Raytherm Commercial Swimming Pool Heater
Models 514–824
WARNING: If these instructions are not followed exactly, a fire 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 combustible materials in the vicinity of this or any other appliance.
To do so may result in an explosion or fire.
• 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 another safe place for
future reference.
CATALOG NO. 6200.50S
Effective: 07-01-16
Replaces: 06-16-15
P/N 240499 Rev. 20
Rev. 20 reflects the following:
Changes to: None
Additions: None
Deletions: Warranty on page 33
Pay Attention to These Terms
Start-Up Procedures
Operating Instructions and Shut-Off
Automatically Lighted Pilots
Electronic Ignitions Systems
Maintenance and Care
Pool & Spa Water Chemistry
Receiving Equipment
General Specifications
Installation Instructions
Combustion Air
Vent Piping
Gas Supply Connections
Plumbing for Water Connections
Piping Diagrams
Electrical Wiring
Wiring Diagram—Models 514–724
Wiring Diagram—Model 824
Wiring Diagram—Models 514–724
Wiring Diagram—Model 824—Spa
Replacement Parts
Pay Attention to These Terms
Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored.
Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
DANGER: Failure to install the draft hood on indoor
installations and properly vent the heater to the
outdoors as outlined in the Venting section of this
manual can result in unsafe operation of the heater.
To avoid the risk of fire, explosion, or asphyxiation
from carbon monoxide, never operate this heater
unless it is properly vented and has an adequate air
supply for proper operation. Be sure to inspect the
vent system for proper installation at initial start-up;
and at least annually thereafter. Refer to the
Maintenance section of this manual for more
information regarding vent system inspections.
WARNING: Both natural gas and propane have an
odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
WARNING: UL recognized fuel gas detectors are
recommended in all enclosed propane and natural
gas applications wherein there is a potential for an
explosive mixture of fuel gas to accumulate and their
installation should be in accordance with the
detector manufacturer's recommendations and/or
local laws, rules, regulations, or customs.
DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
DANGER: There is a Hot Water SCALD Potential if
the poolstat is set too high.
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
DANGER: When servicing or replacing components
that are in direct contact with the water, be certain
• There is no pressure in the heater. (Pull the release
on the relief valve. Do not depend on the pressure
gauge reading).
• The heater water is not hot.
• The electrical power is off.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
WARNING: This product must be installed by a
licensed plumber or gas fitter when installed within
the Commonweatlh of Massachusetts.
WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
Always keep the area around the heater free of
combustible materials, gasoline, and other flammable liquids and vapors.
Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
NOTE: Heat exchanger damage resulting from
chemical imbalance is not covered under the warranty.
For your health and the protection of your pool equipment, it is essential that your water be chemically
balanced. The following levels must be used as a
guide for balanced water.
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 obtained from your pool or
spa builder, accredited pool shop, or chemical
supplier for the correct levels for your water.
Occasional chemical shock dosing of the pool or
spa water should not damage the heater providing
the water is balanced.
Other Pool and Spa
Recommended Level(s)
Fiberglass Pools
Fiberglass Spas
Water Temperature
68-88°F (20-31°C)
89-104°F (31-40°C)
Total Alkalinity (ppm)
Calcium Hardness (ppm)
Salt (ppm)
6000 Maximum
6000 Maximum
6000 Maximum
Free Chlorine (ppm)*
3000 Maximum
3000 Maximum
3000 Maximum
Total Dissolved Solids
*Free Chlorine MUST NOT EXCEED 5 ppm!
Table A: Water Chemistry
68-104°F (20-40°C)
OPERATING: WARNING: If you do not follow
these instructions exactly, a fire or explosion may
result, causing property damage, personal injury or
Start-Up Procedures
Do not try to light any appliance.
Do not touch any electric switch; do not use any
telephone in your building.
Immediately call your gas supplier from a neighbor's telephone. Follow the gas supplier’s
If you cannot reach your gas supplier, call the fire
C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push
in or turn by hand, do not try to repair it; call a qualified service technician. Force or attempted repair
may result in fire or explosion.
Before Start-Up
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from combustibles, flammable liquids and chemicals. Do not
obstruct the flow of combustion and ventilating air.
First thing, ensure that system is filled with water and
have pump operating. Water must be flowing through
the heater during operation.
CAUTION: Propane gas is heavier than air and will
settle on the ground. Since propane can accumulate
in confined areas, extra care should be exercised
when lighting propane heaters.
Operating Instructions and
Shut-Off Procedures
Automatically Lighted Pilots
Electronic Ignitions Systems
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
B. BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and will
settle on the floor.
After Start-Up
checked and adjusted for proper operation by a qualified service person at the time of installation and
periodically checked thereafter. Refer to pressure
switch servicing instruction in this manual).
Feel the inlet and outlet pipes. Outlet pipe should be
only slightly warmer than the inlet. It should not be hot.
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to
the heater. Such damage is not covered under warranty.
WARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
to the appliance.
Visual Inspection
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.
Elevated water temperature can be hazardous, and
the U.S. Consumer Product Safety Commission recommends the following guidelines:
1. Spa or hot tub water temperatures should never
exceed 104°F (40°C). A temperature of 100°F
(38°C) is considered safe for a healthy adult.
