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Raypak C-R185B User's Manual

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1. 27 WIRING DIAGRAM Low NOx 81626 1310 Mg N33439 9 O M ama 38 MOTA xovi8 Q3H 3lIHM M M Xov18 MOTIA 8 A 8 M 8 A pov18 39NVMO X0v18 N33H9 58 9 38 B9NV3O 32Y18 O LAN 63 071315 mem qii Ave l AVE A 3 3L0W3M 10114 LL una 907 981 3215 G69106 S3ONVHO 1 02 000666 NYHL 000181 330 NO 3QON 1919890 01 NONI ISVO 8 3 009501 z 0 92 9 945 9 ONnOSS 43 0 SV 2 081 MO 2 601 1 31 03 YOSE 0350 SLI 38 38
2. LSAW L E Y3LY3H 3H LIM 03119905 SV JHL 40 ANY 4l 3 8 3 08440 310N LC cas sanas Zd 03 LAN Q3TIVISNI 07314 63 b EMT 8 y HOLIMS 0134 M81 A 343 JOMdS AVE 14 45 404 554 JHYSH 421145 HOLIMS 110 1104 104 CIVNOlLdO LN3A 421145 M3QV3H 131100 131 ZH 3L1ON 33S M30V3H 100 LINN 2 310N 339 LNO NI HOLIMS 3MhSS3Md SMd GOv S9C 130 JAIVA SV9 5143 804 SV9 8 9 23 NOISN3L HOI Lu d 91 td S8l SOv SS8Ll 140091 JAIVA SVO TISMASNOI vd I300N 3AIVA SVO 5143 804 ANWA 599 8 M 69106 S3J39ONVHO 0 MOSN3S 18 OVAvZ 48 0 VdS 38 100d 18 2 310W39 VdsdO 3NVdOsSd 140 dVNS z y HOLIMS M3MOd i LIOA OVE 404 4 OVA 5 945 EE NN 21 M NOILVYSdO LIOA OV SIL 404 027109 pua C 4MeagAeM 9 24VAC HI 24VAC RET GROUND 9d
3. Board SPK RS Pressure switch Very water flow and pressure CLEAN FILTER STRAINER backwash IT High limi switch water flow Inspact intemal Iharmaostat Linithanm Ceovemor and valeas Rollout sensor replace fusible link Check for bocka hea enhancer and snot Fireman or Remolie connected bio safety loop 18 in f e OFF mode Flame icon displayed Went switch open Check connections to the board flashing If extractor installed extractar pilot bt and rectified spark will display until pilot is up to 2 minutes maximum Ignition contro faduna Check power Pig alura Check bad ignition or to the healer Verify valve gas present Sting Verihy clean pikat and clenrance fom ignitar bo ground hood E piot is venfy that the flame is rectified f spark will NN 3 Verify power at MV on IID replace board cee Verify power to valve voltage replace valve 42 SECTION 6 REPLACEMENT PARTS NOTE To supply you with the correct part itis impor If determined defective by the Company and within tant that you supply the model number serial number warranty alike part or equal substitution will be returned and type of gas when applicable freight collect Credit will not be issued Any part returned for re
4. GAS CONTROL LEVER SHOWN IN OFF _ POSITION ROBERTSHAW 7200 GAS VALVE MODEL 185 GAS INLET Fig 8934 1 TO TURN OFF GAS TO APPLIANCE Set the thermostat at the lowest setting Turn off all the electric power to the appliance if service is to be performed Remove heater door panel For Honeywell VR 8300 and Robertshaw 7000 gas valve Turn gas control knob clockwise to Off Make sure knob rest against stop For Robertshaw 7200 gas valve Push in and move gas control lever counter clockwise 4 to Off position 5 Replace heater door panel AFTERSTART UP Feelthe inletand outlet pipes Outlet pipe should be only slightly warmer than the inlet It should not be hot 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 Fig 8205 2 MAIN BURNER FLAME Fig 8964 1 PILOT BURNER FLAME A yellow or floating flame indicates restricted air open ings or incorrect orifice size Should this occur shutthe heater off and contact your installer or gas supplier WATER PRESSURE SWITCH A water pressure switch is provided in the heater to shut offthe burners inthe eventthat water supply to the heater is interrupted Itis very importantto verify
5. for combustion air as outlined in the latest edition of the National Fuel Gas Code ANSI 22231 b All Air From Outdoors CGA B149 1 and B149 2 and any local codes thatmay When air is supplied directly from outside of building have jurisdiction each opening shall have a minimum net free square inches as noted Model Square Inches CAUTION Combustion air must not be contaminated 185 46 by corrosive chemical fumes which can damage the 265 66 heaterand void the warranty 335 84 405 100 16 VENT PIPING WARNING Indoor boilers require a drafthood 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 as the draft hood outlet is recommended however when the total vent heightis at least ten 10 feet draft hood relief opening to vent terminal the vent pipe size may be reduced as speci fied in Chapter 10 of the National Fuel Gas Code ANSI Z 223 1 Canada CAN CGA B149 1 and B149 2 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 musthave a minimum of 1 4 inch perfoot rise and should be supported at not more thanfivefootintervals Plumberstape criss crossed will serve to space both horizontal and vertical piping Gas vents supported only bythefla
6. screws that secure the control box Disconnect pilot wire from the ignition module Disconnect wire harness from the combustion blower Carefully slide out the burner tray assembly Reverse above procedure to reinstall GAS VALVE REMOVAL N Remove burner drawer following above procedure Disconnect pilot tubing from gas valve Turn vertical gas pipe from manifold slightly and un screw gas valve Reverse above procedure to reinstall MAIN BURNER AND ORIFICE REMOVAL N Remove burner drawer following above procedure Remove pilot See pilot removal procedure Remove 8 total screws from the hold down brack ets front and rear of tray Remove 8 total screws from the left and right sides of the manifold assembly Detach the manifold as sembly from the burner tray assembly Remove burners by raising the bracket on the back end of the burners up and out of their slots Use a long 9 16 socket wrench to remove orifices from the gas manifold 38 Reverse above procedure to reinstall IID PILOT Fig 9477 PILOT REMOVAL 1 2 3 4 5 Disconnect pilot tubing from gas valve Remove 4 screws from control box Open the con trol box Remove the pilot wire from the ignition wire Remove 2 screws that mount the pilot bracket to the air manifold assembly Pull the pilot bracket slightly then drop and pull downwards and outwards Reverse above procedure to reinstall Make sure
7. 10 11 sd 12 ROBERTSHAW 13 Fig 8081 0 GAS VALVE MILLIVOLT Fig 4 8079 0 TO TURN OFF GAS TO APPLIANCE 1 Setthe thermostat to the lowest setting 2 2 Turn On Off switch to the Off position 3 Remove heater door panel 5 Replace heater door panel CAUTION Propane gas is heavier than air and will settle the ground Since propane can accumulate in confined areas extra care should be exercised when lighting propane heaters Co OPERATING INSTRUCTIONS AND SHUT OFF PROCEDURES AUTOMATICALLY LIGHTED PILOTS ELECTRONIC IGNITIONS SYSTEMS This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand 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 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric 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 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 don t try to repair it call a qualified service technician Force or attempted repair may result in fire or explo sion D
8. 34 High Limit 7 After Start Up 34 Pilot Safety Burner Drawer Removal 7 SECTION2 35 Gas Valve Removal CAUTION 35 Main Burner and Orifice Removal 35 Pilot Removal and Cleaning 7 SECTION 9D Heat Exchanger Removal MAINTENANCE amp CARE PROCEDURES 36 Tube Cleaning Procedure 36 Desooting Procedure 8 Pool amp Spa Water Chemistry 36 Combustion Chamber Removal 8 Cold Weather Operation 36 Immersion Well Replacement 9 Winterizing the Pool amp Spa Heater 36 Unitherm Governor U G Replacement 37 Low NOx Pool Heaters PART TWO INSTALLATION amp SERVICE INSTRUCTIONSBE SECTION 5 TROUBLE SHOOTING GUIDE 39 Mechanical 40 Electrical MV Units 41 Electrical IID Units 42 Digital Control Logic 10 SECTION 1 RECEIVING EQUIPMENT 10 SECTION2 GENERAL SPECIFICATIONS 11 SECTION 3 43 SECTION6 INSTALLATION INSTRUCTIONS ECT 11 Code Requirements 44 Illustrated Parts List 46 Part Numbers 11 Clearances 12 Outdoor Heater Installation 12 Indoor Heater Installation 16 Specifications and Dimensions 16 Combustion Air 17 Vent Piping 17 Gas Supply Connections 19 Plumbing For Water Connections 29 Heat Exchanger Reversal Procedure 24 Electrical Wiring 25 Transformer Wiring 26 Wiring Diagram Millivolt Mechanical Therm 27 Wiring Diagram lID Atmospheric 28 Wiring Diagram IID Low NOx FOR YOUR SAFETY READ BEFORE OPERATING WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROP
9. Alcove Right Side 12 Water Side Left Side 6 Opposite Water side OUTDOORINSTALLATION Unobstructed Stackless top or outdoor stack Back 6 Side 6 Clearance from top of vent terminal Vent 6 When installed according to the listed minimum clear ances from combustible construction materials the Raypak pool heaters can still be serviced without remov ing permanentstructural construction around the heater However for ease of servicing we recommend a clear ance of at least 24 in the front and at least 18 on the water connection side This will enable the heater to be serviced in its installed location that is without move ment or removal of the heater Clearances less than these 6 minimum may require removal of the heater to service either the heat exchanger or the burner tray In either case the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater OUTDOORHEATERINSTALLATION These heaters are design certified for outdoor installation when equipped with the approved tops designated for outdooruse WARNING The heater shall notbe 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 internal rusting or damage some electrical components and this would void the warranty WARNING Do notinstall within 3 feetof a heat
