Raypak Swimming Pool Heater P R185B To P R405B, C R185B To P R405B, P R185BL To P R405BL, C R185BL To C R405BL, RP2100 User Guide

CATALOGNO.6000.52-AH

Effective: 11-01-03

Replaces: 09-01-03

INSTALLATION

AND OPERATING

INSTRUCTIONS

Models

P-R185B to P-R405B

C-R185B to P-R405B

Low NOx

P-R185BL to P-R405BL

C-R185BL to C-R405BL

RP2100

SWIMMING POOL

and

Fig.#9478

SPAHEATER

WARNING: If the information in these instructions are not followed exactly, a fire or

explosion may result causing property damage, personal injury or death.

— Do not 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'sinstructions.

• 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.

Thismanualshouldbemaintainedinlegibleconditionandkeptadjacenttothe

heater or kept in a safe place for future reference.

Part No. 240612

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CONTENTS

PARTONE

OWNER'SOPERATINGINSTRUCTIONS

SECTION4

SERVICINGINSTRUCTIONS

GeneralLocationofControls

ControlAdjustments

SECTION1

START-UPPROCEDURES

DigitalThermostatControls

Digital Diagnostics and Faults

RemoteControlOperationandInstallation

Pressure Switch Adjustment

Flame Roll-Out Safety Switch

HighLimitRemoval

Pilot Safety Millivolt and IID

BurnerDrawerRemoval

GasValveRemoval

MainBurnerandOrificeRemoval

PilotRemovalandCleaning

HeatExchangerRemoval

TubeCleaningProcedure

DesootingProcedure

ImmersionWellreplacement

UnithermGovernor(U.G.)Replacement

LowNox

BeforeStart-Up

LightingInstructions&Shut-OffProcedure

(ManuallyLightedPilotMV)

OperatingInstruction&Shut-OffProcedures

(Automatically Lighted Pilot IID)

AfterStart-Up

SECTION2

CAUTION

SECTION3

MAINTENANCE&CAREPROCEDURE

Pool & Spa Water Chemistry

ColdWeatherOperation

Winterizing the Pool & Spa Heater

PART TWO

INSTALLATION/SERVICEINSTRUCTIONS

SECTION5

TROUBLESHOOTINGGUIDE

Mechanical

SECTION1

RECEIVINGEQUIPMENT

Electrical MV Units

Electrical IID Units

DigitalControlLogic

SECTION2

GENERALSPECIFICATIONS

SECTION6

REPLACEMENTPARTS

SECTION3

INSTALLATIONINSTRUCTIONS

IPLDrawing

PartNumbers

Clearances

OutdoorInstallation

IndoorInstallation

SpecificationsandDimensions

CombustionAir

Vent Piping

Gas Supply Connections

Gas Line Sizing Chart

Plumbing For Water Connections

RP2100HeatExchangerReversalProcedure

Electrical Wiring

TransformerWiring

WiringDiagram-Millivolt(MechanicalTherm.)

WiringDiagram-Atmospheric

WiringDiagram-LowNOx

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PARTONE-OWNER'SOPERATINGINSTRUCTIONS

FORYOURSAFETY-READBEFOREOPERATING

WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY

RESULT,CAUSINGPROPERTYDAMAGE,PERSONALINJURYORLOSSOFLIFE.

SECTION 1 - START-UP PROCEDURES

YourRaypakPool/Spaheaterhasbeendesignedforyearsofsafeandreliablepool/spawaterheating.Itisavailable

in millivolt or electronic control options. ASME certified units, typical used in commercial applications, are also

available.Thismanualprovidesoperation,installation,maintenance,andserviceinformationfortheseheaters.

OFF

Fig.#9472

If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the heater

containsthecontrolcenterthatallowsyoutoturntheheateronoroffandadjustthetemperaturesettingsforthepool

or spa. The temperature range is factory set from 65°F (18°C) to 104°F (40°C). The heater is also equipped with a

toggleswitchtoturntheheateronandoff,seefig.#9472aboveforlocation.Section4ofthismanualcontainsmore

details about the use of the controls in the Controls Adjustments subsection.

BEFORESTART-UP

BURNERS

WATER

Clean main burners, combustion fan and air louvers of Water must be flowing through the heater during opera-

dust,lintanddebris. Keepheaterareaclearandfreefrom tion. Insurethatsystemisfilledwithwaterandhavepump

combustibles, flammableliquidsandchemicals. Donot operating.

obstruct the flow of combustion and ventilating air.

Fig.#9478

RP2100DIGITALIIDPOLYMER

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CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in

confined areas, extra care should be exercised when lighting propane heaters.

LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES

MANUALLY LIGHTED PILOTS

MILLIVOLT SYSTEM

*If you cannot reach your gas supplier, call

the fire department.

This appliance has a pilot that must be lighted

by hand. When lighting the pilot, follow these

instructions exactly.

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.

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.

*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.

Do not use 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.

LIGHTING INSTRUCTIONS

STOP! Read the safety information above.

Set the thermostat on the lowest setting.

Turn On/Off switch to the "Off" position.

Remove heater door panel.

Push in gas control knob slightly and turn

clockwise

to "Off".

NOTE: Knob cannot be turned from "Pilot" to Off"

unless knob is pushed in slightly. Do not

force.

HONEYWELL PILOT

ROBERTSHAW PILOT

Wait5minutestoclearoutanygas. Ifyou then

smell gas, STOP! Follow "B" in the safety

information above. If you don't smell gas, go

to the next step.

Fig. # 8083.0

Fig. # 8084.1

8. Turn knob on gas control counter-clockwise

to "Pilot"

Locate pilot mounted on the right side panel of

theburnerdrawer. Forburnerdrawerlocation,

see location of control section, page 20.

9. 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. Ifitgoesout, repeatsteps5through9.

*If knob does not pop up when released, stop

and immediately call your service technician

or gas supplier.

GAS CONTROL KNOB SHOWN IN OFF POSITION

HONEYWELL

GAS VALVE

MILLIVOLT

10. Stand to the side of the heater and turn the gas

control knob counter clockwise to

11. Replace heater door panel.

"On".

12. Turn On/Off switch to the "On" position.

13. Set thermostat to the desired setting.

ROBERTSHAW

GAS VALVE

Fig. # 8081.0

MILLIVOLT

Fig. # 8079.0

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

2. Turn On/Off switch to the "Off" position.

3. Remove heater door panel.

4. Push the gas control knob slightly and turn

clockwise to "Off". Do not force.

5. Replace heater door panel.

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CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in

confined areas, extra care should be exercised when lighting propane heaters.

OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES

AUTOMATICALLY LIGHTED PILOTS

ELECTRONIC IGNITIONS SYSTEMS

This appliance is equipped with an ignition

device which automatically lights the pilot. Do

not try to light the pilot by hand.

*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.

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.

D. Do not use 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

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition

device which automatically lights the pilot.

Do not try to light the pilot by hand.

GAS CONTROL KNOB SHOWN IN "ON" POSITION

HONEYWELL

VR 8300 GAS

GAS

INLET

VALVE IID

5. Remove heater door panel.

6. For Honeywell Valve: Turn gas control

knob clockwise

For Robertshaw valve: Turn gas control

knob clockwise to "Off".(Models

265-405) Push in and move gas control

to "Off".

ROBERTSHAW 7000

GAS VALVE IID

MODEL 265-405

lever counter-clockwise

position. (Model 185)

to "Off"

7. 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.

8. Turn gas control knob counter-clockwise

to "On". (Honeywell VR 8300 and

Robertshaw 7000)

Fig. # 8080.0

GAS CONTROL

LEVER SHOWN

IN "OFF"

POSITION

ROBERTSHAW

7200 GAS VALVE

IID MODEL 185

9. Replace heater door panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the

instructions "To Turn Off Gas To Appliance"

and call your service technician or gas

supplier.

GAS

INLET

Fig. # 8934.1

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat at the lowest setting.

2. Turn off all the electric power to the appliance

if service is to be performed.

3. Remove heater door panel.

4. For Honeywell VR 8300 and Robertshaw

7000 gas valve.

to "Off". Make sure knob rest against stop.

For Robertshaw 7200 gas valve.

Push in and move gas control lever counter-

clockwise

to "Off" position.

5. Replace heater door panel.

Turn gas control knob clockwise

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AFTERSTART-UP

SECTION 2 - CAUTION

Feeltheinletandoutletpipes. Outletpipeshouldbeonly

slightly warmer than the inlet. It should not be hot.

