Raypak B-R266A-EP-X Digital Asme Propane Gas Commercial Swimming Pool Heater User Guide

: June 5, 2024
: Raypak

Table of Contents

B-R266A-EP-X Digital Asme Propane Gas Commercial Swimming Pool Heater
Product Information
Specifications
Product Usage Instructions
FAQs

B-R266A-EP-X Digital Asme Propane Gas Commercial Swimming Pool Heater

Product Information

Specifications

Model: Digital Gas Heater
Recommended Water Chemistry Levels:
- Fiberglass Pools:
- Water Temp. (Deg. F): 68 to 88
- pH: 7.3 to 7.4
- Total Alkalinity (PPM): 120 to 150
- Calcium Hardness (PPM): 200 to 300
- Salt (PPM): 4500 MAXIMUM
- Free Chlorine (PPM): 2 to 3
- Total Dissolved Solids (PPM): 3000 MAXIMUM
- Fiberglass Spas: Same as Fiberglass Pools
- Other Pool & Spa Types:
- Water Temp. (Deg. F): 68 to 104
- pH: 7.6 to 7.8
- Total Alkalinity (PPM): 80 to 120
- Calcium Hardness (PPM): 200 to 400
- Salt (PPM): 4500 MAXIMUM
- Free Chlorine (PPM): 2 to 3
- Total Dissolved Solids (PPM): 3000 MAXIMUM

Product Usage Instructions

Model & Serial Number Location

The model and serial numbers can be found in the following
locations:

Inside the control panel above the digital display.
On the rating plate of the unit.
On the carton label.

Before contacting service, ensure you have the model and serial
numbers at hand.

Minimum Clearances

When installing the heater, ensure the following minimum
clearances:

Indoor:
- Above Drafthood: 30 inches (762 mm)
- Water Side: 18 inches (456 mm)
- Opposite Side: 6 inches (152 mm)
- Front (Alcove): Open
- Back: 6 inches (152 mm)
Outdoor:
- Top (Stackless): 36 inches (914 mm)
- Water Side: 18 inches (456 mm)
- Opposite Side: 6 inches (152 mm)
- Back: 6 inches (152 mm)

Flooring and Clearances

This unit can be installed on combustible flooring, but do not
install on carpet. Additionally:

Avoid installing near sprinklers.
Maintain a minimum clearance of 3 feet from a heat pump pool
heater or air conditioning condensing unit.
Check state and local codes before installation as per NFGC
guidelines.

Gas Line Sizing

The gas line sizing varies based on the model and type of gas
supply. Refer to the following table for details:

Model	Natural Gas Input (KBTU)	Propane Gas Input (KBTU)
206/207	N: 199.5, P: 25	N: 60, P: 90
266/267	N: 266.0, P: 15	N: 35, P: 50
336/337	N: 332.5, P: 10	N: 20, P: 30
406/407	N: 215, P: 360	N: 140, P: 320

FAQs

Q: What are the consequences of unbalanced water chemistry

levels?

A: Unbalanced water chemistry levels can lead to excessive
chlorine levels which can damage your heater.

Q: Can I install the unit near sprinklers?

A: No, it is advised not to install the unit near
sprinklers.

Q: How do I determine the appropriate gas line sizing for my

unit?

A: Refer to the Gas Line Sizing section in the user manual based
on your model and gas supply type.

Digital Gas Heater
Tool Box Quick Reference Guide

Water Chemistry

GENERAL

For your health and the protection of your pool equipment, it is essential that your water be chemically balanced1. The following levels must be used as a guide for balanced water.

Recommended Levels

Fiberglass Pools

Fiberglass Spas

Other Pool & Spa Types

Water Temp. (Deg. F)

68 to 88

89 to 104

68 to 104

pH

7.3 to 7.4

7.6 to 7.8

Total Alkalinity (PPM)

120 to 150

80 to 120

Calcium Hardness (PPM)

200 to 300

150 to 200

200 to 400

Salt (PPM)

4500 MAXIMUM

Free Chlorine (PPM)2

2 to 3

Total Dissolved Solids (PPM)

3000 MAXIMUM3

1 Damage from corrosive water is not covered under warranty. Consult your product manual for more information. 2 Free Chlorine MUST NOT EXCEED 5PPM.
3 In salt water chlorinated pools, the total TDS can be as high as 6000PPM.

· Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is

balanced.

· Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water, unless controlled,

they can lead to excessive chlorine level which can damage your heater.

· Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier for the

correct levels for your water.

2

· Warning: Electrolytic Corrosion and pH instability may be present with salt chlorinated pools.

Model Number and Serial Number Location

GENERAL

Model & Serial number can also be found inside the control panel above
digital display.
Model & Serial number located on rating plate.

Model & Serial number located on carton label.

Before you call Raypak service, make sure you have the MODEL NUMBER and SERIAL NUMBER.

3

Minimum Clearances

CLEARANCES

INDOOR View TOP (above Drafthood) WATER SIDE OPPOSITE SIDE FRONT (Alcove) BACK FLOOR

in. (mm) 30 (762) 18 (456) 6 (152)
Open 6 (152)
0

OUTDOOR

View

in. (mm)

TOP (Stackless)

36 (914)

WATER SIDE

18 (456)

OPPOSITE SIDE

6 (152)

BACK

6 (152)

FLOOR

0

See product manual for more information.

4

FLOORING: THIS UNIT CAN BE INSTALLED ON COMBUSTIBLE FLOORING. DO NOT INSTALL ON CARPET.

Minimum Clearances* Outdoor

CLEARANCES

DO NOT install near sprinklers.
DO NOT install within 3 feet of a heat pump pool heater or air conditioning condensing unit.
*Check state and local codes before proceeding. The minimum clearances provided are defined by NFGC (National Fuel Gas Code).