Special caution is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use can cause drowsiness which
could lead to unconsciousness and subsequently
result in drowning.
Fig. 1: Main Burner Flame
3. Pregnant Women Beware! Soaking in water over
102°F (39°C) can cause fetal damage during the
first three months of pregnancy, resulting in the
birth of a brain damaged or deformed child.
Pregnant women should stick to the 100°F (38°C)
maximum rule.
4. Before entering the spa or hot tub, users should
check the water temperature with an accurate
thermometer; spa or hot tub thermostats may err
in regulating water temperatures by as much as
4°F (2.2°C).
Fig. 2: Pilot Burner Flame
5. Persons with a medical history of heat disease,
circulatory problems, diabetes, or blood pressure
problems should obtain a physician’s advice
before using pools or hot tubs.
A yellow or “floating” flame indicates restricted air
openings or incorrect orifice size. Should this occur,
shut the heater off and contact your installer or gas
6. Persons taking medications which induce drowsiness, such as tranquilizers, antihistamines, or
anticoagulants, should not use spas or hot tubs.
Water Pressure Switch
A water pressure switch is provided in the heater to
shut off the burners in the event that water supply to
the heater is interrupted. It is very important to verify
that the switch electrically opens and shuts off the gas
valve when water flow to the heater is interrupted.
Otherwise, rapid and severe damage will likely occur
to the heater. (The water pressure switch should be
Maintenance and Care
4. Your pump strainer basket may be full. If so
remove debris.
5. Your filter may be dirty. If so, backwash or clean filter. (To tell if your filter is dirty, the gauge pressure
will be higher than usual).
To be followed one month after start-up and then semiannually.
1. Inspect top of heater and drafthood for soot, (a
sticky black substance around finned tubes and
“V” baffles), and open flue gas passageways.
6. The pump may have lost its prime. It may be running dry, check the pressure gauge on the filter. If
there is no pressure; then you are not moving
water (or your gauge is broken). Try to get the
pump to run at it's normal flow rate.
CAUTION: Soot may be combustible. Wet sooted
surfaces completely prior to cleaning. Do not use
steel wire brush.
Pool & Spa Water Chemistry
Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain your
water chemistry according to the chart on page 5. If
the mineral content and dissolved solids in the water
become too high, scale forms inside the heat exchanger tubes, reducing heater efficiency and also
damaging the heater, If the pH drops below 7.2, the
heater will be severely damaged. This will result in corrosion of the heat exchanger. Heat exchanger
damage resulting from chemical imbalance is not
covered by the warranty.
2. Clean main burners and pilot burner of dust and
3. Inspect and operate all controls, gas valve and
pressure relief valve.
4. Make visual check of the burner and pilot flame.
Flame pattern on the main burner and pilot is indicated in the previous illustration. Yellow flame
means restriction of the air openings. Lifting or
blowing flame indicates high gas pressure. Low
flame means low gas pressure. Should this occur,
shut the heater off and contact your gas supplier
or qualified service agency.
When heaters installed outdoors in freezing climate
areas are to be shut down for the winter, observe the
following step-by-step procedure:
5. On indoor heater, clean room air intake openings
to ensure adequate flow of combustion and ventilation air.
1. Turn off gas valve, manual gas valve, and electrical supply to the heater.
2. Open drain cock located on the inlet/outlet header,
(under water pipes).
CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can
damage the heater and void the warranty.
3. Disconnect compression fittings from the pressure
switch and return header that connect to the 1/4"
copper tube and allow the tube to drain.
6. Keep air around heater clear and free from combustible materials, gasoline and other flammable
and corrosive vapors and liquids.
Basic Tips If Heater Will Not Fire
1. If you have no electrical power, it may be that your
circuit breakers" have tripped. Try re-setting them.
2. If you have electrical power but the heater will not
fire, check the following:
3. The time clock must be moved to the "ON" position.
Installation Instructions
NOTE: These instructions are intended for the use
of qualified personnel only, 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. If your state is such,
be sure your contractor bears the appropriate
license. Persons not qualified shall not attempt to fix
this equipment nor attempt repair according to these
Receiving Equipment
On receipt of your equipment it is suggested that you
visually check for external damage to the carton. If the
carton is damaged, a note should be made on the Bill
of Lading when signing for equipment. Remove the
heater from the carton and if it is damaged, report the
damage to the carrier immediately.
WARNING: Improper installation, adjustment,
alteration, service or maintenance may damage the
equipment, create a hazard resulting in
asphyxiation, explosion or fire, and will void the
On occasion, we ship some items loose. Be sure that
you receive the number of packages indicated on the
Bill of Lading.
Code Requirements
When ordering parts, you must specify model and serial number of heater. When ordering under warranty
conditions, you must also specify date of installation.
NOTE: The heater should not be located in an area
where possible water leakage will result in damage
to the area adjacent to the appliance or to the
structure. When such locations cannot be avoided, it
is recommended that a suitable drain pan,
adequately drained, be installed under the
appliance. The pan must not restrict combustion air
Raypak recommends that this manual be reviewed
thoroughly before installing your Raypak pool/spa
heater. If there are any questions that this manual
does not answer, please contact the factory or your
local Raypak representative.
