Raypak P R185B To R P405B C R405B R185Bl R405Bl Users Manual 6000.52 New RP2100 AI.pmd

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Page Count: 52

Part No. 240612

CATALOG NO. 6000.52-AK

Effective: 05-01-04

Replaces: 03-15-04

INSTALLATION

AND OPERATING

INSTRUCTIONS

This manual should be maintained in legible condition and kept adjacent to the

heater or kept in a safe place for future reference.

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

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

—WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas

supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

—Installation and service must be performed by a qualified installer, service agency or

the gas supplier.

—Do not store or use gasoline or other flammable vapors and liquids in the vicinity of

this or any other appliance.

Fig.# 9478

RP2100

SWIMMING POOL

and

SPA HEATER

Atmospheric Models

P-R185B to P-R405B

C-R185B to C-R405B

Low NOx Models

P-R185BL to P-R405BL

C-R185BL to C-R405BL

CONTENTS

3

4 PART ONE

OWNER'S OPERATING INSTRUCTIONS

4 SECTION 1

START-UP PROCEDURES

4 Before Start-Up

5 Lighting Instructions & Shut-Off Procedures-

Manually Lighted Pilots MV

6 Operating Instruction & Shut-Off Procedures-

Automatically Lighted Pilots IID

7 After Start-Up

7 SECTION 2

CAUTION

7 SECTION 3

MAINTENANCE & CARE PROCEDURES

8 Pool & Spa Water Chemistry

8 Cold Weather Operation

9 Winterizing the Pool & Spa Heater

10 PART TWO

INSTALLATION & SERVICE INSTRUCTIONS

10 SECTION 1

RECEIVING EQUIPMENT

10 SECTION 2

GENERAL SPECIFICATIONS

11 SECTION 3

INSTALLATION INSTRUCTIONS

11 Code Requirements

11 Clearances

12 Outdoor Heater Installation

12 Indoor Heater Installation

16 Specifications and Dimensions

16 Combustion Air

17 Vent Piping

17 Gas Supply Connections

19 Plumbing For Water Connections

23 Heat Exchanger Reversal Procedure

24 Electrical Wiring

25 Transformer Wiring

26 Wiring Diagram-Millivolt (Mechanical Therm.)

27 Wiring Diagram-IID (Atmospheric)

28 Wiring Diagram-IID (Low NOx)

29 SECTION 4

SERVICING INSTRUCTIONS

29 General Location of Controls

29 Millivolt Controls

30 Digital Thermostat Controls

31 Digital Diagnostics and Codes

32 Remote Control and Operation Installation

34 Pressure Switch

34 Flame Roll-Out Safety Switch

34 High Limit

34 Pilot Safety

35 Burner Drawer Removal

35 Gas Valve Removal

35 Main Burner and Orifice Removal

35 Pilot Removal and Cleaning

35 Heat Exchanger Removal

36 Tube Cleaning Procedure

36 Desooting Procedure

36 Combustion Chamber Removal

36 Immersion Well Replacement

36 Unitherm Governor (U.G.) Replacement

37 Low NOx Pool Heaters

39 SECTION 5

TROUBLE SHOOTING GUIDE

39 Mechanical

40 Electrical MV Units

41 Electrical IID Units

42 Digital Control Logic

43 SECTION 6

REPLACEMENT PARTS

44 Illustrated Parts List

46 Part Numbers

4

BEFORE START-UP

BURNERS

Clean main burners, combustion fan and air louvers of

dust, lint and debris. Keep heater area clear and free from

combustibles, flammable liquids and chemicals. Do not

obstruct the flow of combustion and ventilating air.

RP2100 DIGITAL IID POLYMER

SECTION 1 - START-UP PROCEDURES

Your Raypak Pool/Spa heater has been designed for years of safe and reliable pool/spa water heating. It is available

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

available. This manual provides operation, installation, maintenance, and service information for these heaters.

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

contains the control center that allows you to turn the heater on or off and adjust the temperature settings for the pool

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

toggle switch to turn the heater on and off, see fig. # 9472 above for location. Section 4 of this manual contains more

details about the use of the controls in the Controls Adjustments subsection (page 29).

WATER

Water must be flowing through the heater during opera-

tion. Insure that system is filled with water and have pump

operating.

Fig.# 9472

ON

OFF

Fig.# 9478

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.

4. Push the gas control knob slightly and turn

clockwise to "Off". Do not force.

5. Replace heater door panel.

1. Set the thermostat to the lowest setting.

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

3. Remove heater door panel.

TO TURN OFF GAS TO APPLIANCE

A. This appliance has a pilot that must be lit by

hand. When lighting the pilot, follow these

instructions exactly.

B. BEFORE LIGHTING smell all around the

appliance area for gas. Be sure to smell next

to the floor because some gas is heavier than

air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

*Do not try to light any appliance.

*Do not touch any electric switch; do not use

any phone in your building.

*Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

*If you cannot reach your gas supplier, call

the fire department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will

not push in or turn by hand, do not try to repair

it. Call a qualified service technician. Force or

attempted repair may result in a fire or explo-

sion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified serv-

ice technician to inspect the appliance and to

replace any part of the control system and any

gas control which has been under water.

LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES

MANUALLY LIGHTED PILOTS

MILLIVOLT SYSTEM

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat on the lowest setting.

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

4. Remove heater door panel.

5. 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.

6. Wait 5 minutes to clear out any gas. If you then

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

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

to the next step.

7. Locate pilot mounted on the right side panel of

the burner drawer. For burner drawer location,

see location of control section, page 20.

HONEYWELL PILOT ROBERTSHAW PILOT

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.

8. Turn knob on gas control counter-clockwise

to "Pilot"

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. If it goes out, repeat steps 5 through 9.

*If knob does not pop up when released, stop

and immediately call your service technician

or gas supplier.

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

control knob counter clockwise to "On".

11. Replace heater door panel.

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

13. Set thermostat to the desired setting.

Fig. # 8083.0 Fig. # 8084.1

GAS CONTROL KNOB SHOWN IN OFF POSITION

HONEYWELL

GAS VALVE

MILLIVOLT

ROBERTSHAW

GAS VALVE

MILLIVOLT

Fig. # 8081.0

Fig. # 8079.0

5

A. This appliance is equipped with an ignition

device which automatically lights the pilot. Do

not try to light the pilot by hand.

B. BEFORE OPERATING, smell all around the

appliance area for gas. Be sure to smell next

to the floor because some gas is heavier than

air and will settle on the floor.

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.

OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES

AUTOMATICALLY LIGHTED PILOTS

ELECTRONIC IGNITIONS SYSTEMS

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.

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.

