Raypak 206A Installation And Operation Manual
Gas-fired pool and spa heater, atmospheric models
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INSTALLATION AND
OPERATION MANUAL
Gas-Fired Pool
and Spa Heater
Atmospheric Models 206A, 266,
266A, 336A, 399, and 406A
WARNING: If the information in the instructions is not followed exactly, a fire or explosion may result
A
causing property damage, personal injury or death.
- Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in
the vicinity of this or any other appliance. To do so may result in an explosion or fire.
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• 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.
• 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.
Catalog No. 6000.59AG
Effective: 11-15-19
Replaces: 10-01-19
P/N 241236 Rev. 34
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Table of Contents
Related Manuals for Raypak 206A
Summary of Contents for Raypak 206A
- Page 1 OPERATION MANUAL Gas-Fired Pool and Spa Heater Atmospheric Models 206A, 266, 266A, 336A, 399, and 406A WARNING: If the information in the instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
- Page 2 QUICK START GUIDE CLEARANCES WATER CHEMISTRY † Space required: See page 12. † Water chemistry requirements: See page 5. † Minimum and service clearances: See page 7 for clearances table. Note that local codes prevail. POWER † Supply voltage: See page 23 for acceptable input voltages.
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Page 3: Table Of Contents
CONTENTS 1. WARNINGS ............. 4 6. WIRING DIAGRAM - MILLIVOLT ....... 24 Pay Attention to These Terms ......... 4 7. WIRING DIAGRAM - DIGITAL ......25 2. WATER CHEMISTRY ..........5 8. CONTROLS ............26 Automatic Chlorinators and Chemical Feeders..5 Control Panel Removal ......... -
Page 4: Warnings
1. WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe personal injury, death or DANGER substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause severe personal injury, WARNING death or substantial property damage if ignored. -
Page 5: Water Chemistry
severely damage the heater. Heat exchanger damage CAUTION: Elevated water temperature can be resulting from chemical imbalance is not covered by hazardous. The U.S. Consumer Product Safety the warranty. Commission has these guidelines: For your health and the protection of your pool equipment, Spa water temperatures should never exceed 104°F it is essential that your water be chemically balanced. -
Page 6: Before Installation
3. BEFORE INSTALLATION Rating and certifications These heaters are design-certified and tested under the Receiving equipment latest requirements of the ANSI Z21.56 / CSA 4.7 Standard The manufacturer recommends that this manual be for Gas-Fired Pool Heaters. All heaters can be used either reviewed thoroughly before installing the pool/spa heater. -
Page 7: Installation
4. INSTALLATION Installation Codes Installation must be in accordance with local codes, or, WARNING: This unit contains refractory ceramic in the absence of local codes, with the latest edition of fiber (RCF) insulation in the combustion chamber. RCF, the National Fuel Gas Code, ANSI Z223.1/NFPA54 and as manufactured, does not contain respirable crystalline National Electrical Code, ANSI/NFPA 70, and for Canada, silica. -
Page 8: Outdoor Heater Installation
When installed according to the listed minimum clearances Clearances less than these may require removal of the from combustible construction, the pool heater can still be heater to service either the heat exchanger or the burner serviced without removing permanent construction around tray. - Page 9 For installations in Florida and Texas, that must comply with the Florida or Texas Building Code, follow the directions shown in Figure 5 for the installation of hurricane tie-down brackets for all models. 4' (1.2 m) Minimum Indoor Heater Installation 4' (1.2 m) The heater is also design-certified for indoor installation Minimum...
- Page 10 FLORIDA AND TEXAS BUILDING CODES WIND SPEED = 150 MPH, 3 SECOND GUST EXPOSURE = C Model in. (mm) 206A 20 (508) 266/266A 23 (584) 336A 26 (660) 399/406A 29 (737) 38" (965 mm) F10648 28" (711 mm) 2" x 6" x 1/8" Pallet Anchor Bracket (4 Total) (Kit# 011636) 3"...
