Raypak RAYTHERM P-926 User manual

CATALOGNO.6200.51O
Effective: 04-09-07
Replaces: 05-15-05
Models2100-4001
P/N240251Rev.16
INSTALLATION
AND OPERATING
INSTRUCTIONS
RAYTHERMTM
COMMMERCIAL
SWIMMINGPOOL
HEATER
Models
P-926 to P-1826
and
P-2100 to P-4001
Thismanualshouldbemaintainedinlegibleconditionandkeptadjacenttothe
heaterorinasafeplaceforfuturereference.
WARNING: If the information in these instructions is not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
—WHAT 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
supplier'sinstructions.
• If you cannot reach your gas supplier, call the fire department.
—Installationandservicemustbeperformedbyaqualifiedinstaller,serviceagencyor
the gas supplier.
—Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
Models1287-1758

Contents
SECTION 1: RECEIVING EQUIPMENT
SECTION 2: GENERAL SPECIFICATIONS
SECTION 3: INSTALLATION INSTRUCTIONS
Code Requirements
Base Installation
Clearances
Combustion Air
Venting Connections
Gas Supply Connections
Water connections
Controls
WiringDiagrams
SECTION 4: SERVICING INSTRUCTIONS
General Location of Controls
Start-Up Procedures
Inspection Procedures
Servicing Procedures
Maintenance & Care
SECTION 5: TROUBLE SHOOTING
Mechanical
Electrical
SECTION6:REPLACEMENTPARTS
WARRANTY
3
3
3
3
3
4
4
5
6
7
8
14
18
18
19
20
21
24
25
25
27
28
35

12"
Minimu
m
12"
M
inimum
4"
Minimum
HEATER
Sheet Metal
24 Gauge
IMPORTANTNOTICE
Theseinstructionsareintendedfortheuseofqualified
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 li-
censed. If your state is such, be sure your contractor
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 equipment, 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 appliance or to the structure.
When such locations cannot be avoided, it is recom-
mended that a suitable drain pan, adequately drained,
be installed under the appliance. The pan must not
restrict combustion air flow.
Installation must be in accordance with local codes,
or,intheabsenceoflocalcodes,withthelatesteditions
ofthe National Fuel GasCode,ANSIZ223.1/NFPA54,
andNationalElectricalCode,ANSI/NFPA70.
BASEINSTALLATION
DoNOTusetheshippingbasecrateasaninstallation
base.
Heater must be mounted on a level base, such as
cement slab, cement blocks or other non-combustible
surface. Anoptionalnon-combustiblebaseisavailable
for Indoor Heater 962 through 1826. An alternative
method for providing a base for combustible floors as
illustrated below. Heaters may not be installed on
carpeting.
Hollowconcretecinderblock; alignholesandleave
endsopen.Alternativemethodforprovidinganon-com-
bustiblebase.
SECTION 1 / RECEIVING EQUIPMENT
Onreceiptoftheequipment,visuallycheckforexternal
damagetothecartonortheshippingcrate. Ifthecarton
orshippingcrateisdamaged,makeanoteontheBillof
LadingandreportthedamagetotheCarrierimmediately.
Removetheboilerfromthecartonorshippingcrate.
DoNOTusetheshippingbasecrateasaninstallation
base.
Onoccasion,weshipsomeitemsloose. Besurethat
you receive the number of packages indicated on the
Bill of Lading.
When ordering parts, you must specify Model and
SerialNumberofboiler. Whenorderingunderwarranty
conditions, you must also specify date of installation.
Raypak recommends that this manual be reviewed
thoroughlybeforeinstallingyourRaypakPoolHeater. If
there are any questions which this manual does not
answer,pleasecontactthefactoryoryourlocalRaypak
representative.
Claimsforshortagesanddamagesmustbefiledwith
carrierby consignee. Permission to return goods must
be factory authorized and are subject to a stocking
charge.
Purchased parts are subject to replacement only
underthemanufacturer'swarranty. Debitsfordefective
replacement parts will not be accepted and will be
replaced in kind only per our standard warranties.
SECTION 2 / GENERAL SPECIFICATIONS
Models 962, 1125, 1223, 1336, 1468, 1631, 1826 &
2100 through 4001 are specifically designed for indoor
installation only. Models 926, 1083, 1178, 1287, 1414,
1571&1758arespecificallydesignedforoutdoorinstal-
lation only. All heaters are standard with electronic
ignitionforbothnaturalandpropaneapplications.Heat-
ersrequire115Vpowersupply.Controlcircuitsoperate
at 24V, to be supplied by a 115V to 24V transformer.
Theseheatersaredesigncertifiedandtestedunderthe
requirements of ANSI Z21.56 / CSA 4.7 American Na-
tionalStandardforGas-FiredPoolHeaters.Ratedinputs
suitableforupto2000feetelevation.Forelevationsabove
2000feet,reduceinput4%foreach1000feetabovesea
level, as high elevation reduces combustion perfor-
mance.
SECTION 3 / INSTALLATION
INSTRUCTIONS
CALIFORNIA PROPOSITION 65 WARNING:
This product contains chemicals known to the State of
Californiatocausecancer,birth defectsorotherreproductive
harm.
3
Fig.#8148