*If you cannot reach your gas supplier, call the fire

department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will

not push in or turn by hand, don't try to repair

it; call a qualified service technician. Force or

attempted repair may result in fire or explo-

sion.

D. 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.

5. Remove heater door panel.

6. For Honeywell Valve: Turn gas control

knob clockwise to "Off".

For Robertshaw valve: Turn gas control

knob clockwise to "Off".(Models

265-405) Push in and move gas control

lever counter-clockwise to "Off"

position. (Model 185)

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)

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. 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.

Turn gas control knob clockwise

GAS CONTROL KNOB SHOWN IN "ON" POSITION

GAS

INLET

HONEYWELL

VR 8300 GAS

VALVE IID

ROBERTSHAW

7200 GAS VALVE

IID MODEL 185

GAS CONTROL

LEVER SHOWN

IN "OFF"

POSITION

GAS

INLET

ROBERTSHAW 7000

GAS VALVE IID

MODEL 265-405

Fig. # 8080.0

6

Fig. # 8934.1

AFTER START-UP

Feel the inlet and outlet pipes. Outlet pipe should be only

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

VISUAL INSPECTION

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

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

with a well-defined pattern.

4" MAX

Fig. # 8205.2

MAIN BURNER FLAME

Fig. # 8964.1

PILOT BURNER FLAME

A yellow or "floating" flame indicates restricted air open-

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

heater off and contact your installer or gas supplier.

WATER PRESSURE SWITCH

A water pressure switch is provided in the heater to shut

off the burners in the event that water supply to the heater

is interrupted. It is very important to verify that the switch

electrically opens and shuts off the gas valve when water

flow to the heater is interrupted. Otherwise, rapid and

severe damage will likely occur to the heater. (The water

pressure switch should be checked and adjusted for

proper operation by a qualified service person at the time

of installation and periodically checked thereafter. Refer

to Pressure Switch Adjustment on pg. 34 of this manual).

SECTION 2 - CAUTION

Elevated water temperature can be hazardous, and the

U. S. Consumer Product Safety Commission recom-

mends the following guidelines:

1. Spa or hot tub water temperatures should never

exceed 104°F (40°C). A temperature of 100°F (38°C)

is considered safe for a healthy adult. Special

caution is suggested for young children.

2. Drinking of alcoholic beverages before or during spa

or hot tub use can cause drowsiness which could

lead to unconsciousness and subsequently result in

drowning.

3. Pregnant Women Beware! Soaking in water over

102°F (39°C) can cause fetal damage during the first

three months of pregnancy resulting in the birth of a

brain-damaged or deformed child. Pregnant women

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

4. Before entering the spa or hot tub, users should

check the water temperature with an accurate 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

problems should obtain a physician's advice before

using pools or hot tubs.

6. Persons taking medications which induce drowsi-

ness, such as tranquilizers, antihistamines, or anti-

coagulant, should not use spas or hot tubs.

SECTION 3 - MAINTENANCE AND

CARE PROCEDURES

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

annually.

1. Inspect top of heater and drafthood for soot, a sticky

black substance around finned tubes and "V"

baffles), and open flue gas passage ways. Any visible

soot should be cleaned for proper operation.

7

WARNING: Operation of the heater without water

circulation will cause rapid and severe damage to the

heater.

CAUTION: Soot may be combustible. Wet sooted

surfaces completely prior to cleaning. Do not use steel

wire brush.

2. Clean main burners and pilot burner of dust and lint.

3. Inspect and operate all controls, gas valve and

pressure relief valve.

WARNING: Should overheating occur or the gas

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

to the appliance.

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

Flame pattern on the main burner and pilot is indi-

cated in the previous illustration. Yellow flame

means restriction of the air openings. Lifting or

blowing flame indicates high gas pressure. Low

flame means low gas pressure. Should the latter

occur, shut the heater off and contact your gas

supplier or qualified service agency.

5. On indoor heaters, clean room intake openings to

assure adequate flow of combustion and ventilation

air.

6. Keep area around heater clear and free from combus-

tible materials, gasoline and other flammable and

corrosive vapors and liquids.

BASIC TIPS IF HEATER WILL NOT FIRE:

If you have no electrical power; it may be your "circuit

breaker" has tripped. Try re-setting it.

If you have electrical power but the heater will not fire

check the following:

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

2. Your pump strainer basket may be full. If so remove

debris.

3. Your filter may be dirty. If so, backwash or clean

filter. (To tell if your filter is dirty, look to see if the

filter pressure will be higher than usual).

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

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

no pressure; then you are not moving water (or your

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

normal flow rate.

POOL & SPA WATER CHEMISTRY

Chemical imbalance can cause severe damage to your

heater and associated equipment. Maintain your water

pH between 7.4 and 7.8 and total alkalinity between 100

and 150 p.p.m. If the mineral content and dissolved solids

in the water become too high, scale forms inside the heat

exchanger tubes, reducing heater efficiency and also

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

heater will be severely damaged. This will result in

corrosion of the heat exchanger. Heat exchanger

damage resulting from chemical imbalance is not

covered by the warranty.

AUTOMATIC CHLORINATORS AND

CHEMICAL FEEDERS

All chemicals must be introduced and completely diluted

into the pool or spa water before being circulated through

the heater. Do not place chlorine tablets or bromine

sticks in the skimmer. High chemical concentrations will

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

Chlorinators must feed downstream of the heater and

have an anti-siphoning device to prevent chemical back-

up into the heater when the pump is shut off.

NOTE: High chemical concentrates from feeders and

chlorinators that are out of adjustment will cause very

rapid corrosion to the heat exchanger. Such damage is

not covered under the warranty.

COLD WEATHER OPERATION

8

CAUTION: Combustion air must not be contaminated

by corrosive chemical fumes which can damage the

heater and void the warranty.

MODERATE CLIMATE: Heater operation can con-

tinue during short term cold spells. When tempera-

tures are below freezing, flow (continuous pump opera-

tion) must be maintained.

CAUTION: Do not use the heater to maintain water

temperatures just above freezing or for freeze protec-

tion. When heater is used during freezing weather,

care must be taken to avoid freeze ups. Continuous

pump operation is a must. Additional protection may

be required. The heater is not warranted against freeze

ups.

COLD CLIMATE: Prolonged operation with water tem-

peratures below 50°F is not recommended. When

starting the heater with pool temperatures below 50°F

operate the heater continuously until higher tempera-

tures are reached. Operating the heater for prolonged

periods with pool water below 50°F can seriously

damage the heater, and is not covered by the warranty.

For cold climate areas, please follow the winterizing

procedures listed.

