For installations in Canada, pool heaters shall not be installed with the top of the vent assembly within 10 ft
below, or to either side, of any opening into the building. Refer to the latest revisions of CAN/CSA-B149.
4ft
Minimum
4ft
Minimum
1ft
Minimum
4ft
Minimum
3ft
Minimum
10 ft
Minimum
Forced Air Inlet
For installations in Florida and Texas, that must comply with the lorida or Texas Building Code, follow the
directions on page 13 for the installation of hurricane tie-down brackets for all models.
12

FLORIDA AND TEXAS BUILDING CODES
WIND SPEED = 150 MPH, 3 SECOND GUST
EXPOSURE = C
TO
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. Tapcon Bolt & Washer (Field Supplied)
Ea. Pallet Anchor Bracket
Use hole closest to unit (4 total)
(1)–1/4” x 1-3/4” S.S. Tapcon Bolt & Washer (Field Supplied)
Ea. Pallet Anchor Bracket
Use hole closest to unit (4 total)
2” x 6” x 1/8” Pallet
Anchor Bracket (4 Total) (Kit# 011636)
1/4” x 1-3/4” S.S. Tapcon Bolt & Washer (Field Supplied)
NOTE: Use hole closest to unit with
washer overlapping edge of unit.
6”
6”
268/408 Atmospheric
MODEL # B
268 23”
408 29”
13

WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to
the outside. ailure to follow this procedure can cause fire or fatal carbon monoxide poisoning.
INDOOR EATER INSTALLATION
The heater is also design-certified for indoor installation when equipped with the approved drafthood.
For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly commu-
nicate with an occupied area. Refer to the latest edition of CAN/CSA-B149 for specific requirements. Locate
heater as close as is practical to a chimney or gas vent. Heater must always be vented to the outside. See Vent
Piping section (pg. 16-17) for details. Minimum allowable space is shown on the nameplate.
OUTDOOR STACK / INDOOR STACK
NOTE: The outdoor and indoor stacks are optional equipment and do not come standard with the heater.
OUTDOOR STACK KIT INCLUDES:
(1) Drafthood, painted
(1) Adapter plate
(3) Mounting brackets (clips)
(1) Top panel cover
(2) 1-foot sections of metal tape
(3) Screws
(1) Instructions Clips
INDOOR STACK KIT INCLUDES:
(1) Drafthood, unpainted
(1) Adapter plate
(3) Mounting brackets (clips)
(3) Screws
(1) Instructions
Clips
** RE ER TO INSTALLATION INSTRUCTIONS
INSIDE BOX OR INSTRUCTIONS ON HOW TO
INSTALL OUTDOOR/INDOOR STACK.
OUTDOOR
STACK INDOOR STACK
Model Part No. Part No.
268
408
009835
009837
009839
009841
14
NOTE: The outdoor drafthood kit does not require any additional vent pipe for proper operation. This drafthood
functions as the vent termination.

SPECIFICATIONS AND DIMENSIONS
eater
Model
BTU
Input
(000)
(A)
Cabinet
Width
(B)
Flue
Dia.
(C)
Indoor
Drafthood
(D) (J)
Min. Gas
Conn.
Water
Conn.
Shipping Weights (lbs)
Standard
eater
w/Stackless
Top
ASME
eater
w/Stackless
Top
Indoor
Draft-
hood
R268 266.0 23” 7” 62” 11.5” 11” 3/4” 2” 210 229 16
R408 399.0 29” 9” 64-9/16” 14.5” 12-1/8” 3/4” 2” 249 268 21
Designation for a heater using propane gas is “EP”; a heater using natural gas is “EN”.
Prefix “B” is for brass (ASME) headers.
Suffix “X” is for cupro-nickel tubing.
EXAMPLE: B-R408-EN-X = Brass headers, 408 model size, A T, natural gas, cupro-nickel.
Reduce input 4% for each 1000 ft above sea level when installed above 2000 ft elevation.
or Canada, no de-rating is required for elevations up to 4500 ft
*Note: or outdoor stack, use J dimension in the table above for appropriate size PLUS six (6) inches.
B
C
INDOOR
DRAFTHOOD
38"
13-1/4"
GAS
CONNECTION
J*
A
28-5/8"
32-11/16"
ELECTRICAL
CONNECTION
40"
STACKLESS
OUTDOOR TOP
28"
3-3/8"
6-5/8"
D
10"
FLUE
L
C
Amp Draw
120 Volt 240 Volt
4 2
15