4
Fig. #8245
CLEARANCES
ALL HEATERS
For clearances from combustible surfaces, see chart
below. Werequireaminimalverticalclearanceofthree
feetbetweentheuppersurfaceoftheflueoutlettoanon-
combustiblematerial.
MINIMUM CLEARANCES FROM COMBUSTIBLE
CONSTRUCTION
INDOOR HEATERS
Top - 24" *Vent - 6"
Back - 24"
Right Side - 24"
Left Side - 24"
OUTDOOR HEATERS (926-1758)
Top - unobstructed
Back - 24"
Right side - 24"
Left Side - 24"
Forservicingprovidea frontclearanceasshownbelow
Model 926/962-758/1826 - 24"
Model 2100-4001 - 48"
*Vent includesfactorysupplieddrafthoodanddoesnot
include field supplied vent systems above the draft-
hood. On Models 2100-4001 drafthood is built into
boiler.
Forservicing, provide at least24"infrontof the heater
onModels926-1826&48"infrontoftheheateronModels
2100-4001forburnertrayremoval,andatleast18"onthe
right side of the heater to inspect and delime the heat
exchanger.
OUTDOOR HEATERS (MODELS 926-1758)
These heaters are design certified for outdoor
installation,whenequippedwiththeapprovedtopdesig-
nated for outdoor use. Heaters must not be installed
underanoverhangoflessthanthree(3)feetfromthetop
of the heater. Three (3) sides must be open in the area
undertheoverhang. Roofwaterdrainagemustbediverted
awayfromtheheatersinstalledunderoverhangswiththe
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
andintotheheater. Thiscouldcauseheavyinternal
rusting or damage some electrical components,
and this would void the warranty.
The point from where the flue products exit the heater
must be a minimum of four (4) feet below, four (4) feet
horizontallyfromorone(1)footaboveanydoor,window
orgravityinlettoabuilding. Thetopsurfaceoftheheater
shallbeatleastthree(3)feetaboveanyforcedair inlet,
orintakeducts located within ten (10)feethorizontally.
HIGHWINDCONDITIONS(OUTDOORUNITSONLY)
In areas where high winds are frequent, it may be
necessary to locate the heater a minimum of 3' from
high vertical walls, or install a wind break so the heater
is not in direct wind current.
INDOOR HEATERS
The design is also certified for indoor installation
whenequippedwithapproveddrafthood. Locateheater
as close as practical to a chimney or gas vent.
COMBUSTION AIR (INDOOR UNITS ONLY)
The heater must have both combustion and venti-
lation air. Openings must not be obstructed. Minimum
requirements are as follows:
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
1. Free combustion air 1 sq. in. per 1000 BTU
input within 12" of the floor.
2. Free ventilation air 1 sq. in. per 1000 BTU input
within 12" of the ceiling level.
NOTE: If the room the heater is installed in is located
against an outside wall and air openings communicate
directlywith the outdoors,theopeningsmay be 1/4the
size specified above (ANSI Z223.1/NFPA 54, latest
edition)
4 foot
Minimum
4 foot
Minimum
1 foot
Minimum
4 foot
Minimum
3 foot
Minimum
10 foot
Minimum
Forced Air Inlet