IMPORTANT FREEZE INFORMATION

WINTERIZING THE POOL & SPA HEATER

Heaters installed outdoors in freezing climate areas are

subject to be shut down for the winter. Observe the

following procedure for winterizing the heater:

1. 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

inspection panel on the side opposite water piping to

gain access to the drain plug on the return header.

Open drain plug on return header.

9

Return Header

Drain Plug

3. For ASME Heaters only: Disconnect compression

fittings from the pressure switch and return header

that connects to the 1/4" copper tube and allow the

tube to drain. For ASME Heaters only.

SECTION 1 - RECEIVING EQUIPMENT

On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the carton

is damaged, a note should be made on the Bill of Lading when signing for equipment. Remove the heater from the

carton and if it is damaged, report the damage to the carrier immediately. Save the carton.

These items are shipped loose inside the carton with the heater:

STANDARD UNIT (POLYMER HEADERS) ASME UNIT (CAST IRON HEADERS)

1. "Pagoda" Top 1. "Pagoda" Top

2. 2" CPVC Union with "O" rings (2) 2. In/Out Flanges (2)

3. Plastic pipe finish flange for gas line 3. 1-1/2" Flange Gaskets (2)

4. Bonding lug with mounting screw 4. 2" Flange Gaskets (2)

(IID units only) 5. Flange Bolts (4)

6. Pressure Relief Valve

7. 2" CPVC Adapters (2)

8. Plastic pipe finish flange for gas line.

9. Bonding lug with mounting screw. (IID units only).

Be sure that you receive the number of packages indicated on the Bill of Lading.

When ordering parts, you must specify model and serial number of heater. When ordering under warranty conditions,

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

installing your Raypak pool/spa heater. If there are any questions that this manual does not answer, please contact

the factory or your local Raypak representative.)

SECTION 2 - GENERAL SPECIFICATIONS

These heaters are design certified and tested under the requirements of ANSI Z21.56 / CSA 4.7 American National

Standard / CSA Standard for Gas-Fired Pool Heaters. All heaters can be used either indoor or outdoors. The

appropriate top designated for that type of use is required. If desired, the top can be changed at a later date to change

from outdoor to indoor or vice versa. Millivolt heater contains a self-generating electrical system 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

*Requires 120V or 240V Power Supply

Atmospheric heaters:

Rated inputs suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1000

feet above sea level, as high elevation reduces combustion performance.

Low NOx heaters:

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

10

PART TWO

INSTALLATION AND SERVICE INSTRUCTIONS

12"

Minimu

m

12"

M

inimum

4"

Minimum

HEATER

Sheet Metal

24 Gauge

11

IMPORTANT NOTICE

These instructions are intended for the use of qualified

personnel only, specifically trained and experienced in

the installation of this type of heating equipment and

related system components. Installation and service

personnel may be required by some states to be li-

censed. If your state is such, be sure your contractor

bears the appropriate license. Persons not qualified shall

not attempt to fix this equipment nor attempt repairs

according to these instructions.

CODE REQUIREMENTS

NOTE: The heater should not be located in an area

where possible water leakage will result in damage to

the area adjacent to the appliance or to the structure.

When such locations cannot be avoided, it is recom-

mended that a suitable drain pan, adequately drained,

be installed under the appliance. The pan must not

restrict combustion air flow.

Installation must be in accordance with local codes, or,

in the absence of local codes, with the latest edition of the

National Fuel Gas Code, ANSI Z223.1 and National

Electrical Code, ANSI/NFPA 70, and for Canada, the

latest edition of CAN/CGA-B149.1 and B149.2, and

Canadian Electrical Code, CSA C22.1 Part 1 and Part

2.

BASE INSTALLATION

Heater must be mounted on a level base, such as cement

slab, cement blocks or other non-combustible surface.

An optional non-combustible base is available for all

models.

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California

to cause cancer, birth defects or other reproductive harm.

An alternative method for providing a base for combustible

floors is illustrated below. Heaters must not be installed

on carpeting.

CLEARANCES

ALL HEATERS

For clearances from combustible surfaces, see the chart

below.

SECTION 3 - INSTALLATION INSTRUCTIONS

WARNING:

Improper installation, adjustment, alteration, service or

maintenance may damage the equipment, create a

hazard resulting in asphyxiation, explosion or fire, and

will void the warranty.

Fig. # 8148.1

Utilize hollow concrete cinder blocks, align holes and

leave ends open.

When installed according to the listed minimum clear-

ances from combustible construction materials, the

Raypak pool heaters can still be serviced without remov-

ing permanent structural construction around the heater.

However for ease of servicing, we recommend a clear-

ance of at least 24" in the front, and at least 18" on the

water connection side. This will enable the heater to be

serviced in its installed location, that is, without move-

ment or removal of the heater.

Clearances less than these (6" minimum), may require

removal of the heater to service either the heat exchanger

or the burner tray. In either case, the heater must be

installed in a manner that will enable the heater to be

serviced without removing any structure around the

heater.

CLEARANCE FROM

COMBUSTIBLE CONSTRUCTION

INDOOR INSTALLATIONS:

Top*- 30"(Drafthood) Back - 6"

Front - Alcove Right Side - 12" (Water Side)

Vent - 6" Left Side - 6"

(Opposite Water side)

OUTDOOR INSTALLATION:

Top* - Unobstructed (Stackless top or outdoor stack)

Back - 6"

Side - 6"

*Clearance from top of vent terminal

Heaters must not be installed under an overhang of less than three (3) feet from the top of the heater. Three (3) sides

must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters installed

under overhangs with the use of gutters.

For U.S. installations,the point from where the flue products exit the heater must be a minimum of four (4) feet below,

four (4) feet horizontally from, or one (1) foot above any door, window or gravity inlet into any building. The top surface

of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10) feet

horizontally.

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. #RP8280.1

12

Fig. # 8278.2

OUTDOOR HEATER INSTALLATION

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

outdoor use.

HEATER WITH OUTDOOR STACKLESS TOP

Fig# 8245.1

U.S. Installations only

WARNING: The heater shall not be located in an area where water sprinklers, or other devices, may cause water

to spray through the cabinet louvers and into the heater. This could cause internal rusting or damage some electrical

components, and this would void the warranty.

WARNING: Do not install within 3 feet of a heat pump or an outdoor condensing unit. Strong air intake from these

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

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.

INDOOR HEATER INSTALLATION

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

For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly communicate

with occupied area. Refer to the latest edition of CAN/CGA-B149.1 and B149.2 for specific requirements.

Locate heater as close as practical to a chimney or gas vent. Heater must always be vented to the outside. See

Vent Piping section (pg. 17) for venting details. Minimum allowable space is shown on the nameplate.