General Specifications
These heaters are design-certified and tested under
the requirements of ANSI Z21.56/CSA 4.7 American
National Standard for Gas-Fired Pool Heaters.
Installation must be in accordance with local codes, or,
in the absence of local codes, with the latest edition of
the National Fuel Gas Code (NFGC), ANSI
Z223.1/NFPA 54 and National Electrical Code (NEC),
Rated inputs suitable for natural gas at elevations up
to 2000 feet. For propane inputs, multiply the natural
gas rating by 0.94.
Heater must be mounted on a level base, such as
cement slab, cement blocks or other non-combustible
surface. An optional non-combustible base is available
for all models. An alternative method for providing a
base for combustible floors is illustrated in Fig. 3.
Heater must not be installed on carpeting.
All heaters are interchangeable and can be used
either indoor or outdoors. The appropriate top designated for that type of use is required. If desired, the top
can be changed at a later date from outdoor to indoor
or vice versa.
Base Installation
For elevations above 2000 feet, reduce input 4% for
each 1000 feet above sea level, as height elevation
reduces combustion performance.
Fig. 3: Alternate Mounting Base
WARNING: The heater shall not be located in an
area where water sprinklers, or other devices, may
cause water to spray through the cabinet louvers
and into the heater. This could cause heavy internal
rusting or damage some electrical components, and
this would void the warranty.
All Heaters
For clearances from combustible surfaces, see
Table B.
Heater Side
Top (Indoor)
Top (Outdoor)
Min. Clearance from
Combustible Surfaces
See note 1
Water Side
Other Side
See note 2
The point from where the flue products exit the heater
must be a minimum of four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top surface of the
heater shall be at least three (3) feet above any forced
air inlet, or intake ducts located within ten (10) feet horizontally.
See note 3
NOTE 1 - 36” minimum from top of vent terminal.
NOTE 2 - Must not be installed on carpeting.
Combustible floor base required for installation on a combustible surface
NOTE 3 - Combustible floor sheild optional for outdoor installation.
NOTE 4 - For servicing, provide at least 24" in front of
the heater for burner tray removal, and at
least 18" on water connection side of the
heater to inspect and delime the heat
Fig. 4: Minimum Distance from Openings
High Wind Conditions
(Outdoor Units Only)
In areas where high winds are frequent, it may be necessary to locate the heater a minimum of 3' from high
vertical walls, or install a wind break so the heater is
not in direct wind current.
Table B: Minimum Clearances from Combustible
Outdoor Heaters
Indoor Heaters
These heaters are design-certified for outdoor installation, when equipped with the approved tops
designated for outdoor use.
The design is also certified for indoor installation when
equipped with the approved draft hood and (if necessary) combustible floor shield. Locate heater as close
as practical to a chimney or gas vent. Heater must
always be vented to the outside. See Vent Piping
Section on page 13 for venting details. Minimum allowable space is shown on the nameplate.
Heaters must not be installed under an overhang of
less than three (3) feet from the top of the heater.
Three (3) sides must be open in the area under the
overhang. Roof water drainage must be diverted away
from the heaters installed under overhangs with the
use of gutters.
Combustion Air (Indoor Units Only)
Venting Connections
Air For Combustion and Ventilation
(Indoor Units Only)
Vent Terminal (Outdoor)
1. Lower outdoor “Stackless” top on to unit. Position
top so it is centered on unit from side to side and
front to rear.
The heater must have both combustion and ventilation
air. Minimum requirements for net free air supply
openings, one 12 inches from ceiling for ventilation
and one 12 inches from the floor for combustion air as
outlined in the latest edition of ANSI Z 223.1/NFPA 54
and any local codes that may have jurisdiction.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty.
a. All air from inside the building:
Each opening shall have a minimum net free
square inches as noted in Table C.
Square Inches
Fig. 5: Lower Outdoor “Stackless” Top Onto Unit
2. Tighten the (4) screws (See Fig. 6) until they come
in contact with the unit jacket top, then evenly
tighten all (4) screws to secure to unit.
Table C: Air from Inside the Building
b. All air from outdoors:
When air is supplied directly from outside of building, each opening shall have a minimum net free
square inches as noted in Table D.
Square Inches
Fig. 6: Tighten the (4) Screws (TYP.)
Table D: Air from Outside the Building
Vent Terminal (Indoor)
codes, to the latest edition of the National Fuel Gas
Code, ANSI Z 223.1/NFPA 54.
Locate and assemble as shown below. Secure with
screws supplied in envelope in carton.
The discharge opening must be a minimum of two feet
vertically from the roof surface and at least two feet
higher than any part of the building within ten feet.
Vent stack shall be at least five feet in vertical height
above the draft hood outlet.
The vent cap location shall have a minimum clearance
of 4 feet horizontally from, and in no case above or
below, unless a 4-foot horizontal distance is maintained, from electric meters, gas meters, regulators
and relief equipment.
The weight of the vent stack or chimney must not rest
on heater draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible
Fig. 7: Vent Terminal (Indoor)
Vent Piping
Type “B” double-wall or equivalent vent pipe, certified
for Category I vent conditions, is recommended.
