Rheem Raypak X94 SR-410 User manual
X94 Professional
Gas-Fired
Pool & Spa
Heater
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
AAVERTISSEMENT: Assurez-vous de bien
suivre les instructions données dans cette notice
pour réduire au minimum le risqué d’incendie
ou d’explosion ou pour éviter tout dommage
matériel, toute blessure ou la mort.
vapors and liquids or other combustible materials in
the vicinity of this or any other appliance. To do so
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’s
instructions.
•
department.
Installation and service must be performed by a
AWARNING: If the information in these
explosion may result causing property damage,
personal injury or death.
Ne pas entreposer ni utilizer d’essence ou ni d’autres
appareil ou de tout autre appareil.
CE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAS:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez á aucun interrupteur; ne pas vous
bâtiment.
•
gaz depuis un voisin. Suivre les instructions du
fournisseur.
• Si vous ne pouvez rejoinder le fournisseur,
appelez le service es incendies.
INSTALLATION AND
OPERATION MANUAL
Low NOx Model SR-410
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
2
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
3
CONTENTS
1. WARNINGS ............................................................ 4
Pay Attention to these Terms ..................................
General Safety ........................................................
2. WATER CHEMISTRY ............................................. 5
Automatic Chlorinators And Chemical Feeders ......
3. BEFORE INSTALLATION...................................... 6
Receiving Equipment ..............................................
.......................................
Ambient Temperature Rating ..................................
Elevation .................................................................
...............................
4. INSTALLATION...................................................... 8
Installation Codes.................................................... 8
Clearances.............................................................. 8
Indoor Heater Installation........................................
Combustion And Ventilation Air .............................
Direct Vent and Ducted Combustion Air Systems.
Venting ..................................................................
Support of Vent Stack ...........................................
Vent Terminal Location..........................................
Venting Installation Tips ........................................
Condensate Management.....................................
..........................................
Vertical Venting (Category IV) Installation.............
............
Direct Vent – Vertical ............................................
Outdoor Installation...............................................
Florida Building Code............................................
Gas Supply Connections.......................................
Supply Pressures..................................................
Gas Pressure Adjustment Locations.....................
Pipe Sizing For Gas Connections .........................
Heat Exchanger Pressure Drop Tables.................
Flow Rates ............................................................
External Automatic Bypass Valve..........................
External Auxiliary Bypass Valve ............................
Auxiliary Bypass Valve Adjustment .......................
Pressure Relief Valve Piping.................................
....................................................
...............................................
............................
Loose Plumbing Parts Setup.................................
Recommended Plumbing Setups..........................
5. WIRING DIAGRAM............................................... 26
6. CONTROLS........................................................... 27
General Control Locations ....................................
Control Adjustments..............................................
Control Panel Removal .........................................
.....
Installer Setup Mode .............................................
Status And Diagnostics .........................................
Remote Control Installation And Operation...........
Remote Operation.................................................
Activating The Remote..........................................
..........................................
..........................
..................
Time Clock/Fireman’s Switch................................
High Limits ............................................................
Flow Switch...........................................................
Blocked Vent Switch..............................................
Adjusting Valve Manifold Pressure........................
Visual Inspection ...................................................
Electrical................................................................
.....................................................
Combustion Settings.............................................
Igniter Removal.....................................................
7. OWNER’S OPERATING INSTRUCTIONS ........ 37
.............................................
8. MAINTENANCE AND CARE............................... 38
Care Procedures...................................................
Lighting and Shutdown..........................................
........................
.......................................
....................
9. TROUBLESHOOTING ......................................... 41
Mechanical............................................................
...
10. ILLUSTRATED PARTS LIST............................... 43
11. IMPORTANT INSTRUCTIONS FOR THE
COMMONWEALTH OF MASSACHUSETTS .... 47
12. INSTALLER SETUP RECORD............................ 48
13. WARRANTY .......................................................... 49
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
4
1. WARNINGS
Pay Attention to these Terms
ADANGER Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial
property damage if ignored.
AWARNING Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or
substantial property damage if ignored.
ACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product
or property damage if ignored.
CAUTION
cause minor personal injury or product or property damage if ignored.
NOTE Indicates special instructions on installation, operation, or maintenance which are important but not related
to personal injury hazards.