VENT PIPING
Vent piping the same size as the drafthood outlet is recommended, however, when the total vent height is at
least 10 ft (drafthood relief opening to vent terminal), the vent pipe size may be reduced as specified in Chapter
10 of the National uel Gas Code, ANSI Z223.1 (Canada - CAN/CSA-B149). As much as possible, avoid long
horizontal runs of vent pipe and too many elbows. If installation requires horizontal runs, the vent pipe must have
a minimum of 1/4 in. per ft 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 recommend use of insulated vent pipe spacers through the roofs and walls. Another option for
installation that requires horizontal runs is using the D-2 power vent kit option.
The unit, when installed as directed, is capable of operating in applications such as through-the-wall venting and
reduced horizontal and vertical vent pipe sizes in new and current installations. The unit is factory-wired for 240
VAC, with capability of rewiring for 120 VAC.
or protection against rain or blockage by snow, the vent pipe must terminate with a vent cap which complies
with the local codes or, in the absence of such codes, to the latest edition of the National uel Gas Code, ANSI
Z223.1 (Canada - CAN/CSA-B149).
COMBUSTION AND VENTILATION 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 the ceiling for ventilation, and one opening that is 12 inches from the
floor for combustion air as outlined in the latest edition of the National uel Gas Code, ANSI Z223.1(Canada-
CAN/CSA-B149) and any local codes that may have jurisdiction.
CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the
heater and void the warranty.
WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to
the outside. ailure to follow this procedure can cause fire or fatal carbon monoxide poisoning.
Power Vent Kit
Model 120 VAC
Part No.
240 VAC
Part No.
268 010744 009832
408 010745 009833
Optional Raypak D-2
Power Vent
For more information consult the D-2 Power Vent manual, (Catalog No. 6000.57.1).
The D-2 Power Vent oper-
ates with a positve vent stat-
ic pressure and with a vent
gas temperature that pre-
vents excessive condensate
production in the vent, and
as such, is a CATEGORY III
appliance.
16
B. All Air rom Outdoors:
When air is supplied directly from outside the building, each opening shall have a minimum net free area
as noted:
A. All Air rom Inside The Building:
Each opening shall have a minimum net free area as noted:
Model Square Inches Model Square Inches
268 266 408 399
Model Unrestricted Opening (sq. in.) Typical Screened or
Louvered Opening (sq. in.)
Typical Screened and
Louvered Opening (sq. in.)
268 67 101 134
408 100 150 200

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. Vent 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 a 4 ft horizontal distance is maintained, from
electric meters, gas meters, regulators and relief
equipment.
The weight of the vent stack or chimney must not rest
on heater drafthood. Support must be provided in
compliance with applicable codes. The heater top and
drafthood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from combustible
construction.
Type "B" double-wall or equivalent vent pipe is recom-
mended. However single-wall metal vent pipe may be
used as specified in the latest edition of the National
lue Gas Code ANSI Z223.1 (Canada - CAN/CSA-
B149).
GAS SUPPLY CONNECTIONS
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve locat-
ed outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.
CAUTION: The heater and its manual shut-off valve
must be disconnected from the gas supply during any
pressure testing of that system at test pressures in
excess of 1/2 psi (3.45 k a). Dissipate test pressure
in the gas supply line before reconnecting the heater
and its manual shut off valve to gas supply line. FAIL-
URE TO FOLLOW THIS ROCEDURE MAY DAM-
AGE THE GAS VALVE. OVER RESSURIZED GAS
VALVES ARE NOT COVERED BY WARRANTY. The
heater and its gas connections shall be leak tested
before placing the appliance in operation. Use soapy
water for leak test. DO NOT use open flame.
5' MIN
2' MIN
10' OR LESS
2' MIN
VENT CAP
VENT PIPE
DRAFT HOOD
HEATER
NOTE: Do not use Teflon tape on gas line pipe thread.
A pipe compound rated for use with natural and
propane gases is recommended. Apply sparingly only
on male pipe ends, leaving the two end threads bare.
A minimum of 6 in. WC and a maximum of 14 in. WC
upstream pressure under load and no-load conditions
must be provided for natural gas. A minimum of 12 in.
WC and a maximum of 14 in. WC are required for
propane gas under load and no-load conditions.
SUPPLY PRESSURES
NOTE: With venting application of two or more
heaters, contact the factory.
17