10. Donotuse this appliance if any part has been underwater Immediately call a qualified serv ice technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater OPERATING INSTRUCTIONS STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Remove heater door panel For Honeywell Valve Turn gas control knob clockwise to Off For Robertshaw valve Turn gas control knob clockwise a to Off Models 265 405 Push in ana move gas control lever counter clockwise z to Off position Model 185 Wait 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information previously stated If you don t smell gas go to the next step Turn gas control knob counter clockwise to Honeywell VR 8300 and Robertshaw 7000 Replace heater door panel Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier GAS CONTROL KNOB SHOWN IN ON POSITION HONEYWELL ROBERTSHAW 7000 GAS VALVE IID MODEL 265 405 Fig 8080 0
11. PILOT SAFETY Millivolt The heaters equipped with the standing pilot millivolt system have pilot generators which act as a safety device to shut off the flow of gas to the main burners and the pilot burner in case the pilot flame is extinguished The pilot burner must be manually relighted to place the heater in operation again Refer to the lighting instruc tions provided on the heater label PILOT SAFETY Electronic 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 34 BURNER DRAWER REMOVAL 1 Shutoff main electrical power switch to heater 2 Shutoffgas upstream of heater 3 Removefrontdoor 4 Disconnect gas line from gas valve 5 Remove 2 screws that mount burner tray to unit and 2 screws that secure gas valve to jacket 6 Disconnect wires that terminate at gas valve 7 Slide out burner tray 8 Reverseabove procedure to reinstall GAS VALVE REMOVAL 1 Shutoffgassupplytothe heater Remove gas piping to gas valve inlet 2 Disconnect wires pilot tubing and bleed line if required 3 Turn vertical gas pipe from manifold slightly and unscrew gas valve 4 Reverse above procedure to reinstall MAIN BURNERAND ORIFICE REMOVAL 1 Remove burner drawer following
12. a pressure relief valve The valve shall be installed in a vertical position ASME HEADER Pressure Relief Valve PRV Discharge Connection 58095 0 Inlet Outlet Header Fig 8095 0 NOTE avoid water damage or scalding due to valve operation drain pipe must be connected to valve outlet and runto a safe place of discharge Drain pipe must be the same size as the valve discharge connection throughout its entire length and must pitch downward from the valve No shutoff valve shall be installed between the relief valve and the drain line Valve lever should be tripped at least once a year to ensure that waterways are Clear PRESSURE DROP TABLES FLOW PRESSURE DROP FT OF HEAD 185 265 335 405 20 15 28 41 4i 30 17 46 58 58 49 21 52 65 65 50 24 56 72 72 60 28 61 77 77 37 65 82 82 80 46 73 87 87 90 57 88 102 102 100 68 100 130 130 22 ASME HEADER FLOW PRESSURE DROP FT OF HEAD 185 265 335 20 18 39 39 39 30 22 80 80 80 40 25 90 90 90 27 98 98 98 33 105 105 105 43 110 110 110 55 115 115 115 68 140 140 140 82 170 170 170 HEAT EXCHANGER REVERSAL PROCEDURE POLYMER HEADER MODELS 1 8 9 Remove right and left sid
13. contaminated by corrosive chemical fumes which can damage the heaterand void the warranty 6 Keep areaaroundheater clear and free from combus tible materials gasoline and other flammable and corrosive vapors and liquids BASIC TIPS IF HEATER WILL NOT FIRE If you have no electrical power it may be your circuit breaker has tripped Try re setting it If you have electrical power but the heater will not fire check the following 1 The time clock must be moved to the ON position 2 Yourpump strainer basket may be full If so remove debris 3 Your filter may be dirty If so backwash or clean filter To tell if your filter is dirty look to see if the filter pressure will be higher than usual 4 The pump may have lost it s prime It may be run ning dry check the pressure 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 POOL amp SPA WATER CHEMISTRY Chemical imbalance can cause severe damage to your heater and associated equipment Maintain your water pH between 7 4 and 7 8 and total alkalinity between 100 and 150 p p m Ifthe mineral content and dissolved solids inthe 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 He
14. is heavier than air and will settle the ground Since propane can accumulate in confined areas extra care should be exercised when lighting propane heaters LIGHTING INSTRUCTIONS AND SHUT OFF PROCEDURES MANUALLY LIGHTED PILOTS MILLIVOLT SYSTEM A This appliance has a pilot that must be lit by hand When lighting the pilot follow these instructions exactly B BEFORE LIGHTING 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 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance D Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department 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 a fire or explo sion Do not use this appliance if any part has been under water Immediately call a qualified serv ice technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water LIGHTING INSTRUCTIONS STOP Read the safety information above Set the thermostat on the lowest setting Turn On Off
15. mounted pressure switch See Parts List pg 47 for 11 psi pressure switch TWO SPEED PUMPS In some cases the flow on the low speed is insufficient to operate the heater Thisis apparent when the pressure switch cannot be further adjusted or if the heater makes banging noises or goes off on high limit In these cases the pump must be run at high speed when heating the water CAUTION Do not operate the heater without the function of a properly adjusted pressure switch or flow switch FLAME ROLL OUT SAFETY SWITCH Atmospheric heaters are equipped with a thermal cutoff device to prevent flame roll out in the event the heat exchanger becomes blocked Thisisa single use type fusible link or thermal fuse that must be replaced when disabled by an over temperature condition caused by excessive restriction in the heat exchanger flue passage 7 Fx Ee Fig 9440 HIGH LIMITS The heater is equipped with two automatic high limits Both are located in the inlet outlet header Both are set to open at 135 F NOTE An erratic high limit is often characteristic of internal heat exchanger problem e g scale buildup defective bypass Referto troubleshooting sections pg 39 HIGHLIMIT REMOVAL 1 Shut off main electrical power switch to heater 2 Remove inlet outlet in spection panel 3 Remove defective high limit and replace with a new high limit 4 Replace inspection panel Fig 9439
16. operate the heater continuously until higher tempera tures are reached Operating the heater for prolonged periods with pool water below 50 F can seriously damage the heater and is not covered by the warranty For cold climate areas please follow the winterizing procedures listed WINTERIZING THEPOOL amp SPAHEATER Heaters installed outdoors in freezing climate areas are subject to be shut down for the winter Observe the following procedure for winterizing the heater 1 2 Turn off gas valve manual gas valve and electrical supply to the heater Open drain plug located on the inlet outlet header under water pipes Remove the heat exchanger inspection panel on the side opposite water piping to gain access to the drain plug on the return header Open drain plug on return header Return Header Drain Plug For ASME Heaters only Disconnect compression fittings from the pressure switch and return header that connects to the 1 4 copper tube and allow the tube to drain For ASME Heaters only SECTION 1 RECEIVING EQUIPMENT On receipt of your equipment it is suggested that you visually check for external damage to the carton Ifthe 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 Save the carton These items are shipped loose inside the carton with the heater STANDARD
17. procedure above 2 Removescrews and burner hold down bracket NOTE f the heat exchanger is sooted badly the burner hold down bracket and spacer can become dis torted from direct flame impingement and this usually necessitates replacement of these parts 3 Lift burners from slotted spacers and slide from orifices Clean with a wire brush 4 Orificesusually do notneed to be replaced Toclean run either copper wire or wood toothpick through orifice Do not enlarge hole To remove orifice use asocketwrench and remove from manifold DO NOT overtighten when reinstalling Burners Burner Hold Down Bracket 9479 35 PILOT REMOVAL AND CLEANING 1 Disconnect pilot tubing and wires from gas valve 2 Removepilot assembly from burner tray 3 Remove pilot from bracket 4 Remove pilotorifice and air opening Honeywell MV unit only and clean with wire or small brush CAUTION Do not enlarge hole in pilot orifice 5 Reverse above procedure to reinstall HONEYWELL PILOT ROBERTSHAW PILOT Air Orifice Fig 8045 1 HEAT EXCHANGERREMOVAL 1 Shutwater gas and electricity off close valves and relieve pressure andremoverelief valve Removeside inspection panels 2 Remove top holding screws 3 Remove draft diverter lift and remove top and flue collector Remove inspection panels 4 Disconnect wires from high limits and pressure switch Remove temperature sensor 5 Disconnectflange nutsoninl
18. switch to the Off position Remove heater door panel Push in gas control knob slightly and turn clockwise to Knob cannot be turned from Pilot to Off unless knob is pushed in slightly Do not force 6 Wait5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Locate pilot mounted on right side panel of 25297922 8 HONEYWELL PILOT Fig 4 8083 0 ROBERTSHAW PILOT Fig 8084 1 Turn knob on gas control counter clockwise amp to Pilot Place flame to end of pilot tube Push in control knob all the way and hold to light pilot Continue to hold control knob in for about one minute after the pilot is lighted release knob and it will pop back up Pilot should remain lighted Ifitgoes out repeat steps 5 through 9 If knob does not pop up when released stop and immediately call your service technician or gas supplier Standto the side ofthe heater and turn the gas control knob counter clockwise to On Replace heater door panel Turn On Off switch to the On position Set thermostat to the desired setting Push the gas control knob slightly and turn clockwise to Off Do not force the burner drawer For burner drawer location 9 see location of control section page 20 GAS CONTROL KNOB SHOWN IN OFF POSITION HONEYWELL GAS VALVE MILLIVOLT