13

OUTDOOR STACK / INDOOR STACK INSTALLATION

OUTDOOR KIT INCLUDES:

1- Draft hood, painted

1- Adapter plate

3- Mounting brackets (clips)

1- Top panel cover

2- 1 foot sections of metal tape

3- Screws

1- Instructions Clips

Clips

INDOOR KIT INCLUDES:

1- Draft hood, unpainted

1- Adapter plate

3- Mounting brackets (clips)

3- Screws

1- Instructions

ASSEMBLY PROCEDURE

1. Make sure that the gas and electricity to the unit has

been turned off.

2. Remove the "pagoda" top from the louvered top and

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.

5 Install adapter plate on top of heater flue collector.

See Fig. 5.

6. Reinstall louvered top on heater and fasten with

Phillips screws set aside in step 3.

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.

NOTE: The outdoor and indoor stack are optional equipment and do not come standard with the heater.

OUTDOOR STACK INDOOR STACK

Model Part No. Part No.

185 006751 006696

265 006752 006697

335 006753 006698

405 006754 006699

14

SECURING THE TOP PANEL COVER

INDOOR KIT ONLY

7. Reinstall the louvered top.

8. Mount the draft hood onto the adapter plate lip inside

the heater. See Fig. 6.

9. Proceed to installing the clips, step 14.

SECURING THE TOP PANEL COVER

OUTDOOR KIT ONLY

10. After removing the drafthood from the box, slide the

top panel cover over the draft hood.

11. Holding both pieces together, mount the draft hood

on the adapter plate lip inside the heater. See Fig. 6.

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

of the drafthood leaving 6" hanging down.

13. Slide the top panel cover up and attach the tape to the

underneath side. This is to temporarily keep the top

panel cover out of the way while you are attaching the

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

INSTALLING THE CLIPS

INDOOR & OUTDOOR KITS

14. Notice that there are three pilot holes above the base

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

locations where the three clips are to be attached.

15. Insert the long edge of one clip between the top panel

cover and the drafthood, see Fig. 9.

16. With a twisting motion, rotate the clip up, see Fig. 10.

17. Pull up on clip, see Fig. 11.

18. Hold the clip up and align the clip hole to the pilot

hole, see Fig. 12.

19. Insert screw into hole and secure using a 5/16" nut

driver.

20. Repeat steps 15-19 using remaining two clips.

21. This completes the indoor drafthood installation. If

installing an outdoor drafthood, proceed to step 22.

15

INSTALLING THE TOP COVER

OUTDOOR KIT ONLY

22. Remove the two pieces of metal tape holding the top

panel cover up and discard.

23. Insert the rear two tabs into the slots on the heater top

and slide the top panel cover backwards. See Fig.13.

24. Lower the top panel cover and using your thumbs,

push tabs in and insert the two front tabs into the

slots on the top of the heater. See Fig.14.

25. Lower the top panel cover flush to the top and release

the tabs. They will spring into place as shown in

Fig.15.

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

16

SPECIFICATIONS AND DIMENSIONS

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

a. All Air From Inside The Building:

Each opening shall have a minimum net free square

inches as noted:

Model Square Inches Model Square Inches

185 181 335 333

265 264 405 399

b. All Air From Outdoors:

When air is supplied directly from outside of building,

each opening shall have a minimum net free square

inches as noted:

Model Square Inches

185 46

265 66

335 84

405 100

COMBUSTION AND VENTILATION AIR

(Indoor Units Only)

The heater must have both combustion and ventilation air.

Minimum requirements for net free air supply openings,

one opening that is 12 inches from the ceiling for

ventilation and one opening that is 12 inches from the floor

for combustion air as outlined in the latest edition of the

National Fuel Gas Code, ANSI Z2231(Canada-CAN/

CGA-B149.1 and B149.2) and any local codes that may

have jurisdiction.

*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-rating is required for elevations up to

4500 feet. Manufactured under Patent No. 3,623,458. Note: Plastic (Polymer) headers cannot be used for ASME installations.

Fig # 9037.2

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B581R181"4/1-81"6"8/5-26"61/1-21"4/3"219127121

B562R462"8/3-22"7"8/7-26"8/1-11"4/3"241259151

B533R433"4/3-52"8"4/3-36"4/3-01"4/3"243251271

B504R993"4/1-92"9"8/3-56"2/1-21"4/3"235243202

CAUTION: Combustion air must not be contaminated

by corrosive chemical fumes which can damage the

heater and void the warranty.

VENT PIPING

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 speci-

fied in Chapter 10 of the National Fuel Gas Code, ANSI

Z 223.1 (Canada-CAN/CGA-B149.1 and B149.2). As

much as possible avoid long horizontal runs of vent pipe

and too many elbows. If installation requires horizontal

non-vertical runs, the vent pipe must have a minimum of

1/4 inch per foot rise and should be supported at not more

than five foot intervals. Plumbers tape, criss-crossed, will

serve to space both horizontal and vertical piping. Gas

vents supported only by the flashing and extending above

the roof more than five feet should be securely guyed or

braced to withstand snow and wind loads. We recom-

mend use of insulated vent pipe spacer through the roofs

and walls. Another option for installation that requires

horizontal runs is using the D-2 power vent kit option.

For more detailed D-2 installation information consult the

D-2 Power Vent manual 6000.57.

The power vent assembly is a fan-assisted combustion

system designed for application to Raypak Pool Heater

Models 185-405. The unit, when installed as directed, is

capable of operating in applications such as through-the-

wall venting and reduced horizontal and vertical vent pipe

sizes in new and current installations. It is certified for

Category III venting up to 40 feet equivalent 4" diameter

venting. The unit is factory wired for 240V, with capability

of rewiring for 120V.

For protection against rain or blockage by snow, the vent

pipe must terminate with a vent cap which complies with

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

the latest edition of the National Fuel Gas Code, ANSI

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

Fig. #RP 8119.2

17

GAS SUPPLY CONNECTIONS

The discharge opening must be a minimum of two feet

vertically from the roof surface and at least 2 feet higher

than any part of the building within 10 feet. Vent stack

shall be at least five feet in vertical height above the

drafthood outlet. The vent cap location shall have a

minimum clearance of 4 feet horizontally from, and in no

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

tained, from electric meters, gas meters regulators and

relief equipment.

The weight of the vent stack or chimney must not rest on

heater draft hood. Support must be provided in compli-

ance with applicable codes. The heater top and draft

hood must be readily removable for maintenance and

inspection. Vent pipe should be adequately supported to

maintain proper clearances from combustible construc-

tion.

Type "B" double wall

or equivalent vent pipe

is recommended.

