Raypak 406A Installation And Operation Manual
Gas-fired pool and spa heater, bronze asme and polymer atmospheric heat exchanger
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- Installation & operating instructions manual (60 pages) ,
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INSTALLATION AND
OPERATION MANUAL
Gas-Fired Pool
and Spa Heater
Bronze ASME and Polymer
Atmospheric Heat Exchanger 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.
PRELIMINARY
UNCONTROLLED DOCUMENT IF PRINTED
A
S
M
E
HLW
BR models only
Effective: 11-10-21
Replaces: 08-27-21
P/N 241236 Rev. 41
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Table of Contents
Related Manuals for Raypak 406A
Summary of Contents for Raypak 406A
- Page 1 Spa Heater Bronze ASME and Polymer Atmospheric Heat Exchanger Models 206A, 266, 266A, 336A, 399, and 406A BR models only 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 PRELIMINARY 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
PRELIMINARY TABLE OF 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
PRELIMINARY 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
PRELIMINARY 2. WATER CHEMISTRY CAUTION: Elevated water temperature can be hazardous. The U.S. Consumer Product Safety NOTE: Damage due to poor water chemistry is not a Commission has these guidelines: warrantable defect. Spa water temperatures should never exceed 104°F (40°C). A temperature of 100°F (38°C) is considered Chemical imbalance can cause severe damage to your safe for a healthy adult. -
Page 6: Before Installation
PRELIMINARY skimmer. High chemical concentrations will result when the THE MODEL AND SERIAL NO. CAN pump is not running (e.g. overnight). ALSO BE FOUND INSIDE THE BEZEL ABOVE THE DISPLAY Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the heater when the pump is shut off. -
Page 7: Installation
The pan must not restrict combustion air flow. RECOMMENDATION: For regions with snow, Raypak recommends installing these units indoors. UNCONTROLLED DOCUMENT IF PRINTED... -
Page 8: Outdoor Heater Installation
PRELIMINARY 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 PRELIMINARY 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 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" (76 mm) Min.
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Page 11: Combustion And Ventilation Air
12" from the floor and the ventilation opening no more than 12" from the ceiling. For opening sizes 336A 009836 009840 using this method, see below. 399/406A 009837 009841 All Air from Inside the Building: Table D. Outdoor and Indoor Stack Kit Number... - Page 12 (97.4) (660) (203) (1600) (330) (270) (104) (8.6) 64-9/16 14.5 12-1/8 399/406A (116.9) (737) (229) (1640) (368) (309) (113) (9.5) *Note: For outdoor stack height, use "J" dimension for appropriate size plus 6 inches (152 mm). Table G. Residential - Copper Heater Specifications and Dimensions...
- Page 13 PRELIMINARY Shipping Weights Residential - Cupronickel Heat Exchanger lbs. (kg) Standard BTUH (J)* Indoor Heater Cabinet Flue Indoor Heater Input Draft- Mode Width Dia. Drafthood w/Stackless (kwh) (mm) (mm) Hood in. (mm) in. (mm) in. (mm) 180.0 61-5/8 10.0 11-3/4 P-_206A-EN-X (52.7) (508)
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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
PRELIMINARY Gas piping must have a sediment trap ahead of the 8' (2.4 m) heater gas controls, and a manual shutoff 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 shutoff valve must be disconnected from the gas supply during any... - Page 16 PRELIMINARY 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
35 (132) 100 (378) Table M. Polymer Heat Exchanger Pressure Drop - Residential Models - (UG Fully Open) 399/406A 1-1/4"–1-1/2"–2" 40 (151) 100 (378) * When flow rates exceed maximum GPM an external auxiliary bypass valve is required. See external bypass valve section for details. -
Page 18: Protek Shield Assembly
PRELIMINARY Pressure Drop - Ft. of Head (m of Head) O-RING Flow GPM (lpm) HEADER FLANGE 206A 266A 336A 406A (CPVC) 20 (75) 8.2 (2.5) HEADER FLANGE NUT (CPVC) 30 (113) 9.5 (2.90) 9.5 (2.90) 40 (151) 9.7 (2.95) 9.7 (2.95) 11 (3.3) -
Page 19: Unitherm Governor Operation
206A, 266A. The "green" spring is used 100°F (38°C). It is also needed to inhibit scale formation on models 336A, 406A. in the tubes by maintaining temperatures well below accelerated scaling temperatures. -
Page 20: Auxiliary Bypass Valve Adjustment
PRELIMINARY 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
PRELIMINARY Plumbing Diagrams Water Connection ISOLATION VALVE BALL VALVE PRESSURE THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED RELIEF VALVE TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER PUMP Figure 31. Single 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
PRELIMINARY 2. Disconnect wires at high limit, AGS (automatic gas 5. Reconnect high limit, AGS, water pressure switch shutoff), water pressure switch on the in/out header wires, and ProTek Shield bonding wire. and ProTek Shield bonding wire. See Figure 33. 6. -
Page 23: Electrical Power Draw
PRELIMINARY 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
PRELIMINARY 6. WIRING DIAGRAM - MILLIVOLT UNCONTROLLED DOCUMENT IF PRINTED... -
Page 25: Wiring Diagram - Digital
PRELIMINARY 7. WIRING DIAGRAM - DIGITAL UNCONTROLLED DOCUMENT IF PRINTED... -
Page 26: Controls
PRELIMINARY 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 Millivolt Models SWITCH... -
Page 27: Control Adjustments - Digital Models
PRELIMINARY Control Adjustments – Digital Models The pool heater touch-pad 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 PRELIMINARY 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
PRELIMINARY 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
PRELIMINARY Millivolt models are not designed for operation with remote Remote Control Installation and Operation control system. 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 PRELIMINARY • 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 PRELIMINARY 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 PRELIMINARY Pilot Safety - Millivolt Models CAUTION: Do not operate the heater without the function of a properly-adjusted water pressure switch or Heaters equipped with the standing pilot (millivolt system) 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 PRELIMINARY 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 PRELIMINARY 1. Remove top and flue collector from cabinet. 2. Remove “V” baffles from heat exchanger. 3. Remove burner tray. See page 33. 4. If ProTek Shield Assy is attached to the heater, F10670 remove ProTek Shield Assy bonding wire from heat exchanger stud.