Elevatedwatertemperaturecanbehazardous,andtheU.

S.ConsumerProductSafetyCommissionrecommends

thefollowingguidelines:

WARNING: Should overheating occur or the gas

supply fail to shut off, turn off the manual gas control

to the appliance.

1. Spa or hot tub water temperatures should never

exceed104°F(40°C). Atemperatureof100°F(38°C)

is considered safe for a healthy adult. Special

caution is suggested for young children.

VISUAL INSPECTION

With the heater on, remove the door and make a visual

check of the pilot and burner. The flame should be blue

withawell-definedpattern.

2. Drinkingofalcoholicbeveragesbeforeorduringspa

or hot tub use can cause drowsiness which could

leadtounconsciousnessandsubsequentlyresultin

drowning.

4" MAX

3. Pregnant Women Beware! Soaking in water over

102°F(39°C)cancausefetaldamageduringthefirst

three months of pregnancy resulting in the birth of a

brain-damagedordeformedchild. Pregnantwomen

should stick to the 100°F (38°C) maximum rule.

Fig. # 8205.2

MAIN BURNER FLAME

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 temperatures by as much as 4°F

(2.2°C).

5. Persons with a medical history of heart disease,

circulatory problems, diabetes, or blood pressure

problemsshouldobtainaphysician'sadvicebefore

using pools or hot tubs.

Fig. # 8964.1

6. Persons taking medications which induce drowsi-

ness, such as tranquilizers, antihistamines, or anti-

coagulant, should not use spas or hot tubs.

PILOT BURNER FLAME

Ayellowor"floating"flameindicatesrestrictedairopen-

ings or incorrect orifice size. Should this occur, shut the

heater off and contact your installer or gas supplier.

SECTION 3 - MAINTENANCE AND

CARE PROCEDURES

WATERPRESSURESWITCH

Awaterpressureswitchisprovidedintheheatertoshut

offtheburnersintheeventthatwatersupplytotheheater

isinterrupted. Itisveryimportanttoverifythattheswitch

electricallyopensandshutsoffthegasvalvewhenwater

flow to the heater is interrupted. Otherwise, rapid and

severedamagewilllikelyoccurtotheheater.(Thewater

pressure switch should be checked and adjusted for

properoperationbyaqualifiedservicepersonatthetime

ofinstallationandperiodicallycheckedthereafter. Refer

to pressure switch servicing instruction in Section 4 of

this manual).

To be followed one month after start-up and then semi-

annually.

1. Inspecttopofheateranddrafthoodforsoot,asticky

black substance around finned tubes and "V"

baffles),andopenfluegaspassageways.Anyvisible

soot should be cleaned for proper operation.

CAUTION: Soot may be combustible. Wet sooted

surfacescompletelypriortocleaning. Donotusesteel

wirebrush.

2. Cleanmainburnersandpilotburnerofdustandlint.

WARNING: Operation of the heater without water

circulation will cause rapid and severe damage to the

heater.

3. Inspect and operate all controls, gas valve and

pressurereliefvalve.

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4. Make visual check of the burner and pilot flame. AUTOMATICCHLORINATORSAND

Flame pattern on the main burner and pilot is indi- CHEMICALFEEDERS

cated in the previous illustration. Yellow flame

means restriction of the air openings. Lifting or Allchemicalsmustbeintroducedandcompletelydiluted

blowing flame indicates high gas pressure. Low intothepoolorspawaterbeforebeingcirculatedthrough

flame means low gas pressure. Should this occur, the heater. Do not place chlorine tablets or bromine

shut the heater off and contact your gas supplier or sticksintheskimmer. Highchemicalconcentrationswill

qualified service agency.

result when the pump is not running (i.e. overnight).

5. On indoor heaters, clean room intake openings to Chlorinators must feed downstream of the heater and

assureadequateflowofcombustionandventilation haveananti-siphoningdevicetopreventchemicalback-

air.

up into the heater when the pump is shut off.

CAUTION:Combustionairmustnotbecontaminated

by corrosive chemical fumes which can damage the

heaterandvoidthewarranty.

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

notcoveredunderthewarranty.

6. Keepareaaroundheaterclearandfreefromcombus-

tible materials, gasoline and other flammable and COLDWEATHEROPERATION

corrosivevaporsandliquids.

IMPORTANT FREEZE INFORMATION

BASIC TIPS IF HEATER WILL NOT FIRE:

MODERATE CLIMATE: Heater operation can con-

tinue during short term cold spells. When tempera-

turesarebelowfreezing,flow(continuouspumpopera-

tion) must be maintained.

1. Ifyouhavenoelectricalpower;itmaybeyour "circuit

breakers" have tripped. Try re-setting them.

Ifyouhaveelectricalpowerbuttheheaterwillnotfire

check the following:

CAUTION: Do not use the heater to maintain water

temperaturesjustabovefreezingorforfreezeprotec-

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

berequired. Theheaterisnotwarrantedagainstfreeze

ups.

3. The time clock must be moved to the "ON" position.

4. Yourpumpstrainerbasketmaybefull. Ifsoremove

debris.

5. 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).

COLDCLIMATE:Prolongedoperationwithwatertem-

peratures below 50°F is not recommended. When

startingtheheaterwithpooltemperaturesbelow50°F

operatetheheatercontinuouslyuntilhighertempera-

turesarereached. Operatingtheheaterforprolonged

periods with pool water below 50°F can seriously

damagetheheater,andisnotcoveredbythewarranty.

6. The pump may have lost it's prime. It may be run-

ning dry, check the pressure on the filter. If there is

nopressure;thenyouarenotmovingwater(oryour

gauge is broken). Try to get the pump to run at it's

normalflowrate.

For cold climate areas, please follow the winterizing

procedureslisted.

POOL & SPA WATER CHEMISTRY

Chemical imbalance can cause severe damage to your

heater and associated equipment. Maintain your water

pHbetween7.4and7.8andtotalalkalinitybetween100

and150p.p.m. Ifthemineralcontentanddissolvedsolids

inthewaterbecometoohigh,scaleformsinsidetheheat

exchanger tubes, reducing heater efficiency and also

damaging the heater. If the pH drops below 7.2, the

heater will be severely damaged. This will result in

corrosion of the heat exchanger. Heat exchanger

damage resulting from chemical imbalance is not

covered by the warranty.

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WINTERIZINGTHEPOOL&SPAHEATER

Heaters installed outdoors in freezing climate areas are

subject to be shut down for the winter. Observe the

following step-by-step procedure for winterizing the

heater:

1. Turn off gas valve, manual gas valve, and electrical

supply to the heater.

2. Open drain plug located on the inlet/outlet header,

(under water pipes). Remove the heat exchanger

inspectionpanelonthesideoppositewaterpipingto

gain access to the drain plug on the return header.

Opendrainplugonreturnheader.

Return Header

Drain Plug

Disconnect compression fittings from the pressure

switchandreturnheaderthatconnectstothe1/4"copper

tube and allow the tube to drain. For ASME Heaters only.

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PART TWO

INSTALLATION AND SERVICE INSTRUCTION

SECTION 1 - RECEIVING EQUIPMENT

Onreceiptofyourequipmentitissuggestedthatyouvisuallycheckforexternaldamagetothecarton. Ifthecarton

isdamaged, anoteshouldbemadeontheBillofLadingwhensigningforequipment. Removetheheaterfromthe

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:

STANDARDUNIT

ASME UNIT

1. "Pagoda"Top

2. 2" CPVC Union with "O" rings (2)

3. Plastic pipe finish flange for gas line

4. Bonding lug with mounting screw

(IIDunitsonly)

2. In/OutFlanges(2)

3. 1-1/2" Flange Gaskets (2)

4. 2" Flange Gaskets (2)

5. Flange Bolts (4)

6. PressureReliefValve

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.

Whenorderingparts,youmustspecifymodelandserialnumberofheater. Whenorderingunderwarrantyconditions,

you must also specify date of installation. Raypak recommends that this manual be reviewed thoroughly before

installingyourRaypakpool/spaheater. Ifthereareanyquestionsthatthismanualdoesnotanswer,pleasecontact

the factory or your local Raypak representative.

