Raypak 406A User Manual (English)

Other manuals for Raypak 406A

Installation And Operation Manual52 pages

Questions and Answers:

O
ogarciaAug 22, 2025
Why is my Raypak 406A Gas Heater turning on and off repeatedly?
- R
  Rachel DawsonAug 22, 2025
  If your Raypak Gas Heater is going on and off continuously, the issue could stem from a few different causes. The filter might be dirty, requiring a cleaning or replacement. The water level in your pool might be too low, so try raising it. The external bypass setting may be out of adjustment, requiring an adjustment. Lastly, the pressure switch could be out of adjustment, and you should adjust it.
M
Meredith SchmidtAug 25, 2025
Why does my Raypak 406A Gas Heater have a yellow lazy flame?
- R
  ruth82Aug 25, 2025
  If your Raypak Gas Heater is producing a yellow, lazy flame, it could be due to low gas pressure, in which case you should adjust the gas pressure. Another potential cause is insects or debris clogging the burner intake ports; if this is the case, clean the burners.
L
Leslie SolomonAug 25, 2025
What to do if the combustion fan is not running on my Raypak 406A Gas Heater?
- J
  jacksonjohnAug 26, 2025
  If the combustion fan in your Raypak Gas Heater is not running, it could be due to several reasons. The fan relay might be faulty, so replace it. There might be a loose connection or a failed motor in the fan itself. A burned motor due to incorrect wiring could also be the cause, so replace the blower. Finally, the air pressure switch might need replacement.
A
Angela FryeAug 26, 2025
What to do if my Raypak 406A Gas Heater takes too long to heat pool or spa?
- A
  Amanda ThomasAug 27, 2025
  If your Raypak Gas Heater is taking too long to heat your pool or spa, consider these potential causes: * The heater might be undersized. Calculate the heating capacity of the heater using the formula: Heater output (BTUH) = Pool gallonage x 8.33, or refer to the heater sizing chart. * The filter might not be running long enough; reset the time clock. * The filter could be dirty; clean the filter. * The gas line or meter may be undersized; refer to the installation instructions.
E
Erin BarnettAug 27, 2025
What to do if Raypak 406A combustion fan is not running?
- R
  Ronald BarrAug 27, 2025
  If the combustion fan in your Raypak Gas Heater isn't running, it could be due to a few reasons. The fan relay might be faulty, requiring replacement. There could be a loose connection or a failed motor in the fan itself. A burned motor due to incorrect wiring could also be the cause, necessitating blower replacement. Finally, the air pressure switch might need replacing.
M
Michael WalkerAug 28, 2025
Why does my Raypak 406A take so long to heat my pool or spa?
- E
  Emma EatonAug 28, 2025
  If your Raypak Gas Heater takes too long to heat your pool or spa, several factors could be at play. It may be that the heater is undersized. You can calculate the heating capacity of your heater using the formula: Heater output (BTUH) / (Pool gallonage x 8.33), or refer to the heater sizing chart. Remember that this calculation doesn't account for heat loss due to weather. The filter may not be running long enough, so try resetting the time clock. A dirty filter could also be the culprit, so try cleaning it. Finally, the gas line or meter might be undersized.
U
umatthewsAug 30, 2025
What causes sooting in my Raypak Gas Heater?
- F
  fgarzaAug 30, 2025
  If your Raypak Gas Heater is sooting, it could be due to several reasons. High flow rates might be the cause; reduce them by adding a manual bypass valve and adjust it until the heater outlet water temperature is between 105°F and 110°F. The U.G. might be inoperative; check its movement by putting it in hot water (110°F or higher), and replace it if there's no movement. Air starvation could be the issue. Improper venting could also cause sooting. Insects or debris clogging the burner intake ports can also lead to sooting; clean the burners in this case.
D
Dana PopeAug 31, 2025
What to do if the outer jacket of my Raypak 406A is very hot and the paint is blistered?
- M
  meganduranAug 31, 2025
  If the outer jacket of your Raypak Gas Heater is very hot and the paint is blistered, it could be due to a broken refractory caused by shipping damage or improper combustion, in which case you should replace the refractory panels. Another cause could be excessive sooting of the heat exchanger; determine the cause of sooting and correct it.
G
Greg StephensSep 1, 2025
What causes a pilot outage or weak flame signal in my Raypak 406A Gas Heater?
- K
  Katelyn JonesSep 1, 2025
  If you're experiencing a pilot outage or a weak flame signal in your Raypak Gas Heater, it could be due to low gas pressure, so adjust the gas pressure. It could also be due to a restricted or dirty pilot, so clean the pilot and/or electrode. Alternatively, the pilot generator might be weak, in which case you should replace the pilot.
R
Roger ShafferSep 2, 2025
How to fix harmonics or whining noise coming from my Raypak Gas Heater?
- C
  Christopher CoxSep 3, 2025
  If your Raypak Gas Heater is producing harmonics or a whining noise, it could be due to several reasons. The U.G. might be inoperative; check its movement by putting it in hot water (110°F or higher), and replace it if there's no movement. There might be debris or a restriction in the system; locate the restriction and remove it, then flush and clean the system. Debris in the gas line could also be the cause; remove the debris or blow out the gas line. Low flow could also be the problem; scale may be forming in the heat exchanger, so clean the heat exchanger and check the pool's pH and total alkalinity.