However single wall

metal vent pipe may

be used as specified

in the latest edition of

the National Flue Gas

Code ANSI Z 223.1

(Canada-CAN/CGA-

B149.1 and B149.2).

Gas piping must have a

sediment trap ahead of

the heater gas controls,

and a manual shut-off

valve located outside the

heater jacket. All gas

piping should be tested

after installation in ac-

cordance with local

codes.

Fig. #RP 8090.0

Fig. # 9469

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.

Optional Raypak D-2

Power Vent

Power Vent Kit

Model Part No.

185 008086

265 008086

335 008087

405 008087

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.

Fig. # 8149

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

A flexible sealant is recommended.

A minimum of 7" W.C. and a maximum of 14" W.C.

upstream pressure under load, and no load conditions

must be provided for natural gas or a minimum of 12"

W.C. and a maximum of 14" for propane gas.

GAS PRESSURE REGULATOR

The gas pressure regulator is preset at 4" W. C. for natural

gas, and 11" W. C. for propane gas. The pressure at the

gas valve, taken with a manometer, should be about 3.7"

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

C. propane gas. If an adjustment is needed, remove seal

and turn adjustment screw clockwise to increase

pressure or counter-clockwise_____to decrease pres-

sure.

18

Gas

Pressure

Adjustment

GAS PRESSURE ADJUSTMENT LOCATIONS

MILLIVOLT GAS VALVES

ELECTRONIC IGNITION GAS VALVES

Robertshaw 7000

Models 185 thru 405

Gas

Pressure

Adjustment

Honeywell VR8304

Models 185 thru 405

Robertshaw 7200

Model 185

ELECTRONIC IGNITION GAS VALVES-CONTINUED

Robertshaw 7000 BDER

Model 265-335

Robertshaw 7000 DERHC

Model 405

Gas

Pressure

Adjustment

Gas

Pressure

Adjustment

Fig # 9263

Fig # 9264

Fig # 9328

Fig # 9327

Fig # 9329

Fig. # 9365

ATMOSPHERIC LOW NOx

PIPE SIZING FOR GAS CONNECTIONS

Low NOx units are not available in propane.

19

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.

INLET/OUTLET HEADER (Polymer)

POLYMER HEADERS (STANDARD MODELS)

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

header, make sure the o-rings are properly seated in the

grooves. Use AquaLube or equivalent non-petroleum

based lubricant on the o-ring. Hand tighten the unions.

Glue PVC piping directly to the unions.

PLUMBING FOR WATER CONNECTIONS

HEATER LOCATION (Relative to the pump and filter)

The RP 2100 heater requires water flow and positive

pressure to fire and operate properly. It must therefore be

installed downstream of the discharge side of the filter

pump. A typical installation is plumbed as follows:

1. The inlet side of the filter is plumbed directly to the

discharge side of the filter pump;

2. The outlet side of the filter is then plumbed to the inlet

of the heater; and

3. The outlet of the heater is plumbed to the return line

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

thus plumbed in series.

Plumbing from the heater back to the pool must not have

any valves or restriction that could prevent flow when the

pump is operating.

Heater must be located so that any water leaks will not

damage the structure of adjacent area. PVC pipe may

be glued directly into header unions.

FLOW RATES

MODEL PIPE SIZE MIN.GPM *MAX.GPM

185 1-1/4"-1-1/2" - 2 20 125

265 1-1/4"-1-1/2" - 2 25 125

335 1-1/4"-1-1/2" - 2 35 125

405 1-1/4"-1-1/2" - 2 40 125

ASME-Cast Iron

Header Flange Nut

(CPVC)

Inlet

Header Flange

(CPVC)

Flange Gasket

Fig. #2002.1

POLYMER HEADERS

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

a solar system, must be connected to the main line

ahead of the heater inlet pipe in order for it to act as the

primary heat source. If the primary system provides

adequate heat to maintain set-point, the RP2100

heater will not fire. Be advised that the RP2100 control

panel will then display sensed water temperatures

downstream of the primary heating system, rather than

the temperature of the water exiting the pool.

*When flow rates exceed maximum GPM an external

auxiliary bypass valve is required. See external bypass

valve section for details.

20

CAST IRON HEADRERS (ASME MODELS)

Heater must be located so that any water leaks will not

damage the structure of adjacent area. High temperature

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

header flanges. This is not the same as the Schedule 80

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

immediately after the CPVC adapters.

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.

#1 #2

Fig. # 8095.1 Fig. # 8097.1

INLET/OUTLET HEADER - ASME

Header Flange

2" CPVC Adapters

PVC Pipe

ASME

Inlet/Outlet Header

Flange Gasket

Fig. # 8093.1

UNITHERM GOVERNOR OPERATION

CAUTION: NEVER install PVC directly into header

flanges. Use the 2" CPVC adapter supplied loose with

the heater.

CAUTION:

The patented Unitherm Governor is a thermostatic

mixing valve specifically designed to maintain constant

heater internal temperature between 105° to 115°F

despite continually changing flow rates from the filter

and changing pool temperatures. This narrow range is

needed to prevent damaging condensation on the

burners which will occur if the heater runs for any length

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

formation in the tubes by maintaining temperatures

well below accelerated scaling temperatures.

GASKET

UNITHERM

GOVERNOR

U.G. PLUG

(Polymer)

21

PRESSURE RELIEF VALVE INSTALLATION

To conform to local building codes, it may be necessary

to install a pressure relief valve. A 3/4" pressure relief

valve having a capacity equal to BTU/HR output of the

model to be installed is recommended for this heater. The

maximum acceptable pressure relief valve setting is 125

psi.

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

for installation of a pressure relief valve. The valve shall be

installed in a vertical position. Do not over tighten. Install

pressure relief valve hand tight plus 1/2 turn.

POLYMER HEADER

Pressure Relief Valve

PRV Discharge

Connection

Inlet/Outlet Header

Fig. #2004

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

installation of a pressure relief valve. The valve shall be

installed in a vertical position.

ASME HEADER

(Cast Iron)

NOTE: To avoid water damage or scalding due to valve

operation, drain pipe must be connected to valve outlet

and run to a safe place of discharge. Drain pipe must be

the same size as the valve discharge connection

throughout its entire length and must pitch downward

from the valve. No shutoff valve shall be installed

between the relief valve and the drain line. Valve lever

should be tripped at least once a year to ensure that

waterways are clear.

INTERNAL AUTOMATIC BY-PASS VALVE

In addition to the Unitherm Governor, a built-in automatic

by-pass valve is provided in the in/out header. While the

Unitherm Governor responds to the changes in water

temperature in the heater, the internal by-pass valve

automatically responds to changes in water pressure in

the piping system. Proper amount of water flow is

maintained through the heater under varying pressures

dictated by the conditions of the pump and filter.