ADANGER: Failure to properly vent the heater to
the outdoors as outlined in the Venting section of this
manual can result in unsafe operation of the heater. To
carbon monoxide, never operate this heater unless it
is properly vented and has an adequate air supply for
proper operation. Be sure to inspect the vent system
for proper installation at initial start-up; and at least
annually thereafter. Refer to the Maintenance section of
this manual for more information regarding vent system
inspections.
ADANGER: Make sure the gas on which the heater
heater rating plate.
ADANGER: When servicing or replacing components
that are in direct contact with the water, be certain that:
• There is no pressure in the heater. (Pull the release
on the relief valve. Do not depend on the pressure
gauge reading).
• The heater water is not hot.
• The electrical power is off.
AWARNING: All venting types must be of the same
material or product throughout the entire exhaust
installation to ensure proper securing and sealing.
AWARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube bundle
headers, or any ASME parts not manufactured and/or
approved by Raypak will instantly void the ASME and/or
CSA ratings of the vessel and any Raypak warranty on
the vessel. Altering the ASME and/or CSA ratings of the
vessel also violates national, state, and local approval
codes.
AWARNING: Both natural gas and propane have
an odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or recognize
this odorant. If you are unsure or unfamiliar with the
smell of natural gas or propane, ask your local gas
supplier. Other conditions, such as “odorant fade,”
which causes the odorant to diminish in intensity, can
AWARNING - CALIFORNIA PROPOSITION 65:
This product contains chemicals known to the State
of California to cause cancer, birth defects or other
reproductive harm.
AWARNING: 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.
AWARNING: Do not use this heater if any part has
technician to inspect the heater and to replace any part
of the control system and any gas control which has
been under water.
AWARNING: UL-recognized fuel gas detectors are
recommended in all enclosed propane and natural gas
applications wherein there is a potential for an explosive
mixture of fuel gas to accumulate and their installation
should be in accordance with the detector manufacturer’s
recommendations and/or local laws, rules, regulations,
or customs.
AWARNING: This product must be installed by a li-
Commonwealth of Massachusetts.
AAVERTISSEMENT: N’utilisez pas cet appareil
s’il a été plongé dans l’eau, même partiellement.
remplacez toute partie du système de contrôle et toute
commande qui ont été plongés dans l’eau.
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
5
Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool and Spa Types
pH
Total Alkalinity (ppm)
Calcium Hardness (ppm)
Salt (ppm)
Free Chlorine (ppm)*
Total Dissolved Solids (ppm)
*Free Chlorine MUST NOT EXCEED 5 ppm!
Table A. Pool Water Chemistry
General Safety
Elevated water temperature can be hazardous. The
safe for a healthy adult. Special caution is suggested
for young children.
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.
three months of pregnancy resulting in the birth of a
Before entering the spa or hot tub, users should
check the water temperature with an accurate
thermometer; spa or hot tub thermostats may err in
Persons with a medical history of heart disease,
circulatory problems, diabetes, or blood pressure
problems should obtain a physician’s advice before
using spas or hot tubs.
Persons taking medications which induce
drowsiness, such as tranquilizers, antihistamines, or
anticoagulants, should not use spas or hot tubs.
2. WATER CHEMISTRY
NOTE: Damage due to poor water chemistry is not a
warrantable defect.
Chemical imbalance can cause severe damage to your
heater and associated equipment. Maintain your water
chemistry according to Table A. If the mineral content
and dissolved solids in the water become too high, scale
forms inside the heat exchanger tubes, reducing heater
severely damage the heater. Heat exchanger damage
resulting from chemical imbalance is not covered by
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.
CAUTION: Free chlorine must not exceed 5 ppm
which can damage the heater and is not covered under
warranty.
• 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.
• Check valve should be installed between the heater
outlet and a chlorinator or other chemical dosing
device.
• Further advice should be obtained from your pool
or spa builder, accredited pool shop, or chemical
supplier for the correct levels for your water.
Automatic Chlorinators And
Chemical Feeders
All chemicals must be introduced and completely diluted
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
be installed between the heater outlet and the chlorinator.
See plumbing diagrams found in Figure 24 thru Figure 27.
NOTE: High chemical concentrates from feeders and
chlorinators that are out of adjustment will cause rapid
corrosion of the heat exchanger. Such damage is not
covered under the warranty.