GAS PRESSURE REGULATOR
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 and 10.5 in. WC propane gas. If an adjustment is
needed, remove seal and turn adjustment screw clock-
wise to increase pressure or counter-clockwise
to decrease pressure.
GAS PRESSURE ADJUSTMENT LOCATIONS
Gas Pressure
Adjustment
oneywell VR8304
( eater Models 268 and 408)
Gas Pressure
Adjustment
Robertshaw 7000 BDER
( eater Model 268)
Gas Pressure
Adjustment
Robertshaw 7000 DER C
( eater Model 408)
PIPE SIZING FOR GAS CONNECTIONS
Maximum Equivalent Pipe Length (ft)
Natural Gas 1000 BTU/FT30.60
Specific Gravity @ 0.5 in. WC Pressure Drop
Propane Gas 2500 BTU/FT31.53
Specific Gravity @ 0.5 in. WC Pressure Drop
Input 3/4” 1” 1-1/4” 1-1/2”
Model (KBTU) N P N P N P N P
268 266.0 15 35 50 125 210 480 445
408 399.0 * 15 20 55 95 225 215 480
MANOMETER
UNION
MANUAL
SHUT-OFF
VALVE
*A 3/4” gas line can be used for up to 5 ft maximum length from the
gas valve in addition to the sediment trap.
18

MODEL PIPE SIZE MIN. GPM MAX. GPM*
268 1-1/4”–1-1/2” - 2” 25 125
408 1-1/4”–1-1/2” - 2” 40 125
*When flow rates exceed maximum GPM an external auxil-
iary bypass valve is required. See external bypass valve
section for details.
FLOW RATES EAT EXC ANGER PRESSURE DROP
FLOW
GPM
PRESSURE DROP (FT OF EAD)
268 408
30 8.0
40 9.0 9.0
50 9.8 9.8
60 10.5 10.5
70 11.0 11.0
80 11.5 11.5
90 14.0 14.0
100 17.0 17.0
19

WATER CONNECTION INSTALLATION
Gather the loose items that were shipped with the
heater. They will be as shown below:
The components should be assembled onto the
inlet/outlet header of the unit as shown below.
Once all components are in place and installed prop-
erly, the water connections will appear as shown
below:
UNIT ERM GOVERNOR OPERATION
CAUTION:
The patented Unitherm Governor is a thermostatic
mixing valve specifically designed to maintain con-
stant heater internal temperature between 105° and
115° despite continually changing flow rates from
the filter and changing pool temperatures. This nar-
row range is needed to prevent damaging condensa-
tion on the burners which will occur if the heater runs
for any length of time below 100° . It is also needed
to inhibit scale formation in the tubes by maintaining
temperatures well below accelerated scaling temper-
atures.
UNITHERM
GOVERNOR
UG SPRING
UG PLUG
GASKET
(BEHIND UG)
The heater must be located so that any water leaks will
not damage the structure of adjacent area. High tem-
perature 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
adapters.
DO NOT use petroleum-based assembly fluids (such
as petroleum jelly or lubricating oil). If assembly lube is
required, use a silicon base such as AquaLube etc.
20
T&P GAUGE
(SUPPLIED)
CPVC MANIFOLD
(SUPPLIED)
FLOW SWITCH
&COVER
(SUPPLIED)
CPVC TAILPIECE
O-RING & RING NUT
(SUPPLIED)
MALE CPVC
CONNECTOR
(SUPPLIED)
HEADER FLANGE
(SUPPLIED)
PLUMBING
GASKET (SUPPLIED)