Rheem Raypak 408A - User Manual

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Gas-Fired Pool

and Spa Heater

E󰀨ective: 06-10-22

Replaces: 03-11-22

P/N 241452 Rev. 14

HLW

INSTALLATION AND

OPERATION MANUAL

Atmospheric Models

268A and 408A

This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future

reference.

WARNING: If the information in the instructions is not followed exactly, a re or explosion may result

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 CAN BE VIEWED ELECTRONICALLY

USING YOUR SMART DEVICE. SEE PAGE 46 FOR QR

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This document is an installation and operation manual for the Raypak Professional Gas-Fired Pool and Spa Heater, specifically for Atmospheric Models 268A and 408A. It provides comprehensive information for qualified installers, service agencies, and gas suppliers, emphasizing safety, proper installation, and maintenance procedures.

Function Description:

The Raypak Professional Gas-Fired Pool and Spa Heater is designed to heat pool and spa water. It utilizes an atmospheric gas combustion system to transfer heat to the water circulating through its heat exchanger. The heater is design-certified for both indoor and outdoor installations, requiring specific venting configurations for each. It features an electronic intermittent ignition device that automatically lights the pilot and main burners upon a call-for-heat. The control panel allows users to select between POOL or SPA operation and adjust the setpoint temperature, with an LCD display showing the mode and actual water temperature. Remote control operation is also supported. The heater incorporates several safety features, including high limit switches, a water flow switch, and a flame roll-out safety switch, to ensure safe and reliable operation.

Important Technical Specifications:

Models: 268A and 408A (Atmospheric)
Heat Exchanger: ASME-certified with bronze headers and cupronickel tubes.
Electrical Power: Factory-wired for 240 VAC, 1 Ph, 60 Hz. Can be field-rewired for 120 VAC.
- 120 VAC: 4 Amps
- 240 VAC: 2 Amps
Gas Supply Pressure (under load and no-load conditions):
- Natural Gas: Minimum 6" WC, Maximum 10.5" WC
- Propane Gas: Minimum 12" WC, Maximum 13" WC
Gas Pressure Regulator Preset:
- Natural Gas: 4.0" WC
- Propane Gas: 10.5" WC
Flow Rates:
- Model 268A: Minimum 25 GPM (95 lpm), Maximum 100 GPM (378 lpm)
- Model 408A: Minimum 40 GPM (151 lpm), Maximum 100 GPM (378 lpm)
Rated Input (BTUH):
- Model 268A: 266,000 BTUH (77.9 kwh)
- Model 408A: 399,000 BTUH (116.9 kwh)
Elevation: Rated inputs suitable for up to 2,000 ft (610 m). For elevations above 2,000 ft, input reduces 4% for each 1,000 ft (305 m).
Ambient Temperature Rating (Electronic Ignition Heater): -32°F to 175°F (-35°C to 79°C).
Vent Pipe Requirements (Indoor): CATEGORY I (or better) vent per National Fuel Gas Code. Type "B" double-wall or equivalent vent pipe recommended. Draft of -0.01" to -0.08" WC must be maintained.
D-2 Power Vent Kit: Optional for horizontal runs, operates as a CATEGORY III appliance.
Minimum Clearances from Combustible Surfaces:
- Indoor: Top (drafthood) 30", Front (alcove open) 0", Vent 6", Floor 0", Back 6", Right Side (water side) 12", Left Side (opposite water side) 6".
- Outdoor: Top (unobstructed) 0", Top (stackless top) 36", Floor 0", Back 6", Right Side (water side) 12", Left Side (opposite water side) 6".
Water Chemistry Requirements (Table A):
- Water Temperature: 68-104°F (20-40°C)
- pH: 7.3-7.8
- Total Alkalinity: 80-150 ppm
- Calcium Hardness: 150-400 ppm
- Salt: 4500 Maximum ppm
- Free Chlorine: 2-3 ppm (MUST NOT EXCEED 5 ppm)
- Total Dissolved Solids: 3000 Maximum ppm (6000 ppm for saltwater chlorinated pools)

Usage Features:

Control Panel: Touch-pad located on the upper front panel for selecting POOL or SPA mode and adjusting setpoint temperature. LCD display shows mode and actual water temperature. Manual power switch to turn control power ON/OFF.
Temperature Adjustment: UP/DOWN buttons to adjust desired setpoint temperature. Default range 50-104°F (10-40°C), adjustable up to 107°F (42°C) for both pool and spa.
Remote Control: Heaters are remote-ready, allowing external controls to manage operation. Activation involves pressing and holding UP and DOWN arrow buttons for 3-5 seconds. Keypad mode and temp buttons are disabled in remote operation. Supports 2-wire (on-off) and 3-wire (pool-off-spa) remote systems.
Diagnostics: Displays various status and diagnostic messages on the LCD, including "Heating," "Spark," "No Demand," "Sensor Failure," "Hi Limit Open," "Ignition Lockout," and "Ignition Failure."
Fault History: Stores up to ten faults in memory, accessible via the Service Menu.
Control Lockout: Feature to prevent unauthorized tampering, activated by pressing DOWN and MODE buttons for 5 seconds and setting a three-digit PIN.
Fahrenheit/Celsius Selection: Option to change temperature display scale.
Unitherm Governor: Patented thermostatic mixing valve designed to maintain constant internal heater temperature (105-115°F / 41-46°C) to prevent condensation and inhibit scale formation.
Internal Automatic Bypass Valve: Responds to changes in water pressure to maintain proper flow through the heater.
External Auxiliary Bypass Valve: Recommended for flow rates exceeding 100 GPM (378 lpm) to complement the internal bypass and reduce pressure drop.

Maintenance Features:

Regular Inspections: Recommended one month after start-up and then semi-annually. Includes checking for soot, cleaning burners and pilot, inspecting controls, gas valve, and pressure relief valve.
Water Chemistry: Maintaining balanced water chemistry according to Table A is crucial to prevent damage to the heat exchanger. Chemical imbalance is not covered by warranty.
ProTek Shield Assembly: Provides protection against galvanic corrosion. Should be replaced when its weight is reduced to about 40% of its original weight. Removal and reinstallation instructions provided.
Tube Cleaning: Regular inspection and cleaning of heat exchanger tubes to prevent clogging. Instructions for reaming and descaling provided.
Desooting Procedure: If soot is present, a detailed procedure for removing top and flue collector, baffles, burner tray, and heat exchanger for cleaning.
Burner Tray Removal: Steps for disconnecting gas line, wires, and sliding out the burner tray for cleaning or replacement.
Pilot Removal and Cleaning: Instructions for disconnecting pilot tubing and wires, removing the pilot assembly, and cleaning the pilot orifice.
Heat Exchanger Removal: Detailed steps for draining water, disconnecting piping, and removing the heat exchanger for service or replacement.
High Limit Removal: Procedure for replacing defective high limit switches.
Winterizing: For heaters in freezing climate areas, instructions for shutting down, draining water, and disconnecting unions to prevent freeze-ups. Continuous pump operation is a must in moderate cold.
Replacement Parts: A comprehensive illustrated parts list is provided, with part numbers for various components. It is important to provide the heater model number, serial number, and gas type when ordering parts.
QR Codes: Provided for easy access to the most current version of the installation manual and the D-2 Power Vent Manual via smart devices.