19. thatthe switch electrically opens and shuts offthe gas valve when water flow to the heater is interrupted Otherwise rapid and severe damage will likely occurto the heater The water pressure switch should be checked and adjusted for properoperation by a qualified service person atthe time ofinstallation and periodically checked thereafter Refer to Pressure Switch Adjustment on pg 34 of this manual WARNING Operation of the heater without water circulation will cause rapid and severe damage to the heater SECTION 2 CAUTION Elevated water temperature can be hazardous and the U S Consumer Product Safety Commission recom mends the following guidelines 1 Spa or hot tub water temperatures should never exceed 104 F 40 C Atemperature of 100 F 38 C is considered safe for a healthy adult Special caution is suggested for young children 2 Drinkingofalcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning 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 maximum rule 4 Before entering the spa or hot tub users should check the water temperature with an accurate ther mometer spa or hot tub thermostats may err in regulating water tem
20. the pilot bracket is all the way up on the pilot side see drawing below FOR HEATERS MADE PRIOR TO AUGUST 2001 CORRECT INCORRECT Fig amp 9368 CORRECT INCORRECT COMBUSTION FAN REMOVAL 1 2 Remove burner drawer See Burner Drawer Removal procedure on this page Remove 4 screws that mount the combustion blower to the manifold assembly Reverse above procedure to reinstall SECTION 5 TROUBLESHOOTING GUIDE MECHANICAL FOR QUALIFIED SERVICE PERSONNEL ONLY IMPORTANT NOTICE 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 instructions PROBLEM CAUSE Harmonics or whining noise UG inoperative e Debris or restriction system Debis imi gas LOW MON A mI Heater going on and off continuously Bgm Low water level in pool External bypass setting out of CCS WNC Pressure switch out of ACIUS TNE MEE TT Liming or scale forming 20 02 S
21. with a very close tolerance to ensure accuracy of the set temperature Thus slight fluctuations in water temperature may cause your heater to cycle on and off frequently This phenomenon is not a problem It will not harm the heater nor interfere with its function to precisely control the temperature of the pool or spa Fig 49480 LCD DISPLAY TEMP BUTTONS BUTTON THERMOSTAT CONTROL OPERATION The pool heater thermostat on the upper front panel of the heater controls the pool spa water temperature This control center contains a mode button up and down temperature adjustment buttons and a LCD display Mode Button The MODE button functions as a means to turn the heater off or on in either the pool or spa temperature setting The LCD display indicates the mode the heater is in and the actual water temperature Temp Buttons If the mode is in POOL or SPA the desired pool or spa temperature will also be displayed and may be changed using the UP or DOWN buttons A manual toggle switch is also provided right below the MODE button to allow the heater to be turned off Operation In the POOL or SPA modes the actual water temperature is displayed along with the desired pool or spa temperature If the heater is firing a flame icon will be visible To adjust the desired pool or spa temperature setting make sure the control is in the appropriate mode POOL or SPA and push the UP or DOWN buttons to get the desired set point tem
22. 10 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 Recommended pH should be between 7 4 and 7 8 Total alkalinity 100 150 PPM maximum Hardness 150 400 PPM maximum Reduce by adding manual bypass valve Adjust manual bypass valve until heater outlet water temperature is between 105 and 110 F Check movement by putting in hot water 110 F or higher If no movement replace Refer to installation instructions Follow recommended installation instructions Clean burners Adjust gas pressure Clean pilot Replace pilot Adjust gas pressure Clean burners Replace refractory panels Determine cause of sooting amp correct Heat rise hr Htr 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 Inspect bypass for movement if no movement replace Replace if no movement when heated Replace well and maintain water chemistry properly Replace heat exchanger and maintain chemistry properly See pressure switch adjustment Replace refractory Determine cause of sooting and correct Replace fan relay Loos
23. Bonding lug is provided loose with the unit Install bonding lug on lower right or left side of jacket as necessary for bonding the unit Mounting hole is provided on the jacket The Electronic Intermittent Ignition Device automatically lights the pilot and main burners upon a call for the heat The heater is supplied with a dual voltage transformer for 120V or 240V input power hookup 24 Option Location For Left Control Box Side Field Wiring Factory Mounted Location Bonding Lug Fig 9470 Bonding Lug Optional Location Standard Location ATMOSPHERIC Wiring locations OPTIONAL CONTROL BOX LOCATION FACTORY MOUNTED FOR LEFT SIDE N LOCATION FIELD WIRING SWAY BONDING LUG BONDING LUG OPTIONAL AN STANDARD LOCATION LOCATION Fig 4 9366 1 LOW NOx Wiring locations TRANSFORMER WIRING 120V WIRING 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 For Low NOx pool heaters wire nut each red wire independently 120V ATMOSPHERIC HEATER 120V LOW NOx HEATER BLACK E LINE 1 LINE 1 BLACK BLACK BUE WHITE LINE 2 gt 2 SIDE WHITE SUPPLY WHITE A TE SIDE HEATER 4 WIRES
24. ERTY DAMAGE PERSONAL INJURY ORLOSS OF LIFE SECTION 1 START UP PROCEDURES Your Raypak Pool Spa heater has been designed for years of safe and reliable pool spa water heating Itis available in millivolt or electronic control options ASME certified units typical used in commercial applications are also available This manual provides operation installation maintenance and service information for these heaters Fig 9472 If your heater has been installed correctly operating the heater is an easy task The upper front panel of the heater contains the control center that allows you to turn the heater on or off and adjust the temperature settings for the pool or spa The temperature range is factory set from 65 F 18 C to 104 F 40 C The heater is also equipped with toggle switch to turn the heater on and off see fig 9472 above for location Section 4 of this manual contains more details about the use of the controls in the Controls Adjustments subsection page 29 BEFORE START UP BURNERS WATER Clean main burners combustion fan and air louvers of Water must be flowing through the heater during dust lintand debris Keep heaterarea clearandfreefrom tion Insure that system is filled with water and have pump combustibles flammable liquids and chemicals Donot gt operating obstruct the flow of combustion and ventilating air Fig 9478 RP2100 DIGITAL IID POLYMER CAUTION Propane gas
25. Fig RP 8267 29 CONTROL ADJUSTMENTS Temperature Adjust Buttons Mode Button ON OFF LCD Display Fig 9472 MILLIVOLT CONTROLS The pool or spa water temperature is controlled by the pool heater thermostat on the upper front panel of the heater The control center contains an On Off switch and one or two thermostats Thermostats are fitted with a means of limiting the upper temperature limit below the maximum level The knob stop adjustment ring illustrated below is adjustable by loosening the set screw rotating the knobstop ring tothe desired location and retightening the set screw SPATEMPERATURE POOL TEMPERATURE RANGE RANGE i A c7 BN 1 T f P N Vn 77 ad p LET STAND BY 1 E TEMPERATURE KNOB STOP RING SETSCREW Fig 9473 KNOB STOP SHOWN ABOVE IS IN THESPATEMPERATURE RANGE DIGITAL THERMOSTAT CONTROLS Notice to owner Thermostat operation Your heater is equipped with a microprocessor controlled thermostat that controls the pool or spa temperature by measuring the temperature of the water coming back through the heater It will then monitor the water temperature and turn the heater back on when it senses that the water temperature is falling below the set point Itis normal to experience small fluctuations in the return water temperature during the operation of the heater The thermostat is calibrated
26. GROUND 7 WIRES GREEN GROUND GREEN 1 RED Spa pu i RED Fig 9471 240V WIRING 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 operation For Low NOx pool heaters wire nut each white wire independently 240V ATMOSPHERIC HEATER 240V LOW NOx HEATER BLACK LINE 1 LINE 1 SUPPLY SIDE mE RED poen HEATER GROUND 7 WIRES EN ME Ed a WHI TE 9471 1 Heater must be electrically grounded and bonded in accordance with local codes absence of local codes with the latest edition of the National Electrical code ANSI NFPA 70 Canada Canadian Electrical Code CSA C22 1 Part 1 and Part 2 NOTE Input power to the heater 120 240V can be supplied from the load pump side of time clock or directly from the switch GFCI power source It is preferred to make connection to the load pump side of the time clock When using the switched GFCI power source the heater could display false service indicators on the delay panel if the pump is turned off 25 WIRING DIAGRAM MILLIVOLT MECHANICAL THERMOSTAT HI LIMIT LIMIT THERMO MANUAL IN OUT AGS IN OUT STAT SWITCH TO FI
27. Heater Components Millivolt Heater with Honeywell Gas Valve 32 F to 175 F Millivolt Heater with Robertshaw Gas Valve O F to 175 F Electronic Ignition Heaters 32 F to 175 F Requires 120V or 240V Power Supply Atmospheric heaters Rated inputs suitable for up to 2000 feet elevation For elevations above 2000 feet reduce input 4 for each 1000 feet above sea level as high elevation reduces combustion performance Low NOx heaters Rated inputs suitable for up to 5000 feet elevation For elevations above 5000 feet consult the factory SECTION 3 INSTALLATION INSTRUCTIONS CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm IMPORTANT NOTICE 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 li censed 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 repairs according to these instructions 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 warranty CODEREQUIREMENTS NO