4′ (1.2 m) Minimum

3′ (0.9 m) Minimum

10′ (3 m) Minimum

Forced Air Inlet

4′ (1.2 m) Minimum
1′ (0.3 m) Minimum

5

Minimum Clearances Indoor

CLEARANCES

The heater must have both combustion air and ventilation air.
· Ventilation air opening 12″(305 mm) max from the ceiling
· Combustion air opening 12″(305 mm) max from the floor All air from outdoors, each opening shall have a net free area as shown in table.

Model 206/207 266/267 336/337 406/407

Unrestricted Opening
Sq. In. (m2)
50 (0.03)
67 (0.04)
84 (0.05)
100 (0.06)

Typical Screened or
Louvered opening Sq. In. (m2)
75 (0.05)
101 (0.06)
126 (0.08)
150 (0.1)

Typical Screened and
Louvered opening Sq. In. (m2)
100 (0.06)
134 (0.09)
168 (0.11)
200 (0.13)

8′ (2.4 m) OR LESS
2′ MIN (0.6 m)

VENT CAP 2′ MIN (0.6 m)

VENT PIPE DRAFT HOOD

5′ MIN (1.5 m)
VENTILATION AIR OPENING

HEATER

COMBUSTION AIR OPENING

6

Check state and local codes before proceeding. Some states do not recognize the NFGC and require larger openings.

Gas Line Sizing

GAS SUPPLY

Model
206/207 266/267 336/337 406/407

Maximum Equivalent Pipe Length

Natural Gas 1000 BTU/FT3 0.60 Specific Gravity @ 0.5 in. WC Pressure Drop

Propane Gas 2500 BTU/FT3 1.53 Specific Gravity @ 0.5 in. WC Pressure Drop

Input

3/4″

1″

1-1/4″

(KBTU) N

P

N

P

N

P

199.5 25 60 90 215 360

266.0 15 35 50 125 210 480

332.5 10 20 30 80 140 320

399.0

15 20 55 95 225

1-1/2″

N

P

445 290 215 480

EFFECTS OF LOW GAS PRESSURE

· Pulsating burner flame

·

· Delay Ignition/Hard light off

·

· Pilot won’t light

·

Exposure to condensation Emissions not at compliance levels Damage to Low NOx burners

7

Gas Pressure Test

GAS SUPPLY

INLET GAS PRESSURE
MANIFOLD GAS PRESSURE

6
GAS
5
VALVE
4

3

2

1

0

SLACK TUBE

1 MANOMETER

(INDICATES 8″ W.C. AS SHOWN)
2

3

4

5

6

TO BURNER MANIFOLD

Gas Unit Supply Pressure Manifold

Type

Min.

Max. Pressure

ATM

6″

10.5″

4.0″

Nat

Low NOx

5″

10.5″

3.1″

Pro

ATM

12″

13″

10.5″

· Supply pressures given are under load (dynamic)

· 1 PSI = 27.7″ Water Column

· Propane requires an external “pounds to inches regulator”

8

GAS SUPPLY

Gas Line Sediment Trap

Sediment Trap should be located as close to the inlet of the appliance as practical.

INCORRECT

GAS COCK
(WITHIN 6 FEET
OF THE HEATER)

UNION

GAS VALVE

CORRECT
PROVIDE CHANGE OF DIRECTION IN GAS FLOW

GAS COCK
(WITHIN 6 FEET OF THE HEATER)
UNION

GAS VALVE

REDUCER RISER

AS CLOSE AS PRACTICAL TO HEATER

Check state and local codes before proceeding. Some states do not recognize the NFGC.

9

Power Connections

ELECTRICAL

10

Note: Heater will not work properly if wired to a 208VAC power source.

ELECTRICAL

Circuit Board
LCD Display is removable and serviceable.
The LCD P/N is 013640F
Printed circuit board. Fully updated and backwards compatible to all digital heaters manufactured since 2004.
11

Circuit Board Ignition and Temperature Control

Safety Circuit

Hi Limit 1

Hi Limit

PRS

2

Fireman/ Clock
Roll Out Switch

SPR Vent

Gas Valve

Ground PV
MV/PV MV

Low NOx Tab and Fan Wiring
Connection (Model 207-407 only)

ELECTRICAL

5 Amp 32V Fast Acting Automotive
Fuse P/N 013733F
24 VAC Power Supply
Ground Common
Hot Pool Spa 24V Out
Remote
Connections (Optional)
12

Water Sensor

Mode Up
Down Common
Ground Ground

Propane 15 sec.
Tab

Keypad

Program Switch (re-boot button)
Propane 90 sec.
tab

ELECTRICAL

Low NOx PC Board – Tab Configuration

1a
Sp a S e t 104F LoNox Tab Fault

NOTE: If TAB is NOT broken and the board detects power at Low NOx connector, Low NOx Tab Fault is displayed and the heater will not operate.

Break Off Low NOx Tab Models 207-407 ONLY

Connect White/ Violet wire from “Low NOx” connector to air Switch

Break TAB 207-407

Don’t Break TAB 206-406

Break Low NOx TAB for model 207-407 only. Do not break

tab for atmospheric models, 206 – 406.