EXTERNAL AUXILIARY BYPASS VALVE

(Where Required)

An auxiliary bypass valve should be used when flow rates

exceed 125 GPM (usually a high performance pump size

larger than two horsepower will exceed this flow rate).

This valve is required to complement the function of the

automatic bypass valve, particularly when starting the

heater in winter or early spring when the spa or pool

temperature is down below 50°F. It also serves to

eliminate needless pressure drop through the heater and

accompanying reduction in the flow rate to the spa jets,

etc.

From Heater To Heater

To Pool From Pool

AUXILIARY BYPASS VALVE

(DO NOT USE GATE VALVE)

PRV Discharge

Connection

Inlet/Outlet Header

Pressure Relief

Valve

Fig. # 8095.0

Fig. # 8150.0ss

Fig.#2003

AUXILIARY BYPASS VALVE ADJUSTMENT

To set bypass: With clean filter, adjustment is made by

feeling the inlet and outlet pipes at the heater. Outlet

pipes should be slightly warmer than inlet and comfort-

able to the touch. If pipe is hot, close bypass; if cold, open

bypass.

SPRING

BYPASS DISC

BYPASS

BODY

22

HEAT EXCHANGER PRESSURE DROP TABLES

23

1. Remove right and left side access panels (Figure 1).

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

shutoff), and pressure switch on the inlet/outlet

header (Figure 2).

3. Electronic Ignition Heaters: Remove the thermo-

stat temperature sensor by loosening the compres-

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

left side of the heater.

4. Millivolt Heaters: Remove the temperature sensor

bulb and retainer clip from the sensor well (Figure 4).

Reroute the sensor bulb to the left side of the heater.

5. Remove (12) bolts holding the inlet/outlet and return

headers to the tube sheets. Clean off tube sheet area

where the gasket seats. Also clean off the header

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

cant to the gasket such as Aqua Lube. Reattach the

headers to the opposite sides, making sure they are

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

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

6. Reconnect high limit, AGS, and pressure switch

wires.

7. Electronic Ignition Heaters: Insert the temperature

sensor in the compression fitting and tighten 1/2 turn

past hand tight.

8. Millivolt Heaters: Insert sensor bulb and retainer

clip into sensor well.

9. Allow for water flow through the heater and check for

leaks.

10. Reattach access panels to the opposite sides.

For ASME Models call your factory representative.

Fig. #3

JACO FITTING

NOTE:Tighten almost flush

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

Fig. #2

PRESS SWITCH AGS HI-LIMIT

Fig. #4

BULB & CLIP

Fig. #5

REINSTALLED IN/OUT HEADER ON OPPOSITE SIDE.

HEAT EXCHANGER REVERSAL PROCEDURE (POLYMER HEADER MODELS)

Fig. #1

ACCESS PANEL

24

Option Location For Left

Side Field Wiring

Sway

Brace

Bonding Lug

(Standard Location)

Bonding Lug

(Optional Location)

Fig. # 9470

Control Box

(Factory Mounted Location)

LOW NOx

Wiring locations

ATMOSPHERIC

Wiring locations

Fig.# 9366.1

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.

MILLIVOLT SYSTEM

The Millivolt System residential heater is equipped with a

self-generating electrical system in which the electric

current is provided by means of a pilot generator. No

external electrical connections are required.

When installing a remote switch, do not exceed 10 feet

of wiring from the heater. Use 18 gage stranded wire.

ELECTRONIC

INTERMITTENT IGNITION DEVICE SYSTEM (IID)

The standard field wiring connection is on the right side

of the heater.

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

below:

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

junction box to the sway brace. Untie excess yellow

wires located behind the junction box.

2. Move the junction box to the left side of unit and

attach the box to the sway brace.

3. Secure 24V yellow wires to sway brace panel with

existing wire retainers.

4. Connect the wires inside the junction box, either

120V or 240V depending on the field wiring.

NOTE: 7/8" Dia. holes not utilized on jacket and control

box can be used for fireman switch or auxiliary control

interface wiring.

NOTE: Heater must be electrically grounded and

bonded. Bonding lug is provided loose with the unit.

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

necessary for bonding the unit. Mounting hole is provided

on the jacket.

The Electronic Intermittent Ignition Device automatically

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

The heater is supplied with a dual voltage transformer for

120V or 240V input power hookup.

NOTE:

Heaters are factory wired for 240V power supply.

25

NOTE: Input power to the heater (120/240V) can be supplied from the load (pump) side of time clock or directly from

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

using the switched GFCI power source the heater could display false service indicators on the delay panel if the pump

is turned off.

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

Heater must be electrically grounded and bonded in accordance with local codes, or, in the absence of local codes,

with the latest edition of the National Electrical code, ANSI/NFPA 70. (Canada- Canadian Electrical Code, CSA

C22.1, Part 1 and Part 2.)

TRANSFORMER WIRING

26

WIRING DIAGRAM - MILLIVOLT (MECHANICAL THERMOSTAT)

WIRING DIAGRAM - IID (Atmospheric)

27

WIRING DIAGRAM - IID (Low NOx)

28

Control Panel

Mounting Screws (4)

Fig. #RP 8267

CONTROL ADJUSTMENTS

MILLIVOLT CONTROLS

The pool or spa water temperature is controlled by the

pool heater thermostat on the upper front panel of the

heater. The control center contains an On/Off switch and

one or two thermostats.

Thermostats are fitted with a means of limiting the upper

temperature limit below the maximum level. The knob

stop adjustment ring illustrated below is adjustable by

loosening the set screw, rotating the knobstop ring to the

desired location and retightening the set screw.

29

Bypass

Hi Limit on

I/O header

(ASME on

Return

Header)

AGS Hi-

Limit

(Located

on Inlet/

Outlet

Header)

Unitherm

Governor

Drain Plug

Fig #2005

SECTION 4 - SERVICING INSTRUCTIONS

Drain Plug

(Located in

Return

Header)

Digital

Thermostat

Circuit Board

Roll-Out

Switch

Gas Valve

Pilot

CONTROL PANEL REMOVAL

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

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

force.

NOTE: Caution must be taken not to damage controls or

wiring.

Transformer

Fig.# 9472

ON

OFF

Temperature

Adjust Buttons

Mode Button

LCD Display

GENERAL LOCATION OF CONTROLS

SPA TEMPERATURE

RANGE

POOL TEMPERATURE

RANGE

SET SCREW

STAND-BY

TEMPERATURE

KNOB STOP RING

KNOB STOP SHOWN ABOVE IS

IN THE SPA TEMPERATURE RANGE

Fig. #9473

30

PROGRAM MODE BUTTON

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.