5' MIN
2' MIN
10' OR LESS
2' MIN
VENT CAP
VENT PIPE
DRAFT HOOD
HEATER
For protection against rain or blockage by snow, the
ventpipemustterminatewithaventcapwhichcomplies
with the local codes or, in the absence of such codes,
tothelatesteditionoftheNationalFuelGasCode,ANSI
Z223.1/NFPA54.
Thedischargeopeningmustbeaminimumoftwofeet
vertically from the roof surface and at least two feet
higherthananypartofthebuildingwithintenfeet. Vent
stack shall be at least five feet in vertical height above
thedrafthoodoutlet. Thevent caplocationshallhavea
minimumclearanceof4feethorizontallyfrom,andinno
case above or below, unless a 4-foot horizontal dis-
tance is maintained, from electric meters, gas meters
regulators and relief equipment.
Theweightoftheventstackorchimneymustnotrest
onboilerdrafthood. Supportmustbeprovidedincompli-
ance with applicable codes. The heater top and draft
hood must be readily removable for maintenance and
inspection. Ventpipeshouldbeadequatelysupportedto
maintainproperclearancesfromcombustibleconstruc-
tion.
Type"B"doublewallorequivalentventpipeisrecom-
mended. However single wall metal vent pipe may be
used as specified in the latest edition of the National
FuelGasCodeANSIZ223.1/NFPA 54.
Fig. #8119
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
placedinoperation,whiletheotherappliancesremaining
connected to the common venting system are not in
operation.
VENTINGCONNECTIONS
DRAFTHOOD(INDOOR)MODELS962-1826
Locate and assemble as shown below. Secure with
screws supplied in envelope in carton.
Models2100-4001havebuilt-indrafthoodsthatmustbe
properlyventedto the outside.
VENTPIPING
WARNING:
Indoor heater requires 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.
Ventpipingthesamesizeorlargerthanthedrafthood
outlet is recommended, however, when the total vent
heightisatleastten(10)feet(drafthoodreliefopeningto
vent terminal), the vent pipe size may be reduced as
specified in Chapter 10 of the National Fuel Gas Code,
ANSI Z 223.1/NFPA 54 - latest edition. Avoid long
horizontal runs of vent pipe and too many elbows. If
installation requires horizontal or non-vertical runs, the
ventpipe must haveaminimumof1/4 inch per footrise
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
supportedonlybytheflashingandextendingabovethe
roof more than five feet should be securely guyed or
braced to withstand snow and wind loads. We recom-
menduseofinsulatedventpipespacerthroughtheroofs
andwalls.
5
Fig # 8165