28. INSTALLATION AND OPERATING INSTRUCTIONS RP2100 SWIMMING POOL and SPA HEATER Atmospheric Models P R185B to P R405B C R185B to C R405B Low NOx Models P R185BL to P R405BL C R185BL to C R405BL CATALOG 6000 52 AK Effective 05 01 04 Replaces 03 15 04 Fig 9478 Donot store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance 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 should be maintained in legible condition and kept adjacentto the heater or kept in a safe place for future reference Part No 240612 CONTENTS PART ONE 29 SECTION 4 OWNER S OPERATING INSTRUCTIONS SERVICING INSTRUCTIONS 4 SECTION Eee DARE ESO 30 Digital Thermostat Controls 4 Before Start Up 31 Digital Diagnostics and Codes 5 Lighting Instructions amp Shut Off Procedures 32 Remote Control and Operation Installation Manually Lighted Pilots MV 34 Pressure Switch 6 Operating Instruction amp Shut OffProcedures 34 Flame Roll Out Safety Switch Automatically Lighted Pilots IID
29. LACK ORANGE wire for the POOL operation 5 Installthe Remote Interface Harness to the P8 connec tor and turn power ON to the heater CONNECTOR i See instructions on previous page to activate the Fig 9493 remote control 33 PRESSURE SWITCH The pressure switch or heater actuator insures thatthe heater operates only when the filter pump is in operation Itis located on the inlet outlet header 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 itis necessary to reset the pressure switch utilize the following procedure PRESSURE SWITCHADJUSTMENT 1 With pump and heater on turn adjustment knob clock wise until a click is heard from the gas valve Turn adjustment knob counter clockwise 1 4 turn Turn pump off and on several times Heater should shut off immediately If it does not repeat steps above until proper adjustments made Fig 9438 Adjustment Knob PRESSURE SWITCH ADJUSTMENT RANGE REO SIE ALS TAME FOR LOVER PRA ADSL Te HT Fig 8152 2 NOTE fheater is installed outside of the limits shown a higher pressure rated 11 psi switch may be used ora flow switch mounted and wired adjacent to the heater may be used in place ofthe factory
30. LSAW SHL 0319905 SV 3HL 40 dl Ig 7 e 1 HOLIMS 33MOd 27 1 OpZ SNVML AYOLOVS ae L1 M Q3TIVISNI 01314 E Peewee 72010085 SNVIGHL M8 i 3OlldS 0 M M jMVdS MO4 443 321145 HOLIMS 100 1108 103 CIVNOILdO 1 404 M3QV3H 131100 131 LINN IH Z TH s SV9 2 310N 335 xg OV 0821 100 LINN x8 A 2 310 33S E m E 43 b NOlLVM3dO LNO NI HOLIMS X04 440 dVNS 05 35 um PAP e Ld 9 5 NOISN3L jg xw X8 lOOd 100 28 SECTION 4 SERVICING INSTRUCTIONS GENERALLOCATION OF CONTROLS Bypass Hi Limit on Drain Plug header Located N Return Header AGS Hi Limit Located on Inlet Digital Thermostat Circuit Board Header Unitherm Roll Out Governor Switch Drain Plug Gas Valve Transformer Fig 2005 CONTROL PANEL REMOVAL 1 Remove 4 screws from sides of control panel 2 Rotate control panel down until panel stops Do not force NOTE Caution must be taken not to damage controls or wiring Control Panel Mounting Screws 4
31. REMANS SWITCH FIELD INSTALLED ROBERTSHAW GAS VALVE PRESS THERMAL mE SWITCH FUSE HONEYWELL GAS VALVE APPROVED BY CHECKED BY a 2207 REPLACE WIRING WITH 105 C WIRE 150 C WIRE AS NOTED 9 7 4 98 Cane WIRING DIAGRAM STANDING PILOT MILLIVOLT 100700 LSU 239 000 18204820 ATER TYPE 26 WIRING DIAGRAM Atmospheric 3 416291 d 1715 111001 NMONS 88 N33439 9 ALIHM 0 000 669 0007181 3307 3QON 7100 GI NVYOVIG SILNdNI Q3M M SH3QV3H ama NOM LSVO SH3LV3H NYNLIY NO 201 Z ALON SV 2 081 2 901 038
32. TE heater should not be located 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 recom mended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Installation must be in accordance with local codes or inthe absence oflocal codes with the latest edition ofthe National Fuel Gas Code ANSI Z223 1 and National Electrical Code ANSI NFPA 70 and for Canada the latest edition of CAN CGA B149 1 and B149 2 and Canadian Electrical Code CSA C22 1 Part 1 and Part 2 BASEINSTALLATION 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 Non Combustible MODEL SIZE Base 185 265 335 405 005182 005183 005184 005185 11 An alternative method for providing a base for combustible floors is illustrated below Heaters must not be installed on carpeting 12 Minimum 12 Minimum Fig 8148 1 Sheet Metal 24 Gauge P T Utilize hollow concrete cinder blocks align holes and leave ends open CLEARANCES ALL HEATERS Forclearances from combustible surfaces see the chart below CLEARANCE FROM COMBUSTIBLE CONSTRUCTION INDOORINSTALLATIONS Top 30 Drafthood Back 6 Front
33. TION Flame can be observed through the slot opening above the plenum Flame coloris blue and evenly spread onthe top surface of the burner At least every three months visual inspection should be made ofthe burners In case flame lifting is observed on the burner check gas pres surein manifold Gas pressure in manifold should be 3 9 W C ELECTRICAL Be sure that electrical service to the boiler has proper overload fuse orcircuit breaker protection wire size and connections which comply with all applicable codes FLAME ROLL OUT SAFETY SWITCH Low NOx heaters are equipped with a cutoff device to prevent flame roll out in the event the heat exchanger becomes blocked This is a manual reset type roll out switch that must be reset by a service technician after any overtemperature conditions have been fixed Exces sive restriction in the heat exchanger flue passage may cause the switch to disable the heater LOW NOx HEATERS CONTINUED BURNER __ COMBUSTION AIR BLOWER AIR SHUTTER ADJUSTMENT GAS VALVE Fig 9362 LOW NOx BURNER TRAY ASSEMBLY BURNER DRAWER REMOVAL 02 7 0 1 Shut off main electrical power switch to heater Shut off gas upstream of heater Remove front door Disconnect gas line from gas valve Remove 2 screws that mount burner tray to the base of the unit and 2 screws that secure gas valve to jacket Disconnect wires that terminate at gas valve Unscrew 4
34. UNIT POLYMER HEADERS ASME UNIT CAST IRON HEADERS 1 Pagoda Top 1 Pagoda Top 2 2 CPVC Union with O rings 2 2 In OutFlanges 2 3 Plastic pipe finish flange for gas line 3 1 1 2 Flange Gaskets 2 4 Bonding lug with mounting screw 4 2 Flange Gaskets 2 IID units only 5 Flange Bolts 4 6 Pressure Relief Valve 7 2 CPVC Adapters 2 8 Plastic pipe finish flange for gas line 9 Bonding lug with mounting screw IID units only Be sure that you receive the number of packages indicated on the Bill of Lading When ordering parts you must specify model and serial number of heater When ordering under warranty conditions you must also specify date of installation 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 SECTION 2 GENERAL SPECIFICATIONS These heaters are design certified and tested under the requirements of ANSI Z21 56 CSA4 7 American National Standard CSA Standard for Gas Fired Pool Heaters All heaters 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 ata later date to change from outdoor to indoor or vice versa Millivolt heater contains a self generating electrical system operating between 25 and 5 volts Ambient Temperature Rating of
35. aks REINSTALLED IN OUT HEADER ON OPPOSITE SIDE Fig 5 23 ELECTRICAL WIRING NOTE f it is necessary to replace any of the original wiring it must be replaced with 105 C wire or its equivalent and or 150 C wire or its equivalent as originally built MILLIVOLT SYSTEM The Millivolt System residential heater is equipped with a self generating electrical system in which the electric current is provided by means of a pilot generator No external electrical connections are required When installing a remote switch do not exceed 10 feet of wiring from the heater Use 18 gage stranded wire ELECTRONIC INTERMITTENT IGNITION DEVICE SYSTEM IID NOTE Heaters are factory wired for 240V power supply The standard field wiring connection is on the right side ofthe heater To wire the heater from the left side follow the steps below 1 Remove the two 2 screws that hold down the junction boxto the sway brace Untie excess yellow wires located behind the junction box 2 Move the junction box to the left side of unit and attach the box to the sway brace 3 Secure 24V yellow wires to sway brace panel with existing wire retainers 4 Connect the wires inside the junction box either 120V or 240V depending on the field wiring NOTE 7 8 Dia holes not utilized on jacket and control box can be used for fireman switch or auxiliary control interface wiring NOTE Heater must be electrically grounded and bonded
36. are thus plumbed in series Plumbing from the heater back to the pool must not have any valves or restriction that could prevent flow when the pump is operating CAUTION An additional source of heated water e g a solar system must be connected to the main line ahead of the heater inlet pipe in order for it to actas the primary heat source If the primary system provides adequate heat to maintain set point the RP2100 heater will Be advised that the RP2100 control panel will then display sensed water temperatures downstream ofthe primary heating system rather than the temperature of the water exiting the pool Heater must be located so that any water leaks will not damage the structure of adjacent area PVC pipe may be glued directly into header unions FLOW RATES MODEL PIPE SIZE MIN GPM MAX GPM 185 1 1 4 1 1 2 2 20 125 265 1 1 4 1 1 2 2 25 125 335 1 1 4 1 1 2 2 35 125 405 1 1 4 1 1 2 2 40 125 When flow rates exceed maximum GPM an external auxiliary bypass valve is required See external bypass valve section for details ASME CastlIron POLYMERHEADERS POLYMERHEADERS STANDARD MODELS Before attaching the 2 inch unions to the inlet outlet header make sure the o rings are properly seated in the grooves Use AquaLube or equivalent non petroleum based lubricant on the o ring Hand tighten the unions Glue PVC piping directly to the unions INLET OUTLET HEADER Polymer Flange Gas