13

Wiring Diagram Atmospheric

24VAC HI 24VAC RET GROUND
ELECTRICAL

BK W
R

L1 FOR 115 AC VOLT
L2 OPERATION

SPG

G

GROUND

G 24 VAC

BK W

L1 FACTORY WIRED
FOR 240 VOLT

BL

POWER SWITCH

TRANS

R

L2

“PRS” PRESSURE SWITCH (IN/OUT HEADER)

Y
G 1
P6

1 P4

“HL1” HI LIMIT (IN/OUT HEADER) “HL2” HI LIMIT (INLET/OUTLET HEADER)
“ROL” ROLL-OUT SWITCH

P/PV 1

C/

MV PV

2

M/MV 3

SPG 4

R/BK Y/BK V/BK
G/BK

BURNER TRAY

TH 1 V/BK TR 2 Y/BK

D 3 Y/BK

D4

R/BK

SPG 5 G/BK

R/BK

BURNER TRAY

SPLICE HERE FOR VENT (OPTIONAL)
SPLICE HERE FOR FLOW SWITCH (OPTIONAL)
SPLICE HERE FOR FIREMAN’S SWITCH (FIELD INSTALLED OPTIONAL)

R
R RW

Y BK O Y BK O
O

GAS VALVE

HONEYWELL GAS VALVE MODEL 206-406

INVENSYS GAS VALVE MODEL 266-406

14

INVENSYS GAS VALVE MODEL 206

P2 1

FOR 120 AC VOLT
OPERATION L1 RETURN
(NEUTRAL)
GROUND
L1 FACTORY WIRED FOR 240 VOLT
L2
GROUND

BK R W
BK
W R G
BK
R
W BK W
R G

Wiring Diagram Low NOx

V/BK

AIR

HONEYWELL

SWITCH GAS VALVE

V/BK Y/BK

P/PV 1

C/

MV PV

2

M/MV 3

R/BK
Y/BK V/BK

Y/BK

AIR SWITCH

GND 4

G/BK

V/BK

W/V

P10

P4

INVENSYS GAS VALVE

V/BK

BURNER TRAY

1

TH 1 TR 2

V/BK Y/BK

“PRS” PRESSURE SWITCH (IN/OUT HEADER)

BK/W

RELAY

8

7

R

6

5

D3 D4
GND 5

Y/BK

R/BK G/BK

“HL1” HI LIMIT (IN/OUT HEADER) “HL2” HI LIMIT (IN/OUT HEADER)

R/W

BURNER TRAY

4

3

P4

SPLICE HERE FOR VENT (OPTIONAL)

2

1

4

G

3

BK

2

R

1

W

1 BLOWER

“ROL” ROLL-OUT SWITCH

OPTIONAL AUTO RESET

MANUAL RESET BK

TRANS

24 VAC

GG

POWER SWITCH

SPG

G

Y BL 1

SPLICE HERE FOR FLOW SWITCH (OPTIONAL)
SPLICE HERE FOR FIREMAN’S SWITCH (FIELD INSTALLED OPTIONAL)

R
R RW

Y BK O Y BK O
O

P6

P2

1

15

ELECTRICAL

Wiring Diagram Common Wiring

ELECTRICAL

REMOTE (OPTIONAL)
1

P8

P1

POOL BK/O

SPA

O/BK

(24VAC)

BL

G BK G

T1

FLOW SWITCH (OPTIONAL)

W/R

W/BL

W

PILOT

TEMP SENSOR

HIGH TENSION
BURNER TRAY

16

Start-Up Operating Displays

OPERATION & CONTROLS

1

2

5a

5b

Off

Po o l S e t 85F

W a t e r Te m p 69F

Wa t e r Te m p 69F

3
Re v i s i o n 1 . 01
5c
Sp a S e t 50F W a t e r Te m p 69F

4
Off W a t e r Te m p 69F
6
Po o l S e t 104F Wa t e r Te m p 69F

1. Backlit L.C.D. Display indicates power to PC Board (Microcontroller)
2. All Digits display 1 Second,
3. Software Revision Displays 1.5 Seconds
4. Normal Display Indicates Mode of Operation and Inlet Water Temperature from Pool or Spa
5. Press MODE button to Select OFF, SPA or POOL
6. Press Up and DOWN to adjust Temp Set between 50ºF (10ºC) minimum and 104ºF (40ºC) maximum

DOWN ARROW BUTTON UP ARROW BUTTON MODE BUTTON
17

Operating Displays

OPERATION & CONTROLS

Sp a S e t 104F W a t e r Te m p 69F
3
Sp a S e t 104F Heating

1
Sp a S e t 104F Spark

2a
Sp a S e t 104F W a t e r Te m p 69F

4a
Sp a S e t 104F

4b
Sp a S e t 104F

W a t e r Te m p 104F

No Demand

2b
Sp a S e t Spark

104F

1. Spark confirms Call for Heat (CFH) and all Safeties CLOSED. Power applied to Ignition Controller which produces 3 Pulses of Spark and PV (Pilot Voltage).
2. Operating Status (2b) & Water Temp (2a) alternate every two seconds.
3. Heater continues to Spark until Pilot lights, Flame Sensing occurs and voltage is supplied to main valve. Heater fires… After 1.5 seconds, spark STOPs. If flame is present after 8 more seconds, steady Heating begins.
4. When Pool/Spa SET temperature is satisfied No Demand will display.
18

Sequence of Operations

OPERATION & CONTROLS

SUPPLY (Power to Heater)
1. 120/240 VAC from circuit breaker/time clock to transformer. 2. 24 VAC out of transformer, toggle switch ON. 3. 24 VAC to PC board, fuse, interface controller. 4. LCD display ON.

APPLY 24 VAC to Ignition/Gas Control
1. Call for Heat… Pool/Spa selected, TEMP set above water temp. 2. ALL SAFETIES CLOSED (Pressure Switch , High Limit Switch 1, High Limit Switch 2, Rollout Sensor). 3. Control board initiates spark sequence. “Spark” displayed.