(a) Seal any unused openings in the common
venting system.
(b) Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restriction, leakage, corrosion
and other deficiencies which could cause an
unsafe condition.
(c) Insofar as is practical, close all building doors
and windows and all doors between the space
in which the appliances remaining connected
to the common venting system are located and
other spaces of the building. Turn on clothes
dryers and any appliance not connected to the
common venting system. Turn on any exhaust
fans, such as range hoods and bathroom
exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan.
Close fireplace dampers.
(d) Placeinoperationtheappliancebeinginspected.
Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
(e) Testforspillageatthedrafthoodreliefopening
after 5 minutes of main burner operation. Use
the flame of a match or candle, or smoke from
a cigarette, cigar or pipe.
(f) After it has been determined that each
appliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans, fireplace dampers and any other gas
burning appliance to their previous conditions
of use.
(g) Any improper operation of the common venting
system should be corrected so the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54. When
re-sizinganyportionofthecommonventing
system, the common venting system should be
re-sized to approach the minimum size as
determinedusingtheappropriatetablesinPart
11ofthe National Fuel Gas Code, ANSIZ223.1/
NFPA 54.
For special venting applications that require reduced
vent sizes and through the wall venting, the optional D
Series Power Vent can be used. Consult the factory or
yourlocalRaypakrepresentative.
GASSUPPLYCONNECTIONS
Gas piping must have a sediment trap ahead of the
heatergascontrols,andamanualshut-offvalvelocated
outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.
MANUAL SHUT HEATER GAS VALVE
OFF VALVE JACKET
GAS INLET UNION
SEDIMENT
TRAP
FIG.#8090.0
CAUTION:Theheateranditsmanualshut-offvalvemust
bedisconnectedfromthegassupplyduringanypressure
testing of that system at test pressures in excess of 1/
2 psig (3.45 KPA). Dissipate test pressure in the gas
supplylinebeforereconnectingtheheateranditsmanual
shut-offvalvetogassupplyline. FAILURETOFOLLOW
THISPROCEDUREMAYDAMAGETHEGASVALVE.
OVERPRESSURIZEDGASVALVESARENOTCOV-
EREDBYWARRANTY. Theheateranditsgasconnec-
tionsshallbeleaktestedbeforeplacingtheappliancein
operation. Usesoapywaterforleaktest. DONOTuse
openflame.
NOTE: Do not use teflon tape on gas line pipe thread.
A flexible sealant is recommended.
Aminimumof7in.WCandamaximumof10.5in.WC
upstream pressure under load, and no load conditions
mustbeprovidedfornaturalgasoraminimumof11in.
WC and a maximum of 13 in. WC for propane gas.
6

GAS PRESSURE REGULATOR
Thegaspressureregulatorispresetandsealedat4in.
WC for natural gas, and 11 in. WC for propane gas.
Betweenthegasvalveandtheburnersisa1/8"pipeplug.
The pressure at this point, taken with a manometer,
shouldbeabout3.7in.WCnaturalgasand10.5in.WC
propane gas. If an adjustment is needed, remove seal
and turn adjustment screw clockwise , to
increase pressure or counterclocwise , to
decreasepressure.
GAS PRESSURE MANOMETER
TEST UPSTREAM
MANUAL
SHUT-OFF
VALVE
GAS PRESSURE TEST
AT GAS VALVE
GAS PRESSURE TEST
AT HEATER Fig.#8149.0
PIPE SIZING FOR GAS CONNECTIONS
VENTINGOFDIAPHRAGMGASCOMPONENTS
Heaters have gas train components that have dia-
phragms in their construction are supplied with a bleed
line connection that must be connected to the outside
atmosphereasrequiredbytheNationalFuelGasCode.
Under NO circumstances shall bleed lines terminate in
the gas utilization equipment flue or exhaust system.
7
Bleed
Line Connection Fig. # 8185.2
WATERCONNECTIONS
LOCATION
Theheater requires water flow andpositive 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 outlet side of the filter is then plumbed to the
inlet of the heater; and
3.The outlet of the heater is plumbed to the return
line to the pool or spa. The pump, filter and heater
are thus plumbed in series.
Heatermustbelocatedsothatanywaterleakswillnot
damage the structure of adjacent area. High tempera-
tureplasticpipe(CPVC)maybeconnecteddirectlyinto
the heater Models 926-1223, if local codes permit and
if controls operate the pump for at least fifteen minutes
after the heater is turned off.
CAUTION (Models 926-1223): NEVER install PVC
directlyintoheater. Fourfeetofcopperorhightempera-
ture pipe and two elbows are required between the
heater and the PVC connections.
Fig. # 8129.0