THERMOSTAT CONTROL OPERATION

The pool heater thermostat on the upper front panel of

the heater controls the pool/spa water temperature. This

control center contains a mode button, up and down

temperature adjustment buttons, and a LCD display.

Mode Button

The MODE button functions as a means to turn the

heater off or on in either the pool or spa temperature

setting. The LCD display indicates the mode the heater

is in and the actual water temperature.

Temp Buttons

If the mode is in POOL or SPA, the desired pool or spa

temperature will also be displayed and may be changed

using the UP or DOWN buttons. A manual toggle switch

is also provided right below the MODE button to allow

the heater to be turned off.

Operation

In the POOL or SPA modes, the actual water temperature

is displayed along with the desired pool or spa

temperature. If the heater is firing, a flame icon will be

visible.

To adjust the desired pool or spa temperature setting,

make sure the control is in the appropriate mode (POOL

or SPA) and push the UP or DOWN buttons to get the

desired set point temperature.

LCD DISPLAY TEMP

BUTTONS

MODE

BUTTON

Set Points

The electronic thermostat cannot be set above selected

maximum set points. The maximum default set points

are factory set at 104°F for both pool and spa. These

can be changed to a higher or lower value to suit your

needs, but can never be set above 107°F.

Program Mode Button

To adjust the set point, press the Mode button until the

display reads OFF. Remove the four screws holding the

control cover on. Swing control panel down so the back

side of the board is visible (see page 27). Locate the

Program Mode button as show in figure 9481.

Hold this button and use the Mode button to select “Set”

on the digital display. You can release the button once

“Set” appears. Using the “Up” and “Down” buttons will

change the Maximum Temperature Setting. The control

can be set for a maximum of 107°F. A separate value

can be set for either Pool or Spa by using the Mode

button to select Pool or Spa and using the “Up” and

“Down” arrows to select the desired Max temp for each.

Once this is done reassemble the control panel.

Fahrenheit vs Centigrade

The digital display is capable of displaying Centigrade

as well as Fahrenheit temperatures. To change the

display follow the instruction above to access the

Program Mode Button. Hold this button and use the

Mode button 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.

Fig #9481

Fig #9480

DIGITAL THERMOSTAT CONTROLS

DISPLAY

call for heat FLAME ICON

SET POINT

TEMPERATURE

MODE

POOL or SPA

WATER

TEMPERATURE

Fig# 9484

31

DIAGNOSTICS

The RP2100 Digital heater is equipped with on-board

diagnostic controls. If there is a safety fault, a fault code

will be displayed along with a service indication.

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.

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.

STATUS CODES

Display Definition

CFH Call for heat

CLK Time clock

LOW Caution - low water temperature

OFF Off mode

REM Remote control activated

SPK Spark

SPR Spare fault code indicator

FAULT CODES

Display Definition

BD1 Board failure

FFL Flame sensing when pilot and gas

valves are closed

HL1 Hi limit switch #1 open

HL2 Hi limit switch #2 open

IGN Ignition control failure

ILO Ignition lock out

PLT Pilot failure

PRS Pressure switch open

ROL Heat roll-out safety switch open

SNS Sensor failure

VNT Vent switch open

PROGRAM MODES

Display Definition

CCC Celsius setting

F/C Change from Fahrenheit to Celsius

FFF Fahrenheit setting

RES Reset defaults

SET Set point max adjustment

READING A FAULT

The word “SERVICE” will flash on and off if the PC board

detects a known fault. The fault will be displayed in

three big letters on the lower left of the display.

SERVICE WILL FLASH

3 LETTER FAULT CODE

See table for fault definition

Fig# 9482

Fig# 9485

32

REMOTE CONTROL INSTALLATION AND OPERATION

CAUTION: Before installing remote controls to the RP2100 Digital Heater, read the following:

The Raypak RP 2100 Digital Heater is remote ready in most cases. The digital liquid crystal display (LCD)

shows the actual pool temperature, operating status, and service codes (See examples below). The touch pad

on the control panel allows you to select the desired pool or spa temperature. It also indicates when a remote

system is controlling the heater by displaying REM in the display. When connecting the RP2100 Digital to a

remote system, identify whether it is a two- or three-wire remote system. Select the appropriate instruction

listed below to properly install the remote to the heater.

OFF Mode Heating in the POOL Mode Heating in the SPA Mode Remote Mode

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.

POOL COMMON

(BLK/ORG)

SPA COMMON

(ORG/BLK)

24VAC HOT

(BLU)

7-PIN REMOTE

WIRING CONNECTOR

PART NUMBER 071494

Note: Electrostatic Discharge (ESD) damage can be caused by direct

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/removal practices and reducing that charge by holding on

to the heater enclosure for 5 seconds before proceeding.

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

ACTIVATING THE REMOTE

The RP2100 digital has the ability to disconnect from

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

remote follow these steps:

The digital display format will change and indicate

REMoff or REMon.

Press either temperature button to switch remote modes.

External remote control

disabled

External remote control

active

IMPORTANT - Please Read

When the heater is to be controlled by a remote you

must choose REMon and the heater thermostat dis-

play must be in the OFF mode. If the heater thermostat

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

setting and the remote shut-off feature will not be

functional.

Fig# 9494

Fig# 9480

Fig# 9489

Fig# 9490

Fig# 9488

Fig# 9486

Fig# 9484

Fig# 9487

33

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 is 200 feet.

• For both two- and three- wire remote systems, the provided 7-pin wiring connector must be utilized. Please refer

to the wiring instructions.

1. Turn on power to the heater.

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

and set the desired temperature for each.

(eg. 80° for Pool and 102°F for Spa)

3. Turn the mode button to "OFF" and remove power from the

heater.

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

wire to one side of the "REMOTE" switch and connect the

ORANGE/BLACK wire for "SPA" operation and the

BLACK/ORANGE wire for the "POOL" operation.

5. Install the "Remote Interface Harness" to the P8 connec-

tor and turn power "ON" to the heater.

See instructions on previous page to activate the

remote control.

1. Turn on power to the heater.

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

set the desired temperature for each. (eg. 102°F)

3. Turn the mode button to "OFF" and remove power from the

heater.

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

wire to one side of the "REMOTE" switch and connect the

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

operation or the BLACK/ORANGE wire for "POOL" opera-

tion.

5. Place wire nut on unused wire on the "Remote Interface

Harness."

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

connector and turn on power to the heater.

See instructions on previous page to activate the

remote control.