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
6
3. BEFORE INSTALLATION
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
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
Bonding lug with mounting screw
PVC/Polypropylene/Stainless Steel vent adapter
8.
Be sure that you receive the number of packages indicated
on the Bill of Lading.
serial numbers of the heater. See Figure 2 for location of
you must also specify date of installation.
2" NPT ADAPTER
O-RING
2" SLIP TAILPIECE
UNION LOCKRING
BONDING LUG
W/ MTG SCREW UNION P/N 015464F
BYPASS ASSEMBLY
P/N 015459F
VENT ASSEMBLY
P/N 015451
F10317
FLUE ADAPTER
P/N 015508F
WASHER
MOUNTING
SCREW
F10318
Figure 1. Standard Unit
MODEL & SERIAL
NO. LOCATED ON
RATING PLATE
MODEL & SERIAL NO.
CAN ALSO BE FOUND
INSIDE THE UNIT ON THE
LEFT FRONT SUPPORT
SERIAL
NUMBER
F10319
Figure 2. Serial No. Location
indoor or outdoors. The heat exchanger bears the ASME
Ambient Temperature Rating
•
•
to operate properly. Frozen condensate may damage
exposure to freezing temperatures.
Elevation
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
7
Notes
ignition using natural gas with a stainless steel heat
exchanger.
EXTERNAL
BY-PASS
FLUE EXHAUST
COMBUSTION AIR
INLET
CONTROLS
21.8
(552)
21.3
(540)
0.8
(19)
18.3
(464)
34.1
(861)
24.3
(618)
18.1
(460)
8.0
(203)
WATER INLET
(2X) 2" PVC SLIP CONNECTION
SERVICE ACCESS PORT
WATER OUTLET
(2X) 2" PVC SLIP CONNECTION
PRESSURE RELIEF VALVE
GAS CONNECTION
CONDENSATE
DRAIN PVC, 3/4
T & P GAUGE
35.5
(901)
1.5
(38)
28.7
(730)
4.0
(102)
4.0
(102)
POWER
CONNECTION
45.8
(1164)
20.2
(514)
4.3
(109)
5.3
(135)
28.5
(723)
27.5
(698)
14.3
(362)
4.7
(118)
10.0
(254)
12.7
(323)
5.5
(141)
F10322
ALL DIMENSIONS ARE IN INCHES AND (MILLIMETERS)
MBTUH Input
(kWh)
Inches (mm) GPM (LPM) Approx.
Shipping Weight
Lbs. (Kg)
Flue Diameter
(B)
Air Inlet
(C) Minimum Flow Maximum Flow
Table B.
Figure 3.
Heaters are suitable for operation at full rated input
factory.
Flue gases must be properly vented with Cat IV vent
PVC pipe. See the venting section of this manual for
complete venting details.
gas and air density. No hardware changes are required to
Adjust as required to maintain proper combustion and
emissions.
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
8
4. INSTALLATION
CALIFORNIA PROPOSITION 65 WARNING:
This product contains chemicals known to the State
of California to cause cancer, birth defects or other
reproductive harm.
AWARNING: This unit contains refractory ceramic
as manufactured, does not contain respirable crystalline
silica. However, following sustained exposure to
very high temperatures (>2192°F [1200°C]), the RCF
can transform into crystalline silica (cristabolite).
The International Agency for Research on Cancer
silica (cristabolite) as carcinogenic to humans.
When removing the burner or heat exchanger, take
precautions to avoid creating airborne dust and avoid
engineering controls such as local exhaust ventilation or
dust collecting systems to minimize airborne dust. Wear
appropriate personal protective equipment including
gloves, safety glasses with side shields, and appropriate
AWARNING: Improper installation, adjustment,
alteration, service or maintenance may damage the
equipment, creating a hazard resulting in asphyxiation,
warranty.
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 combustion
IMPORTANT NOTICE
These instructions are intended only for the use
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
not attempt to repair this equipment according to these
instructions.
Installation Codes
Installation must be in accordance with local codes, or,
in the absence of local codes, with the latest edition of
Clearances
All Heaters
For indoor and outdoor clearances from combustible
surfaces see the chart below.