37. at exchanger damage resulting from chemical imbalance is not covered by the warranty AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS 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 inthe skimmer High chemical concentrations will result when the pump is not running e g overnight Chlorinators must feed downstream of the heater and haveananti siphoning device to prevent chemical back up 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 Such damage is notcovered underthe warranty COLDWEATHER OPERATION IMPORTANT FREEZE INFORMATION MODERATE CLIMATE Heater operation can con tinue during short term cold spells When tempera tures are below freezing flow continuous pump opera tion must be maintained CAUTION Do not use the heater to maintain water temperatures just above freezing or for freeze protec tion When heater is used during freezing weather care must be taken to avoid freeze ups Continuous pump operation is a must Additional protection may be required The heateris not warranted against freeze ups COLD CLIMATE Prolonged operation with water tem peratures below 50 F is not recommended When starting the heater with pool temperatures below 50 F
38. ay Definition Board failure FFL Flame sensing when pilot and gas valves are closed Hi limit switch 1 open Hi limit switch 2 open Ignition control failure Ignition lock out Pilot failure Pressure switch open Heat roll out safety switch open Sensor failure VNT Vent switch open PROGRAM MODES Display Definition CCC Celsius setting F C Change from Fahrenheit to Celsius FFF Fahrenheit setting RES Reset defaults SET Set point max adjustment 31 REMOTE CONTROL INSTALLATION AND OPERATION CAUTION Before installing remote controls to the RP2100 Digital Heater read the following The Raypak RP 2100 Digital Heater is remote ready in most cases The digital liquid crystal display LCD shows the actual pool temperature operating status and service codes See examples below The touch pad on the control panel allows you to select the desired pool or spa temperature It also indicates when a remote system is controlling the heater by displaying REM in the display When connecting the RP2100 Digital to a remote system identify whether it is a two or three wire remote system Select the appropriate instruction listed below to properly install the remote to the heater Fig 9487 Fig amp 9484 Fig 9486 Fig 9488 OFF Mode Heating in the POOL Mode Heating in the SPA Mode Remote Mode POOLCOMMON ACTIVATING THE REMOTE BLK ORG RP2100 digital has the ability to disconnect from remot
39. charge ESD damage can be caused by direct or indirect contact with the wiring or circuit board When one walks to A ATTENTION the heater area an electrostatic charge accumulates on the body OBSERVE PRECAUTIONS Contact of a finger allows the body to discharge possibly causing ELECTROSTATIC device damage This damage can be limited if the service person sensitive DEVICES discharges himself by removing that charge by adhering to ESD preventative removal practices and reducing that charge by holding on to the heater enclosure for 5 seconds before proceeding 32 CONTROL WIRING Important Installation Notes for Remote or External Wiring Configuration e Remote wiring must be run in separate conduit e Remote wiring must not be run parallel to high voltage lines Forruns of under 30 feet remote wiring should have stranded conductors with a minimum of 22 AWG 600V cable twisting 1 5 to 2 5 and jacketed Forruns over 30 feet the conductors should be a minimum of 20 AWG 600V cable twisting 1 5 to 2 5 inch lay that is shielded and jacketed e Maximum cable length is 200 feet For both two and three wire remote systems the provided 7 pin wiring connector must be utilized Please refer to the wiring instructions Note The remote wires must be connected to the 7 connector before it is connected to the board 2 Wire Remote Control On Off This application assumes that only one heatin
40. clip between the top panel cover and the drafthood see Fig 9 16 With a twisting motion rotate the clip up see Fig 10 17 Pull up on clip see Fig 11 18 Hold the clip up and align the clip hole to the pilot hole see Fig 12 19 Insert screw into hole and secure using a 5 16 nut driver 20 Repeat steps 15 19 using remaining two clips 21 This completes the indoor drafthood installation If installing an outdoor drafthood proceed to step 22 PILOT HOLE INSTALLING THETOP COVER OUTDOOR KIT ONLY 22 Remove the two pieces of metal tape holding the top panel cover up and discard 23 Insertthe rear two tabs into the slots on the heater top and slide the top panel cover backwards See Fig 13 24 Lower the top panel cover and using your thumbs push tabs in and insert the two front tabs into the slots on the top of the heater See Fig 14 25 Lower the top panel cover flush to the top and release the tabs They will spring into place as shown in Fig 15 26 Turn the gas and electricity to the heater on 15 SPECIFICATIONS AND DIMENSIONS Cast I C 9 0 Heater Heater Heater Cabinet Flue Indoor Gas Water w stackless w Stackless Model 000 Width Dia Drafthood Conn Conn To Top 81858 181 18 1 4 6 62 5 8 12 1 16 3 4 2 R265B R335B 334 25 3 4 8 63 3 4 10 3 4 3 4 2 R405B 399 29 1 4 9 65 3 8 3 4 Designation for Pr
41. cludes Sensor Adapter Digital Electronic Sensor Well Bypass Bypass Spring Al Sizes included Linithann Sovernar Unithanmm Govemor Plug Drain Plug Header Dam 2 PVC Connector amp Mut 2 O05266F D3898F n3epar 04306F 007424 DB amp 703F 006827 DBTDGF 006707 709 nsz5grF 0887 13F 0087194 008815 O87 15F 0087 te DET18F 0087 19 0087 20F 008721 08722 08723 008724 005219 005223 05227 005231 00623 152388 201210124 DOB723F 08723 005232 Q05236F 301210 29 D5268F 008 7058 0006827 008706 ODS OFF 08711 008259 08713 0067 14F 0088605 0D8718F 008747 DG718F 008719F 0086720 008721 0086722 0D8723F DGT24F 2 ALTITUDES ABOVE 2 000 FEET LEVEL CONSULT THE FACTORY MARINES The Hydraulic conditions or water chemistry thal Gaused the tube bundle to fail have very also damaged the bypass valve and Unitherm Gowamor We recommend you replace thi Linithanm Govemor and inspect the bypass assembly Fisdure to do so could cause premature failure of this replacement 46 Heat Exchange Assy ASME Complete iniet Dutiet Header ASME Return Header ASME Tube Bundie ASME Siud Bok Header Gaskel 9 Governor Pressur
42. e Switch 1 75 PSI Pressure Swich 11 PSI Spacia 3ee Adjustment in Service Manual Thermostat Knob 1 Thermostat Shaft MV Knobetop 1 Control Bazal MV Includes Dial Dacal Dial Derai Control Includes Switch Dacal Pilot amp Pro Aimospharic Pint Mat Low Nox Pict Orica Pro Pict Orce Nat 11020 Pict Orica Pro 110 012 Hi Tension Wine 100 with Pilal Pilot Shak 47 6006268 OO2003F 008155 003901 01949835 D B7B4F D GT3TF 00981338 09499895 DOGBSEF 058905 DUB SSF 00172248 0873 ng133F pg4gsr DGD35F 007224 000158F 2 004078 0078684 our DESCRIPTION 2058 3358 mme Common Lia 4 R insulation sinps Hear Nat to Pro Pilot Pro Mat Pitot Mat 12 Pro II Pigi Pro Pigi Gas conversions are to be done only by qualified agency 48 51 Registered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada L4T 1G2 905 677 7999 Fax 905 677 8036 Litho in U S A
43. e access panels Figure 1 Disconnect wires at high limit AGS automatic gas shutoff and pressure switch on the inlet outlet header Figure 2 Electronic Ignition Heaters Remove the thermo stat temperature sensor by loosening the compres sion fitting nut Figure 3 Reroute the sensor to the left side of the heater Millivolt Heaters Remove the temperature sensor bulb and retainer clip from the sensor well Figure 4 Reroute the sensor bulb to the left side of the heater Remove 12 bolts holding the inlet outlet and return headers to the tube sheets Clean offtube sheet area where the gasket seats Also clean off the header and the gasket Apply a non petroleum based lubri cant to the gasket such as Aqua Lube Reattach the headers to the opposite sides making sure they are installed in an upright position Figure 5 Do not over tighten Torque should not exceed 7 ft lbs Reconnect high limit AGS and pressure switch wires Electronic Ignition Heaters Insert the temperature sensor inthe compression fitting and tighten 1 2 turn past hand tight Millivolt Heaters Insert sensor bulb and retainer clip into sensor well Allow for water flow through the heater and check for leaks 10 Reattach access panels to the opposite sides For ASME Models call your factory representative BULB amp CLIP ACCESS PANEL JACOFITTING NOTE Tighten almost flush Fig 3 1 32 to 1 8 to the header to avoid le
44. e connection or failed motor Incorrect wiring replace blower ELECTRICAL STANDING PILOT MILLIVOLT RAYPAK POOL ORSPAHEATER ELECTRICAL CHECK WITH MV GAS VALVE CAUTION For qualified service personnel only 1 Filter must be on with adequate water flow through heater 2 Gas valve must be ON position Thermostat set higher than pool water temperature 3 Jumpers are for temporary check only If left in place they could cause the heater to burn up Light pilot If pilot burner goes out If pilot burner when main burner lights does not light or when gas valve knob Jump across both TH 5 released Check gas supply gas wires on gas valves line size gas pressure Also check for insects If main burner fires If main burner does not remove jumper fire remove jumper Jump across pressure switch terminals If pilot burner stays on If burner does not remain lit attach millivolt meter If main burner fires If main burner does not and read pilot output remove jumper fire remove jumper Problem is a wire or component short to if above 500m cabinet or low gas Clean filter Jump across thermostat pressure i replace gas valve Check for adequate water If main burner does If below 500mV check If pilot burner remains lit Replace Remove both TH or debris in pilot output wires from gas valve Relight pilot gas valve flow from filter If main burner fires NOT fire gas pressure Also check remove jumper