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Page 36: Operating Instructions
PRELIMINARY 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 PRELIMINARY OPERATING INSTRUCTIONS AND SHUTOFF 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 PRELIMINARY OPERATING INSTRUCTIONS AND SHUTOFF 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
PRELIMINARY 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
PRELIMINARY 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 PRELIMINARY TROUBLESHOOTING (CONT:) Problem Possible Cause Corrective Action Takes too long to heat pool or Under-sized heater ......... Calculate heating capacity of heater Htr. output (BTUH) Pool gallonage x 8.33 or refer to heater sizing chart This does not take into account heat loss due to weather Filter not running long enough ....
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Page 42: Millivolt - Flow Chart
PRELIMINARY 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 43: Digital - Flow Chart
PRELIMINARY 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 44: Control Logic - Flow Chart - Digital
PRELIMINARY 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 45: Replacement Parts
PRELIMINARY 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 46: Illustrated Parts List
PRELIMINARY 13. ILLUSTRATED PARTS LIST 3 -V I - S 14 - M I 3 -S 4- V 1 - V 2 - S 2- V 6 -H P 5 -H P 7 -H P 15- HP 2 - H P 3 - HP 7 - H P 6 -H P... - Page 47 PRELIMINARY 8-HP 8-HP 6-HM 21-M 27-HM 5-HM 26-HM 2-HM 7-HM INLET 3-HM 4-HM 28-HM OUTLET 18-HP 17-HP 20-HP FOR UNITS WITH ASME BRONZE HEADERS FROM 12/2019 (PROTEK SHIELD AVAILABLE ON ASME HEATERS AFTER END OF Q3 2020) ( O P T I O N A L ) 14-HM 16-HM 13-HM...
- Page 48 PRELIMINARY 19-HP 19-HP (OPTIONAL) (OPTIONAL) 19-HP 11-HP 11-HP 8-HP 16-HP 12-HP 18-HP 8-HP 10-HP 10-HP 18-HP 16-HP 12-HP 2-HP 13-HP 2-HP 15-HP INLET OUTLET 13-HP 14-HP 17-HP 14-HP 17-HP 20-HP PROTEK ADPTER AND POLYMER UNITS PRIOR TO 10/2019 F OR UN ITS W ITH P O LYMER H EADERS F ROM 10/2 0 19 HONEYWELL IID ATMOSPHERIC PILOT HONEYWELL MILLIVOLT PILOT 19-M...
- Page 49 PRELIMINARY CALL OUT DESCRIPTION BURNER TRAY - SPECIFY ELEVATION* 206A 266/266A 336A 399/406A Polymer Cu HX, or Burner Tray w/Burners Nat (sea level)* 010391F 010392F 010393F 010394F ASME HX (Cu or Cupro) Burner Tray w/Gas Valve Nat Millivolt (sea level)*...
- Page 50 PRELIMINARY CALL OUT DESCRIPTION 206A 266/266A 336A 399/406A HEAT EXCHANGER - METAL (ASME-CERTIFIED, FOR COMMERCIAL USE) 1-HM Heat Exchanger Assy.Copper ASME Units manufactured from 12/2019 (Bronze) 017983F 017984F 017985F 017986F Units manufactured prior to 12/2019 (Cast Iron) 010051F 016193F 010053F 010054F Heat Exchanger Assy.Cupronickel ASME...
- Page 51 PRELIMINARY CALL OUT DESCRIPTION 206A 266/266A 336A 399/406A PILOT Pilot Nat. MV 600525B 600525B 600525B 600525B Pilot Pro. MV 600575B 600575B 600575B 600575B Pilot Orifice Nat. MV 003901F 003901F 003901F 003901F Pilot Orifice Pro. MV 003902F 003902F 003902F 003902F Pilot Generator MV...
- Page 52 PRELIMINARY NOTES Raypak, Inc. 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 www.raypak.com UNCONTROLLED DOCUMENT IF PRINTED...