SECTION 2 - GENERAL SPECIFICATIONS

TheseheatersaredesigncertifiedandtestedundertherequirementsofANSIZ21.56/CSA4.7AmericanNational

Standard/CSAStandardforGas-FiredPoolHeaters. Allheatersareinter-changeableandcanbeusedeitherindoor

or outdoors. The appropriate top designated for that type of use is required. If desired, the top can be changed at

alaterdatetochangefromoutdoortoindoororviceversa. Millivoltheatercontainsaself-generatingelectricalsystem

operating between .25 and .75 volts.

Ambient Temperature Rating of Heater Components

Millivolt Heater with Honeywell Gas Valve +32°F to +175°F

Millivolt Heater with Robertshaw Gas Valve 0°F to +175°F

Electronic Ignition Heaters* -32°F to + 175°F

*Requires120Vor240VPowerSupply

Atmosphericheaters:

Ratedinputssuitableforupto2000feetelevation. Forelevationsabove2000feet, reduceinput4%foreach1000

feetabovesea level, ashighelevationreducescombustionperformance.

Low NOx heaters:

Rated inputs suitable for up to 5000 feet elevation. For elevations above 5000 feet, consult the factory.

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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.

Analternativemethodforprovidingabaseforcombustible

floorsisillustratedbelow. Heatersmust notbeinstalled

IMPORTANTNOTICE

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

bearstheappropriatelicense. Personsnotqualifiedshall

not attempt to fix this equipment nor attempt repairs

according to these instructions.

oncarpeting.

12"

Minimum

12"

Minimum

TER

HEA

Fig.#8148.1

Sheet Metal

24 Gauge

WARNING:

Minimum

Improperinstallation,adjustment,alteration,serviceor

maintenance may damage the equipment, create a

hazardresultinginasphyxiation,explosionorfire,and

willvoidthewarranty.

Utilize hollow concrete cinder blocks, align holes and

leaveendsopen.

CODEREQUIREMENTS

NOTE: The heater should not be located in an area CLEARANCES

ALLHEATERS

Forclearancesfromcombustiblesurfaces,seethe chart

below.

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.

CLEARANCEFROM

COMBUSTIBLECONSTRUCTION

INDOORINSTALLATIONS:

Installation must be in accordance with local codes, or,

intheabsenceoflocalcodes,withthelatesteditionofthe

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

Top*- 30"(Drafthood)

Front-Alcove

Vent - 6"

Back - 6"

Right Side- 12" (Water Side)

LeftSide-6"

(Opposite Water side)

OUTDOORINSTALLATION:

Top* - Unobstructed (Stackless top or outdoor stack)

Back - 6"

Side - 6"

BASEINSTALLATION

Heatermustbemountedonalevelbase,suchascement

slab, cement blocks or other non-combustible surface.

An optional non-combustible base is available for all

models.

*Clearancefromtopofventterminal

When installed according to the listed minimum clear-

ances from combustible construction materials, the

Raypakpoolheaterscanstillbeservicedwithoutremov-

ingpermanentstructuralconstructionaroundtheheater.

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

removaloftheheatertoserviceeithertheheatexchanger

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.

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OUTDOORHEATERS

These heaters are design certified for outdoor installation, when equipped with the approved tops designated for

outdooruse.

WARNING:Theheatershallnotbelocatedinanareawherewatersprinklers,orotherdevices,maycausewater

tospraythroughthecabinetlouversandintotheheater. Thiscouldcauseinternalrustingordamagesomeelectrical

components, and this would void the warranty.

WARNING:Donotinstallwithin3feetofaheatpumporanoutdoorcondensingunit. Strongairintakefromthese

equipment can disturb the combustion process and cause damage or personal injury.

HEATERWITHOUTDOORSTACKLESSTOP

VENT TERMINAL (Outdoor) Stackless Top Installation

1. Insert tabs into keyhole (4 places).

Pagoda Top

(Shipped

Loose with

Heater)

2. Snap tabs into keyholes so as not to pull out.

Fig.#8278.2

Fig. #RP8280.1

Heatersmustnotbeinstalledunderanoverhangoflessthanthree(3)feetfromthetopoftheheater. Three(3)sides

mustbeopenintheareaundertheoverhang. Roofwaterdrainagemustbedivertedawayfromtheheatersinstalled

under overhangs with the use of gutters.

ForU.S.installations,thepointfromwheretheflueproductsexittheheatermustbeaminimumoffour(4)feetbelow,

four(4)feethorizontallyfrom,orone(1)footaboveanydoor,windoworgravityinletintoanybuilding. Thetopsurface

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

B149.2.

Fig# 8245.1

U.S. Installations only

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INDOORHEATER

The design is also certified for indoor installation when equipped with the approved draft hood.

ForCanada,indoorinstallationisrestrictedtoanenclosurethatisnotoccupiedanddoesnotdirectlycommunicate

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 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.

INDOORKITINCLUDES:

1-Drafthood,unpainted

1- Adapter plate

OUTDOORKITINCLUDES:

1-Drafthood, painted

1- Adapter plate

3- Mounting brackets (clips)

3- Screws

1-Instructions

3- Mounting brackets (clips)

1-Toppanelcover

2- 1 foot sections of metal tape

3- Screws

Clips

1-Instructions

Clips

OUTDOORSTACK

INDOORSTACK

Part No.

006696

Model

185

265

335

405

Part No.

006751

006752

006753

006754

006697

006698

006699

ASSEMBLY PROCEDURE

1. Makesurethatthegasandelectrichasbeenturned

off to the unit.

2. Removethe"pagoda"topfromthelouveredtopand

discard. See Fig. 3.

3. Remove the louvered top and set aside, saving the

four phillips screws for reassembly. See Fig. 3.

4. Remove and discard the rain shield. See Fig. 4.

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.

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SECURINGTHETOPPANELCOVER

INDOORKITONLY

7. Reinstallthelouveredtop.

8. Mountthedrafthoodontotheadapterplatelipinside

the heater. See Fig. 6.

9. Proceed to installing the clips, step 14.

SECURINGTHETOPPANELCOVER

OUTDOORKITONLY

10. Afterremovingthedrafthoodfromthebox, slidethe

top panel cover over the draft hood. See Fig. 1.

11. Holding both pieces together, mount the draft hood

ontheadapterplatelipinsidetheheater.SeeFig.6.

12. Take the two pieces of tape and attach to each side

ofthedrafthoodleaving6"hangingdown.

13. Slidethetoppanelcoverupandattachthetapetothe

underneath side. This is to temporarily keep the top

panelcoveroutofthewaywhileyouareattachingthe

clips as shown in the next steps. See Fig. 7.

INSTALLINGTHECLIPS

INDOOR&OUTDOORKITS

14. Noticethattherearethreepilotholesabovethebase

of the drafthood as shown in Fig.8. These are the

locations where the three clips are to be attached.

15. Insertthelongedgeofoneclipbetweenthetoppanel

cover and the drafthood, see Fig. 9.

16. Withatwistingmotion,rotatetheclipup,seeFig.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 6-10 using remaining two clips.

21. This completes the indoor drafthood installation. If

installing an outdoor drafthood, proceed to step 13.

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INSTALLINGTHETOPCOVER

OUTDOORKITONLY

22. Removethetwopiecesofgmetaltapeholdingthetop

panel cover up and discard.

23. Insertthereartwotabsintotheslotsontheheatertop

andslidethetoppanelcoverbackwards.SeeFig.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. Lowerthetoppanelcoverflushtothetopandrelease

the tabs. They will spring into place as shown in

Fig.15.

26. Turn the gas and electricity to the heater on.

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SPECIFICATIONSANDDIMENSIONS

Shipping Weights (lbs)

Cast Iron

Capron

Heater

w/Stackless

Top

BTUH

Input

(000)

181

264

334

399

(A)

Cabinet

Width

(B)

Flue

(C)

Indoor

(J)

Heater

w/Stackless

Top

Indoor

Draft-

hood

Heater

Model

R185B

R265B

R335B

R405B

Gas

Conn.

3/4"

Water

Conn.

Dia. Drafthood

18-1/4"

62-5/8"

62-7/8"

63-3/4"

65-3/8"

12-1/16"

11-1/8"

10-3/4"

12-1/2"

191

214

234

253

172

195

215

234

22-3/8"

25-3/4"

29-1/4"

*Designation for Propane is "EP", Natural gas is "EN". Prefix "C" is for Cast Iron (ASME) Headers; "P" is for Plastic (Polymer)

Headers. Atmospheric heaters: reduce input 4% for each 1000 ft. above sea level when installed above 2000 ft. elevation.