However, single-wall metal vent pipe may be used as
specified in the latest edition of the National Flue Gas
Code ANSI Z 223.1/NFPA 54.
WARNING: Indoor heaters require a draft hood
that must be connected to a vent pipe and properly
vented to the outside. Failure to follow this procedure
can cause fire or fatal carbon monoxide poisoning.
Vent piping the same size or larger than the draft hood
outlet is recommended (but not to exceed listing in
chapter 13 of ANSI Z 223.1/NFPA 54), however, when
the total vent height is at least ten (10) feet (draft hood
relief opening to vent terminal), the vent pipe size may
be reduced as specified in Chapter 13 of the latest edition of the National Fuel Gas Code, ANSI Z
223.1/NFPA 54.
2' MIN
2' MIN
5' MIN
As much as possible avoid long horizontal runs of vent
pipe and too many elbows. If installation requires horizontal non-vertical runs, the vent pipe must have a
minimum of 1/4 inch per foot rise and should be supported at not less than five-foot intervals. Plumber’s
tape, crisscrossed, will serve to space both horizontal
and vertical piping. Gas vents supported only by the
flashing and extending above the roof more than five
feet should be securely guyed or braced to withstand
snow and wind loads. We recommend use of insulated
vent pipe spacer through the roofs and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which complies with the local codes or, in the absence of such
Fig. 8: Venting Clearances
Gas Supply Connections
At the time of removal of an existing heater, the following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remaining connected to the common venting system are not
in operation.
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut off valve located outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.
(a) Seal any unused openings in the common venting
(b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
(c) Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliance remaining connected to the common
venting system are located and other spaces of
the building. Turn on clothes dryers and any appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer
exhaust fan. Close fire place dampers.
Fig. 9: Gas Connections
CAUTION: The heater and its manual shut off
valve must be disconnected from the gas supply
during any pressure testing of that system at test
pressures in excess of 1/2 Psig (3.45 KPA).
Dissipate test pressure in the gas supply line before
reconnecting the heater and its manual shut off valve
to gas supply line. FAILURE TO FOLLOW THIS
COVERED BY WARRANTY. The heater and its gas
connections shall be leak tested before placing the
appliance in operation. Use soapy water for leak
test. Do NOT use open flame.
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
(e) Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a cigarette, cigar or pipe.
NOTE: Do not use teflon tape on gas line pipe
thread. A flexible sealant approved for the fuel being
used is recommended.
(f) After it has been determined that each appliance
remaining connected to the common venting system properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.
A minimum of 7 in. WC and a maximum of 10.5 in. WC
upstream pressure under load, and no-load conditions
must be provided for natural gas or a minimum of 12
in. WC and a maximum of 13 in. WC for propane gas.
(g) Any improper operation of the common venting
system should be corrected so the installation conforms with the latest edition of the National Fuel
Gas Code, ANSI Z 223.1/ NFPA 54. When re-sizing any portion of the common venting system, the
common venting system should be re-sized to
match the minimum size as determined using the
appropriate tables in part 11 of national Fuel Gas
Code, ANSI Z 223.1/NFPA 54.
For special venting applications that require reduced
vent sizes and through the wall venting, the Type D
Induced Draft Assembly can be used. Consult the factory or your local Raypak representative.
Gas Pressure Regulator
The gas pressure regulator is preset and sealed at 4
in. WC for natural gas, and 11 in. WC for propane gas.
Between the gas valve and the burners is a 1/8” pipe plug.
The pressure at this point, taken with a manometer,
should be about 3.7 in. WC natural gas and 10.5 in.
WC propane gas. If an adjustment is needed, remove
seal and turn adjustment screw clockwise
increase pressure or counter clockwise
to decrease pressure
Natural gas, 1000 BTU/Ft .60 Specific Gravity @ 0.5 in. WC Pressure Drop
Propane Gas, 2500 BTU/Ft 1.53 Specific Gravity @ 0.6 in. WC Pressure Drop
Table E: Pipe Sizing for Gas Connections
The heater must be located so that any water leaks will
not damage the structure of adjacent area. High-temperature plastic pipe (CPVC) may be connected
directly into the heater if local codes permit and if controls operate the pump for at least fifteen minutes after
the heater is turned off.
CAUTION: NEVER install PVC directly into heater.
Four feet of copper or high-temperature pipe and two
elbows are required between the heater and the
PVC connections
Fig. 10: Gas Pressure Test Points
Plumbing For Water Connections
Fig. 11: Water Piping Connections
The heater requires water flow and positive pressure
to fire and operate properly. It must therefore be
installed downstream of the discharge side of the filter
pump. A typical installation is plumbed as follows:
When local codes permit the use of less than four feet
high-temperature piping or two elbows, provisions
should be made to always shut the heater off a minimum of 15 minutes prior to pump shut down in order
to carry away residual heat and prevent damage to the
low temperature piping.
1. The inlet side of the filter is plumbed directly to the
discharge side of the filter pump;
2. The outlet side of the filter is then plumbed to the
inlet of the heater; and
3. The outlet of the heater is plumbed to the return
line to the pool or spa. The pump, filter and heater
are thus plumbed in series.