Location Indoor Installation
Top
Front Alcove (Open
Vent
Floor *
Back
Right Side
Left Side
Location Outdoor Installation
Top
Floor
Back
Right Side
Left Side
* Do not install on carpeting
Table C. Minimum Clearances from Combustible Surfaces
from combustible construction, the pool heater can still be
serviced without removing permanent construction around
the heater.
However, for ease of servicing, Raypak recommends a
This will enable the heater to be serviced in its installed
location, without movement or removal of the heater.
NOTE: The heater must be installed in a manner that
will enable the heater to be serviced without removing
any structure around the heater.
FLOORING
The controls are on the angled face, which must be
accessible. Installing the unit in such a way that the controls
are not accessible is not recommended and not supported.
Description Location Distance
in. (mm)
a.
masonry walls without
ventilated air space
Back
Right
Left
Vent
Indoor Top
Outdoor Top
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
9
b.
wool batts
Back
Right
Left
Vent
Indoor Top
Outdoor Top
c.
or mineral wool batts
reinforced with wire on
rear face with ventilated
air space
Back
Right
Left
Vent
Indoor Top
Outdoor Top
d.
masonry wall with
ventilated air space
Back
Right
Left
Vent
Indoor Top
Outdoor Top
e.
ventilated air space
Back
Right
Left
Vent
Indoor Top
Outdoor Top
f.
insulation board with
ventilated air space
Back
Right
Left
Vent
Indoor Top
Outdoor Top
g.
ventilated air space over
ventilated air space.
Back
Right
Left
Vent
Indoor Top
Outdoor Top
h.
or mineral wool batts
sandwiched between two
with ventilated air space
Back
Right
Left
Vent
Indoor Top
Outdoor Top
Table D. Reduction of Clearances to Protected Surfaces
Heaters must not be installed under an overhang of less
requirements. 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
any door, window or gravity inlet into any building. The vent
m) horizontally.
For installations in Canada, pool heaters shall not be
below, or to either side, of any opening into the building.
For installations in Florida and Texas that must comply
with the Florida or Texas Building Code, follow the
4’ (1.22 m)
Minimum
4’ (1.22 m)
Minimum
3’ (0.91 m)
Minimum
10’ (3.05 m)
Minimum 1’ (0.3 m)
Minimum
4’ (1.22 m)
Minimum
Figure 4. Clearances
Outdoor Heater Installation
installation, when equipped with the approved vent
terminals designated for outdoor use. The heaters are
only. Freezing conditions may cause condensate to freeze
in the condensate drain line and trap causing the unit to
shut down from a blocked condensate drain. Additionally,
components of the condensate management system may
climates for seasonal use must be winterized to avoid
AWARNING: 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; such damage is not covered
under warranty.
AWARNING: Do not install within 3' (0.91 m) 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.
Indoor Heater Installation
The heater must always be vented to the outside. See
Minimum allowable space is shown on the nameplate.
Also see Figure 3 and Table B.
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
10
U.S. Installations1Canadian Installations 2
AClearance above grade, veranda, porch, deck, or
balcony
B Clearance to window or door that may be opened
cm) above opening
C Clearance to permanently closed window * *
D
the centerline of the terminal
*
E * *
F Clearance to outside corner * *
G Clearance to inside corner *
HClearance to each side of center line extended above
meter/regulator assembly
*
regulator assembly
I Clearance to service regulator vent outlet *
building or the combustion air inlet to any other
appliance
opening
LClearance above paved sidewalk or paved driveway
located on public property
Slip hazard due to frozen
condensate
Slip hazard due to frozen
condensate
M Clearance under veranda, porch, deck or balcony *
Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal, and underside
dwellings
*Clearances in accordance with local installation codes and the requirements of the gas supplier.
Table E. Vent/Air Inlet Termination Clearances
A
INSIDE
CORNER DETAIL
V = VENT
X = AIR INLET
F10692
V
G
H
A
B
B
V
V
B
BV
AJ
X
IM
VX
K
V
V
B
F
C
OPERABLE FIXED
CLOSED
FIXED
CLOSED
OPERABLE
D
L
B
E
V
V
Figure 5. Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
11
Combustion And Ventilation Air
(Indoor Units Only)
The heater must have both combustion and ventilation air.