Low NOx heaters: for elevations above 5,000 feet consult factory. For Canada, no de-rate 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.

Fig#9037.2

*Electrical Connection On Left Side is 19-1/8".

COMBUSTION AIR (Indoor Units Only)

Air For Combustion And Ventilation

a. All Air From Inside The Building:

Each opening shall have a minimum net free square

inches as noted:

Theheatermusthavebothcombustionandventilationair.

Minimum requirements for net free air supply openings, Model SquareInches Model SquareInches

one 12 inches from ceiling for ventilation and one 12

inchesfromthefloorforcombustionairasoutlinedinthe

latest edition of the National Fuel Gas Code, ANSI

185

265

181

264

335

405

333

399

Z2231(Canada-CAN/CGA-B149.1andB149.2) andany b. All Air From Outdoors:

local codes that may have jurisdiction.

When air is supplied directly from outside of building,

each opening shall have a minimum net free square

inches as noted:

CAUTION:Combustionairmustnotbecontaminated

by corrosive chemical fumes which can damage the

heaterandvoidthewarranty.

Model Square Inches

185

265

335

405

100

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The discharge opening must be a minimum of two feet

verticallyfromtheroofsurfaceandatleasttwofeethigher

than any part of the building within ten feet. Vent stack

shall be at least five feet in vertical height above the

drafthood outlet. The vent cap location shall have a

minimumclearanceof4feethorizontallyfrom,andinno

case below, unless a 4-foot horizontal distance is main-

tained, from electric meters, gas meters regulators and

reliefequipment.

VENT PIPING

WARNING: Indoor boilers require a drafthood that

mustbeconnectedtoaventpipeandproperlyvented

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,whenthetotalventheightisat

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

muchaspossibleavoidlonghorizontalrunsofventpipe

and too many elbows. If installation requires horizontal

non-verticalruns,theventpipemusthaveaminimumof

1/4inchperfootriseandshouldbesupportedatnotmore

thanfivefootintervals. Plumberstape,criss-crossed,will

serve to space both horizontal and vertical piping. Gas

ventssupportedonlybytheflashingandextendingabove

the roof more than five feet should be securely guyed or

braced to withstand snow and wind loads. We recom-

menduseofinsulatedventpipespacerthroughtheroofs

and walls. Another option for installation that requires

horizontal runs is using the D-2 powervent kit option.

Theweightoftheventstackorchimneymustnotreston

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. Ventpipeshouldbeadequatelysupportedto

maintainproperclearancesfromcombustibleconstruc-

tion.

Type "B" double wall

orequivalentventpipe

is recommended.

However single wall

metal vent pipe may

be used as specified

in the latest edition of

theNationalFlueGas

Code ANSI Z 223.1.

(Canada-CAN/CGA-

B149.1andB149.2)

Power Vent Kit

Model Part No.

185

265

335

405

008086

008087

Fig.#RP8119.2

GASSUPPLYCONNECTIONS

Gas piping must have a

sediment trap ahead of

the heater gas controls,

and a manual shut-off

valvelocatedoutsidethe

heater jacket. All gas

piping should be tested

after installation in ac-

cordance with local

Fig.#9469

OptionalRaypakD-2

PowerVent

FormoredetailedD-2installationinformationconsultthe

D-2PowerVentmanual6000.57.

ThePowerVentAssemblyisafanassistedcombustion

system designed for application to Raypak Pool Heater

Models185-405.Theunit,wheninstalledasdirected,is

capableofoperatinginapplicationssuchasthroughthe

wallventingandreducedhorizontalandverticalventpipe

sizes in new and current installations. It is certified for

category III venting up to 40 feet equivalent 4" diameter

venting.Theunitisfactorywiredfor240V,withcapability

ofrewiringfor120V.

codes.

Fig.#RP8090.0

CAUTION: The heater and its manual shut off valve

must be disconnected from the gas supply during any

pressure testing of that system at test pressures in

excess of 1/2 psig (3.45 KPA). Dissipate test pressure

in the gas supply line before reconnecting the heater

and its manual shut off valve to gas supply line.

FAILURE TO FOLLOW THIS 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.

Forprotectionagainstrainorblockagebysnow,thevent

pipemustterminatewithaventcapwhichcomplieswith

the local codes or, in the absence of such codes, to

the latest edition of the National Fuel Gas Code, ANSI

Z223.1.(Canada-CAN/CGA-B149.1andB149.2)

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NOTE: Do not use Teflon tape on gas line pipe thread.

ELECTRONICIGNITIONGASVALVES-CONTINUED

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.

GASPRESSUREREGULATOR

Fig # 9328

Fig # 9329

Thegaspressureregulatorispresetat4"W.C.fornatural

gas, and11"W. C. forpropanegas. Thepressureatthe

gasvalve,takenwithamanometer,shouldbeabout3.7"

W. C. natural gas (3.9" W.C. for Low NOx) and 10.5" W.

C.propanegas. Ifanadjustmentisneeded,removeseal

and turn adjustment screw clockwise

pressure or counter-clockwise_____to decrease pres-

sure.

Gas

Pressure

Adjustment

Robertshaw7200

Model185

Robertshaw7000BDER

Model265-335

to increase

Gas

Pressure

Adjustment

Fig # 9327

Robertshaw7000DERHC

Model405

PIPE SIZING FOR GAS CONNECTIONS

Fig. # 8149

Fig.#9365

ATMOSPHERIC

LOW NOx

GASPRESSUREADJUSTMENTLOCATIONS

MILLIVOLTGASVALVES

Gas

Low NOx units are not available in propane.

Pressure

Adjustment

Fig # 9263

Robertshaw7000

Models 185 thru 405

ELECTRONICIGNITIONGASVALVES

Gas

Pressure

Adjustment

Honeywell VR8304

Models 185 thru 405

Fig # 9264

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PLUMBINGFORWATERCONNECTIONS

HEATERLOCATION-Relativetothepumpandfilter

The RP 2100 heater requires water flow and positive

pressuretofireandoperateproperly. Itmustthereforebe

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. Theoutletsideofthefilteristhenplumbedtotheinlet

of the heater; and

3. Theoutletoftheheaterisplumbedtothereturn line

to the pool or spa. The pump, filter and heater are

thus plumbed in series.

POLYMERHEADERS

Plumbingfromtheheaterbacktothepoolmustnothave

anyvalvesorrestrictionthatcouldpreventflowwhenthe

pump is operating.

CONNECTIONS(POLYMERHEADER)

Before attaching the 2-inch unions to the inlet/outlet

header,makesuretheo-ringsareproperlyseatedinthe

grooves. Use AquaLube or equivalent non-petroleum

based lubricant on the o-ring. Tighten the unions hand

tight. Glue PVC piping directly to the unions.

CAUTION: An additional source of heated water, i.e.

a solar system, must be connected to the main line

aheadoftheheaterinletpipeinorderforittoactasthe

primary heat source. If the primary system provides

adequate heat to maintain set-point, the RP2100

heaterwillnotfire.BeadvisedthattheRP2100control

panel will then display sensed water temperatures

downstreamoftheprimaryheatingsystem,ratherthan

the temperature of the water exiting the pool.

INLET/OUTLETHEADER(Polymer)

Flange Gasket

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.

Header Flange

(CPVC)

Header Flange Nut

(CPVC)

FLOW RATES

MODEL

185

265

335

405

PIPE SIZE

MIN.GPM *MAX.GPM

1-1/4"-1-1/2" - 2

1-1/4"-1-1/2"-2

125

Inlet

*When flow rates exceed maximum GPM an external

auxiliarybypassvalveisrequired. Seeexternalbypass

valvesectionfordetails.

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.

ASME-CastIron

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CONNECTIONS(ASMEMODELS)

INLET/OUTLETHEADER-ASME

FlangeGasket

Heater must be located so that any water leaks will not

damagethestructureofadjacentarea.Hightemperature

2" plastic pipe (CPVC) may be threaded directly into the

headerflanges.ThisisnotthesameastheSchedule80

PVC pipe which is also colored gray. PVC may be used

immediately after the CPVC adapters.

