SECTION 1 / START-UP PROCEDURES Your Raypak Pool/Spa heater has been designed for years of safe and reliable pool/spa water heating. Reduce input 4% for each 1000 ft. above sea level when installed above 2000 ft. elevation. ELECTRONIC CONTROLS The pool heater thermostat on the upper front panel of the heater controls the pool/spa water temperature. 3,623,458. SECTION 5 / TROUBLE SHOOTING 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. 2. 2. 1. #RP8280.1 Heaters must not be installed under an overhang of less than three (3) feet from the top of the heater. This control center contains a mode button, up and down temperature adjustment buttons, and a LCD display. ELECTRICAL ( STANDING PILOT MILLIVOLT) RAYPAK POOL OR SPA HEATER ELECTRICAL CHECK WITH MV GAS VALVE CAUTION: For qualified service personnel only. If determined defective by the Company and within warranty, the part will be returned in kind or equal substitution, freight collect. VENT PIPING WARNING: Indoor boilers require a drafthood that must be connected to a vent pipe and properly vented to the outside. 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. Outdoor Top Pagoda Top (Shipped Loose with Heater) 2. If left in place, they could cause the heater to burn up. The heater may be cleaned from the return header side, without breaking pipe connections. SECTION 2/CAUTION AFTER START-UP Feel the inlet and outlet pipes. WIRING DIAGRAM - IID UNITS (atmospheric) 22. NOTE: Do not use teflon tape on gas line pipe thread. Filter must be on with adequate water flow through heater. 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. 4. Make visual check of the burner and pilot flame. 3. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters. The touch pad on the control panel allows you to select the desired pool or spa temperature. Open drain plug located on the inlet/outlet Drain Plug header, (under water pipes). This manual should be maintained in legible condition and kept adjacent to the. RP2100+ Heat Exchanger Reversal Procedure (Capron Resin Header Models) 1. 4. 8. LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES MANUALLY LIGHTED PILOTS MILLIVOLT SYSTEM A. Locate heater as close as practical to a chimney or gas vent. Spa or hot tub water temperatures should never exceed 104F (40C). It is factory set at 1.75 PSI for deck level installations. Remove gas piping to gas valve inlet. JACO FITTING Fig. ADDENDA: 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. HEATER WITH OUTDOOR STACKLESS TOP VENT TERMINAL (Outdoor) Stackless Top Installation 1. A 3/4" NPT connection is provided in the inlet/outlet header for installation of a pressure relief valve. Flame pattern on the main burner and pilot is indicated in the previous illustration. WARNING HIGH VOLTAGE For qualified Technicians ONLY ELECTRICAL (ELECTRONIC IGNITION IID) NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. A flexible sealant is recommended. Shut off main electrical power switch to heater. The initial connection to the heater is made with a 2" PVC union adapter to which PVC may then be connected with appropriate cement. 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. GAS PRESSURE REGULATOR Fig # 9328 The gas pressure regulator is preset at 4" W. C. for natural gas, and 11" W. C. for propane gas. 7. TO WHOM IT MAY CONCERN: The new Raypak series RP2100 pool heaters have been designed to eliminate the need for conventional heat sinks (high temperature piping). Extension Pieces (2) Auger with Carbide Tip TUBE CLEANING PROCEDURE Establish a regular inspection schedule, frequency depending on local water condition and severity of service. *If you cannot reach your gas supplier, call the fire department. SECTION 4 / SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS Drain Plug (Located in Return Header) CONTROLS/ADJUSTMENTS/REPLACEMENTS Bypass Temperature Adjust Buttons Hi Limit (Located in Return Header) Mode Button LCD Display AGS HiLimit (Located in Inlet/ Oulet Header) Ignition Control (IID) Digital Thermostat Module Unitherm Governor Roll-Out Switch Fig. Ltd, 7 Geddes St., Mulgrave, Victoria, Australia 3170 (6139) 560 4944 FAX (6139) 560 4974 Litho in U.S.A. SPECIFICATIONS AND DIMENSIONS *Designation for Propane is "EP", Natural gas is "EN". SECTION 3 / INSTALLATION INSTRUCTIONS IMPORTANT NOTICE CLEARANCES ALL HEATERS For clearances from combustible surfaces, see the chart below. In addition to the Unitherm Governor, a built-in automatic by-pass valve is provided in the in/out header. Vent piping the same size as the draft hood outlet is recommended, 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 10 of the National Fuel Gas Code, ANSI Z 223.1. Remove front door. Shut off gas upstream of heater. 7. Fig. Disconnect gas line from gas valve. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning. Manufactured under Patent No. RP2100 REMOTE CONTROL INSTALLATION 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. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters. For Low NOx pool heaters wire nut each red wire independently. Shut off gas supply to the heater. For 120 V input power to the unit, connect the black wire to the L1 or hot leg of the power supply. Remove right and left side access panels (Figure 1). Do not try to light the pilot by hand. The MODE button functions as a means to turn the heater off or on in either the pool or spa temperature setting. 2. ELECTRONIC IGNITION GAS VALVES-CONTINUED 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. It should not be hot. # 8278.1 Fig. For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with occupied area. Do not over tighten. When lighting the pilot, follow these instructions exactly. Gas valve must be "ON" position. ASME certified units, typical used in commercial applications, are also available. WINTERIZING THE POOL & SPA HEATER Return Header When heaters installed outdoors in freezing climate areas are to be shut down for the winter, observe the following step-by-step procedure: 1. The valve shall be installed in a vertical position. Prefix "C" is for Cast Iron (ASME) Headers; "P" is for Plastic (Capron) Headers. Fig. Lifting or blowing flame indicates high gas pressure. ELECTRICAL WIRING Option Location For Left Side Field Wiring Control Box (Factory Mounted Location) NOTE: If 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. OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES AUTOMATICALLY LIGHTED PILOTS ELECTRONIC IGNITIONS SYSTEMS A. B. This newly authorized piping arrangement is described in the installation manual provided by Raypak, and has been successfully tested by Raypak to assure its acceptability. Above input ratings are per A.G.A. INDOOR HEATER The design is also certified for indoor installation when equipped with the approved draft hood. LIMITED WARRANTY RAYPAK RESIDENTIAL SWIMMING POOL AND SPA HEATERS GAS MODELS 185, 265, 335 & 405 MILLIVOLT 185, 265, 335 & 405 ELECTRONIC GENERAL Raypak, Inc. warrants that the cabinet, burner tray (minus controls) and refractory will be free from defects in materials and workmanship under normal use and service for a period of FIVE YEARS FROM THE DATE OF ORIGINAL PURCHASE FOR A SINGLE FAMILY RESIDENCE (ONE YEAR IF OTHER THAN FOR SINGLE FAMILY RESIDENCE USE). The heater should be installed to meet all local codes, the latest editions of the National Fuel Gas Code Z223.1 and the National Electrical Code, ANSI/NFPA 70. Yellow flame means restriction of the air openings. Remove front door. Electronic Ignition Heaters: Remove the thermostat temperature sensor by loosening the compressionfitting nut (Figure 3). Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START TURN GAS SUPPLY OFF. ADDENDA: LOW NOX HEATERS (CONTINUED) 6. If your state is such, be sure your contractor bears the appropriate license. It is available in millivolt or electronic control options. Should this occur, shut the heater off and contact your gas supplier or qualified service agency. heater or kept in a safe place for future reference. SECTION 6/REPLACEMENT PARTS LIST NOTE: To supply the correct part it is important that you state the model number, serial number and type of gas when applicable. B. GAS VALVE REMOVAL 1. Insert tabs into keyhole (4 places). #8107 38 Fig. Disconnect wires at high limit, AGS (automatic gas shutoff), and pressure switch on the inlet/outlet header (Figure 2). Snap tabs into keyholes so as not to pull out. VISUAL INSPECTION Flame can be observed through the slot opening above the plenum. Shut off main electrical power switch to heater. Note: Plastic (Capron) Headers cannot be used for ASME installations. This appliance has a pilot that must be lighted by hand. 2. Fig # 9363 IID PILOT Fig # 9362 PILOT REMOVAL LOW NOx BURNER TRAY ASSEMBLY BURNER DRAWER REMOVAL 1. Attach the wire nut to the red wire. Slide out burner tray. The LCD display indicates the mode the heater is in and the actual water temperature. Reverse above procedure to reinstall. For Canada, no de-rate is required for elevations up to 4500 feet. Jumpers are for temporary check only. 3. Remove (2) screws that mount burner tray to unit, and (2) screws that secure gas valve to jacket. 2. 6000.52-Z Effective: 11-01-01 Replaces: 08-01-01 INSTALLATION AND OPERATING INSTRUCTIONS Models P-R185A to P-R405A C-R185A to P-R405A Low NOx P-R185AL to P-R405AL C-R185AL to C-R405AL RP2100 SWIMMING POOL and SPA HEATER WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Installation and service must be performed by a qualified installer, service agency or, Do not store or use gasoline or other flammable vapors and liquids in the vicinity of, - Raypak Swimming Pool And Spa Heater Operating Instructions, RP2100, P-R185A, P-R405A, C-R185A, P-R405A. The maximum acceptable pressure relief valve setting is 125 psi. 2. 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. Shut off gas upstream of heater. Installation and service personnel may be required by some states to be licensed. 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. Outlet pipe should be only slightly warmer than the inlet. 5. Credit will not be issued. 6. #4 RE-INSTALLED IN/OUT HEADER ON OPPOSITE SIDE. PART ONE - OWNER'S OPERATING INSTRUCTIONS FOR YOUR SAFETY - READ BEFORE OPERATING WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. INTERNAL AUTOMATIC BY-PASS VALVE Plumbing from the heater back to the pool must not have any valves or restriction that could prevent flow when the pump is operating. explosion may result causing property damage, personal injury or death. See Vent Piping Section for venting details. 4. A 3/4" pressure relief valve having a capacity equal to BTU/HR output of the model to be installed is recommended for this appliance. 1. WIRING DIAGRAM KEY PINK CONNECTOR BLUE CONNECTOR Fig. Reverse above procedure to re-install. Three (3) sides must be open in the area under the overhang. CAUTION: Propane gas is heavier than air and will settle on the ground. The digital liquid crystal (LCD) display shows the actual pool temperature, operating status, and service codes (See examples below). CATALOG NO. Low flame means low gas pressure. 5. 4. Disconnect gas line from gas valve. Clean out deposits over 1/16" in thickness. #2000 Drain Plug Gas Valve Pilot On-Off Switch Transformer Fig #2005 CONTROL PANEL REMOVAL 1. BURNER ADJUSTMENT This burner assembly does not require any primary air adjustments. Connect the white wire to the L2 or neutral leg of the power supply. Low NOx BURNER TRAY PILOT ASSEMBLIES 3-P 3-P 7-P 3-P 14-P 16-P 16-P 17-P Honeywell IID Atmospheric units Fig. #3 BULB & CLIP Fig. WARNING: If the information in these instructions are not followed exactly, a fire or. Elevated water temperature can be hazardous, and the U. S. Consumer Product Safety Commission recommends the following guidelines: WARNING: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control to the appliance. Refer to the latest edition of CAN/CGA-B149.1 and B149.2 for specific requirements. Thermostat set higher than pool water temperature. 3. There should be no connection to the red wire for 120V operation. #8124 for units produced prior to 06/01/2000 Honeywell IID Low NOx and Atmospheric units for units produced after to 06/01/2000 Use KIT Number 008155F for Low NOx units Use KIT Number 002003F for Atmospheric units 1-P 9-P 15-P 13-P 5-P 16-P Honeywell MV Fig. specifications. To reset, interrupt power to heater. BURNER DRAWER REMOVAL 1. # RP8096 WIRING DIAGRAM MILLIVOLT UNITS WITH MECHANICAL THERMOSTAT Fig. CONTENTS 4 PART ONE OWNER'S OPERATING INSTRUCTIONS 4 SECTION 1 START-UP PROCEDURES 4 5 Before Start-Up Lighting Instructions & Shut-Off Procedure (Manually Lighted Pilot MV) Operating Instruction & Shut-Off Procedures (Automatically Lighted Pilot IID) After Start-Up 6 7 7 SECTION 2 CAUTION 7 SECTION 3 MAINTENANCE & CARE PROCEDURE 8 8 9 Pool & Spa Water Chemistry Cold Weather Operation Winterizing the Pool & Spa Heater 9 PART TWO INSTALLATION/SERVICE INSTRUCTIONS 24 SECTION 4 SERVICING INSTRUC. Heater must always be vented to the outside. Do not let the tubes clog up solidly. CAUTION: Propane gas is heavier than air and will settle on the ground. 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. Larry J. Ashton, P.E. This appliance is equipped with an ignition device which automatically lights the pilot. Reroute the sensor to the left side of the heater. 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 Raypak Australia Pty. Use a long 9/16 socket wrench to remove orifices from the gas manifold. 3. It is located on the inlet/outlet header. Remove the heat Fig. Turn off gas valve, manual gas valve, and electrical supply to the heater. PRESSURE SWITCH The pressure switch, or heater actuator, insures that the heater operates only when the filter pump is in operation. BEFORE LIGHTING smell all around the appliance area for gas. PRESSURE RELIEF VALVE INSTALLATION To conform to local building codes, it may be necessary to install a pressure relief valve. Disconnect wires that terminate at gas valve.
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