A fireman switch included in the time clock may be
used for this purpose with instruction not to override
this sequence manually. See wiring diagram section
for electrical hookup location of the fireman switch in
the electrical circuit.
Piping Diagram—Single Heater
Piping Diagram—Two Heaters
NOTE: When 2” piping is used into the heater, this
piping must be anchored (copper) or screwed into
the flange (metal) if operating pressures above 30
PSI are encountered.
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.
NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will cause
very rapid corrosion to the heat exchanger and
unwarrantable damage to the heater,.
NOTE: Any restrictions between heater outlet and
pool will void the warranty.
514 - 824
Pipe Size
Min. gpm
Table F: Flow Rates
Unitherm Governor Operation
Max. gpm
The patented Unitherm Governor is a thermostatic
mixing valve specifically designed to maintain constant
heater internal temperature between 105°F to 115°F
despite continually changing flow rates from the filter
and changing pool temperatures. This narrow range is
needed to prevent damaging condensation on the
burners which will occur if the heater runs for any
length of time below 100°F. It is also needed to inhibit
scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures.
Companion Flange Connections
DO NOT use petroleum base assembly fluids (such as
Petroleum Jelly or lubricating oil). If assembly tube is
required use a silicone base such as Armoral etc. The
inlet/outlet header flange accepts a 2” copper tube as
a slip connection directly into the header. The flange is
also threaded for a 2” copper male threaded adapter.
External Auxiliary Bypass Valve
(Where Required)
An auxiliary bypass valve should be used when flow
rates exceed 115 gpm (usually a high-performance
pump size larger than two HP will exceed this flow
rate). This valve is required to complement the function of the automatic bypass valve, particularly when
starting the heater in winter or early spring when the
spa or pool temperature is below 55°F. It also serves
to eliminate needless pressure drop through the
heater and accompanying reduction in the flow rate to
the spa jets, etc.
Fig. 12: Flange Connections
Automatic Chlorinators and Chemical
All chemicals must be introduced and completely diluted into the pool or spa water before being circulated
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (i.e.
Fig. 13: Auxiliary Bypass Valve
Auxiliary Bypass Valve Adjustment
To set bypass: with clean filter, adjustment is made by
feeling the inlet and outlet pipes at the heater. Outlet
pipes should be slightly warmer than inlet and comfortable to the touch. If pipe is hot, close bypass; if cold,
open bypass.
The heater is also equipped with a manual bypass
built into the header. This is in addition to the automatic bypass valve. This may be used with flow rates up
to 120 gpm and adjusted as below.
Fig. 15: Pressure Relief Valve Location
NOTE: Sooting or liming caused by improper
bypass adjustment voids the warranty
To avoid water damage or scalding due to valve operation, drain pipe must be connected to the PRV outlet
and run to a safe place of discharge per local code
requirements. Drain pipe must be the same size as the
PRV discharge connection throughout its entire length
and must pitch downward from the PRV. No shutoff
valve shall be installed between the PRV and the drain
line. Valve lever should be tripped at least once a year
to ensure that waterways are clear.
Electrical Wiring
NOTE: If it is necessary to replace any of the
original wiring, it must be replaced with 105°C wire or
its equivalent, except all black wires must be
replaced with 150°C wire or its equivalent.
NOTE: Heaters are factory wired for 240V power
supply, except Cal Code units wired for 120V Power
The heater draws less than 1 amp when operated
on either 120VAC or 240VAC power.
Fig. 14: Manual Bypass Adjustment
The Electronic Intermittent Ignition Device automatically lights the pilot and main burners upon a call for
heat. The heater is supplied with a dual voltage transformer for 120V or 240V input power hookup.
Pressure Relief Valve Installation
A 3/4 NPT, 125 psi pressure relief valve (PRV) is standard with this heater. Local building codes may
require a PRV with a different pressure setting. The
maximum allowable PRV rating is 150 psi. ASME
Code requirements mandate that any PRV used must
have a relief capacity equal to or larger than the
BTU/hr input of the heater.
The standard PRV is mounted in a 3/4 NPT connection
on the inlet/outlet header, as shown in Fig. 15. If the
required PRV calls for a larger connection, mount it in
a tee in the outlet piping and plug the 3/4 NPT port.
The PRV must be installed in the vertical position.
Fig. 16: Ignition Control
For 120 V input power to the unit, connect the black
wire to the “L1” or hot leg of the power supply. Connect
the white wire to the “L2” or neutral leg of the power
supply. Attach the wire nut to the red wire. There
should be no connection to the red wire for 120V operation.
Fig. 18: 240V Connections
Heater must be electrically grounded and bonded in
accordance with local codes, or, in the absence of
local codes, with the latest edition of the National
Electrical code, NFPA 70.
Fig. 17: 120V Connections
NOTE: Input power to the heater (120/240V) should
be supplied from the load (Pump) side of time clock
or switch. Connecting heater to continuous power
source will allow "Fail" indications (service and
pressure switch) when pump is not operating.