REPLY (Spark and 24 VAC to Gas Valve)

1. Control Board produces SPARK and PILOT VOLTAGE.

2. Pilot Valve energized, Gas supplied to PILOT, Pilot LIGHTS.

3. FLAME SENSING (Rectification) OCCURS.

4. Control Board supplies voltage to Main Gas Valve (and Low-NOx Fan Relay, if applicable). Valve ener-

gized. Heater fires. Spark stops after 1.5 seconds.

5. “Heating” Displayed with steady Heating after 8 more seconds of Flame Sensing.

19

Remote Wiring Connections and Setup

OPERATION & CONTROLS

Part Number 071494
7-Pin Remote Wire Harness

Pool Spa 24V Hot

Wire Harness Connection

A remote may be wired to provide an “On-Off” switching function (two wire) or as a three-way “Pool-Off-Spa” selector switch (three wire). Modern automation systems use a two-wire configuration and can operate the heater in either Pool or Spa mode (See wiring, page 16). Water temp will not exceed the setting on the heater, regardless of the automation set temp. To access the full range of temp settings with the remote, the heater should be set (at the control pad) to the maximum safe temperature.
20

OPERATION & CONTROLS

Remote Operation

1
Sp a S e t 104F W a t e r Te m p 69F

3
Re m o t e Wa t e r Te m p 69F

4a

4b

Re m o t e Po o l 104F

Re m o t e Sp a 104F

Wa t e r Te m p 69F

1. Pre-set Pool/Spa Set temperature (Set at 104°F if Remote has independent thermostat).

2. Turn Power OFF to heater, wire REMOTE to 7-pin/3-wire pigtail, turn Power ON.

3. Set heater mode to OFF on touch pad. Press UP and DOWN buttons simultaneously for 3 seconds until REMOTE displays on LCD. (This will ENABLE remote operation and DISABLE the touchpad.)

DOWN ARROW BUTTON

4. Remote Pool or Remote Spa Displays when remote is activated.

UP ARROW BUTTON

TEMP

MODE

MODE BUTTON
21

OPERATION & CONTROLS

Remote Error Displays

1
Sp a S e t 104F Remote Error

2

3

Ex i t Re m o t e Mo d e

Sp a S e t 104F

To Ad j u s t Te m p

W a t e r Te m p 69F

1. Remote Error – Remote is wired improperly. Orange/black (Spa) and black/orange (Pool) are connected together.
2. Remote operation has been initiated and touchpad is disabled 3. To Adjust Pool/Spa set temperature exit Remote operation. Press UP and
DOWN buttons for 3 seconds until normal display appears.
Correct ways to connect remote wiring

22

POOL

SPA

POOL/OFF/SPA

Microcontroller Self-Diagnostics

1
Sp a S e t 104F Lo w Vo l t a g e

2
Sp a S e t 104F In t e r n a l Fa u l t

3
Sp a S e t 104F EEPROM Fa u l t

OPERATION & CONTROLS

Can Be Displayed in Pool, Spa, Remote & EOL Modes
1. Low Voltage – Self Test indicates power supply from transformer is below 20 VAC. 24-28 VAC required for reliable operation! Verify correct 120/240 VAC power supply to heater. 208VAC IS NOT ACCEPTABLE.
2. Internal Fault – Self Test of Internal Communication and Processor Functions – Turn Heater off and on, replace the control if the fault doesn’t clear.
3. EEPROM Fault – Controller Memory Error. Reset Pool Set and Spa Set temperatures. Turn heater off and on. Replace control if fault re-occurs.
23

OPERATION & CONTROLS

Temperature Sensor

1
Sp a S e t 104F W a t e r Te m p 69F

3a
Sp a S e t Spark

104F

3b
Sp a S e t 104F W a t e r Te m p 69F

3c
Sp a S e t Spark

104F

1. Heat Demand is when water temperature is 1ºF (0.5ºC) or more below Pool/Spa SET Temperature
2. Temperature display accurate within 0.5ºF (0.3ºC)
3. Sensor Failure Temperature readings more than 2ºF (1ºC) different from each sensor see (3a) Sensor Open (cut wire/bad connection) see (3b) Sensor Short (bare wire touching cabinet) see (3c)

Water Sensor

Part Number 009577F

24

Sensor Connection

100,000 OHM Dual Thermistor

OPERATION & CONTROLS

Temperature Sensor Lockout

1

2

Sp a S e t 104F

Po o l S e t 50F

Low Temp Lockout

Wa t e r Te m p 50F

1. Low-Temp Lockout – Inlet Water Temperature below 36ºF (2ºC). Heater will not operate (Prolonged operation with inlet temperatures below 50ºF (10ºC) will create condensation that will damage the heater).
2. For cold weather operation, consider maintaining a preset temperature of 50ºF to 70ºF (10ºC – 21ºC), or the lowest point at which condensation does not occur. Set temperature can then be raised to the desired swim temp.
For convenience, a remote switch may be connected to allow temperature setting with a three-way switch located inside house. (See remote operation, page 21).

25

OPERATION & CONTROLS

Safety Circuit

1
Sp a S e t 104F W a t e r Sw Op e n

2

3

Sp a S e t 104F

Hi Limit 1 Fault

Hi Limit 2 Fault

R o l l O u t Sw Op e n

1. WATER PRESSURE SWITCH – verify adequate water flow and pressure (CLEAN POOL FILTER / STRAINER BASKET)
2. HIGH LIMIT SWITCHES 1 and 2 Fault – Verify adequate water flow. Adjust (close) external bypass. Check Unitherm Governor and internal bypass. Inspect for scale, restricted flow.
3. ROLLOUT SWITCH – verify gas pressure, combustion air, blocked heat exchanger, proper vent size/connections, high wind conditions.