Minimum requirements for net free air supply openings
All Air from Inside the Building:
Each opening shall have a minimum net free area as
Sq. in. (m²)
Table F. Opening Minimum Net Free Requirements -
Indoor Air
All Air from Outdoors:
Unrestricted
Opening
sq. in. (m)
Typical Screened or
Louvered Opening
sq. in. (m)
Typical Screened and
Louvered Opening
sq. in. (m)
Table G. Opening Minimum Net Free Requirements -
Outdoor Air
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater. Such damage will not be covered by the warranty
Direct Vent and Ducted
Combustion Air Systems
If outside air is drawn through the intake pipe directly to
Install combustion air direct vent as instructed by
manual.
Provide adequate ventilation of the space occupied
by the heater(s) by an opening(s) for ventilation air
at the highest practical point communicating with the
outdoors.
a.
in the room when the opening is communicating
directly with the outdoors or through vertical
in the room when the opening is communicating
with the outdoors through horizontal duct(s).
b. In Canada, there shall be permanent air supply
location of the opening(s) shall not interfere with
the intended purpose of the opening(s) for the
ventilation air.
Damper (by others) to prevent the circulation of cold
air through the heater during the
Venting
CAUTION:
General
Appliance Categories
Heaters are divided into four categories based on the
pressure produced in the exhaust and the likelihood of
condensate production in the vent.
Category I
vent static pressure and with a vent gas temperature that
avoids excessive condensate production in the vent.
Category II
vent static pressure and with a vent gas temperature that
may cause excessive condensate production in the vent.
Category III – A heater which operates with a positive
vent pressure and with a vent gas temperature that avoids
excessive condensate production in the vent.
Category IV – A heater which operates with a positive vent
pressure and with a vent gas temperature that may cause
excessive condensate production in the vent.
See the table Table H for appliance category requirements.
NOTE: For additional information on appliance
categorization, see appropriate ANSI Z21 Standard
and the NFGC (U.S.), or B149 (Canada), or applicable
provisions of local building codes.
AWARNING: Contact the manufacturer of the vent
material if there is any question about the appliance
categorization and suitability of a vent material for
application on a Category IV vent system. Using improper
venting materials can result in personal injury, death or
property damage.
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
12
Support of Vent Stack
The weight of the vent stack or chimney must not rest on
the heater vent connection. Support must be provided
in compliance with applicable codes. The vent should
also be installed to maintain proper clearances from
where the vent passes through combustible roofs and
walls.
Vent Terminal Location
NOTE: During winter months check the vent cap and
make sure no blockage occurs from build-up of snow
or ice.
Condensate can freeze on the vent cap. Frozen
condensate on the vent cap can result in a blocked
flue condition.
Give special attention to the location of the vent
termination to avoid possibility of property damage
or personal injury.
Gases may form a white vapor plume in winter. The
plume could obstruct a window view if the termination
is installed near windows.
temperatures, can cause freezing of condensate and
The bottom of the vent terminal and the air intake
grade, including normal snow line.
equipment.
appliances shall not terminate over public walkways
or over an area where condensate or vapor could
create a nuisance or hazard or could be detrimental
to the operation of regulators, relief valves, or other
condensate is a problem with Category I and III
Combustion Air Supply Exhaust
Heater Venting
Category
(Must be UL 1738 or ULC S636)
Combustion Air
Inlet Materials
From Inside Building
Vertical Venting IV
Metallic Vent
Horizontal
Venting
IV
From Outside Building
(Direct Vent or
Ducted Combustion Air)
Vertical Venting with
Ducted Combustion
Air
IV Galvanized Steel
PVC
ABS
CPVC
Vertical Direct Vent IV
Horizontal Direct Vent IV
Table H. Venting Category Requirements
appliances, this provision shall also apply.
8. Locate and guard vent termination to prevent
accidental contact by people or pets.
DO NOT terminate vent in window well, stairwell,
alcove, courtyard or other recessed area.
window, or gravity air intake. Condensate can freeze,
causing ice formations.
Locate or guard vent to prevent condensate from
sheet metal backing plate against brick or masonry
surfaces.
DO NOT extend exposed vent pipe outside of
building beyond the minimum distance required for
the vent termination. Condensate could freeze and
block the vent pipe.
U.S. Installations
Refer to the latest edition of the National Fuel Gas Code.
door, window or gravity air inlet to the building.
grade when located adjacent to public walkways.
horizontal distance is maintained, from electric
meters, gas meters, regulators, and relief equipment.
adjacent walls.
roof overhang.
terminal clearance from the wall.