2" CPVC Adapters

Fig.#8093.1

HeaderFlange

UNITHERMGOVERNOROPERATION

CAUTION:

ASME

Inlet/OutletHeader

PVC Pipe

The patented Unitherm Governor is a thermostatic

mixingvalvespecificallydesignedtomaintainconstant

heater internal temperature between 105° to 115°F

despite continually changing flow rates from the filter

andchangingpooltemperatures. Thisnarrowrangeis

needed to prevent damaging condensation on the

burnerswhichwilloccuriftheheaterrunsforanylength

of time below 100°F. It is also needed to inhibit scale

formation in the tubes by maintaining temperatures

wellbelowacceleratedscalingtemperatures.

CAUTION: NEVER install PVC directly into header

flanges.Usethe2"CPVCadaptersuppliedloosewith

theheater.

DO NOT use petroleum base assembly fluids (such as

Petroleum Jelly or lubricating oil). If 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.

U.G. PLUG

(Polymer)

UNITHERM

GOVERNOR

Fig.#8095.1

Fig.#8097.1

GASKET

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INTERNALAUTOMATICBY-PASSVALVE

PRESSURERELIEFVALVEINSTALLATION

InadditiontotheUnithermGovernor,abuilt-inautomatic To conform to local building codes, it may be necessary

by-passvalveisprovidedinthein/outheader. Whilethe to install a pressure relief valve. A 3/4" pressure relief

Unitherm Governor responds to the changes in water valve having a capacity equal to BTU/HR output of the

temperature in the heater, the internal by-pass valve modeltobeinstalledisrecommendedforthisheater.The

automatically responds to changes in water pressure in maximumacceptablepressurereliefvalvesettingis125

the piping system. Proper amount of water flow is psi.

maintained through the heater under varying pressures

A 3/4" NPT connection is provided in the plastic header

dictated by the conditions of the pump and filter.

forinstallationofapressurereliefvalve. Thevalveshallbe

installedinaverticalposition. Donotovertighten. Install

pressure relief valve hand tight plus 1/2 turn.

BYPASS DISC

POLYMERHEADER

Pressure Relief Valve

SPRING

PRV Discharge

Connection

BYPASS

BODY

EXTERNALAUXILIARYBYPASSVALVE

(WhereRequired)

Anauxiliarybypassvalveshouldbeusedwhenflowrates

exceed125GPM(usuallyahighperformancepumpsize

larger than two horsepower will exceed this flow rate).

This valve is required to complement the function of the

Inlet/Outlet Header

Fig.#2004

automatic bypass valve, particularly when starting the A 3/4" NPT connection is provided in the header for

heater in winter or early spring when the spa or pool installation of a pressure relief valve. The valve shall be

temperature is down below 50°F. It also serves to installed in a vertical position.

eliminateneedlesspressuredropthroughtheheaterand

accompanying reduction in the flow rate to the spa jets, ASME HEADER

PressureRelief

Valve

etc.

(CastIron)

Fig.#2003

From Heater

To Heater

PRVDischarge

Connection

To Pool

From Pool

AUXILIARYBYPASS VALVE

(DO NOT USE GATE VALVE)

Inlet/OutletHeader

Fig.#8095.0

Fig.#8150.0ss

NOTE: To avoid water damage or scalding due to valve

operation, drain pipe must be connected to valve outlet

andruntoasafeplaceofdischarge. Drainpipemustbe

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

waterwaysareclear.

AUXILIARYBYPASSVALVEADJUSTMENT

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-

abletothetouch. Ifpipeishot,closebypass;ifcold,open

bypass.

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HEATEXCHANGERPRESSUREDROPTABLES

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RP2100 HEATEXCHANGERREVERSALPROCEDURE(POLYMERHEADERMODELS)

1. Removerightandleftsideaccesspanels(Figure1).

2. Disconnect wires at high limit, AGS (automatic gas

shutoff), and pressure switch on the inlet/outlet

header(Figure2).

3. Electronic Ignition Heaters: Remove the thermo-

stattemperaturesensorbylooseningthecompres-

sion fitting nut (Figure 3). Reroute the sensor to the

left side of the heater.

4. MillivoltHeaters:Removethetemperaturesensor

bulbandretainerclipfromthesensorwell(Figure4).

Reroutethesensorbulbtotheleftsideoftheheater.

5. Remove(12)boltsholdingtheinlet/outletandreturn

headerstothetubesheets.Cleanofftubesheetarea

where the gasket seats. Also clean off the header

and the gasket. Apply a non-petroleum based lubri-

canttothegasketsuchasAquaLube. Reattachthe

headerstotheoppositesides,makingsuretheyare

installed in an upright position (Figure 5). Do not

over tighten. Torque should not exceed 7 ft/lbs.

6. Reconnect high limit, AGS, and pressure switch

wires.

Fig. #1

HI-LIMIT

ACCESSPANEL

PRESSSWITCH

AGS

7. ElectronicIgnitionHeaters:Insertthetemperature

sensorinthecompressionfittingandtighten1/2turn

past hand tight.

8. Millivolt Heaters: Insert sensor bulb and retainer

clip into sensor well.

9. Allowforwaterflowthroughtheheaterandcheckfor

leaks.

Fig. #2

JACOFITTING

10. Reattach access panels to the opposite sides.

For ASME Models call your factory representative.

Fig. #3

NOTE:Tighten almost flush

(1/32" to 1/8") to the header to avoid leaks.

BULB&CLIP

REINSTALLEDIN/OUTHEADERONOPPOSITESIDE.

Fig. #4

Fig. #5

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ELECTRICAL WIRING

NOTE: If it is necessary to replace any of the original

wiring, it must be replaced with 105° C wire or its

equivalent, and/or 150° C wire or its equivalent as

originally built.

Control Box

(Factory Mounted Location)

Option Location For Left

Side Field Wiring

MILLIVOLT SYSTEM

TheMillivoltSystemresidentialheaterisequippedwitha

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.

Sway

Brace

ELECTRONIC

INTERMITTENTIGNITIONDEVICESYSTEM (IID)

Bonding Lug

(Standard Location)

Fig.#9470

Bonding Lug

(Optional Location)

NOTE:

Heatersarefactorywiredfor240V powersupply.

The standard field wiring connection is on the right side

of the heater.

ATMOSPHERIC

Wiring locations

To wire the heater from the left side, follow the steps

below:

1. Remove the two (2) screws that hold down the

junctionboxtotheswaybrace. Untieexcessyellow

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

interfacewiring.

Fig.#9366.1

LOW NOx

NOTE: Heater must be electrically grounded and

bonded. Bonding lug is provided loose with the unit.

Install bonding lug on lower right or left side of jacket as

necessaryforbondingtheunit. Mountingholeisprovided

on the jacket.

Wiring locations

TheElectronicIntermittentIgnitionDevice automatically

lights the pilot and main burners upon a call for the heat.

Theheaterissuppliedwithadualvoltagetransformerfor

120V or 240V input power hookup.

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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.

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.

Fig.#9471.1

Heatermustbeelectricallygroundedandbondedinaccordancewithlocalcodes, or, intheabsenceoflocalcodes,

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: Inputpowertotheheater(120/240V)canbesuppliedfromtheload(pump)sideoftimeclockordirectlyfrom

the switch/GFCI power source. It is preferred to make connection to the load/pump side of the time clock. When

usingtheswitchedGFCIpowersourcetheheatercoulddisplayfalseserviceindicatorsonthedelaypanelifthepump

is turned off.

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WIRING DIAGRAM - MILLIVOLT UNITS (MECHANICAL THERMOSTAT)

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WIRING DIAGRAM - IID UNITS (atmospheric)

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WIRING DIAGRAM - IID UNITS (Low NOx)

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SECTION 4 - SERVICING INSTRUCTIONS

CONTROLSANDADJUSTMENTS

GENERALLOCATIONOFCONTROLS

Bypass

Temperature

Adjust Buttons

HiLimiton

I/O header

Mode Button

Drain Plug

(ASME on

(Located in

Return

Header)

OFF

Header)

AGS Hi-

Limit

(Located

on Inlet/

Outlet

Digital

Thermostat

Header)

Circuit Board

Unitherm

Governor

LCDDisplay

Fig.#9472

Roll-Out

Switch

Drain Plug

MILLIVOLT CONTROLS

Gas Valve

Transformer

Pilot

The pool or spa water temperature is controlled by the

pool heater thermostat on the upper front panel of the

heater. ThecontrolcentercontainsanOn/Off switchand

one or two thermostats.