45. e it is wired to activate or deactivate the ORG BLK remote follow these steps 5 T 24VAC HOT BLU Press and hold all three buttons for 5 to 7 seconds 9494 7 PIN REMOTE WIRING CONNECTOR PART NUMBER 07 1494 REMOTE OPERATION The RP2100 Digital heater is equipped with the ability to work with external remote controls The Raypak supplied 7 pin remote wiring connector supplies power out to either a toggle switch or the switch contacts of a i iue third party remote The remote works by either making m or breaking the circuit created by the remote wiring The digital display format will change and indicate Typically a remote does not supply power to the heater REMon it only provides a switching function to turn the heater on or off If your remote is suppling its own voltage to the heater it will not work with the RP2100 and may C CHEN External remote control External remote control disabled active Fig 9489 Fig 9490 damage the digital circuit board Press either temperature button to switch remote modes IMPORTANT Please Read When the heater is to be controlled by a remote you must choose REMon and the heater thermostat dis play mustbe in the OFF mode Ifthe heaterthermostat is left in a heat mode the heater will operate to this setting and the remote shut off feature will not be functional Note Electrostatic Dis
46. ertical height above the drafthood outlet The vent cap location shall have a minimum clearance of 4 feet horizontally from and in no case below unless a 4 foot horizontal distance is main tained 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 compli ance 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 construc tion 10 OR LESS go CAP Type B double wall orequivalentvent pipe 15 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 Canada CAN CGA B149 1 and 149 2 MIN Fig RP8119 2 GAS SUPPLY CONNECTIONS Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valvelocatedoutsidethe rT heater jacket All gas pu piping should be tested after installation in ac cordance with local codes Fig RP 8090 0 CAUTION 7he 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
47. et outlet header loosen union s at gas pipe and slide boiler away from piping 6 Lift heat exchanger straight up using caution not to damage refractory 7 Reverse above procedure to reinstall Make sure the insulation strips are properly replaced on top of the refractory retainer a 9 27 Extension Pieces 2 TUBECLEANING PROCEDURE Establish a regular inspection schedule frequency de pending on local water condition and severity of service Do notletthe tubes clog up solidly Clean out deposits over 1 16 in thickness The heater may be cleaned from the return header 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 heater exchanger generally After reaming mountthe wire brush in place ofthe auger and clean out debris remaining in the tubes Another method is to remove the heat exchanger ream tubes and immerse heat exchanger in non inhibited de scale solvent for severe scale buildup DESOOTINGPROCEDURE CAUTION SOOT 15 COMBUSTIBLE EXERCISE EXTREME CARE Sootwill 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 Remove V baffles fr
48. for insects or debris in the pilot burner Jump across each high limit and remove Replace thermostat Jumper If output is still low Replace high limit that replace pilot generator caused heater to fire HOBERTSHEW TERMINAL ALOK Raw Output 700 100 1 Pilot generator disconnected from valve knob must Tnm be held down to keep pilot on 2 3 SE oe cea Ne White Negative OUTPUT Red Positive 2 5 Pilot Load 500 100 TUUM Pilot generator connected to valve Power applied to 2 pilot solenoid dar E TP Thermopile Robertshaw PP Power Pile Honeywell TH TP Common q Pe 3 Main Valve Load 200 100 Control Limit circuit closed All switches ON TP Thermopile Robertshaw TH E PP Power Pile Honeywell TH TP Common TH PP Common ELECTRICAL ELECTRONIC IGNITION TROUBLESHOOTING WARNING HIGH VOLTAGE For qualified technicians ONLY NOTE Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light To reset interrupt power to heater NOTE Before troubleshooting familiarize yourself with the start up and checkout TURN GAS SUPPLY OFF procedure TURN THERMOSTAT CALL Check line voltage power low voltage transformer limit controller thermostat POWER TO BOARD cont
49. g Totestthe operation ofthe Unitherm Governor place in hot water over 100 F and watch for movement against spring If there is no movement replace unit Fig 2011 LOW NOx POOL HEATERS The Raypak Low NOx Pool Heaters are certified and tested under the ANSI Z21 56 CSA 4 7 standards for gas fired pool heaters Theheatershould be installed to meetalllocal codes the latesteditions ofthe National Fuel Gas Code Z223 1 and the National Electrical Code ANSI NFPA 70 1 1 DETAIL A SEE DETAIL VIEW Fig 9361 OPERATION On call for heat the ignition system consisting of an electronic spark module gas valve and pilot system is energized Providing the pilotis proven blower will start running the main gas valve will open and the heater will operate When the operating control is satisfied the heater will shut down START UP PROCEDURES 1 Turnon power to the heater with gas supply off 2 Checkignition as follows a Setthe thermostat or controller to call for heat b Watch for continuous spark at the pilot burner c Check the ignition spark operation Time must be within the lockout timing period 15 or 90 seconds d Turn control down to end call for heat and wait 60 seconds on lockout models before beginning s
50. g function is required 1 Turn on power to the heater 2 Push the mode button to the POOL or SPA mode and setthe desired temperature for each eg 102 F Turnthe mode buttonto OFF and remove powerfromthe heater 4 On the Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and connectthe other side to either the ORANGE BLACK wire for SPA operation orthe BLACK ORANGE wire for POOL opera tion 5 Place wire nut on unused wire on the Remote Interface Harness 6 Install the 7 Pin Remote Interface Harness to the P8 connector and turn on power to the heater ARID BRIT PH 3 ARTILE SP Fig 9492 See instructions on previous page to activate the remote control 3 Wire Remote Control Using Three Position Switch Pool Off Spa or Low Off High This application assumes that multiple heating functions are required 1 Turn on power to the heater 2 Push the mode button to the POOL or SPA modes BLK ORN POOL and set the desired temperature for each EPA COMM eg 80 for Pool and 102 for Spa y Turnthe mode button to OFF and remove power from the heater 4 On Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and connectthe ORANGE BLACK wire for SPA operation and the B
51. ig 8097 1 20 INLET OUTLET HEADER ASME Flange Gasket Fig 8093 1 Header Flange UNITHERM GOVERNOR OPERATION CAUTION The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105 to 115 F despite continually changing flow rates from the filter and changing pool temperatures This narrowrangeis needed to prevent damaging condensation on the burners which will occur ifthe heater runsfor any length of time below 100 F Itis also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures U G PLUG Polymer UNITHERM N GOVERNOR GASKET INTERNAL AUTOMATIC BY PASS VALVE In addition to the Unitherm Governor a built in automatic by pass valveis provided in the in out header While the Unitherm Governor responds to the changes in water temperature in the heater the internal by pass valve automatically responds to changes in water pressure in the piping system Proper amount of water flow is maintained through the heater under varying pressures dictated by the conditions of the pump and filter BYPASS BODY SPRING EXTERNAL AUXILIARY BYPASS VALVE Where Required An auxiliary bypass valve should be used when flow rates exceed 125 GPM usually a high performance pump size larger than two horsepower will exceed this flow rate This valve is req
52. ket Header Flange CPVC Flange Nut CPVC eo Inlet i E Fig 2002 1 High temperature CPVC Header Flanges and header Flange Nuts are provided If there is any possibility of back siphoning when the pump stops it is suggested that a check valve or valves also be installed in the system 19 CAST IRON HEADRERS ASME MODELS Heater must be located so that any water leaks will not damage the structure of adjacent area High temperature 2 plastic pipe CPVC may be threaded directly into the header flanges This is notthe same as the Schedule 80 PVC pipe which is also colored gray PVC may be used immediately after the CPVC adapters 2 CPVC Adapters ASME Inlet Outlet Header PVC Pipe CAUTION NEVER install PVC directly into header flanges Use the 2 CPVC adapter supplied loose with the heater DO NOT use petroleum base assembly fluids Such as Petroleum Jelly or lubricating oil assembly lube is required use a silicon base such as Amoral etc There are two sets of flange gaskets supplied with your heater Use the appropriate gaskets for all your heater connections Discard unused set GASKET DESIGN 1 Accepts 1 1 2 copper tube or 1 1 4 galvanized pipe as a slip connection GASKET DESIGN 2 Accepts 2 copper tube as a slip connection The flange is threaded for 2 screw in pipe connections Also used with the 2 CPVC adapters 1 2 Fig 8095 1 F