Whenlocalcodespermittheuseoflessthanfourfeet
high temperature piping or two elbows, provisions
shouldbemadetoalwaysshuttheheateroffaminimum
of 15 minutes prior to pump shut down in order to carry
away residual heat and prevent damage to the low
temperature piping. A fireman switch included in the
time clock may be used for this purpose with instruc-
tions not to override this sequence manually. See
wiring diagram section for electrical hookup location of
the fireman switch in the electrical circuit.
NOTE (Models 926-1223): If piping is used into the
heater,thispiping(copper)mustbeanchoredorscrewed
into the flange (metal) if operating pressures above 30
PSIareencountered.
CONTROLS
WATER PRESSURE SWITCH
A water pressure switch is provided in the heater to
shutdownthegasvalvesintheeventthewatersupplyto
theheaterisinterrupted. Itisveryimportanttoverifythat
theswitchelectricallyopensandshutsoffthegasvalve
whenwaterflowtotheheaterisinterrupted. Otherwise,
rapidandsevere damage to the heater will likelyoccur.
(The water pressure switch should be checked and
adjustedforproperoperationbyaqualifiedserviceperson
at the time of installation and periodically checked
thereafter. Refer to pressure switch servicing instruc-
tions in Section 4 of this manual).
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to the
heater.
AUTOMATIC CHLORINATORS AND CHEMICAL
FEEDERS
All chemicals must be introduced and completely
dilutedintothepoolorspawaterbeforebeingcirculated
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer. High chemical concen-
trations will result when the pump is not running (eg,
overnight).
Chlorinatorsmustfeeddownstreamoftheheaterand
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 heater.
Such damage is not covered under the warranty.
8
UNITHERM GOVERNOR OPERATION
The patented Unitherm Governor is a thermostatic
mixingvalvespecificallydesigned to maintain constant
heater internal temperature between 105° to 115°F
despite continually changing flow rates from the filter
andchanging pool temperatures. Thisnarrow range is
neededtopreventdamagingcondensationontheburn-
ers which will occur if the heater runs for any length of
time below 100°F. It is also needed to inhibit scale
formationinthetubesbymaintainingtemperatureswell
below accelerated scaling temperatures.
The Unitherm Governor is built into the inlet/outlet
headeronmodels 926 through 1223. The larger sizes,
models1287through4001,haveanexternallymounted
bypass pump that is designed to maintain the water
entering the heater at the proper temperature that will
prevent condensation and scale. Thermometers are
provided on the inlet and outlet to the heater.
COMPANION FLANGE CONNECTIONS
(Models 926-1223)
DO NOT use petroleum base assembly fluids (such
asPetroleumJelly or Lubricating Oil). If assembly lube
is required use a silicone base such as Armoral etc.
The inlet/outlet header flange accepts a 2" copper
tube as a slip connection directly into the header. The
flangeisalsothreadedfora2"NPTcoppermaleadapter.
MODELS 926 - 1223
INLET/OUTLET HEADER
FLANGE GASKET
OUTLET
INLET
HEADER FLANGE
Fig.#8221.0

9
MODELS 1287/1336 - 1758/1826
Inlet/Outlet
Header
2-1/2" Inlet
2-1/2" Outlet
1-1/2" Slip Ball Valve
2" Slip
Ball Valve
3" Outlet
Fig.#9270
Fig.#9200
Pump
3" Inlet
2 H.P. Pump
Inlet/Outlet
Header
MODELS2100-4001
FLOWRATES/WATERCONNECTIONS
MODEL CONNECTIONSIZE MIN GPM MAX GPM
926-1223 * 60 120
1287-1826 2-1/2"FPT Refertoflowratetable
2100-4001 3" FPT
LOOP* HEATER
FLOW FLOW
RATES RATES
MODELS (GPM) (GPM)
1287/1336 30-50 85
1414/1468 35-55 85
1571/1631 40-65 85
1758/1826 45-70 85
2100 50-80 180
2500 60-95 180
3001 75-115 180
3500 90-135 180
4001 100-150 180 *Loop is secondary piping to
heater from main system.