Fig #2005

CONTROLPANELREMOVAL

Thermostatsarefittedwithameansoflimitingtheupper

temperature limit below the maximum level. The knob

stop adjustment ring illustrated below is adjustable by

looseningthesetscrew,rotatingtheknobstopringtothe

desired location and retightening the set screw.

1. Remove (4) screws from sides of control panel.

2. Rotate control panel down until panel stops. Do not

force.

NOTE:Cautionmustbetakennottodamagecontrols or

wiring.

SPATEMPERATURE

RANGE

POOLTEMPERATURE

RANGE

Control Panel

Mounting Screws (4)

STAND-BY

TEMPERATURE

KNOBSTOPRING

Fig. #9473

SETSCREW

KNOB STOP SHOWN ABOVE IS

INTHESPATEMPERATURERANGE

Fig. #RP 8267

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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.

It is normal to experience small fluctuations in the return water temperature during the operation of the heater.

The thermostat is calibrated 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 #9480

LCD DISPLAY

TEMP

MODE

BUTTONS

BUTTON

Fig #9481

PROGRAM MODE BUTTON

Set Points

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.

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.

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.

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.

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.Amanual toggle switch

is also provided right below the MODE button to allow

the heater to be turned off.

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.

Operation

In the POOLor SPAmodes, 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.

Fahrenheit vs Centigrade

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 temperature.

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 to select “F/C” on the digital display. The

“Up” and “Down” buttons will select “F” or “C” on the

temperature display. Once this is done reassemble the

control panel.

MODE

POOL or SPA

DISPLAY

call for heat

FLAME ICON

Fig#9484

WATER

SETPOINT

TEMPERATURE

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NOTE: The digital temperature display may not coincide with the temperature reading of your pool or 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

there is insufficient flow through the heater. Make sure

the pool filter and pump strainer are clean before calling

a service representative.

SERVICE WILL FLASH

Fig#9485

3 LETTER FAULT CODE

See table for fault definition

Fig#9482

STATUS CODES

Display

CFH

Definition

Call for heat

CLK

Time clock

LOW

OFF

Caution - low water temperature

Off mode

REM

SPK

SPR

Remote control activated

Spark

Spare fault code indicator

FAULT CODES

Display

BD1

Definition

Board failure

FFL

Flame sensing when pilot and gas

valves are closed

HL1

HL2

IGN

ILO

Hi limit switch #1 open

Hi limit switch #2 open

Ignition control failure

Ignition lock out

PLT

PRS

ROL

SNS

VNT

Pilot failure

Pressure switch open

Heat roll-out safety switch open

Sensor failure

Vent switch open

PROGRAM MODES

Display

CCC

F/C

FFF

RES

SET

Definition

Celsius setting

Change from Fahrenheit to Celsius

Fahrenheit setting

Reset defaults

Set point max adjustment

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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 (LCD) display

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.

OFFMode

Heating in the POOL Mode

POOLCOMMON

Heating in the SPA Mode

RemoteMode

ACTIVATING THE REMOTE

(BLK/ORG)

The RP2100 digital has the ability to disconnect from

the remote it is wired to. To activate or deactivate the

remote follow these steps:

SPACOMMON

(ORG/BLK)

24VAC HOT

(BLU)

Press and hold all three buttons for 5 to 7 seconds.

Fig#9494

7-PINREMOTE

WIRINGCONNECTOR

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

third party remote. The remote works by either making

or breaking the circuit created by the remote wiring.

Typically, a remote does not supply power to the heater,

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

damage the digital circuit board.

Fig#9480

The digital display format will change and indicate

REMoff or REMon.

Remote disabled

External remote control

active

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-

playmustbeintheOFFmode. Iftheheaterthermostat

is left in a heat mode the heater will operate to this

setting and the remote shut off feature will not be

functional.

Note:ElectrostaticDischarge(ESD)damagecanbecausedbydirect

or indirect contact with the wiring or circuit board. When one walks to

the heater area, an electrostatic charge accumulates on the body.

Contact of a finger allows the body to discharge, possibly causing

device damage. This damage can be limited if the service person

discharges himself by removing that charge by adhering to ESD

preventative/removalpracticesandreducingthatchargebyholdingon

to the heater enclosure for 5 seconds before proceeding.

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REMOTE CONTROL WIRING

Important Installation Notes for Remote or external wiring configuration

• Remote wiring must be run in separate conduit.

• Remote wiring must not be run parallel to High Voltage lines.

• For runs 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.

• For runs 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.

• Maximum cable length of 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-pin connector before it is connected to the board.

2 Wire Remote Control (On-Off)

In this application, it assumed that only one heating function is required.

1. Turn on power to the heater.

2. Push the mode button to the "POOL" or "SPA" modes

andsetthedesiredtemperature. (example:102°F)

3. Turnthemodebuttonto"OFF"andremovepowerfromthe

heater.

4. On the "Remote Interface Harness" connect the BLUE

wiretoonesideofthe"REMOTE"switchandconnectthe

other side to either the ORANGE/BLACK wire for "SPA"

operationortheBLACK/ORANGEwirefor"POOL"opera-

tion.

5. Wirenutunusedwireonthe"RemoteInterfaceHarness".

6. Install the "7-Pin Remote Interface Harness" to the P8

connector and turn power "ON" to the heater.

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)

In this application, it assumed that multiple heating functions are required.

1. Turn on power to the heater.

2. Push the mode button to the "POOL" or "SPA" modes

and set the desired temperature.

(example: 80° for Pool and 102°F for Spa)

3. Turnthemodebuttonto"OFF"andremovepowerfromthe

heater.

4. On the "Remote Interface Harness" connect the BLUE

wiretoonesideofthe"REMOTE"switchandconnectthe

ORANGE/BLACK wire for "SPA" operation and the

BLACK/ORANGE wire for the "POOL" operation.

5. Installthe"RemoteInterfaceHarness"totheP8connec-

tor and turn power "ON" to the heater.

See instructions on previous page to activate the

Fig#9493

remote control.

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PRESSURESWITCH

FLAMEROLL-OUTSAFETYSWITCH

Thepressureswitch,orheateractuator,insuresthatthe Atmosphericheatersareequippedwithathermalcutoff

heateroperatesonlywhenthefilterpumpisinoperation. device to prevent flame roll-out in the event the heat

It is located on the inlet/outlet header. It is factory set at exchangerbecomesblocked. Thisisa"Single-use"type

1.75 PSI for deck level installations. When the heater is fusible link or thermal fuse, that must be replaced when

located below the level of the spa or pool, it may be disabled by an over temperature condition, caused by

necessary to reset the pressure switch to compensate excessiverestrictionintheheatexchangerfluepassage.

for the no-flow static head. If it is necessary to reset the

pressure switch, utilize the following procedure:

PRESSURESWITCHADJUSTMENT

Fig.#9440

1. With pump and heater on,

turn adjustment knob

(clockwise) until a click is

heardfromthegasvalve.

2. Turn adjustment knob

(counter clockwise) 1/4

turn.

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.

3. Turnpumpoffandonseveral

times. Heater should shut

off immediately. If it does

not,repeatstepsaboveuntil

properadjustmentsmade.

Fig.#9438

NOTE: An erratic high limit is often characteristic of

internal heat exchanger problem, i.e. scale buildup,

defective bypass. Refer to troubleshooting sections.

Adjustment

Knob

HIGHLIMITREMOVAL

1. Shut off main electrical

power switch to heater.

2. Remove inlet/outlet in-

spectionpanel.

PRESSURE SWITCH

ADJUSTMENT RANGE

3. Remove defective high

limit and replace with a

new high limit.

4. Replace inspection

panel.

Fig.#9439

Fig.#8152.2

PILOT SAFETY (Millivolt)

NOTE: If heater is installed outside of the limits shown,

ahigherpressurerated(11psi)switchmaybeusedora

flowswitchmountedandwiredadjacenttotheheatermay

beusedinplaceofthefactorymountedpressureswitch.

See Parts List for 11 psi pressure switch.

The heaters equipped with the standing pilot (millivolt

system), have pilot generators which act as a safety

devicetoshutofftheflowofgastothemainburnersand

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.

TWO SPEED PUMPS

In some cases, the flow on the low speed is insufficient

tooperatetheheater. Thisisapparentwhenthepressure

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.

PILOT SAFETY (Electronic)

Theheateremploysapilotsafetywhichclosesthemain

gas valve within 8/10ths of a second whenever the pilot

flameisinterrupted. Pilotflameisautomaticallylitwhen

thedeviceispowered. Unitperformsitsownsafetycheck

andopensthemainvalveonlyafterthepilot isprovento

be lit.