53. om heat exchanger Remove burner drawer See pg 35 Remove heat exchanger from the heater and wash with a garden hose making sure soot is removed from spaces between fins Reverse above procedure to reinstall 2 3 4 5 NOTE n extreme cases it may be necessary to do steam cleaning at the local car wash DO NOT WIRE BRUSH COMBUSTION CHAMBERREMOVAL To remove combustion chamber you must first have removed the heat exchanger Unbolt metal combustion chamberretainerfromtop and remove combustion cham ber panels individually Fig RP 8155 0 REFRACTORY PANELS TOP VIEW Auger with Carbide Tip 36 Wire Brush Fig 8154 0 IMMERSION WELL REPLACEMENT Millivolt and ASME 1 Shutwater off to heater and drain heat exchanger 2 Remove access panel on water connection side of heater 3 Removeoldimmersion well with bushing and sleeve 4 Installin header NOTE nstallation in plastic should be hand tight plus 1 2 turn ES Assembly Fig 2010 UNITHERM GOVERNOR U G REPLACEMENT 1 Shut water gas and electricity off close valves and relieve pressure 2 Drainheatexchanger 3 Removeretainer plug located nextto the outlet pipe connection 4 Unsnap old U G to remove from retainer plug Snap in new U G 5 Reinstall retainer plug taking care to lubricate gas ket with a non petroleum based grease such as AquaLube Retainer Plug U G Sprin
54. ooting High flow U G Inoperative Air i e ERR TT Improper Insects or debris clogging burner intake ports Pilot outage Low gas pressure I estricteduplobe 222000 8 Weak pilot generator Yellow lazy flame Low gas Insects or debris clogging burner intake ports Outer jacket very hot paint blistered Broken refractory caused by shipping damage or improper COMDUSUOM Excessive sooting of heat exchanger 22222100 02012008 Takes long time to heat pool or spa Calculate temperature in hr Filter not running long enough Py Gas line or meter undersized Liming Bypassing too much Gano iN a 22 2 2 2 72 Leaking at well TOT Leaking at heat exchanger Overa cid 2222 E Gasket brittle and leaking overheated Heater running after pump Refractory Sooted Combustion fan not running Indicates symptom which usually occurs on initial start up 39 SOLUTION Check movement by putting in hot water 1
55. op from the louvered top and discard See Fig 3 nds 3 Remove the louvered top and set aside saving the m four phillips screws for reassembly See Fig 3 Visser lcs 4 Remove and discard the rain shield See Fig 4 5 Install adapter plate on top of heater flue collector See Fig 5 6 Reinstall louvered top on heater and fasten with Phillips screws set aside in step 3 13 SECURING THE TOP PANEL COVER INDOOR KIT ONLY DOWN OVER ADAPTER LIP 7 Reinstall the louvered top 8 Mountthe drafthood onto adapter plate lip inside the heater See Fig 6 9 Proceed to installing the clips step 14 SECURING THETOP PANEL COVER OUTDOORKIT ONLY 10 Afterremoving the drafthood from the box slide the top panel cover over the draft hood 11 Holding both pieces together mount the draft hood onthe adapter plate lip inside the heater See Fig 6 12 Take the two pieces of tape and attach to each side ofthe drafthood leaving 6 hanging down 13 Slide the top panel coverup and attach the tape to the underneath side This is to temporarily keep the top panel cover out ofthe way while you are attaching the clips as shown in the next steps See Fig 7 INSTALLING THE CLIPS INDOOR 8 OUTDOOR KITS 14 Noticethatthere arethree pilot holes above the base of the drafthood as shown Fig 8 These are FIG 7 locations where the three clips are to be attached 15 Insertthelong edge of one
56. opane is EP Natural gas is EN Prefix C is for Cast Iron ASME Headers P is for Plastic Polymer Headers Atmospheric heaters reduce input 496 for each 1000 ft above sea level when installed above 2000 ft elevation Low NOXx heaters for elevations above 5 000 feet consult factory For Canada no de rating is required for elevations up to 4500 feet Manufactured under Patent No 3 623 458 Note Plastic Polymer headers cannot be used for ASME installations Hm 3 n 11 3 Adr Par c URAFTHOUD i i PTa eee SYSTEM SWITCH 4 EIER R NES LI E 18 STACEKLESS OUTDOOR 25 1527 ASME IINE 21 114 1 11 14 345 T T f iud t m i OMETE A a 24 2 COMBOETIELE 9037 2 mm Electrical Connection On Left Side 15 19 1 8 m COMBUSTION AND VENTILATION AIR a All Air From Inside The Building Indoor Units Only Each opening shall have a minimum net free square inches as noted The heater musthave both combustion and ventilation air Minimum requirements for net free air supply openings 4 Square Inches Model Square Inches one opening that is 12 inches from the ceiling for 185 181 390 393 ventilation and one openingthatis 12 inchesfromthefloor 265 264 405 399
57. or indoor installation when equipped with the approved draft hood For Canada indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with occupied area Refer to the latest edition of CAN CGA B149 1 and B149 2 for specific requirements Locate heater as close as practical to a chimney or gas vent Heater must always be vented to the outside See Vent Piping section pg 17 for venting details Minimum allowable space is shown on the nameplate WARNING Indoor boilers require a drafthood 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 OUTDOOR STACK INDOOR STACK INSTALLATION NOTE The outdoor and indoor stack are optional equipment and do not come standard with the heater OUTDOORKIT INCLUDES INDOOR KIT INCLUDES 1 Draft hood painted 1 Draft hood unpainted 1 Adapter plate 1 Adapter plate 3 Mounting brackets clips 3 Mounting brackets clips 1 Top panel cover A 3 Screws 2 1 foot sections of metal tape 1 Instructions 3 Screws 1 Instructions OUTDOORSTACK INDOORSTACK Part No Part No 006751 006696 006752 006697 006753 006698 006754 006699 mai ASSEMBLY PROCEDURE 1 Makesurethatthe gas and electricity to the unithas beenturned off 2 Removethe pagoda t
58. perature MODE DISPLAY POOL or SPA call for heat FLAME ICON WATER SETPOINT TEMPERATURE TEMPERATURE 30 PROGRAM MODE BUTTON Fig 9481 Set Points The electronic thermostat cannot be set above selected maximum set points The maximum default set points are factory set at 104 F for both pool and spa These can be changed to a higher or lower value to suit your needs but can never be set above 107 F Program Mode Button To adjust the set point press the Mode button until the display reads OFF Remove the four screws holding the control cover on Swing control panel down so the back side of the board is visible see page 27 Locate the Program Mode button as show in figure 9481 Hold this button and use the Mode button to select Set on the digital display You can release the button once Set appears Using the Up and Down buttons will change the Maximum Temperature Setting The control can be set for a maximum of 107 F A separate value can be set for either Pool or Spa by using the Mode button to select Pool or Spa and using the Up and Down arrows to select the desired Max temp for each Once this is done reassemble the control panel Fahrenheit vs Centigrade The digital display is capable of displaying Centigrade as well as Fahrenheit temperatures To change the display follow the instruction above to access the Program Mode Button Hold this button and use the Mode button
59. peratures by as much as 4 F 226 5 Persons with a medical history of heart disease circulatory problems diabetes or blood pressure problems should obtain a physician s advice before using pools or hot tubs 6 Persons taking medications which induce drowsi ness such as tranquilizers antihistamines or anti coagulant should not use spas or hot tubs SECTION 3 MAINTENANCE AND CARE PROCEDURES To be followed one month after start up and then semi annually 1 Inspecttop of heater and drafthood for soot a sticky black substance around finned tubes and V baffles and open flue gas passage ways Any visible soot should be cleaned for proper operation CAUTION Soot may be combustible Wet sooted surfaces completely priorto cleaning Do notuse steel wire brush 2 Clean main burners and pilot burner of dust and lint 3 Inspect and operate all controls gas valve and pressurerelief valve 4 Make visual check of the burner and pilot flame Flame pattern on the main burner and pilot is indi cated 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 the latter occur shut the heater off and contact your gas supplierorqualified service agency 5 indoor heaters clean room intake openings to assure adequate flow of combustion and ventilation air CAUTION Combustion air must not be
60. place PC board CALL FOR HEAT ENDS Check for proper thermostat controller operation SYSTEM SHUTS OFF Remove MV lead at module if valve closes recheck temperature controller and YES wiring if not replace gas valve TROUBLESHOOTING ENDS Repeat procedure until trouble free operation is obtained 41 DIGITAL CONTROL LOGIC FLOW CHART Check switch under lid on control Check for 120 240 volts to the temperatura displayed time clock circuit breaker wire connections Check for 24 volts to Circuit Board PB connector YES REM and Waler Temperature displayed and flashing remote is cantralling the Nite Disconnect the remote by turning the remote function off See page 32 fnr instructions Push Temp arrow scroll to desired temperature SERVICE displayed and flashing 5 Tegan sensor TI replace sensor Sansor Failure Inspect thermister wires and connector at F1 Check resiziance value of the thermisier to chart below Replace if not within 111 of value shiar II raplaca 2100 Board Sensor resislanoca varous pid Ws LUE Temp Degnes Fj 40 20 60 70 BO 90 106 2871 1718 8 69 0 72 3 58 display briefly risa 583515 Hokey replaces RP2100
61. placement under standard com RAYPAK INC pany warranties must be properly tagged with a Raypak 2151 Eastman Avenue return parts tag completely filled in with the heater serial Oxnard CA 93030 number model number etc and shipped to the Com pany freight prepaid For Canada RAYPAK CANADALTD 2805 SLOUGH STREET MISSISSAUGA ONTARIO L4T 1G2 43 ILLUSTRATED PARTS LIST OPTIONAL 12 5 3 15 4 2523 AD FOR UNITS WITH ASM OPTIONAL Fig 208225 O2 TICNAL 44 LOW NOx BURNER TRAY Honeywell IID Atmospheric units Fig 8124 Honeywell IID Low NOx and Atmospheric units 89369 for units produced prior to 06 01 2000 for units produced after to 06 01 2000 Use KIT Number 008155F for Low NOx units Use KIT Number 002003F for Atmospheric units Honeywell MV Fig 48107 45 OOS FF D05221F 15225 0052260 5232 005237 301210613 Burner 51 Sea Burner Orifice Pro 857 Sea Level Burnar Hold Down Burner Burner Orifice Hat 30 0 50 017 Burner Orifice M31 above 5000 ermostal Auto Reset 135 Surface Maunt AGS 135 Gas Shut Off Red Epoxy High Limit 140 Black Epoxy C Board Contral 10 Units Combination Valve Hat Combination Valve Pro MV Header includes BHF Ratum Header In
62. pump or an outdoor condensing unit Strong airintake from these equipment can disturb the combustion process and cause damage or personal injury HEATERWITH OUTDOORSTACKLESS TOP VENT TERMINAL Outdoor Stackless Top Installation Outdoor Top 1 Insert tabs into keyhole 4 places __ Pagoda Top Shipped Loose with NC Heater 2 Snaptabs into keyholes so as not to pull out Fig 8278 2 Ne p M Fig RP8280 1 Heaters must installed under an overhang ofless than three 3 feetfrom the top of the heater Three 3 sides must be open inthe area under the overhang Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters For U S installations 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 inletinto any 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 For installations in Canada pool heaters shall not be installed with the top of the vent assembly within 10 feet below or to either side of any opening into the building Refer to the latest revisions of CAN CGA B149 1 and Fig 8245 1 B149 2 Forced Ar iriti U S Installations only 12 INDOORHEATERINSTALLATION The design is also certified f
63. reconnecting the heater and its manual shut off valve to gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVER PRESSURED GAS VALVES ARE NOT 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 17 NOTE Donotuse Teflon tape on gas line pipe thread A flexible sealant is recommended A minimum of 7 W C and a maximum of 14 W C upstream pressure under load and no load conditions must be provided for natural gas or a minimum of 12 W C and a maximum of 14 for propane gas GAS PRESSURE REGULATOR The gas pressure regulator is presetat4 W C for natural gas and 11 W C for propane gas The pressure atthe gas valve taken with a manometer should be about 3 7 W C natural gas 3 9 W C for Low NOx and 10 5 W C propane gas If an adjustmentis needed remove seal and turn adjustment screw clockwise to increase pressure or counter clockwise to decrease pres sure MANOMETER Manometer GAS PRESSURE TEST AT MANIFOLD TAP Manual Shut off Valve Gas Pressure Test at Gas Valve Fig 8149 Fig 9365 ATMOSPHERIC LOW NOx GAS PRESSURE ADJUSTMENT LOCATIONS MILLIVOLT GAS VALVES Gas Adjustment Za Fig 9263 Robertshaw 7000 Models 185 thru 405 ELECTRONIC IGNITION GAS VALVES Gas Pressure c Adju
64. roller and wiring 24 V NOMINAL YES Pull ignition lead and check spark at PC board SPARK ACROSS IGNITER SENSOR GAP Spark Okay YES YES 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 TURN GAS SUPPLY ON Check that all manual gas valves are open supply tubing and pressures are good PILOT BURNER LIGHTS and pilot burner orifice is not blocked YES Check electrical connections between PC board and pilot operator on gas control Check for 24 Vac across PV MV PV terminals on PC board If voltage is okay replace gas control if not replace PC board NOTE If PC board goes into lockout reset system Lockout is used on L P G models MAIN BURNER LIGHTS Check for 24 Vac across MV MV PV terminals If no voltage replace module YES Check electrical connections between PC board and gas control If okay replace gas valve or gas control operator i e pilot gas valve flow switch etc SYSTEM RUNS UNTIL NOTE IF PC board goes into lockout reset system CALL FOR HEAT ENDS YES 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 re
65. shing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads We recom mend use of insulated vent pipe spacer through the roofs and walls Another option for installation that requires horizontal runs is using the D 2 power vent kit option Power Vent Kit Part No 008086 008086 008087 008087 9469 Optional Raypak D 2 Power Vent For more detailed D 2 installation information consultthe D 2 Power Vent manual 6000 57 The power vent assembly is a fan assisted combustion system designed for application to Raypak Pool Heater Models 185 405 Theunit when installed as directed is capable of operating in applications such as through the wall venting and reduced horizontal and vertical vent pipe sizes in new and current installations It is certified for Category Ill venting up to 40 feet equivalent 4 diameter venting Theunitis factory wired for 240V with capability ofrewiring for 120V For protection against rain orblockage by snow the vent pipe mustterminate with a vent cap which complies with the local codes or in the absence of such codes to the latest edition of the National Fuel Gas Code ANSI 2223 1 Canada CAN CGA B149 1 and B149 2 The discharge opening must be a minimum of two feet vertically from the roof surface and atleast 2 feet higher than any part of the building within 10 feet Vent stack shall be at least five feet in v
66. stment Honeywell VR8304 Models 185 thru 405 xr ae d Fig 9264 18 ELECTRONIC IGNITION GAS VALVES CONTINUED Fig 9328 Fig 9329 Gas Pressure Adjustment Robertshaw 7200 Robertshaw 7000 BDER Model 185 Model 265 335 Gas Fig 9327 Pressure Adjustment Robertshaw 7000 DERHC Model 405 PIPE SIZING FOR GAS CONNECTIONS MAXIMUM EQUIVALENT PIPE LENGTH Natural Gas 1000 BTU FT 60 Specific Gravity 0 5 WC Pressure Drop Propane Gas 2500 BTU FT 1 53 Specific Gravity 0 5 WC Pressure Drop va 34 1 1 14 1 112 N P 1858 15 30 65 95 250 400 2658 10 20 40 60 140 250 560 3358 15 25 35 85 150 380 4058 15 25 60 100 260 250 Low NOx units are not available in propane PLUMBING FOR WATER CONNECTIONS HEATER LOCATION Relative to the pump and filter The RP 2100 heater requires water flow and positive pressure tofire and operate properly It musttherefore be installed downstream of the discharge side of the filter pump A typical installation is plumbed as follows 1 The inlet side of the filter is plumbed directly to the discharge side of the filter pump 2 Theoutletside ofthe 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
67. tep 3 Turn on gas supply Set controller to call for heat System should start as follows a Spark will turn on pilot gas valve will open and the blower will begin running b Heater will operate until call for heatis satisfied p 37 BURNER ADJUSTMENT This burner assembly does not require any primary air adjustments BLOWERADJUSTMENT The Raypak RP2100 Low NOx pool heater is equipped with a combustion air baffle mounted at the air intake to the combustion air blower The baffle has a slot that is utilized to align with a square window cutout on the shutter assembly Thefactory setting will be adequate for most field condi tions and adjustment will not normally be required However in some cases field conditions including un usual gas characteristics may create a need for adjust ment to achieve optimum performance When the com bustion air setting is proper there will be some lifting of the flames on some areas ofthe burner deck under cold start conditions After aboutfive minutes of operation the flames should settle down and blue tips should become visible Lifting of flames beyond the five minutes would indicate too much combustion air Loosening the knurled screw and opening the air baffle move to the left increases the amount of combustion air closing it move to the right decreases the amount of combustion air After a steady blue flame is attained the knurled screw must be re tightened VISUAL INSPEC
68. to select F C on the digital display The Up and Down buttons will select F or C on temperature display Once this is done reassemble the control panel NOTE The digital temperature display may not coincide with temperature reading of your pool spa thermometer The RP2100 reads the water temperature at the inlet of the heater Due to the circulation characteristics of any pool or spa the water temperature at the inlet to the heater may differ from that observed at a given location in the pool or spa DIAGNOSTICS READING A FAULT The RP2100 Digital heater is equipped with on board The word SERVICE will flash on and off if the PC board diagnostic controls If there is a safety fault a fault code detects a known fault The fault will be displayed in will be displayed along with a service indication three big letters on the lower left of the display If the PRS fault code is displayed it indicates that SERVICE WILL FLASH there is insufficient flow through the heater Make sure the pool filter and pump strainer are clean before calling a service representative SERVICE CLEAN FILTER STRAIMER SERVICE PRO 7 STATUS CODES Display X Definition CFH Call for heat CLK Time clock LOW Caution low water temperature OFF Off mode REM Remote control activated SPK Spark SPR Spare fault code indicator ONE SPA Fig 9485 3 LETTER FAULT CODE Fig 9482 See table for fault definition FAULT CODES Displ
69. uired 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 down below 50 F It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the flow rate to the spa jets etc From Heater To Heater Fig 2003 To Pool From Pool AUXILIARY BYPASS VALVE DO NOT USE GATE VALVE Fig 8150 0ss 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 comfort able tothe touch If pipe hot close bypass if cold open bypass 21 PRESSURERELIEF VALVE INSTALLATION To conform to local building codes it may be necessary to install a pressure relief valve A 3 4 pressure relief valve having a capacity equal to BTU HR output of the modelto be installed is recommended for this heater The maximum acceptable pressure relief valve setting is 125 psi A 3 4 connection is provided in the plastic header for installation ofa pressure relief valve The valve shall be installed in a vertical position notover tighten Install pressure relief valve hand tight plus 1 2 turn POLYMERHEADER Pressure Relief Valve PRV Discharge Connection Inlet Outlet Header Fig 2004 A 3 4 connection is provided in the header for installation of

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