10
Raypakrecommendstheinstallationofanairbleedventatasuitablelocation(usuallythehighestpoint)toremove
airfromthepipingsystem. Theseunitsshouldbeavailableatyourlocalwholesalesupplier. Raypakdoesnotprovide
this item.
CAUTION:
Power to the heater should be interlocked with the main system pump to make sure the heater does not
fire without the main system pump in operation.
Improperflowcontrolcandamagetheheater. Uncontrolledflow(toohigh)orrestrictedflow(toolow)can
seriouslyaffectheateroperation. Followtheseinstructionstomakesureyourheaterisproperlyinstalled.
Models1287through4001areequippedwithanexternalpumpandbypassarrangementthatblendsoutletwaterwith
theinlettoincreasetheinletwatertemperature,therebyreducingthelikelihoodofcondensationformingontheheat
exchanger. The pump also serves to circulate water through the heater from the main system piping.
Tocompletetheinstallationofthepoolheater,thepoolthermostatneedstobeinstalledinthemainreturnwaterline.
Thiswillensurethattheheaterwillbeenergizedattherighttime. Ifthemainwaterlineistoofarawayfromtheheater
andthecapillarybulbwillnotreachit,locatethepoolthermostatadjacenttothemainlineandrunwiresbacktothe
heater. Follow the instructions listed below to install the pool stat.
MOUNTING THE POOLSTAT CONTROL WITH FRONT-MOUNTED
LOOP USING MOUNTING SLOTS
For heater models:
1287, 1336, 1414, 1468, 1571, 1631, 1758, 1826, 2100, 2500, 3001,
3500, 4001.
Note: For more detail on piping, see figures 9268 and 9269.
1.Removethepoolstatcontrolcoverbyremovingthetwocover
screws at the top. See Figs. 1 & 2.
2.Lacemetalstrappingorclamps,(NOTPROVIDED)throughthe¾”
slots on the cover and fasten securely to pipe as shown in Figs. 3
& 4. NOTE: Do not over-tighten clamps.
3.Remove either the left orright “knock-out” for wiringon the poolstat
control as shown in Fig. 5.
4. Attach appropriate conduit and connectors to the poolstat control.
5. Attach wires to the poolstat wire terminals. See Fig.6.
6. Install poolstat control to the cover and fasten cover screws.
7. Poolstat should be mounted level as shown in Fig. 7.
Fig. 1: Poolstat Control
Fig.2: ControlCover
Fig. 3: Hose Clamp Slots Fig. 4
Fig. 5 Fig. 6 Fig. 7

Note: The drawings and instructions above show only one of several acceptable ways of installing the
dry well into main system loop. The use of saddle clamps and “Weld O Lets” (shown in Fig. 10) are
acceptable. Follow clamp manufacturer’s instructions.
MOUNTING WELL INTO SYSTEM RETURN LOOP PIPE - FRONT-MOUNTED LOOP:
Note: For more detail on piping configurations for large systems, see figures 9268 and 9269.
1. Locate and mark an area on the main system return loop pipe where the well is always exposed to the water
circulating back from the pool. See Fig. 8.
2. Shut off water and drain any water from the pipe as necessary.
3. Drill a 23/32" diameter hole (½” NPT) into the pipe as shown in Fig. 9.
4. Using a ½” NPT tap and appropriate handle, thread the tap into the pipe.
5. Apply pipe dope as necessary to male threads of well and insert into threaded hole.
Note: Do not over-tighten well.
Fig. 8
Fig. 9
Fig. 10