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
13
8.
including normal snow line.
clearance between the ends of vent caps located on
the same horizontal plane.
AWARNING: The Commonwealth of Massachusetts
requires that sidewall vented heaters, installed in every
dwelling, building or structure used in whole or in part
for residential purposes, be installed using special
provisions as outlined on page 47 of this manual.
Canadian Installations
Directly above a paved sidewalk or driveway which
serves both dwellings.
paved driveway located on public property.
any building.
mm) horizontally of the vertical centerline of the
regulator.
outlet.
air supply inlet to any building or the combustion air
inlet of any other appliance.
8.
two sides beneath the floor, and the distance between
the top of the vent termination and the underside of
the veranda, porch or deck
Venting Installation Tips
•
• vertical runs—use braces
• under or near elbows
AWARNING: Examine the venting system at least
once a year. Check all joints and vent pipe connections
for tightness, corrosion or deterioration.
Condensate Management
The condensate must be drained properly to protect the
appliance and drainage system. The condensate from
recommends treating the condensate with a Condensate
is connected to the drain system and contains limestone
(calcium carbonate) chips to raise the pH level of the
damage to the drainage system and to meet local code
Vent pipe condensate drains are also required for
manufacturer instructions for location of condensate drains
in the vent. The vent condensate should also be routed
code requirements.
The treatment kit must be sized to the condensate
generated by the appliance and the vent.
CAUTION: In general, the condensate piping from
horizontal foot. Condensate drain traps must be primed
should be checked at least once per year to ensure that
should be replenished as necessary. When replacing
blockage in the condensate piping. Figure 6 on page
14 is a visual guide only. Follow the manufacturer’s
instructions for the installation of the treatment kit and
condensate drains.
AWARNING: The expected condensate volume shall
not exceed 4 GPH (15 lph).
For heaters connected to gas vents or chimneys, vent
codes.
Vertical Venting (Category
IV) Installation
CAUTION: A listed vent cap terminal, adequately sized,
building.
ACAUTION: This venting system requires the
installation of a condensate drain in the vent piping per
the vent manufacturer’s instructions. Failure to install a
condensate drain in the venting system will cause non-
warrantable damage. Condensate is acidic and highly
corrosive.
NOTE: Ensure adequate clearances to allow annual
inspection of the venting system.
The connection from the appliance vent to the stack must
be as direct as possible and shall be the same diameter
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
14
Z-12 TREATMENT KIT
as the vent outlet. The horizontal breaching of a vent must
The horizontal portions of the vent shall also be supported
for the design and weight of the material employed to
maintain clearances and to prevent physical damage or
separation of joints.
CAT IV
FLUE EXHAUST
VENT CAP
CAT IV FLUE
MATERIAL
CONDENSATION
TRAP
HEATER UNIT
10' (3 m) OR
LESS
2' (61 cm)
MIN 3' (91 cm)
MIN
F10325
Figure 6. Vertical Venting
NOTE:
to connect other types of Category IV vents to the heater.
The supplied vent adapter allows for direct connection
to DuraVent PolyPro, Duravent FasNSeal, Sch 40 PVC
and Sch 40 CPVC.
Termination
The vent terminal should be vertical and should terminate
above the highest point of the roof or building that is within
is maintained) electric meters, gas meters, regulators and
relief equipment.
The distance of the vent terminal from adjacent public
walkways, adjacent buildings, open windows and building
guyed or braced to withstand snow and wind loads.
NOTE: When using PVC Tee vent as termination, insert
the round stainless mesh screens provided with the unit
into the tee ends.
Figure 7. Vertical Venting
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
15
Material
Vent and
Intake Air Size
Vent Length Combustion Air
Intake Pipe
Material
Intake Air Max.
Length
Min. Max.
Stainless Steel,
Polypropylene**
Galvanized
Steel, PVC,
ABS, CPVC
Table I. Category IV Vent Requirements
Size Approved Air Intakes Approved Plastic
Terminals
Approved SS
Terminals
Table J. Horizontal Vent and Air Intake Terminals
Horizontal Through-the-Wall
Venting (Category IV)
Installation
CAUTION: This venting system requires the
installation of a condensate drain in the vent piping per
the vent manufacturer’s instructions. Failure to install
a condensate drain in the venting system will cause
damage which will not be covered under warranty.
vent the combustion products to the outdoors. Combustion
air is taken from inside the room and the vent is installed
horizontally through the wall to the outdoors. Adequate
combustion and ventilation air must be supplied to the
•
•
•
•
•
The vent cap is not considered in the overall length of the
venting system.
must be taken during assembly to ensure that all joints are
sealed properly and are airtight. The vent must be installed
to prevent the potential accumulation of condensate in the
vent pipes. It is recommended that the vent be insulated.
Insulation is required for installations in cold environments
The vent must be installed with a condensate drain
located in proximity to the heater as directed by the
vent manufacturer.
The vent must be installed with a slight upward slope
of horizontal run to the vent terminal.
FLUE EXHAUST
VENT CAP
CONDENSATION
TRAP
HEATER UNIT
F10324
12" (30.5 cm) MIN
12" (30.5 cm)
MIN
Figure 8. Horizontal Through-the-Wall Venting
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
16
Termination
mounted on the exterior of the building. The direct vent cap
cannot be installed in a well or below grade. The direct vent
level and above normal snow levels. A Raypak approved
vent cap must be used. The vent terminal must be located
AWARNING:
cap material are allowed. Such substitutions would
jeopardize the safety and health of inhabitants.
Direct Vent – Horizontal
Through-the-Wall
Installation
draw combustion air from outdoors and vent combustion
products to the outdoors. Connect the air duct to the heater
cannot exceed the values listed in Table I. Each elbow
•
•
•
•
•
considered in the overall length of the venting system.
Care must be taken during assembly that all joints are
sealed properly and are airtight.
The vent must be installed to prevent the potential
accumulation of condensate in the vent pipes. It is
recommended that the vent be insulated. Insulation is
required for installations in cold environments (i.e. below
For installations in extremely cold climate, it is required
• The vent must be installed with a slight upward slope
of horizontal run to the vent terminal. An approved
condensate trap must be installed per applicable
codes.
• The intake vent must be insulated through the length
of the horizontal run.
ALTERNATIVE COMBUSTION
AIR INTAKE LOCATION
HEATER UNIT
F10326
12"
(30.5 cm)
MIN
36" (91 cm)
MIN
D-15 FLUE
TERMINATION
AIR
INTAKE
CONDENSATION
TRAP
Figure 9. Horizontal Through-the-Wall Direct Venting
Termination
be mounted on the exterior of the building. It cannot be
installed in a well or below grade. It must be installed at
snow levels.
intake installed above.
problems with components and poor operation of the
termination to the side of the adjacent vent cap(s). It is
preferable to install multiple vent terminations in a vertical
line, see Figure 10.
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
17
VENT CAPS STACKED VERTICALLY
FLUE GASES MOVING IN PARALLEL
VENT CAPS ALL AT SAME ELEVATION
FLUE GASES MOVING TOWARD EACH OTHER
VENT CAPS AT STAGGERED ELEVATIONS
FLUE GASES MOVING TOWARD EACH OTHER
1" (25 mm)
MIN. (TYP)
2" (50 mm) MIN. (TYP)
DISCHARGE
4' (1.2 m)
MIN. (TYP)
DISCHARGE
4' (1.2 m)
MIN. (TYP)
1" (25 mm)
MIN. (TYP)
F10704
Figure 10.
Combustion air supplied from outdoors must be free of
particulate and chemical contaminants. To avoid a blocked
leaves, debris, etc.
AWARNING:
termination material are allowed. Such substitutions
would jeopardize the safety and health of inhabitants.
ACAUTION: Condensate is acidic and highly
corrosive.
by the heater manufacturer in accordance with its listing.
with appropriate listings may be used. Pipe joints must
be positively sealed. Follow the vent manufacturer’s
installation instructions carefully.
Direct Vent – Vertical
Installation
draw combustion air from outdoors and force the heated
The vent material must be in accordance with the above
instructions for vent materials. Vent material must be listed
be as direct as possible and should be the same size or
larger than the vent outlet.
It is recommended that the intake vent be insulated in
colder climates.