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Page 11: Combustion And Ventilation Air
National Fuel Gas Code (U.S. ANSI Z223.1 Model Outdoor Stack Indoor Stack or Canada CAN/CSA-B149) and any local codes that may have jurisdiction. The most common approach is 206A 009834 009838 the "2-opening" method, with combustion air opening no 266/266A 009835 009839 more than 12"... - Page 12 Mode (000) Width Dia. Drafthood in. (mm) in. (mm) w/Stackless hood (kw) in. (mm) in. (mm) in. (mm) 199.5 61-5/8 10.0 11-3/4 206A (58.4) (508) (152) (1565) (254) (298) (85) (6.4) 266.0 11.5 266/266A (77.9) (584) (178) (1575) (292) (279) (95) (7.3)
- Page 13 Shipping Weights Residential - Cupronickel Heat Exchanger lbs (kg) BTUH Standard (J)* Water Indoor Heater Input Cabinet Flue Indoor Heater Conn. Conn. Draft- Mode (000) Width Dia. Drafthood w/Stackless (mm) (mm) hood (kw) in. (mm) in. (mm) in. (mm) 180.0 61-5/8 10.0 11-3/4...
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Page 14: Vent Piping
The power vent system is a fan-assisted vent system stack shall be at least 5' (1.5 m) in vertical height above designed for use on models 206A-406A. the drafthood outlet. The vent cap location shall have a minimum clearance of 4' (1.2 m) horizontally from, and in The power vent system, when installed as directed, is no case below, unless a 4' (1.2 m) horizontal distance is... -
Page 15: Gas Supply Connections
Gas piping must have a sediment trap ahead of the 8' (2.4 m) heater gas controls, and a manual shut-off valve located OR LESS outside the heater jacket. All gas piping should be tested VENT CAP 2' MIN after installation in accordance with local codes. (0.6 m) CAUTION: The heater and its manual shut-off valve must be disconnected from the gas supply during any... - Page 16 Gas Pressure Adjustment Locations Millivolt Gas Valve PRESSURE ADJUSTMENT Figure 14. Robertshaw 7000 (Heater Models 206A - 406A) Electronic Ignition Gas Valves GAS PRESSURE ADJUSTMENT GAS PRESSURE ADJUSTMENT Figure 17. Robertshaw 7000 BDER (Heater Models 266A - Figure 15. Honeywell VR8340 (Heater Models 206A - 406A)
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Page 17: Flow Rate
Specific Gravity @ 0.5 in WC Pressure Drop Propane Gas 2500 BTU/FT 1.53 Specific Gravity @ 0.5 in WC Pressure Drop 3/4" 1" 1-1/4" 1-1/2" Model F10637-1 Figure 20. Brass Header (ASME) Water Flow 206A (7.6) (18.3) (27.4) (65.5) (109.7) 266/266A (4.6) (10.7) (15.2) (38.1) (64.0) -
Page 18: Protek Shield Assembly
Pressure Drop (Ft. of Head) (m of Head) in the grooves. Use Aqualube or equivalent non-petroleum- Flow GPM (lpm) based lubricant on the O-ring. Hand tighten the unions. 206A 266A 336A 406A Glue PVC piping directly to the unions. 20 (75) -
Page 19: Unitherm Governor Operation
Bypass assy must be replaced. The "red" spring is used occur if the heater runs for any length of time below on models 206A, 266, 266A. The "silver" spring is used 100°F (38°C). It is also needed to inhibit scale formation on models 336A, 399 and 406A. -
Page 20: Auxiliary Bypass Valve Adjustment
Auxiliary Bypass Valve Adjustment NOTE: To avoid water damage or scalding due to valve operation, drain pipe must be connected to valve outlet To set bypass, with clean filter, adjustment is made by and run to a safe place of discharge. Drain pipe must feeling the inlet and outlet pipes at the heater. -
Page 21: Plumbing Diagrams
Plumbing Diagrams Water Connection ISOLATION VALVE BALL VALVE PRESSURE RELIEF VALVE THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER PUMP Figure 31. Single Pool Heater Installation UNION CHECK VALVE THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER Figure 32. -
Page 22: Electrical Wiring
2. Disconnect wires at high limit, AGS (automatic gas 5. Reconnect high limit, AGS, water pressure switch shut-off), water pressure switch on the in/out header wires, and ProTek Shield bonding wire. and ProTek Shield bonding wire. See Figure 33. 6. Digital Models: Insert the temperature sensor into the compression fitting, so that the sensor is flush with the top of the fitting. -
Page 23: Electrical Power Draw
8. Re-route all high-voltage wires and ground wires There should be no connection to the red wire for 120 through the left jacket side of heater. VAC operation. Attach a wire nut to the red wire. 9. Re-install P6 connector, ground wires (SPG), transformer, junction box, front door, and plug right BLACK BLACK... -
Page 24: Wiring Diagram - Millivolt
6. WIRING DIAGRAM - MILLIVOLT... -
Page 25: Wiring Diagram - Digital
7. WIRING DIAGRAM - DIGITAL... -
Page 26: Controls
8. CONTROLS NOTE: Caution must be used to not damage controls or wiring. PRESSURE SWITCH TEMP SENSOR CONTROL HL1 - HIGH LIMIT BEZEL HL2 - HIGH LIMIT KNURLED UNITHERM SCREW GOVERNOR F10646-5 Figure 41. Knurled Screw Location Control Adjustments - ROLL-OUT SWITCH PROTEK... -
Page 27: Control Adjustments - Digital Models
Control Adjustments – Digital Models The pool heater touchpad, located on the upper front panel of the heater, allows the user to select either POOL or SPA operation, and to adjust the setpoint temperature. The LCD display window indicates the mode (OFF, SPA, POOL) and the actual water temperature. - Page 28 Press the DOWN button. The Fault History displays up to Both the POOL and SPA setpoints will revert to 65°F (18°C) ten faults in memory. The order of the faults begins with and both POOL and SPA maximum temperature settings “Fault Last,”...