For 240 V input power to the unit, connect the black
wire to the “L1” or hot leg of the power supply. Connect
the red wire to the “L2” or second hot leg of the power
supply. Attach the wire nut to the white wire. There
should be no connection to the white wire for 240V
NOTE: The wiring diagrams in this manual show all
standard options. Refer to the large wiring diagram
provided with your heater for options installed on
your specific unit(s).
Wiring Diagram—Models 514–724
Wiring Diagram—Model 824
Wiring Diagram—Models 514–724—Spa
Wiring Diagram—Model 824—Spa
General Location of Controls
Fig. 19: General Location of Controls
The heater is built with a single mechanical poolstat,
located in the front panel above the door. The poolstat
may be set for any desired pool or spa temperature
from 66-104ºF.
Fig. 21: Knobstop
Knobstop Adjustment
Fig. 20: Poolstat
If desired, a higher setting of the poolstat can be
obtained by adjusting the knobstop ring on the dial
plate. Loosen the set screw, adjust the knobstop for
the higher desired temperature setting and retighten
the set screw.
Pressure Switch
The pressure switch, or heater actuator, ensures that
the heater operates only when the filter pump is in
operation. It is factory set at 1.75 PSI for deck level
installations. When the heater is located below the
level of the spa or pool it may be necessary to reset
the pressure switch to compensate for the no-flow
static head. If it is necessary to reset the pressure
switch, we recommend the following procedure.
5’ Max
5’ Max
Pressure Switch Adjustment
Fig. 23: Heat Exchanger Height Above/Below Pool
1. Make sure the pool filter is clean before adjusting
the switch.
NOTE: If heater is installed outside of the limits
shown in Fig. 23, a flow switch must be used in
place of the pressure switch when mounted and
wired adjacent to the heater.
2. Set the heater control to the OFF mode.
3. Turn the filter pump on and confirm that the pressure switch is closed (use a multimeter to check).
If the pressure switch fails to close, either the
switch setting is too high or the filter pump is not
supplying enough pressure.
Two-Speed Pumps
In some cases, the flow on the low speed is insufficient
to operate the heater. This is apparent when the pressure switch cannot be further adjusted or if the heater
makes banging noises. In these cases, the pump must
be run at high speed when heating the water.
4. Turn the heater ON.
5. Manually turn the pressure adjustment knob clockwise until the heater shuts off. (A flat screw driver
may be necessary if knob is too tight).
CAUTION: Do not operate the heater without a
functioning and properly adjusted pressure switch.
6. Slowly turn the adjustment knob counter-clockwise until the heater calls for heat again.
High Limits
The heater is equipped with two automatic high limits.
Set to operate at 135°F and 140°F.
7. Turn an additional 1/2 turn counter-clockwise.
8. While the heater is running, check the adjustment
by turning the pump off and on several times. The
burners should shut off immediately when the
pump is turned off. If it does not, repeat the above
steps until proper operation is observed.
NOTE: An erratic high limit is often characteristic of
an internal heat exchanger problem, i.e. scale buildup, U.G. operation. Refer to troubleshooting
Fig. 24: High Limit
Fig. 22: Pressure Switch Adjustment Range
High Limit Removal
Main Burner and Orifice Removal
1. Shut off main electrical power switch to heater.
1. Remove burner drawer. See burner drawer
removal procedure.
2. Remove inspection panels.
2. Remove screws and burner hold down bracket.
3. Drain heater.
NOTE: If the heat exchanger is sooted badly, the
burner hold-down bracket and spacer can become
distorted from direct flame impingement; this usually
necessitates replacement of these parts.
4. Remove defective high limit and replace with a
new high limit.
5. Reverse above procedure to re-install.
Pilot Safety
3. Lift burners from slotted spacers and slide from orifices. Clean with a non-sparking wire brush.
The heater employs a pilot safety which closes the
main gas valve within 8/10ths of a second whenever
the pilot flame is interrupted. Pilot flame is automatically lit when the device is powered. Unit performs its own
safety check and opens the main valve only after the
pilot is proven to be lit.
4. Orifices usually do not need to be replaced. To
clean, run either copper wire or wood toothpick
through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove from
manifold. DO NOT over tighten when reinstalling.
Pilot Removal and Cleaning
Burner Drawer Removal
1. Remove burner drawer. (See burner drawer
removal procedure).
1. Shut off main electrical power switch to heater.
2. Shut off gas upstream of heater.
2. Disconnect pilot tubing, disconnect wires from gas
3. Remove front door.
3. Disconnect pilot bracket from burner shield.
4. Disconnect gas line from gas valve.
4. Remove pilot from bracket.
5. Remove (2) screws that mount burner tray to unit,
and (2) screws that secure gas valve to jacket.
5. Remove pilot orifice and air opening, and clean
with wire or small brush. CAUTION! DO NOT
enlarge hole in pilot orifice.
6. Disconnect wires that terminate at gas valve.
7. Slide out burner tray.
6. Reverse above procedure to re-install.
8. Reverse above procedure to reinstall.
Heat Exchanger Removal
Gas Valve Removal
1. Shut water, gas and electricity off, close valves
and relieve pressure, remove relief valve. Remove
side inspections panels.
1. Shut off gas supply to the heater. Remove gas piping to gas valve inlet.
2. Remove top holding screws.
2. Disconnect wires, pilot tubing and bleed line, if
3. Remove draft diverter, lift and remove top and flue
collector. Remove inspection panels.
3. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.
4. Loosen bolts and disconnect flange nuts on inletoutlet header, loosen union(s) at gas pipe and
slide heater away from piping until stud clear the
4. Reverse above procedure to re-install.
Extension Pieces (5)
Auger with Carbide Tip
Fig. 34: Tube Cleaning Kit
5. Remove heat exchanger corner brackets.
Wire Brush
Shut gas and power off to the unit, close the system off
and drain the heater. Remove the draft diverter.
Remove the access panel and jacket top. Lift flue collector off. Remove “V” baffles over tube(s) to be
replaced. If no pipe unions have been provided, use
the header as a union, remove the flange nuts off the
inlet/outlet header, break gas connection and slide
heater away from piping to allow room to work. Pull
wedge clips out of control wells and remove sensing
bulbs. Remove flange nuts of the return header and
remove header. Lift heat exchanger straight up and
6. Remove combustion chamber clips at the four corners of the heat exchanger.
7. Lift heat exchanger straight up using caution not to
damage refractory.
8. Reverse above procedure to reinstall.
Tube Cleaning Procedure
Establish a regular inspection schedule frequency,
depending on local water condition and severity of
service. Do not let the tubes clog up solidly. Clean out
deposits over 1/16” in thickness.
Heat exchanger header o-rings must be replaced with
new ones. The tube may be cut out with a hacksaw or
hammer and chisel adjacent to both tube sheets, leaving studs in the tube sheets. Then proceed to collapse
studs in the tube sheets with a chisel or screwdriver.
Use caution not to cut into the tube sheet.
Replacement tubes will have the fins stripped off
longer on one end. The long end is inserted into the
opening of the tube sheet first; then the short end is fitted through the opposite tube sheet. If the tube ends
become dented or bent, straighten at least (4) inches
back from the tube and by means of a tapered punch.
The heater may be cleaned from the right side, without
breaking pipe connections. It is preferable, however, to
remove both headers for better visibility through the
tubes and to be sure the ground-up lime dust does not
get into the system.
Note that you do not remove the top panel or the heat
exchanger, generally. After reaming, mount the wire
brush in place of the auger and clean out debris
remaining in the tubes.
Insert tube roller into tube opening up to stop against
tube, then push center rod in until roller is tight. Be
careful to keep replacement tube squared up 1/8” outside each tube sheet. A loose tube will sometimes pull
toward the roller. Attach drill motor to tube roller, holding it straight and level. Proceed to expand tube until
the tool begins to grab. At this point, 1/2” to 1” should
be expose on the tool shank. Reverse drill motor or
wrench out by hand. Care should be exercised to
avoid applying excessive torque during rolling operation and to avoid thinning out any part of the tube wall
excessively over .015''. Use same procedure at the
opposite end of the tube.
Another method is to remove the heat exchanger,
ream tubes and immerse heat exchanger in non-inhibited de-scale solvent for severe scale buildup.
Tube Replacement Procedure
On Raypak units, tube replacement may be effected
without rolling as a temporary means or repair, providing there are two or more tubes rolled in to act as stays
on the left and right side. The “O” rings should provide
a seal up to 120 PSI working pressure.
Apply line pressure test, and re-roll, if necessary,
before reassembly of the heater.
Use 3/8” heavy-duty reversible drill motor or larger to
power the tube roller. If a reversible drill is not available, after rolling the tube in, remove the drill motor
and wrench out the roller. A tube roller is available from
the factory.
De-sooting Procedure
Control Immersion Well Replacement
Remove top, sensing bulb and clip. Collapse well tube
at the open end with a chisel, push through into header
and remove the header. Insert a new well and roll into
place. If a roller is not available, solder or braze.
CAUTION: Soot is combustible. exercise extreme
Soot will clog areas between fins and cause eventual
tube failure. Any sign of soot at the base of the burners
or around the outer jacket indicates a need for cleaning.
1. Remove top and flue collector from cabinet.
2. Remove “V” baffles from heat exchanger.
3. Remove burner drawer. (See burner tray removal).
Fig. 36: Immersion Well
4. Take garden hose and wash heat exchanger, making sure soot is removed from between fins. (Avoid
excessive water against refractory).
Unitherm Governor (U.G.) Replacement
1. Shut water, gas and electricity off, close valves
and relieve pressure.
5. Reassemble. When heater is fired, some steam
will form from wet refractory. This is normal.
2. Drain heat exchanger.
NOTE: In extreme cases it may be necessary to
remove the heat exchanger completely for cleaning.
The simplest method is steam cleaning at the local
car wash. DO NOT WIRE BRUSH.
3. Loosen and remove (2) bolts that secure U.G.
Assembly to header.
4. Remove U.G. Assembly with gasket.
Combustion Chamber Removal
5. Reverse above procedure to re-install.
To remove the combustion chamber, you must first
have removed the heat exchanger. Unbolt metal combination chamber retainer from top and remove
combustion chamber panels individually.
Fig. 37: Location of U.G.
To test the operation of the Unitherm Governor, place
in hot water (over 100°F) and watch for movement
against spring. If there is not movement, replace unit.