26

Safety Circuit Components
Part numbers below apply to polymer header models. For part numbers applicable to specific models, refer to the parts list in your Instructions and Operation manual.

OPERATION & CONTROLS

Part #006715F
Bypass Assembly

Part #005899F
Atmospheric Rollout Swicth

Part #006035F
Low NOx Rollout Switch

Part #006725F

Part #006719F

Limit Switch

Unitherm Governor

27

OPERATION & CONTROLS

Safety Circuit

1

2

3

Sp a S e t 104F

Cl o c k/Fi r e m a n Sw

Ve n t/Fi e l d Sw #1

Fl o w/Fi e l d Sw #2

1. Fireman’s Switch (Time Clock) wired to CLK (red) loop on 14 pin connector, P2, is open. Connection is used in order to turn heater OFF 10-20 minutes prior to turning Pump OFF. Cool-down cycle.
2. Vent Switch (Sail Switch, Air Pressure Switch) wired to VNT (orange) loop on 14 pin connector, P2, is open Indicates Draft Inducer/Power Vent is Off or reduced Vent Pressure.
3. Flow Switch (ASME Code Kit) wired to SPR (WHITE) loop on 14 pin Connector, P2, is open Indicates Pump OFF or restricted flow to heater.

28

Ignition Sequence Natural Gas

OPERATION & CONTROLS

1a
Sp a S e t 104F I g n i t i o n Fa i l u r e

1b
Sp a S e t 104F No Pilot Sensed

(1a & 1b Displays alternate every two seconds)

1. Ignition Failure NATURAL GAS. No pilot flame detected within first 90 seconds. natural gas heaters continue to spark indefinitely or until pilot lights / flame sensing occurs. Probable cause: no gas to heater, gas valve off, obstructed pilot, bad gas valve, flame sensing fail.

2a Sp a S e t 104F 2b Sp a S e t 104F

M a i n I g n Fa i l u r e

No Pilot Sensed

(2a & 2b Display alternate every two seconds)

2. Main Ignition Failure NATURAL GAS. Pilot Initially lit but flame signal lost within 8 second trial ignition (after Main Voltage). Natural gas heaters will re-start spark sequence. Probable cause: weak/distorted pilot flame, windy conditions.

3a Sp a S e t 104F 3b Sp a S e t 104F

M a i n I g n Fa i l u r e

Ign 6min Delay

(3a & 3b Display alternate every two seconds)

3. Ignition 6min Lockout NATURAL GAS. Flame signal lost within 8 second main trial for ignition 4 times in one heat demand. Probable cause: extreme wind conditions.

29

Ignition Sequence Propane

OPERATION & CONTROLS

1a

1b

Sp a S e t 104F

Ignition Lockout

No Pilot Sensed

(1a & 1b Displays alternate every two seconds)

1. Ignition Lockout PROPANE. No pilot flame within first 15/90 seconds (which Tab is broken). The control will not attempt another ignition trial until power is cycled (24V Rocker Switch). Probable cause: empty propane tank, gas valve off, obstructed pilot, flame sensing fail.

2a Sp a S e t 104F 2b Sp a S e t 104F

Ignition Lockout

M a i n I g n Fa i l u r e

(2a & 2b Display alternate every two seconds)

2. Ignition Lockout PROPANE. Main ignition failure. Pilot initially lit but flame signal lost within 8 second trial ignition (after Main Voltage). Propane heaters will not re-start spark sequence. Probable cause: Weak/distorted pilot flame, windy conditions.
3. If flame is lost during steady heating (main valve has been powered for more than 8 seconds), main valve is shut off and pilot lighting process begins again. Natural gas or propane (15 OR 90 TAB broken).
30

OPERATION & CONTROLS

Temperature Sensor Lockout

1

2

Sp a S e t 104F Flame w/o CFH

Sp a S e t 104F PV Ou t p u t Fa u l t

or

Sp a S e t 104F MV Ou t p u t Fa u l t

1. Flame w/o CFH – Pilot flame detected with no Call for Heat. Control Remains locked out until flame is not present. Gas valve (pilot) may be stuck open.
2. PV/MV Output Fault Cause A – Power detected to Pilot Valve and/or Main Valve when not commanded. Cause B – NO Power detected to Pilot Valve and/or Main Valve with commanded. * All outputs shut off for one hour “soft” lockout.

If no power is detected after one hour, normal operation resumes.
Probable cause: 1. 24Volt power wired directly to gas valve. 2. Pilot valve or main valve relay (circuit board) failed open or closed. Replace PC board.

31

Low NOx PC Board Configuration

OPERATION & CONTROLS

1
Sp a S e t 104F Fan 5 Min Delay

2
Sp a S e t 104F Fa n Lo c k o u t

1. Low NOx Air Switch not closed within 20 seconds of supplying main voltage. Control provides 5 minute soft “lock out”, then re-starts Pilot Ignition.

Note: See page 51 for air pressure switch information.

2. If three (3) Lockouts occur in one heat demand, control goes

6

into “Hard Lockout” and power must be removed and

5

4

re-applied to reset.

3

2

1

Possible Cause:

0

1

· Air Switch Fail / Disconnected Tube

2 3

· Fan Motor Fail / Blocked Air Intake vent

4 5

· Fan Relay Fail / Incorrect Power Supply to Relay/Fan

6

Note: Fan will not run on correct speed if wired 208VAC

Activation Pressure W.C.

207 -1.50±.08

267 -1.05±.06

337 -0.75±.08

407 -0.25±.05

How to read pressure on Low NOx Fan.