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Page 29: Status And Diagnostics
The following conditions are displayed only while there is a NOTE: Both the POOL and SPA setpoints will revert demand for heat present. back to 65°F (18°C) and the POOL and SPA maximum temperature settings will be 104°F (40°C). These Display Condition setpoints will need to be readjusted to desired settings. -
Page 30: Remote Control Wiring - Digital Models Only
Millivolt models are not designed for operation with remote Remote Control Installation and Operation control sytem. CAUTION: Before installing remote controls to Activating the Remote the digital heaters, read the following: The digital To activate or deactivate the remote function: thermostat model is remote-ready in most cases. - Page 31 • For both two- and three-wire remote systems, the 3. Turn the MODE button to “OFF” and remove power provided 7-pin wiring connector must be utilized. from the heater. NOTE: The remote wires must be connected to the 7-pin connector before the connector is plugged into the board.
- Page 32 For millivolt heaters, the fireman's switch connection is 8. While the heater is running, check the adjustment a wire nut located in the Violet/Black wiring between the by turning the pump off and on several times. The manual toggle switch and the gas valve. heaters, splice burners should shut off immediately when the pump into the red/white wire to connect the time clock.
- Page 33 Pilot Safety - Millivolt Models CAUTION: Do not operate the heater without the function of a properly adjusted water pressure switch Heaters equipped with the standing pilot (millivolt system) or flow switch. employs a pilot which act as a safety device to shut down the flow of gas to the main burners and the pilot burner in Flame Roll-Out Safety Switch case the pilot flame is extinguished.
- Page 34 4. Turn vertical gas pipe from manifold slightly and Heat Exchanger Removal unscrew gas valve. 1. Shut water, gas and electricity off, close valves and 5. Reverse above procedure to reinstall. relieve pressure, then remove relief valve. Remove side access panels. Main Burner And Orifice Removal 2.
- Page 35 1. Remove top and flue collector from cabinet. 2. Remove “V” baffles from heat exchanger. 3. Remove burner tray. See page 33. 4. Remove ProTek Shield Assy bonding wire from heat F10670 exchanger stud. 5. Remove heat exchanger from the heater and wash Figure 65.
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Page 36: Operating Instructions
9. OPERATING Visual inspection INSTRUCTIONS With the heater on, remove the door and make a visual check of the pilot and burner. The flame should be blue with a well-defined pattern. Before Start-Up A yellow or “floating” flame indicates restricted air openings or incorrect orifice size. - Page 37 OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES MILLIVOLT SYSTEM (MANUALLY-LIGHTED PILOT) FOR YOUR SAFETY READ BEFORE LIGHTING This appliance has a pilot which must be lit *If you cannot reach your gas supplier, call the by hand. When lighting the pilot, follow these fire department.
- Page 38 OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES ELECTRONIC IGNITION DIGITAL MODELS (AUTOMATICALLY-LIGHTED PILOT) FOR YOUR SAFETY READ BEFORE LIGHTING This appliance is equipped with an ignition de- *If you cannot reach your gas supplier, call the vice which automatically lights the pilot. Do not fire department.