Raypak 406A Specifications

General

Model	406A
Category	Gas Heater
BTU Input	400, 000 BTU/hr
Fuel Type	Natural Gas or Propane
Ignition	Electronic
Maximum Water Flow Rate (GPM)	120 GPM
Vent Diameter	6"
Water Connections	2"

Summary

Water Chemistry Guide

Recommended Water Levels

Recommended levels for pool and spa water balance.

Owner's Operating Instructions

Start-Up Procedures Overview

General steps and initial checks before operating the heater.

Before Start-Up Checks

Essential pre-operation checks for burners and water flow.

Millivolt System Operation

Millivolt Lighting Instructions

Step-by-step guide for lighting the pilot on millivolt systems.

Millivolt Shut-Off Procedure

Steps to safely shut down the millivolt system.

Electronic Ignition System Operation

Electronic Ignition Lighting Instructions

Guide for operating heaters with automatic pilot ignition.

Electronic Ignition Shut-Off Procedure

Steps to safely shut down electronic ignition systems.

Post Start-Up Checks and Safety

After Start-Up Checks

Verifying correct operation and temperature after initial start-up.

Visual Inspection of Flames

Checking pilot and main burner flame patterns for proper combustion.

Water Pressure Switch Function

Verifying the water pressure switch operation for safety.

Elevated Water Temperature Hazards

Guidelines on safe water temperatures and related risks.

Maintenance and Care Procedures

Pool and Spa Water Chemistry Management

Maintaining proper water chemistry to protect the heater.

Automatic Chemical Feeder Operation

Proper use of automatic chlorinators and chemical feeders with the heater.

Cold Weather and Winterization

Cold Weather Operation Guidelines

Procedures and precautions for operating the heater in cold weather.

Pool and Spa Heater Winterization

Steps to properly shut down and prepare the heater for winter.

Receiving Equipment for Installation

General Specifications and Installation Requirements

General Heater Specifications

Technical details and ratings of the heater models.

Installation Code Compliance

Requirements for local codes, National Fuel Gas Code, and NEC.

Installation Clearances and Outdoor Setup

Clearances from Combustible Construction

Minimum required clearances around the heater from flammable materials.

Outdoor Heater Installation Guidelines

Specific considerations and warnings for outdoor heater placement.

Venting and Placement Requirements

Flue Product Exit Clearances

Minimum distances for flue gas outlets from building openings.

Florida Building Code Compliance

Specific requirements for installations in Florida, including tie-downs.

Florida Building Code Anchoring

Indoor Installation and Venting Kits

Indoor Heater Venting Requirements

Necessary drafthood and proper venting for indoor installations.

Outdoor and Indoor Stack Kit Contents

Components included in the optional outdoor and indoor stack kits.

Atmospheric Unit Specifications and Dimensions

Dimensional Drawings and Ratings

Visual representation of dimensions and key performance ratings.

Lo NOx Unit Specifications and Dimensions

Lo NOx Dimensional Drawings and Ratings

Visual representation of Lo NOx dimensions and key performance ratings.

Combustion and Ventilation Air Requirements

Air Supply Opening Requirements

Minimum net free area for combustion and ventilation air openings.

Power Vent Kit Information

Details and part numbers for the optional D-2 power vent kit.

Gas Supply and Venting Connections

Vent Discharge and Pipe Requirements

Guidelines for vent discharge location, height, and pipe type.

Gas Supply Piping and Pressure

Requirements for gas piping connections, sediment traps, and supply pressures.

Gas Pressure Adjustment and Pipe Sizing

Gas Pressure Regulator Adjustment

Procedures for adjusting gas pressure regulators on various gas valves.

Gas Line Sizing Chart

Table for determining appropriate pipe size based on BTU input and gas type.

Flow Rates and Pressure Drop

Minimum and Maximum Flow Rates

Required flow rates for different heater models and bypass valve use.

Heat Exchanger Pressure Drop Data

Tables showing pressure drop across heat exchangers for various flow rates.

Header Types and Governor Operation

Polymer and Cast Iron Header Connections

Details on connecting pipes to polymer and cast iron headers.

Unitherm Governor Function and Replacement

Operation and replacement procedure for the Unitherm Governor.

Bypass Valves and Pressure Relief

Bypass Valve Systems and Adjustment

Explanation and adjustment of internal and external bypass valves.

Pressure Relief Valve Installation

Guidelines for installing the pressure relief valve for safety compliance.

Plumbing Water Connections

Single Pool Heater Plumbing Diagram

Diagram showing recommended plumbing for a single pool heater setup.

Multiple Pool Heater Plumbing Diagram

Diagram illustrating plumbing for multiple pool heaters.

Heat Exchanger Reversal Procedure

Electrical Wiring Guide

Millivolt Model Wiring

Wiring requirements for millivolt system heaters.

Digital and AFT Model Wiring

Wiring instructions for digital and AFT controlled heaters.

Transformer Wiring Configurations

120 VAC Transformer Wiring

How to connect the transformer for 120 VAC operation.

240 VAC Transformer Wiring

How to connect the transformer for 240 VAC operation.

Millivolt Wiring Diagram

Digital Atmospheric Wiring Diagram

Digital Lo NOx Wiring Diagram

Servicing Instructions Overview

General Location of Controls

Diagrams identifying the location of key controls on the heater.

Control Panel and Adjustments

Control Panel Removal Procedure

Steps to remove the control panel for servicing or access.

Millivolt Model Control Adjustments

How to adjust the thermostat set point on millivolt models.

Digital/AFT Model Control Adjustments

How to adjust settings using the digital and AFT control interfaces.

Digital Thermostat Operation

Digital Board Thermostat Function

How the microprocessor-controlled thermostat manages pool/spa temperature.

Accessing Fault History File

Procedure to view stored fault codes and service information.

Digital Control Programming and Defaults

Program Button Functions

Using the program button for settings like defaults, F/C, and set points.

Resetting Factory Defaults

Restoring the heater control to its original factory settings.

Diagnostic Codes and Fault Reading

Status and Diagnostic Codes

List of status codes and their meanings for heater operation.

Reading and Interpreting Fault Codes

How to interpret fault codes displayed on the control panel.

Remote Control Operation

Installing and Activating Remote Controls

Steps for connecting and enabling remote control functionality.

Remote Control Operating Modes

Understanding how the heater operates when controlled remotely.

AFT Thermostat Operation and Diagnostics

AFT Board Thermostat Functions

How the AFT thermostat controls pool/spa temperature and displays status.

Service Menu and Fault History Access

Accessing service menus, flame strength, supply voltage, and run time data.

AFT Control Programming and Fault Reset

Viewing and Clearing Fault History

How to view fault logs and clear them from the AFT control.

Configuring AFT Control Settings

Adjusting temperature scales, set points, and factory defaults.

Heater Status and Fault Codes

Heat Status Messages

Understanding messages like Heating, Spark, No Demand during operation.

Detailed Fault Code Definitions

Comprehensive list of fault codes and their causes for troubleshooting.

AFT Remote Control Operation

Installing and Activating AFT Remotes

Steps for connecting and enabling remote control for AFT models.

AFT Remote Control Display and Modes

Understanding remote operation displays and modes on AFT heaters.

Remote Control Wiring

Remote Wiring Installation Notes

Important notes on running and shielding remote control wiring.

2-Wire and 3-Wire Remote Connections

Specific wiring instructions for 2-wire and 3-wire remote systems.

Safety and Control Switches

Time Clock and Fireman's Switch Connection

How to connect external switches for heater control.

Water Pressure Switch Adjustment

Procedure for adjusting the water pressure switch for proper operation.

Flame Roll-Out and High Limit Switches

Function and location of flame roll-out and high limit safety switches.

Component Removal and Pilot Safety

High Limit Switch Removal

Steps to remove and replace high limit switches for safety.

Pilot Safety Mechanisms

Explanation of pilot safety devices for millivolt and digital/AFT models.

Burner Tray and Gas Valve Removal

Procedures for removing burner trays and gas valves on atmospheric units.

Main Burner and Pilot Removal

Steps for removing and cleaning main burners and pilot assemblies.

Heat Exchanger and Tube Maintenance

Heat Exchanger Removal and Cleaning

Steps for removing, cleaning, and desooting the heat exchanger.

Immersion Well Replacement

Procedure for replacing the immersion well in the header.

Lo NOx Heater Operation and Servicing

Unitherm Governor Replacement

Procedure for replacing the Unitherm Governor (U.G.) unit.

Lo NOx Heater Start-Up and Operation

Steps for starting up and operating Lo NOx pool heaters.

Lo NOx Blower Adjustment and Visual Checks

Adjusting the blower and performing visual inspections on Lo NOx heaters.

Lo NOx Component Removal

Lo NOx Main Burner and Orifice Removal

Steps for removing and cleaning main burners and orifices on Lo NOx models.

Lo NOx Burner Tray and Gas Valve Removal

Procedures for removing the burner tray and gas valve on Lo NOx heaters.

Lo NOx Pilot and Blower Removal

Steps for removing pilot assemblies and combustion blowers on Lo NOx models.

Troubleshooting Mechanical Issues

Heater Operation and Flow Problems

Diagnosing and resolving issues like continuous cycling, no flow, or water leaks.

Combustion and Flame Issues

Troubleshooting sooting, pilot outages, weak flames, and yellow flames.

Leaking and Fan Issues

Addressing leaks, fan problems, and combustion fan not running issues.

Millivolt Electrical Troubleshooting

Millivolt Gas Valve Electrical Checks

Procedures for checking electrical components of millivolt gas valves.

Millivolt Wiring Diagram Key

Explanation of wire colors and terminal functions in millivolt wiring.

Electronic Ignition Troubleshooting Flowchart

Digital/AFT Control Logic and Diagnostics

Digital/AFT Control Logic Flowchart

Visual flowchart for understanding the control board's operating logic.

Diagnostic Readouts and Error Identification

Interpreting diagnostic messages, sensor failures, and error codes.

Replacement Parts Information

Atmospheric Heaters - Parts Diagram

Lo NOx Heaters - Parts Diagram

Pilot Assemblies and Header Components

Polymer Header Components

Diagrams of polymer header parts and accessories.

Various Pilot Assembly Diagrams

Visuals of Honeywell IID Atmospheric, Millivolt, and Lo NOx pilot assemblies.

Atmospheric Heater Replacement Parts List

Atmospheric Heater Component Parts

Atmospheric Heater Sheetmetal and Vent Parts

Lo NOx Heater Replacement Parts List

Lo NOx Heater Component Parts

Related product manuals

Raypak Residential Series

32 pages

Raypak 406A User Manual

Table of Contents

Other manuals for Raypak 406A

Questions and Answers:

Raypak 406A Specifications

Summary

Water Chemistry Guide

Recommended Water Levels

Owner's Operating Instructions

Start-Up Procedures Overview

Before Start-Up Checks

Millivolt System Operation

Millivolt Lighting Instructions

Millivolt Shut-Off Procedure

Electronic Ignition System Operation

Electronic Ignition Lighting Instructions

Electronic Ignition Shut-Off Procedure

Post Start-Up Checks and Safety

After Start-Up Checks

Visual Inspection of Flames

Water Pressure Switch Function

Elevated Water Temperature Hazards

Maintenance and Care Procedures

Pool and Spa Water Chemistry Management

Automatic Chemical Feeder Operation

Cold Weather and Winterization

Cold Weather Operation Guidelines

Pool and Spa Heater Winterization

Receiving Equipment for Installation

General Specifications and Installation Requirements

General Heater Specifications

Installation Code Compliance

Installation Clearances and Outdoor Setup

Clearances from Combustible Construction

Outdoor Heater Installation Guidelines

Venting and Placement Requirements

Flue Product Exit Clearances

Florida Building Code Compliance

Florida Building Code Anchoring

Indoor Installation and Venting Kits

Indoor Heater Venting Requirements

Outdoor and Indoor Stack Kit Contents

Atmospheric Unit Specifications and Dimensions

Dimensional Drawings and Ratings

Lo NOx Unit Specifications and Dimensions

Lo NOx Dimensional Drawings and Ratings

Combustion and Ventilation Air Requirements

Air Supply Opening Requirements

Power Vent Kit Information

Gas Supply and Venting Connections

Vent Discharge and Pipe Requirements

Gas Supply Piping and Pressure

Gas Pressure Adjustment and Pipe Sizing

Gas Pressure Regulator Adjustment

Gas Line Sizing Chart

Flow Rates and Pressure Drop

Minimum and Maximum Flow Rates

Heat Exchanger Pressure Drop Data

Header Types and Governor Operation

Polymer and Cast Iron Header Connections

Unitherm Governor Function and Replacement

Bypass Valves and Pressure Relief

Bypass Valve Systems and Adjustment

Pressure Relief Valve Installation

Plumbing Water Connections

Single Pool Heater Plumbing Diagram

Multiple Pool Heater Plumbing Diagram

Heat Exchanger Reversal Procedure

Electrical Wiring Guide

Millivolt Model Wiring

Digital and AFT Model Wiring

Transformer Wiring Configurations

120 VAC Transformer Wiring

240 VAC Transformer Wiring

Millivolt Wiring Diagram

Digital Atmospheric Wiring Diagram

Digital Lo NOx Wiring Diagram

Servicing Instructions Overview

General Location of Controls

Control Panel and Adjustments