CAT IV
FLUE TERMINATION
3' MIN
(91.4 cm)
1' MIN
(30.5 cm)
1' MIN
(30.5 cm)
HEATER
UNIT
ALTERNATIVE
COMBUSTION
AIR INTAKE LOCATION
6" MIN
(15.2 cm)
CONDENSATION
TRAP
12" MIN
(30.5 cm)
AIR
INTAKE
F10327
Figure 11. Direct Vent - Vertical
Termination
AWARNING: No substitutions of vent pipe or vent
termination material are allowed. Such substitutions
would jeopardize the safety and health of inhabitants.
The distance of the vent terminal from adjacent public
walkways, adjacent buildings, open windows and building
braced to withstand snow and wind loads.
the roof line or above normal snow levels that might obstruct
operation of the heater and venting system and reduces
the air inlet opening.
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
18
sealed. Follow the vent manufacturer’s installation
instructions carefully.
Outdoor Installation
installations. If needed additional vent may be added to
locate the vent discharge away from the appliance. The
venting must not exceed the lengths listed in Table I
additional venting is supplied, the vent must be supported
and traps installed. In cold climates, it may be necessary
to insulate the additional venting.
Care must be taken when locating the heater outdoors,
can condense as they discharge. Improper location can
Periodically check venting system. The heater’s
venting areas must never be obstructed in any way
and minimum clearances must be observed.
NOTE: Remove the unused gaskets from the 3 in 1
appliance vent adapter. For example, when using the
supplied PVC vent pipe remove the inner two gaskets.
See Figure 13.
NOTE:
D-11 FLUE EXHAUST
VENT CAP WITH
BIRD GUARDS
F10328
Figure 12. Outdoor Venting
TEST PORT 3 O-RING
GASKETS
REMOVE O-RING
WHEN INSTALLING
PVC/CPVC PIPE
REMOVE O-RING
WHEN INSTALLING SST
OR PVC/CPVC PIPE
Figure 13. Multi-Vent Adapter
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
19
FLORIDA BUILDING CODE 2010
ULTIMATE WIND SPEED = 170 MPH (274 km/h), 3 SECOND GUST
NOMINAL WIND SPEED = 132 MPH (212 km/h)
EXPOSURE = C
Gas Heater Model No. 410
34.1"
(86.6 cm)
20.2"
(51.3 cm)
35.5"
(90.2 cm)
3-1/2" (8.9 cm) MIN.
CONC. PAD BY OTHERS
3-1/2" (8.9 cm) MIN.
CONC. PAD BY OTHERS
6"
(15.2 cm)
6"
(15.2 cm)
6"
(15.2 cm)
6"
(15.2 cm)
F10321
Florida Building Code
Figure 14. Hurricane Tie Down Instructions
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
20
Gas Supply Connections
Gas piping must have a sediment trap ahead of the heater
the heater jacket. All gas piping should be tested after
installation in accordance with local codes.
GAS INLET
3" MIN
(7.6 cm)
SEDIMENT
TRAP
UNION
REAR
JACKET
3/4 NPT
WRENCHING
NIPPLE
MANUAL
BALL
VALVE
MUST BE INSTALLED
BY INSTALLER
F10329
Figure 15. Gas Supply Connections
ACAUTION:
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 kPa). Dissipate test pressure in
the gas supply line before reconnecting the heater and
TO FOLLOW THIS PROCEDURE MAY DAMAGE THE
GAS VALVE. OVER-PRESSURIZED 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
NOTE:
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.
Supply Pressures
load conditions must be provided for natural gas. A
between static pressure and full load.
Set actual gas manifold pressure based on COemissions,
either natural or propane gas.
Gas Pressure Adjustment Locations
ADJUSTING SCREW
+ = MORE GAS
– = LESS GAS
GAS
INLET
F10330
Figure 16. Gas Valve
Pipe Sizing For Gas Connections
Maximum Equivalent Pipe Length, ft. (m)
NAT PRO NAT PRO NAT PRO NAT PRO
*
(8.8)
Pressure Drop.
Pressure Drop.
the gas valve in addition to the sediment trap.
Table K. Gas Line Sizing
Heat Exchanger Pressure
Drop Tables
Heat Exchanger with External Automatic Bypass
WATER FLOW
GPM (lpm)
HEAD LOSS
FT. WC. (kPa)
Table L. Heat Exchanger Pressure Drop
APPROVED
UNCONTROLLED DOCUMENT IF PRINTED
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