CAUTION: Do not operate the heater without the

functionofaproperlyadjustedpressureswitchorflow

switch.

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BURNERDRAWER REMOVAL

PILOTREMOVALANDCLEANING

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Removefrontdoor.

1. Disconnect pilot tubing, and wires from gas valve.

2. Remove pilot assembly from burner tray.

3. Removepilotfrombracket.

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.

4. Removepilotorificeandairopening(HoneywellMV

unit only), and clean with wire or small brush.

CAUTION! Do not enlarge hole in pilot orifice.

5. Reverseaboveproceduretoreinstall.

8. Reverseaboveproceduretoreinstall.

HONEYWELLPILOT

ROBERTSHAW PILOT

GAS VALVE REMOVAL

1. Shutoffgassupplytotheheater. Removegaspiping

to gas valve inlet.

2. Disconnect wires, pilot tubing and bleed line, if

required.

Pilot

3. Turn vertical gas pipe from manifold slightly and

unscrewgasvalve.

4. Reverseaboveproceduretoreinstall.

Air

Opening

MAINBURNERANDORIFICEREMOVAL

1. Removeburnerdrawer. Seeburnerdrawerremoval

procedure.

Orifice

2. Removescrewsandburnerholddownbracket.

NOTE: If the heat exchanger is sooted badly, the

burner hold down bracket and spacer can become

distortedfromdirectflameimpingementandthisusually

necessitates replacement of these parts.

Fig. # 8045.1

Fig. # 8102.0

HEATEXCHANGERREMOVAL

1. Shut water, gas and electricity off, close valves and

relievepressure, removereliefvalve. Removeside

inspectionpanels.

2. Removetopholdingscrews.

3. Remove draft diverter, lift and remove top and flue

collector. Remove inspection panels.

3. Lift burners from slotted spacers and slide from

orifices. Clean with a wire brush.

4. Orificesusuallydonotneedtobereplaced. Toclean,

run either copper wire or wood toothpick through

orifice. Do not enlarge hole. To remove orifice, use

asocketwrenchandremovefrommanifold. DONOT

overtightenwhenreinstalling.

4. Disconnect wires from high limits and pressure

switch. Remove temperature sensor.

5. Disconnectflangenutsoninlet-outletheader,loosen

union(s)atgaspipeandslideboilerawayfrompiping.

6. Lift heat exchanger straight up using caution not to

damagerefractory.

7. Reverseaboveproceduretoreinstall.Makesurethe

insulation strips are properly replaced on top of the

refractoryretainer.

Burners

BurnerHoldDownBracket

Fig.#9479

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Extension Pieces (2)

Auger with Carbide Tip

Wire Brush

Fig. # 8154.0

TUBECLEANINGPROCEDURE

IMMERSIONWELLREPLACEMENT

Establish a regular inspection schedule, frequency de- (Millivolt and ASME)

pendingonlocalwaterconditionandseverityofservice. 1. Shut water off to heater and drain heat exchanger.

Do not let the tubes clog up solidly. Clean out deposits 2. Remove access panel on water connection side of

over 1/16" in thickness.

heater.

3. Removeoldimmersionwellwithbushingandsleeve.

4. Install in header.

Theheatermaybecleanedfromthereturnheaderside,

without breaking pipe connections. It is preferable,

however, to remove both headers for better visibility

throughthetubesandtobesuretheground-uplimedust

does not get into the system.

NOTE: Installation in plastic should be hand tight plus

1/2 turn.

Note that you do not remove the top panel or the heater

exchanger,generally.

Afterreaming,mountthewirebrushinplaceoftheauger

and clean out debris remaining in the tubes.

Well Assembly

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

Fig.#2010

CAUTION: SOOT IS COMBUSTIBLE. EXERCISE

EXTREME CARE:

UNITHERMGOVERNOR(U.G.)REPLACEMENT

1. Shut water, gas and electricity off, close valves and

relievepressure.

2. Drainheatexchanger.

3. Removeretainerpluglocatednexttotheoutletpipe

connection.

4. RemoveoldU.G.fromretainerplug. Itissnappedin

place. Snap in new U.G.

5. Reinstall retainer plug, taking care to lubricate gas-

ket with a non-petroleum based grease such as

AquaLube.

Sootwillclogareasbetweenfinsandcauseeventualtube

failure. Any sign of soot at the base of the burners or

around the outer jacket indicates a need for cleaning.

1. Remove top and flue collector from cabinet.

2. Remove"V"bafflesfromheatexchanger.

3. Removeburnerdrawer. (Seeburnertrayremoval).

4. Remove heat exchanger from the heater and wash

with a garden hose, making sure soot is removed

from spaces between fins.

5. Reverseaboveproceduretoreinstall.

NOTE: In extreme cases it may be necessary to do

steam cleaning at the local car wash. DO NOT WIRE

BRUSH.

Retainer Plug

U.G.

Spring

COMBUSTION CHAMBERREMOVAL

To remove combustion chamber, you must first have

removedtheheatexchanger. Unboltmetalcombustion

chamberretainerfromtopandremovecombustioncham-

berpanelsindividually.

Gasket

Fig.#2011

TotesttheoperationoftheUnithermGovernor, placein

hotwater(over100°F)andwatchformovementagainst

spring. If there is no movement, replace unit.

Fig.#RP8155.0

REFRACTORYPANELS-TOPVIEW

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LOW NOx POOL HEATERS

The Raypak Low Nox Pool Heaters are certified and BURNERADJUSTMENT

testedundertheANSIZ21.56.CSA4.7 Standardsforgas

firedpoolheaters.

This burner assembly does not require any primary air

adjustments.

Theheatershouldbeinstalledtomeetalllocalcodes,the

latesteditionsoftheNationalFuelGasCodeZ223.1and VISUAL INSPECTION

the National Electrical Code, ANSI/NFPA 70.

Flame can be observed through the slot opening above

theplenum. Flamecolorisblueandevenlyspreadonthe

top surface of the burner. At least every three months a

visualinspectionshouldbemadeoftheburners. Incase

flame lifting is observed on the burner, check gas pres-

sure on manifold. Gas pressure in manifold should be

3.9" W.C.

ELECTRICAL

Be sure that electrical service to the boiler has proper

overloadfuseorcircuitbreakerprotection,wiresizeand

connections which comply with all applicable codes.

FLAMEROLL-OUTSAFETYSWITCH

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

anyovertemperatureconditionshavebeenfixed. Exces-

sive restriction in the heat exchanger flue passage may

cause the switch to disable the heater.

Fig#9361

OPERATION

On call for heat, the ignition system, consisting of an

electronic spark module, gas pilot system is energized.

Providing pilot is 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-UPPROCEDURES

1. Turn on power to the heater with gas supply off.

2. Check ignition as follows:

a. Set the 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. Turncontroldowntoendcallforheatandwait60

secondsonlockoutmodelsbeforebeginningstep

3. Turn on gas supply.

4. Set controller to call for heat.

5. System should start as follows:

a. Spark will turn on and pilot gas valve will open

and the blower will begin running.

b.Heaterwilloperateuntilcallforheatissatisfied.

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LOW NOX HEATERS (CONTINUED)

6. Use a long 9/16” socket wrench to remove orifices

from the gas manifold.

7. Reverse above procedure to reinstall.

IIDPILOT

Fig#9477

Fig#9362

PILOT REMOVAL

LOW NOx BURNER TRAY ASSEMBLY

1. Disconnect pilot tubing from gas valve.

2. Remove (4) screws from control box. Open the con-

trol box.

BURNER DRAWER REMOVAL

3. Remove the pilot wire from the ignition wire.

4. Remove (2) screws that mount the pilot bracket to

the air manifold assembly.

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door.

5. Pull the pilot bracket slightly, then drop and pull

downwards and outwards.

6. Reverse above procedure to reinstall. Make sure

the pilot bracket is all the way up on the pilot side,

see drawing below.

4. Disconnect gas line from gas valve.

5. Remove (2) screws that mount burner tray to the

base of the unit, and (2) screws that secure gas

valve to jacket.

6. Disconnect wires that terminate at gas valve.

7. Unscrew (4) screws that secure the control box.

8. Disconnect pilot wire from the ignition module.

9. Disconnect wire harness from the combustion blower.

10. Carefully slide out the burner tray assembly.

11. Reverse above procedure to reinstall.

GAS VALVE REMOVAL

1. Remove burner drawer. See burner removal proce-

dure.

2. Disconnect, pilot tubing from gas valve.

3. Turn vertical gas pipe from manifold slightly and un-

screw gas valve.

4. Reverse above procedure to reinstall.

MAIN BURNERAND ORIFICE REMOVAL

Fig#9368

1. Remove burner drawer. See burner drawer removal

procedure.

2. Remove pilot. See pilot removal procedure.

3. Remove (8) total screws from the hold down brack-

ets, front and rear of tray.

COMBUSTION FAN REMOVAL

4. Remove (8) total screws from the left and right sides

of the Manifold assembly. Detach the manifold as-

sembly from the burner tray assembly.

5. Remove burners by raising the bracket on the back

end of the burners up and out of their slots.

1. Remove burner drawer. See burner drawer

removal procedure.

2. Remove (4) screws the mount the combustion

blower to the manifold assembly.

3. Reverse above procedure to reinstall.

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SECTION 5 / TROUBLE SHOOTING GUIDE

MECHANICAL(FORQUALIFIEDSERVICEPERSONNELONLY)

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

SOLUTION

Harmonics, or whining noise

U.G. inoperative.................................... Check movement by putting in hot water (110°F or

higher). If no movement, replace.

*Debris or restriction in system............ Locate the restriction and remove. Flush system

and clean.

*Debris in gas line................................. Remove debris or blow out gas line.

Low flow.............................................. Scale forming in heat exchanger - clean heat

exchanger and check pool pH and total alkalinity.

Heater going on and off

continuously

Dirty filter.............................................. Backwash filter.

Low water level in pool........................ Raise water level.

External bypass setting out of

adjustment............................................ Adjust bypass

*Pressure switch out of

adjustment............................................. Adjust pressure switch

Liming or scale forming on

heat exchanger

Pool water............................................. Recommended pH should be between 7.4 and 7.8

Totalalkalinity100-150PPMmaximum.

Hardness 150-400 PPM maximum.

Sooting

High flow rates..................................... Reduce by adding manual bypass valve. Adjust

manual bypass valve until heater outlet water

temperature is between 105° and 110°F.

U.G. Inoperative.................................... Check movement by putting in hot water (110°F

or higher). If no movement, replace.

*Air starvation....................................... Refer to installation instructions.

*Improper venting.................................. Follow recommended installation instructions.

*Insects or debris clogging

burner intake ports............................... Clean burners.

Pilot outage

Low gas pressure................................ Adjust gas pressure.

Restricted pilot...................................... Cleanpilot.

Weak pilot generator............................. Replace pilot.

Yellow lazy flame

Low gas pressure................................ Adjust gas pressure.

*Insects or debris clogging

burner intake ports............................... Clean burners.

Outer jacket very hot

(paint blistered)

*Broken refractory caused by

shipping damage or improper

combustion.......................................... Replace refractory panels.

Excessive sooting of heat

exchanger........................................... Determine cause of sooting & correct.

Takes long time to heat

pool or spa.

Calculate temperature in °/hr................ 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.

Filter not running long enough............... Reset time clock.

Dirty filter............................................... Clean filter.

Gas line or meter undersized................ Refer to installation instructions.

Liming

Bypassing too much water................... Inspect bypass for movement, if no movement,

replace.

U.G. not functioning.............................. Replace if no movement when heated.

Leaking at well.

Overacid............................................... Replace well and maintain water chemistry properly.

Leaking at heat exchanger.

Overacid............................................... Replace heat exchanger and maintain chemistry

properly.

Gasket brittle and leaking -

(overheated).

Heater running after pump

shuts off............................................... See pressure switch adjustment.

Refractory damage............................... Replace refractory.

Sooted heater....................................... Determine cause of sooting and correct.

Combustion fan not running

Fan relay............................................... Replace fan relay

Fan........................................................ Loose connection or failed motor

Burned motor ....................................... Incorrect wiring, replace blower

(* Indicates symptom usually occurs on initial start-up.)

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ELECTRICAL ( STANDING PILOT MILLIVOLT)

RAYPAKPOOLORSPAHEATER

ELECTRICALCHECKWITHMVGASVALVE

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

does not light

If pilot burner goes out

when main burner lights

or when gas valve knob

is released

If pilot burner remains lit.

Jump across both "TH"

wires on gas valves

Check gas supply, gas

line size, gas pressure.

Also check for insects

or debris in pilot output.

Remove both "TH"

wires from gas valve.

Relight pilot

Replace

gas

valve

If main burner fires,

remove jumper

If main burner does not

fire, remove jumper

Jump across pressure

switch terminals

If burner does not remain

lit, attach millivolt meter

and read pilot output.

If pilot burner stays on

If main burner fires,

If main burner does not

remove jumper

fire, remove jumper

Problem is a wire or

component short to

cabinet or low gas

pressure

If above 500mV,

replace gas valve

Clean filter

Jump across thermostat

Check for adequate water

flow from filter

If main burner does

If below 500mV, check

If main burner fires,

remove jumper

NOTfire...

gas pressure. Also check

for insects or debris in

the pilot burner

Jump across each

high limit and remove

jumper

Replace pressure switch

Replace thermostat

If output is still low,

Replace high limit that

caused heater to fire

replace pilot generator.

Raw Output (700mV± 100)

Pilot generator disconnected from valve (knob must

be held down to keep pilot on).

White – Negative

Red + Positive

Pilot Load (500mV± 100)

Pilot generator connected to valve-Power applied to

pilot solenoid.

TP(Thermopile-Robertshaw)

PP(Power Pile-Honeywell)

TH TP – Common

TH PP – Common

Main Valve Load (200mV± 100)

Control/Limit circuit closed (All switches "ON")

TP(Thermopile-Robertshaw)

PP(Power Pile-Honeywell)

TH TP – Common

TH PP – Common

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ELECTRICAL (ELECTRONIC IGNITION IID) TROUBLESHOOTING

WARNINGHIGHVOLTAGE

ForqualifiedTechniciansONLY

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.

START

TURN GAS SUPPLY OFF.

TURNTHERMOSTAT

(CONTROLLER) TO CALL

FORHEAT

NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout

procedure.

Check line voltage power, low voltage transformer, limit controller, thermostat

(controller) and wiring.

POWER TO PC BOARD

(24 V NOMINAL)

YES

Pull ignition lead and check spark at PC board.

SPARK ACROSS

IGNITER/SENSOR GAP

YES

Spark Okay?

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

PILOT BURNER LIGHTS?

YES

• Check that all manual gas valves are open, supply tubing and pressures are good,

and pilot burner orifice is not blocked.

• Check electrical connections between 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?

YES

• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.

• 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

CALL FOR HEAT ENDS?

YES

NOTE: IF PC board goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.

NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though

operation is normal at the time of checkout.

• Check that pilot flame covers flame rod and is steady and blue.

• If checks are okay, replace PC board.

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

• Check for proper thermostat (controller) operation.

• Remove MV lead at module; if valve closes, recheck temperature controller and

wiring; if not, replace gas valve.

TROUBLESHOOTING

ENDS

Repeat procedure until trouble free operation is obtained.

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DIGITAL CONTROL LOGIC - FLOW CHART

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SECTION 6 - REPLACEMENT PARTS LIST

If determined defective by the Company and within

warranty, the part will be returned in kind or equal

substitution, freight collect. Credit will not be issued.

NOTE: To supply you with the correct part it is impor-

tantthatyoustatethemodelnumber,serialnumberand

type of gas when applicable.

RAYPAK,INC.

2151 Eastman Avenue

Oxnard, CA 93030

Anypartreturnedforreplacementunderstandardcom-

pany warranties must be properly tagged with a

RAYPAK return parts tag, completely filled in with the

heater serial number, model number, etc., and shipped

to the Company freight prepaid.

For Canada:

RAYPAKCANADALTD.

2805 SLOUGH STREET

MISSISSAUGA,ONTARIO

L4T 1G2

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Low NOx BURNER TRAY

PILOT ASSEMBLIES

2-P

4-P

9-P

4-P

7-P

9-P

10-P

Fig.#8124

Fig.#9369

HoneywellIIDAtmosphericunits

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

5-P

8-P

6-P

3-P

9-P

Honeywell MV

Fig. #8107

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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.

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