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Page 39: Maintenance And Care
10. MAINTENANCE AND CARE Cold Weather Operation WARNING: Check the heater for possible rodent Important Freeze Information nests after long periods of non-use. MODERATE CLIMATE: Heater operation can continue during short-term cold spells. When temperatures are To be followed one month after start-up and then semi- between 0°F (-18°C) and 32°F (0°C), flow (continuous annually. -
Page 40: Troubleshooting
11. TROUBLESHOOTING IMPORTANT NOTICE: These instructions are intended for the use of qualified personnel who are specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions. -
Page 41: Millivolt - Flow Chart
Millivolt - Flow Chart Light pilot If pilot burner If pilot burner goes out If pilot burner remains lit does not light when main burner lights or when gas valve knob is released Jump across both "TH" Check gas supply, gas wires on gas valves line size, gas pressure. -
Page 42: Digital - Flow Chart
Digital - Flow Chart WARNING: HIGH VOLTAGE For qualified technicians ONLY NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. To reset, interrupt power to heater. START TURN GAS SUPPLY OFF. NOTE: Before troubleshooting, familiarize yourself with the start-up and check-out TURN THERMOSTAT procedure. -
Page 43: Control Logic - Flow Chart - Digital
Control Logic - Flow Chart - Digital Power On • Check On/Off switch (under lid on control panel) Is the water • Check for 120/240 volts to the transformer temperature displayed? (time clock, circuit breaker, wire connections) • Check for 24 volts to Circuit Board (P6 connector) “Remote”... -
Page 44: Replacement Parts
12. REPLACEMENT PARTS NOTE: To supply you with the correct part, it is important that you supply the heater model number, serial number and type of gas when applicable. Any part returned for replacement under standard company warranties must be properly tagged with a return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to the Company freight prepaid. -
Page 45: Illustrated Parts List
13. ILLUSTRATED PARTS LIST 14-M I3-S 1 -V 6-HP 5-H P 7-HP 15-H P 2-HP 3-HP 7-HP 6-HP 4-HP I 2-S 14-M 20-HP 17-H M 8 -S 11-S 5 -C 10 -M 3 -M 7- C 9 -M 25-M 4 -M 18-M 11-M 2-B 5-M... - Page 46 19-M (OPTIONAL) 8-HP 20-M 8-HP 6-HM 21-M 27-HM 5-HM 26-HM 2-HM 7-HM 3-HM 4-HM 28-HM 18-HP 17-HP 20-HP FOR UNITS WITH ASME BRASS HEADERS FROM 12/2019 ( O P T I O N A L ) 14-HM 16-HM 13-HM 15-HM 6-HM 5-HM 2-HM...
- Page 47 19-HP 19-HP (OPTIONAL) (OPTIONAL) 19-HP 11-HP 11-HP 8-HP 18-HP 16-HP 12-HP 8-HP 10-HP 10-HP 16-HP 12-HP 15-HP 18-HP 2-HP 2-HP 13-HP 14-HP 17-HP 13-HP 20-HP 14-HP 17-HP F O R UNITS W IT H PO LYM ER H EA D ER S F R OM 1 0/ 201 9 FOR UNITS WITH POLYMER HEADERS PRIOR TO 10/2019 HONEYWELL MILLIVOLT PILOT HONEYWELL IID ATMOSPHERIC PILOT...
- Page 48 CALL OUT DESCRIPTION 206A 266/266A 336A 399/406A BURNER TRAY Burner Tray w/Burners (sea level)* 010391F 010392F 010393F 010394F Burner Tray w/o Burners (sea level)* 010395F 010396F 010397F 010398F Burner Tray w/Gas Valve Nat Millivolt 010399F 010400F 010401F 010402F Burner Tray w/Gas Valve Pro Millivolt...
- Page 49 CALL OUT DESCRIPTION 206A 266A 336A 406A HEAT EXCHANGER - METAL 1-HM Heat Exchanger Assy.Copper ASME Units manufactured from 12/2019 (Brass) 017983F 017984F 017985F 017986F Units manufactured prior to 12/2019 (Cast Iron) 010051F 016193F 010053F 010054F Heat Exchanger Assy.Cupronickel ASME...
- Page 50 CALL OUT DESCRIPTION 206A 266/266A 336A 399/406A PILOT Pilot Nat. MV 600525B 600525B 600525B 600525B Pilot Pro. MV 600575B 600575B 600575B 600575B 002003F 002003F 002003F 002003F Pilot Nat & Pro IID Pilot Orifice Nat. MV 003901F 003901F 003901F 003901F Pilot Orifice Pro. MV...
- Page 51 NOTE...