Fig. 35: Refractory Panels—Top View
These instructions are primarily intended for the use of qualified personnel 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
Harmonics, or whining noise.
U.G. inoperative………………………………
* Debris or restriction in system………………
* Debris in gas line………………………………
Low flow………………………………………
Heater going on and off continuously.
Dirty filter………………………………………
Low water level in pool………………………
External bypass setting out of
* Pressure switch out of
Check movement by putting in hot water (110°F
or higher). If no movement, replace.
Locate the restriction and remove. Flush system
and clean.
Remove debris or blow out gas line.
Scale forming in heat exchanger-clean heat
exchanger and check pool pH and total alkalinity.
Backwash filter.
Raise water level.
Adjust bypass
Adjust pressure switch
Liming or scale forming on heat
Pool water………………………………………
See Water Chemistry page 2.
High flow rates…………………………………
Reduce by adding manual bypass valve and
adjust by putting thermometer in header (1/4”
NPT) drain opening. Set bypass so thermometer
reads between 105° and 110°F.
Check movement by putting in hot water (110°
or higher). If no movement, replace.
Refer to installation instructions.
Follow recommended installation instructions.
U.G. Inoperative………………………………
* Air starvation……………………………………
* Improper venting………………………………
* Insects or debris clogging
burner intake ports……………………………
Pilot outage.
Yellow lazy flame
Outer jacket very hot
(paint blistered)
Takes long time to heat pool or spa.
Clean burners.
Low gas pressure………………………………
Restricted pilot………………………………..
Weak pilot generator…………………………
Adjust gas pressure.
Clean pilot.
Replace pilot.
Low gas pressure………………………………
* Insects or debris clogging
burner intake ports……………………………
Adjust gas pressure.
* Broken refractory caused by
shipping damage or improper combustion……
Excessive sooting of heat
Calculate temperature in °/hr…………………
Filter not running long enough………………
Dirty filter………………………………………
Gas line or meter undersized…………………
(*Usually occurs on initial start-up)
Clean burners.
Replace refractory panels.
Determine cause of sooting & correct.
Heat rise (°/hr.) = Heater output ÷ (Pool gallonage
x 8.33) or refer to heater sizing chart.
This does not take into account heat loss due
to weather.
Reset time clock.
Clean filter.
Refer to installation instructions.
Bypassing too much water……………………
U. G. not functioning…………………………
Inspect bypass for movement, if no
movement, replace.
Replace if no movement when heated.
Leaking at well.
Leaking at heat exchanger.
Replace well and maintain water
chemistry properly.
Gasket brittle and leaking (overheated).
Replace heat exchanger and maintain
chemistry properly.
Heater running after pump shuts off…………
Refractory damage……………………………
Sooted heater…………………………………
See pressure switch adjustment.
Replace refractory.
Determine cause of sooting and correct.
NOTE: Some heaters may be equipped with an
ignition module that shuts off pilot gas if the pilot fails
to light. To reset, interrupt power to the heater.
technicians ONLY.
Intermittent Pilot System
NOTE:Before troubleshooting, familiarize yourself with the startup and checkout
Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring.
Pull ignition lead and check spark at module.
Spark Okay?
• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
• Check boot of the ignition cable for signs of melting or buckling. Take protective
action to shield cable and boot from excessive temperatures.
• Check that all manual gas valves are open, supply tubing and pressures are good,
and pilot burner orifice is not blocked.
• Check electrical connections between module and pilot operator on gas control.
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,
replace gas control; if not, replace module.
NOTE:If S8600H goes into lockout, reset system. Lockout is used on Pro. models.
Check continuity of ignition cable and ground wire.
Clean flame rod.
Check electrical connections between flame rod and module.
Check for cracked ceramic flame rod insulator.
Check that pilot flame covers flame rod and is steady and blue.
Adjust pilot flame.
If problem persists, replace module.
• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.
• Check electrical connections between module and gas control. If okay, replace
gas valve or gas control operator, i.e. pilot gas valve, flow switch etc.
NOTE: IF S8600H goes into lockout, reset system.
• Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though
operation is normal at the time of checkout.
• Check that pilot flame covers flame rod and is steady and blue.
• If checks are okay, replace module.
• Check for proper thermostat (controller) operation.
• Remove MV lead at module; if valve closes, recheck temperature controller and
wiring; if not, replace gas valve.
Repeat procedure until troublefree operation is obtained.
Replacement Parts
Replacement parts for the 514-824 Raytherm
Swimming Pool Heaters may be found in Raypak’s
Illustrated Parts List, Catalog No. 9100.60, which is
available at the Raypak website:
NOTE: To supply the correct part it is important that
you state the model number, serial number and type
of gas when applicable.
Any part returned for replacement under standard
company warranties must be properly tagged with
RAYPAK return parts tag, completely filled in with the
heater serial number, model number, etc., and shipped
to the Company freight prepaid.
If determined defective by the Company and within
warranty, the part will be returned in kind or equal substitution, freight collect. Credit will not be issued.
Raypak, Inc.
2151 Eastman Avenue
Oxnard, CA 93030
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468
Litho in U.S.A.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF