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Raypak 408 User Manual

Raypak 408
40 pages
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Gas-Fired Pool
and Spa Heater
Catalog No. 6000.64B Eective: 07-15-18 Replaces: 11-15-17 P/N 241452 Rev. 3
TM
INSTALLATION AND
OPERATION MANUAL
Atmospheric Models 268 and 408
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
AA
WARNING: If these instructions are not followed exactly, a re or explosion may result causing property
damage, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other com-
bustible 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.
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Raypak 408 Specifications

General IconGeneral
Fuel TypeNatural Gas or Propane
Ignition TypeElectronic
Water Connections2" NPT
TypePool Heater
Heat Exchanger MaterialCupro Nickel
Efficiency82%

Summary

Warnings and Safety Information

Attention to Safety Terms

Defines safety terms like DANGER, WARNING, CAUTION, and NOTE used throughout the manual.

Water Chemistry Guidelines

Automatic Chlorinators and Chemical Feeders

Discusses the proper use of chemical feeders and chlorinators to prevent damage to the heater.

Operating Instructions and Procedures

Start-Up Procedures

Outlines the essential steps for safely starting up the pool/spa heater.

Before Start-Up Checks

Details pre-operation checks, including burner and water flow, before attempting to start the heater.

Visual Inspection of Flames

Describes how to visually inspect the pilot and burner flames for correct operation.

Operational Cautions

Provides important safety cautions regarding water temperature and user health risks.

Routine Maintenance Schedule

Provides a schedule and steps for routine maintenance of the heater.

Cold Weather Operation Guidance

Offers guidance on operating the heater in cold climates and preventing freeze-ups.

Pre-Installation Requirements

Receiving and Inspecting Equipment

Details how to receive and inspect the heater and its components upon delivery.

Heater Rating and Certifications

Lists the design certifications and standards the heater meets.

Component Ambient Temperature Ratings

Specifies the operating temperature range for the heater's components.

Atmospheric Heater Input Ratings

Provides input ratings and elevation derating information for atmospheric models.

Installation Guidelines

Adherence to Installation Codes

Outlines the required local and national codes for heater installation.

Clearances from Combustible Surfaces

Specifies minimum clearances from combustible surfaces for safe heater installation.

Outdoor Heater Installation Requirements

Covers specific requirements for installing the heater outdoors.

Pagoda Top Installation Instructions

Provides instructions for installing the optional pagoda top.

Indoor Heater Installation Requirements

Details the requirements for installing the heater indoors.

Outdoor and Indoor Stack Kit Usage

Explains the use and installation of optional outdoor and indoor stack kits.

Combustion and Ventilation Air Needs

Details the requirements for providing adequate air for combustion and ventilation.

Florida and Texas Building Code Compliance

Specific installation guidelines for Florida and Texas based on wind speed and exposure.

Vent Piping and Categories

Appliance Venting Categories

Classifies heaters based on vent pressure and condensate production.

Gas Supply Connection Requirements

Outlines requirements for connecting the gas supply to the heater.

Gas Supply Pressure Specifications

Specifies minimum and maximum supply pressure requirements for natural and propane gas.

Gas Pressure Regulator Function and Adjustment

Explains the function and adjustment of the gas pressure regulator.

Gas Pressure Adjustment Locations by Model

Shows where to find gas pressure adjustment controls on specific models.

Gas Connection Pipe Sizing Guide

Provides guidelines for selecting the correct pipe size for gas connections based on input and length.

Water Connections and Flow Management

Water Connection Installation Steps

Details how to install the water connections to the heater.

Unitherm Governor Operation Explained

Describes the function of the Unitherm Governor in maintaining internal temperature.

Internal Automatic Bypass Valve Function

Explains the role of the internal bypass valve in managing water flow.

External Auxiliary Bypass Valve Usage

Details when and how to use an external auxiliary bypass valve.

Auxiliary Bypass Valve Adjustment Guide

Provides instructions for adjusting the auxiliary bypass valve.

Pressure Relief Valve Installation

Covers the installation requirements for a pressure relief valve.

General Plumbing Recommendations

General plumbing guidelines for connecting the heater.

Electrical Wiring and Power

Electrical Power Draw Information

Information on the power consumption of the heater.

Transformer Wiring Configurations

Details on wiring the transformer for different voltage inputs.

Wiring Diagram

Heater Controls and Operation

Control Panel Removal Instructions

Instructions for safely removing the control panel for access.

Control Panel Adjustments and Settings

How to adjust temperature settings and select modes using the control panel.

Heater Operation Modes and Displays

Explains how the heater operates and displays status messages.

Service Menu and Fault History Access

Accessing diagnostic information and troubleshooting codes.

Program Button Functions

Instructions for using the program button to set factory defaults or other parameters.

Status and Diagnostic Messages Overview

Overview of status messages and diagnostic readouts displayed by the heater.

Programmable Operations and Settings

Details on setting factory defaults, clearing faults, and changing units or setpoints.

Control Lockout Feature

How to enable and use the control lockout feature to prevent unauthorized changes.

Remote Control Installation and Operation

Guidelines for installing and operating external remote control systems.

Remote Operation of the Heater

How the heater behaves when controlled by a remote system.

Activating and Deactivating Remote Control

Steps to enable or disable the remote control function.

Remote Control Wiring Procedures

Detailed instructions for wiring remote control systems.

2-Wire Remote Control Wiring

Specific wiring for a two-wire remote control setup.

3-Wire Remote Control Wiring

Wiring instructions for a three-wire remote control system.

Time Clock and Fireman's Switch Connections

How to connect and use a time clock or fireman's switch.

Water Flow Switch Functionality

Importance and installation of the water flow switch for safe operation.

Flame Roll-Out Safety Switch

Information on the flame roll-out safety switch and its function.

High Limit Switch Details

Details the two automatic high limit switches and their settings.

Pilot Safety Device Function

Explains the function of the pilot safety device.

Burner Tray Removal Procedure

Step-by-step guide to removing the burner tray for maintenance.

Pilot Removal and Cleaning

Instructions for removing and cleaning the pilot assembly.

Heat Exchanger Removal Process

Procedures for safely removing the heat exchanger.

Heat Exchanger Tube Cleaning

How to clean the heat exchanger tubes based on water conditions.

Desooting Procedure for Heat Exchanger

Steps to remove soot buildup from the heat exchanger fins.

Combustion Chamber Removal

Steps to remove the combustion chamber after heat exchanger removal.

Immersion Well Replacement Guide

Guide for replacing the immersion well in the header.

Unitherm Governor Replacement

Instructions for replacing the Unitherm Governor unit.

Replacement Parts Information

Troubleshooting Mechanical Issues

Mechanical Problem Diagnosis and Correction

Lists common mechanical problems, their causes, and corrective actions.

Control Logic and Fault Flow Chart

A visual flow chart illustrating the heater's control logic and fault diagnosis.

Illustrated Parts List

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