4. Iftheheaterinlettemperatureremainslessthan100°FandValve"A"isfullyopen,leaveValve"A"fullyopenand
throttleValve"B" until the heater inlet temperaturerisesto within the range of 100°F-105°F.
5. Theresultantheateroutlettemperatureshouldbeintherangeof120-130°F.
6. AsthepooltemperaturerisestothedesiredtemperatureascontrolledbythePoolaquastat,smalladjustments
tovalves"A"and"B"willberequiredforoptimumperformance. Heatertemperaturesshouldbecheckedregularly
topreventheatercondensation. Theheaterinlettemperaturecanbehigherthan100°Fwithoutheaterdamage
butoperating at lessthan 100°F inlet can cause damage fromcondensation.
Note: Consult factory if target temperatures cannot be achieved.
To adjust the temperature:
1. Bothisolation valves must be fully open.
2. Adjust Bypass Valve "A" 1/2 open and Balancing Valve "B" fully open. (See piping configuration page 11)
3. Fire your Raypak pool heater and adjust Bypass Valve "A" to obtain a heater inlet temperature approximately
100°F-105°F. TurningValveAintheopendirectionwillraisetheheaterinlettemperatureandclosingValve"A"
willlowertheheaterinlettemperature.

Models 2100 thru 4001
13
PIPINGCONFIGURATIONSFORRAYTHERMCOMMERCIALPOOLHEATERS
Fig#9268 Fig#9269
BLENDEDWATERTEMPERATURE
(THERMOMETERATHEATERINLET)
HEATEROUTLETTEMPERATURE
THERMOMETER
HEATERTHERMOSTAT
RECOMMENDEDFIELDINSTALLED
ISOLATIONVALVESFORSERVICE
TI
To
Tc

14
EXTERNALAUXILIARYBYPASSVALVE
(WhereRequired) 926-1223Modelsonly
An auxiliary bypass valve should be used when flow
rates exceed 120 GPM (usually a high performance
pumpsizelargerthantwoHPwillexceedthisflowrate).
Thisvalveisrequiredtocomplementthefunctionofthe
automatic bypass valve, particularly when starting the
heater in winter or early spring when the spa or pool
temperature is below 55°F. It also serves to eliminate
needlesspressuredropthroughtheheaterandaccompa-
nying reduction in the flow rate to the spa jets, etc.
FROM TO
HEATER HEATER
TO POOL TO POOL
Fig. #8150
AUXILIARY BYPASS VALVE
(DO NOT USE GATE VALVE)
AUXILIARY BYPASS VALVE ADJUSTMENT
To set bypass: With clean filter, adjustment is made
byfeelingtheinletandoutletpipesattheheater. Outlet
pipes should be slightly warmer than inlet and comfort-
able to the touch. If pipe is hot, close bypass; if cold,
open bypass.
NOTE: Do not use a gate valve as an auxiliary bypass
valve on any heaters.
Models 926-1223
Theheater is also equipped with amanualbypass 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.
NOTE: Sooting or liming caused by improper bypass
adjustmentvoidsthewarranty.
BYPASSVALVE
INLET/OUTLET
HEADER
Fig.#8223.0
OPEN POSITION CLOSED POSITION
MANUAL BYPASS ADJUSTMENT
Fig.#8222.0
NOTE:To avoidwaterdamageorscaldingduetovalve
operation,drainpipemustbe connected to valve outlet
andruntoasafeplaceofdischarge. Drainpipemustbe
the same size as the valve discharge connection
throughout its entire length and must pitch downward
from the valve. No shut-off valve shall be installed
between the relief valve and the drain line. Valve lever
should be tripped at least once a year to ensure that
waterways are clear.
TEMPERATURECONTROLS
HIGHLIMITS
Thepoolheaterisequippedwithtwohighlimits.Bothhigh
limits, the non-adjustable auto reset high limit and
adjustable manual reset high limit are attached to the
outlet side of the in/out header.
POOLSTAT
Thepoolheater is equipped with apoolthermostatthat
isattachedtotheinletsideofthein/outheadertocontrol
thepooltemperature.
LOWWATERCUT-OFF
Automaticallyshuts down burner wheneverwater level
drops below probe. 30 second time delay prevents
prematurelockoutduetotemporaryconditionssuchas
power failure or air pockets. Standard on Cal Code
heaters.
Fig.#6043