Note: Pressure is negative, not positive. 32

Service Displays

OPERATION & CONTROLS

1a

1b

2

Fl a m e S t r e n g t h

Su p p l y V o l t a g e

8 Good

4 Weak

28. 2

3
Ru n Ti m e 100h Cy c l e s 134

4
Fault Last All Faults Clear

Service Displays provide critical performance data on the operation of the heater. This information can be viewed from Off, Pool, Spa and Remote Modes by holding the UP and MODE buttons simultaneously until display changes (about 3 seconds).

1. Flame (Pilot Signal) Strength. 5 Bars and above GOOD(1a). 4 Bars and below WEAK(1b). Check Gas Pressure, Pilot Flame, loose/disconnected/corroded ground wire connections.

DOWN ARROW BUTTON

2. Supply Voltage from transformer. Ideal range 24-29 VAC verify correct power supply to heater. 208VAC IS NOT ACCEPTABLE.
3. Run time is the cumulative time the main valve has been energized. Cycle count records the number of times the pilot valve has been cycled on and off.

UP ARROW BUTTON

4. The order of the faults starts with “Fault Last” which is the most recent fault. If not the most recent fault, numerical order (210) of fault is displayed with the higher digits being older faults. The second line of the display shows the fault message.

MODE BUTTON

5. To exit Service Mode and return to previous display press MODE button or wait 15

seconds.

33

Service Display EOL

OPERATION & CONTROLS

1

3a

3b

4

EOL

Off

TP 75F Set 92F

TP 75F Set 54F

W a t e r Te m p 69F

“End-Of-Line” is a test conducted by Raypak before the heater is shipped. We connect water, gas and power to every heater to ensure they are firing and functional.

1. To initiate the EOL Test press and hold the MODE button at power-up. This Initiates a self-test of the Microprocessor Control and all digits display while button is pressed.
2. Release, all break-off tab configurations, all safeties and ignition functions are checked and displayed.

DOWN ARROW BUTTON UP ARROW BUTTON

3. Set Temp of 92°F is displayed and will toggle to 54°F by pressing UP/ DOWN Button. Heater will fire if Heat Demand is present.

MODE BUTTON

4. To exit EOL test and select OFF press MODE Button.
34

Touchpad Evaluation

MODE UP
DOWN COMM
GND GND
OPERATION & CONTROLS

EOL TP 80F Set 92F

If EOL Self-Test was NOT Initiated by a service technician, display may indicate a STUCK MODE button.

Keypad

1. Disconnect blue ribbon connector, P5 from touchpad. Cycle heater on and off (power switch).

P5 Connector Pins

2. To select MODE, jump COM to MDE, each touch alternates MODE, OFF – Spa – OFF – Pool. (See pins in box lower right). If the Set Temp goes to 50°F or 104°F when not prompted, this may indicate a stuck UP or DOWN button.
· To Lower Temp Set, jump COM to DOWN. 1 touch = 1 degree

DOWN ARROW BUTTON UP ARROW BUTTON

· To Raise Temp Set, jump COM to UP. 1 touch = 1 degree
Note: Once MODE is selected and TEMP is SET heater will permanently retain programming information. If POWER is ON heater will operate even with Touchpad disconnected (unplugged).

MODE BUTTON
35

Service Display Fault History

OPERATION & CONTROLS

1

2

Faults Last

Fa u l t 2

Ignition Lockout

W a t e r Sw Op e n

3

5

Fa u l t

10

Hi Limit 1 Fault

Faults Cleared

The ability to recall the MOST RECENT Service Displays. Can be read ANY TIME heater is operational in Off, Pool, Spa and Remote modes by holding the UP and MODE buttons simultaneously until the display changes (about 3 seconds). Press UP or DOWN buttons to scroll through displays until you see Faults Last.

1. First Line displays the actual fault that occurred, followed by numerical listing in the order they occurred: Last, 2,3,4,5,6,7,8,9,10 (oldest)
2. Second line displays the fault. Press UP button to scroll through operating history of heater.
3. Helps identify chronic cycling problems that may not be evident when servicing heater.

DOWN ARROW BUTTON UP ARROW BUTTON

4. To EXIT Service Mode and return to previous display press MODE button or wait 15 seconds.

MODE BUTTON

5. To CLEAR Fault History see page 38.

36

Helps to identify chronic/repeat problems that may not be evident while servicing heater.

OPERATION & CONTROLS

Program Mode

Program Button

Allows Customizing SOFTWARE Program
1. Set Factory Defaults 2. Clear Service Faults 3. Fahrenheit/Celsius 4. Maximum Spa Set 5. Maximum Pool Set

To Initiate Programming Mode:
1. Select OFF mode of operation 2. Hold PROGRAM BUTTON for 5 seconds
until “Set Factory Defaults” appears 3. Press MODE button to select items

Se t F a c t o r y Defaults
37

OPERATION & CONTROLS

Program Mode

Select Program Item with MODE Button

1a
Clear Faults

1b
Faults Cleared

1. To CLEAR all stored faults press both UP and DOWN buttons for 5 seconds until “Faults Cleared” appears on display.

2a

Fahrenheit

2b

Ce l s i u s

2. To Select Fahrenheit or Celsius temperature display push UP or DOWN button. (Fahrenheit is the default setting).
3. To Exit Program Mode press PROGRAM BUTTON or wait 15 seconds.

38

DOWN ARROW BUTTON UP ARROW BUTTON MODE BUTTON

Program Mode Max Temperatures

OPERATION & CONTROLS

Po o l Ma x Te m p 50F

Sp a Ma x Te m p 107F

1. Displays MAXIMUM available Temp Set temperatures (Pool or Spa) and allows adjustment from 50ºF (10ºC) (lowest) up to 107°F (42ºC) (highest) by pressing UP or DOWN Buttons.

Se t F a c t o r y Defaults

D e f a u l t s Se t

2. Resets all adjustable settings back to original factory default. Press and hold UP and DOWN buttons simultaneously for 5 Seconds until Defaults Set is displayed.

DOWN ARROW BUTTON UP ARROW BUTTON

MODE BUTTON

In compliance with Consumer Products Safety Commission standards, do not set

temperature above 104ºF (40ºC) in operating mode.

39

OPERATION & CONTROLS

Control Lockout Lock Box Backdoor
Clear Faults
Lockbox override Touch any button to display “PIN.” · Enter “101” to override Lock Box until power is reset.

Clear Faults

Faults Cleared

Set factory defaults
Initiate PROGRAM MODE, Set Factory Defaults. · Press UP and DOWN BUTTON, simultaneously, for 5 seconds until
“Defaults Set” is displayed.

40

DOWN ARROW BUTTON UP ARROW BUTTON MODE BUTTON

Inlet-Outlet Header Polymer

Water Pressure Switch P/N 006737F

Bypass Assembly P/N 006715F See page 47

COMPONENTS

Temperature Sensor P/N 009577F See page 24
Pressure Relief Valve P/N 017957F
ProTek Shield Assembly P/N 017960F See page 45

High Limit 1 & 2 P/N 006725F

Balancing Baffle P/N 006826F
Dam P/N 006826F

Unitherm Governor P/N 006719F See page 44
41

COMPONENTS

Inlet-Outlet Header Bronze
Temperature Sensor P/N 009577F See page 24
T & P Gauge P/N 014647F
ProTek Shield Adapter P/N 018006F

High Limit 1 P/N 018304F
Unitherm Governor/ Bypass Assembly
P/N 017958F (206-267) P/N 017962F (336-407)
Pressure Relief Valve P/N 017957F

High Limit 2 P/N 006725F
ProTek Shield Assembly P/N 017960F See page 45
42

Inlet-Outlet Header Cast Iron

COMPONENTS

Bypass Valve P/N 016194F

Flow Switch P/N 007142F Flow Switch Paddle P/N 010026F

T & P Gauge P/N 014647F

Unitherm Governer P/N 062234B
U.G. Retainer Spring P/N 062234B U.G. Plug P/N 062234B

Auto Gas Shut-Off P/N 600892B

43

Unitherm Governor

COMPONENTS

The UNITHERM GOVERNOR helps prevent condensation and scale. It is a thermostatic mixing valve used to control and regulate the water temperature in the heat exchanger.

Low temperatures in the exchanger can cause condensation.

This indicates that the heat exchanger is running cool. This may be caused by too much flow. Make sure the pump is not supplying more than 125GPM (100GPM max flow for ASME models). Adjust flow accordingly. Also check the U.G. to make sure it is working properly and not damaged from chemical corrosion or stuck.

U.G. PLUG P/N 006720F
UNITHERM GOVERNOR P/N 006719F

U.G. PLUG GASKET O-RING P/N 800365

U.G. GASKET P/N 800365

44

Residential U.G. Bypass Assembly

U.G. BYPASS ASSY P/N 017958F (206A/207A-266A/267A) P/N 017962F (336A/337A- 406A/407A)
UNITHERM GOVERNOR
ASME U.G. Bypass Assembly

Tech Tip: Test a U.G by placing it in a bowl of hot water (water temp 105ºF / 44.5ºC or higher). Use 130ºF / 54ºC or higher for ASME version. If working properly, it will open as it warms up.
*Do NOT heat U.G. using open flame.

ProTek Shield Assembly

COMPONENTS

This heater is equipped with a ProTek Shield Assembly (located under the inlet connection on polymer headers) and in the ProTek Shield Adapter assembly shipped loose in the accessory carton for field installation on brass ASME headers.

NOTE: ProTek Shield available on ASME models Manufactured in March 2020 or later.

This component provides protection to the heat

exchanger against galvanic corrosion, when properly

bonded to the heat exchanger. It should be replaced

when the weight of the ProTek Shield is reduced to about 40% of the original weight (1.46 #).
NOTE: Make sure the O-ring is properly seated in the O-ring groove before installation.

Follow the steps below to replace the ProTek Shield Assembly:
1. Shut off the pool pump and bleed pressure from the system.

CAUTION: STOP the pool pump before attempting

2. Close isolation valves to minimize pool/spa water loss.

to remove ProTek Shield Assy. Failure to do so

3. Remove wing nut from bottom stud on ProTek Shield Assy.

may result in damage to ProTek Shield Assy, loss of pool water, or personal injury.
CAUTION: Do not use tools to remove (twist) the

4. Remove bonding wire ring terminal from stud.
5. Rotate ProTek Shield assembly clockwise (by hand) to unscrew it from the assembly.

ProTek Shield Assy or the wing nut on the stud of the ProTek Shield Assy. Non- warrantable damage

6. Inspect/replace as necessary and reverse above procedure to reinstall. Hand tighten only! Do not use tools.

may occur.