15
HIGH&LOWGAS PRESSURE SWITCHES
Pressure switches sense either high or low gas
pressureandautomaticallyshutdownburnersifabnor-
malpressuresexsist. StandardonModels3001-4001.
PRESSURE
SWITCH
GAS MANIFOLD
Fig.#8236
ELECTRICAL WIRING
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper
anddangerousoperation. Verifyproperoperationafter
servicing.
DANGER - SHOCK HAZARD - Make sure electrical
power to the heater is disconnected to avoid potential
serious injury or damage to components.
NOTE: If it is necessary to replace any of the original
wiring, it must be replaced with 105° C wire or its
equivalent.
ELECTRONIC IGNITION
The intermittent ignition device conserves energy by
automaticallyextinguishingthepilot whendesiredtem-
peratureisreached. Whenadditionalheatisneeded,the
pilot re-ignites electrically, eliminating the fuel costs of
maintaininga constant pilot. Toensuresafeoperation,
the gas valve cannot open until the pilot relights and is
confirmed.
Model w/out lockout with lockout
926-1826NaturalGas Standard Optional
926-1826Propane N/A Standard
2100-4001 Natural Gas N/A Standard
2100-4001Propane N/A Standard
Heater must be electrically grounded and bonded in
accordancewith localcodes,or, intheabsenceof local
codes, with the latest edition of the National Electrical
Code, ANSI/NFPA 70.
Fig.#8929.1

16
WIRING DIAGRAM
MODELS 926 - 1223

17
WIRING DIAGRAM
MODELS1287-1826

WIRING DIAGRAM
MODELS 2100-2500
18

WIRING DIAGRAM
MODELS 3001-4001
19

TEMPERATURECONTROL
The pool water temperature is controlled by the pool
thermostat.
Theheaterwatertemperaturehighlimitiscontrolledby
the manual reset high limit.
PRESSURESWITCH
Thepressureswitch,orheateractuator,ensuresthat
the heater operates only when the filter pump is in
operation. It is factory set at 1.75 PSI for deck level
installations. Whentheheaterislocatedbelowthelevel
of the spa or pool, it may be necessary to reset the
pressure switch to compensate for the no-flow static
head. Ifit is necessarytoresetthepressure switch, we
recommendthefollowingprocedure:
PRESSURE SWITCH ADJUSTMENT:
1. Make sure the pool filter is clean before adjusting
the switch.
2. Set the heater control to the OFF mode.
3. Turnthefilterpumponandconfirmthatthepressure
switch is closed (use a multimeter to check). If the
pressure switch fails to close, either the switch
settingis toohighor thefilterpumpis notsupplying
enoughpressure.
4. TurntheheaterON.
5. Manuallyturn the pressure adjustment knob clock-
wiseuntiltheheatershutsoff.(Aflatscrewdrivermay
be necessary if knob is too tight).
6. Slowlyturntheadjustmentknobcounter-clockwise
until the heater calls for heat again.
7. Turnanadditional1/2turncounter-clockwise.
8. Whiletheheaterisrunning,checktheadjustmentby
turningthepumpoffandonseveraltimes.The
burnersshouldshutoffimmediatelywhenthepump
isturnedoff.Ifitdoesnot,repeattheabovestepsuntil
properoperationisobserved.
20
MODELS2100-4001
SECTION 4/ SERVICING INSTRUCTIONS
GENERAL LOCATION OF CONTROLS
MODELS 926-1826
Inlet/Outlet Pressure
Header Switch
Unitherm Electrical
Governor Conn.
Hi-limit
control/
Temp. Control Main Burner Gas Valve
Inlet/Outlet
Header w/Bypass
Pump
Electrical
Connection
Main Burner
Gas ValveManual On/Off Valve
Fig.#9261.1