45

Flow Rates and Pressure Drops

COMPONENTS

Polymer Header (Residential Models)

Plastic Internal Baffle (UG Fully Open)

Flow

Pressure Drop (Ft of Head)

GPM 206/207 266/267 336/337 406/407

20

4.0

25

4.0

4.6

30

4.0

5.2

35

4.0

5.8

5.2

40

4.6

5.8

5.2

50

4.6

6.3

6.9

60

4.6

6.9

70

4.6

8.1

9.2

80

4.6

9.2

9.8

90

6.9

10.4

100

8.1

11.0

12.1

110

10.4

11.5

13.3

120

11.0

12.7

17.9

125

11.5

13.8

20.2

Polymer Header (Residential Models) Pressure Drop (Ft of Head)

New Bronze Header (ASME Models)

Manufactured after 12/2019 (UG Closed)

Flow

Pressure Drop (Ft of Head)

GPM 206/207 266/267 336/337 406/407

20

8.2

30

9.5

40

9.7

11.0

13.4

50

10.0

9.8

12.2

13.4

60

11.0

10.4

13.7

13.5

70

11.5

10.9

14.3

14.0

80

12.6

12.0

15.5

15.0

90

14.0

13.0

16.2

100

15.0

14.2

17.5

16.7

Bronze Header (ASME Models)

Pressure Drop (Ft of Head)

Model

Min GPM

Max GPM

206/207

20

100

266/267

25

100

336/337

35

100

406/407

40

100

Old Bronze/Cast Iron Header (ASME Models)

Manufactured before 12/2019 (UG Closed)

Flow

Pressure Drop (Ft of Head)

GPM 206/207 266/267 336/337 406/407

20

1.8

30

2.2

8.0

40

2.5

9.0

50

2.7

9.8

60

3.3

10.5

70

4.3

11.0

80

5.5

11.5

90

6.8

14.0

100

8.2

17.0

Model

Min GPM

Max GPM

206/207

20

125

266/267

25

125

336/337

35

125

46

406/407

40

125

Internal Bypass Valve

COMPONENTS

The Automatic Bypass Assembly allows the heater to be connected to a wide variety of pumps.
With every job site having different flow rates, the Bypass automatically adjusts to provide the proper flow rate to the heater, up to 125GPM max (100GPM for ASME models). If the flow rate exceeds 125GPM condensation may form and erosion of the copper tubes may occur. It is then recommended that an external bypass be installed before the heater.
If the heater is making a knocking noise or cycling the high limits, it may be that the Bypass is missing, stuck open or damaged. It is also possible that the wrong Bypass spring is installed. See table for correct bypass spring assignment.

Tech Tip: You can feel the Bypass by placing your fingers down into the inlet of the header. You can feel the Bypass spring back as you push on it. Note: This tip applies to the polymer bypass only.

Header Style

Polymer

New Bronze*

Old Bronze/Cast Iron

Model

206-267

336-407

206-267

336-407

206-267

336-407

Spring Color

Red

Silver

Yellow

Green

Silver

Black

Part Number 006718F

006718F

017958F

017962F

016196F

*Bypass valve for New Bronze headers is part of the ASME U.G. assembly (see page 44).

47

PRV Installation

COMPONENTS

Polymer Header (Residential Models)

Bronze Header (New ASME Models)

Bronze/Cast Iron Header (Old ASME Models)

These illustrations depict the correct installation of a PRV (pressure-relief valve). All piping must be of suitable metal construction by applicable code.

Larger PRVs may require additional additional plumbing components for fit. Smaller PRV’s can be mounted directly into the header.

48

Be sure to consult your local building code regarding distance of effluent from floor.

0.156 ± .04 0.125 ± .15

Pilot Assemblies Spark Gap
0.18 ± .04

COMPONENTS

Atmospheric Pilot

Low NOx Pilot
49

Blower Location and Combustion Air Orifice Plate
Notches Indicate Heater Model Size:

COMPONENTS

NOTCHES INDICATE HEATER SIZE
Blower Location
50

207
(One Notch)

267
(Two Notches)

337
(Three Notches)

407
(Four Notches)

If replacing blower, remove the combustion air orifice plate and remount it onto the new blower. Refer to illustrations to distinguish between different sizes of combustion air orifice plates if supplied with a new blower.
Note: There is a small 5/16 hex screw holding the blower onto the heater cabinet, behind the blower on the far right hand side at bottom. Removal of burner tray may be required to access.

Low NOx Air Pressure Switch

There are 4 different air pressure switches for the Low NOx heaters. None of the switches are interchangeable.

COMPONENTS

Each switch has a colored decal to help identify the switch. See chart below for proper switch choice.

Note: See page 32 for blower pressure measurement.

207

267

337

407

Color

Blue

Red

Yellow

Green

Part Number 008062F 008135F 010354F 010355F

Activation Pressure W.C.

-1.50±.08

-1.05±.06

-0.75±.08

-0.25±.05

Tech Tip: The air pressure switch senses negative pressure (suction). Testing the air switch by blowing on it will not work. You need to apply light suction. Also to measure the air pressure while the unit is running, you must install a tee fitting in the air hose and connect it to your manometer. See page 32 every switch has a different activation pressure, see chart.

51

Digital Gas Heater
Tool Box Quick Reference Guide
Check our FAQ section on our website for answers to common problems. EMAIL us with technical questions, we pride ourselves on quick answers.
BEFORE YOU CALL
1. What is the incoming power 120 or 240VAC? 208 will not work properly. 2. What is the power at the circuit board? 3. What is the incoming gas pressure? 4. If the unit can fire, what is the pressure at the manifold (burner pressure)? 5. Is the gas line rigid or flex-line?
THIS IS NOT A SUBSTITUTE FOR THE INSTALLATION AND OPERATION MANUAL. THIS MANUAL IS INTENDED TO HELP THE SERVICE TECHNICIAN WITH BASIC TROUBLESHOOTING.
Learn more at Raypak.com
Litho in U.S.A. ©2020 Raypak, Inc. 6500.00A Effective 04-01-21 Replaces 06-15-20