Note: The remote wires must be connected to the

7-pin connector before it is connected to the board.

3-Wire Remote Control Using Three-Position Switch (Pool-Off-Spa, or Low-Off-High)

This application assumes that multiple heating functions are required.

2-Wire Remote Control (On-Off)

This application assumes that only one heating function is required.

Fig# 9492

Fig# 9493

FLAME ROLL-OUT SAFETY SWITCH

Atmospheric heaters are equipped with a thermal cutoff

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

exchanger becomes blocked. This is a "single-use" type

fusible link or thermal fuse, that must be replaced when

disabled by an over temperature condition, caused by

excessive restriction in the heat exchanger flue passage.

HIGH LIMITS

The heater is equipped with two automatic high limits.

Both are located in the inlet/outlet header. Both are set

to open at 135°F.

NOTE: An erratic high limit is often characteristic of

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

defective bypass. Refer to troubleshooting sections (pg.

39).

HIGH LIMIT REMOVAL

34

PRESSURE SWITCH

The pressure switch, or heater actuator, insures that the

heater operates only when the filter pump is in operation.

It is located on the inlet/outlet header. It is factory set at

1.75 PSI for deck level installations. When the heater is

located below the level of the spa or pool, it may be

necessary to reset the pressure switch to compensate

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

pressure switch, utilize the following procedure:

PRESSURE SWITCH ADJUSTMENT

Adjustment

Knob

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

a higher pressure rated (11 psi) switch may be used or a

flow switch mounted and wired adjacent to the heater may

be used in place of the factory mounted pressure switch.

See Parts List (pg. 47) for 11 psi pressure switch.

TWO-SPEED PUMPS

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

to operate the heater. This is apparent when the pressure

switch cannot be further adjusted or if the heater makes

banging noises or goes off on high limit. In these cases,

the pump must be run at high speed when heating the

water.

Fig. # 8152.2

PRESSURE SWITCH

ADJUSTMENT RANGE

Fig. #9440

1. With pump and heater on,

turn adjustment knob clock-

wise until a click is heard

from the gas valve.

2. Turn adjustment knob

counter clockwise 1/4

turn.

3. Turn pump off and on several

times. Heater should shut

off immediately. If it does

not, repeat steps above until

proper adjustments made.

Fig. # 9439

1. Shut off main electrical

power switch to heater.

2. Remove inlet/outlet in-

spection panel.

3. Remove defective high

limit and replace with a

new high limit.

4. Replace inspection

panel.

PILOT SAFETY- Millivolt

The heaters equipped with the standing pilot (millivolt

system), have pilot generators which act as a safety

device to shut off the flow of gas to the main burners and

the pilot burner in case the pilot flame is extinguished.

The pilot burner must be manually relighted to place the

heater in operation again. Refer to the lighting instruc-

tions provided on the heater label.

PILOT SAFETY- Electronic

The heater employs a pilot safety which closes the main

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

flame is interrupted. Pilot flame is automatically lit when

the device is powered. Unit performs its own safety check

and opens the main valve only after the pilot is proven to

be lit.

Fig. #9438

CAUTION: Do not operate the heater without the

function of a properly adjusted pressure switch or flow

switch.

PILOT REMOVAL AND CLEANING

1. Disconnect pilot tubing and wires from gas valve.

2. Remove pilot assembly from burner tray.

3. Remove pilot from bracket.

4. Remove pilot orifice and air opening (Honeywell MV

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

CAUTION! Do not enlarge hole in pilot orifice.

5. Reverse above procedure to reinstall.

HONEYWELL PILOT ROBERTSHAW PILOT

Pilot Pilot

Air

Opening

Orifice

Orifice

Fig. # 8045.1 Fig. # 8102.0

HEAT EXCHANGER REMOVAL

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

relieve pressure and remove relief valve. Remove side

inspection panels.

2. Remove top holding screws.

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

collector. Remove inspection panels.

4. Disconnect wires from high limits and pressure

switch. Remove temperature sensor.

5. Disconnect flange nuts on inlet-outlet header, loosen

union(s) at gas pipe and slide boiler away from piping.

6. Lift heat exchanger straight up using caution not to

damage refractory.

7. Reverse above procedure to reinstall. Make sure the

insulation strips are properly replaced on top of the

refractory retainer.

35

BURNER DRAWER REMOVAL

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door.

4. Disconnect gas line from gas valve.

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

and (2) screws that secure gas valve to jacket.

6. Disconnect wires that terminate at gas valve.

7. Slide out burner tray.

8. Reverse above procedure to reinstall.

GAS VALVE REMOVAL

1. Shut off gas supply to the heater. Remove gas piping

to gas valve inlet.

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

required.

3. Turn vertical gas pipe from manifold slightly and

unscrew gas valve.

4. Reverse above procedure to reinstall.

MAIN BURNER AND ORIFICE REMOVAL

1. Remove burner drawer, following procedure above.

2. Remove screws and burner hold-down bracket.

NOTE: If the heat exchanger is sooted badly, the

burner hold-down bracket and spacer can become dis-

torted from direct flame impingement and this usually

necessitates replacement of these parts.

3. Lift burners from slotted spacers and slide from

orifices. Clean with a wire brush.

4. Orifices usually do not need to be replaced. To clean,

run either copper wire or wood toothpick through

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

a socket wrench and remove from manifold. DO NOT

overtighten when reinstalling.

Burners

Burner Hold-Down Bracket

Fig. # 9479

TUBE CLEANING PROCEDURE

Establish a regular inspection schedule, frequency de-

pending on local water condition and severity of service.

Do not let the tubes clog up solidly. Clean out deposits

over 1/16" in thickness.

The heater may be cleaned from the return header side,

without breaking pipe connections. It is preferable,

however, to remove both headers for better visibility

through the tubes and to be sure the ground-up lime dust

does not get into the system.

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

exchanger, generally.

After reaming, mount the wire brush in place of the auger

and clean out debris remaining in the tubes.

Another method is to remove the heat exchanger, ream

tubes and immerse heat exchanger in non-inhibited de-

scale solvent for severe scale buildup.

DESOOTING PROCEDURE

Soot will clog areas between fins and cause eventual tube

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

around the outer jacket indicates a need for cleaning.

1. Remove top and flue collector from cabinet.

2. Remove "V" baffles from heat exchanger.

3. Remove burner drawer. (See pg. 35).

4. Remove heat exchanger from the heater and wash

with a garden hose, making sure soot is removed

from spaces between fins.

5. Reverse above procedure to reinstall.

NOTE: In extreme cases it may be necessary to do

steam cleaning at the local car wash. DO NOT WIRE

BRUSH.

COMBUSTION CHAMBER REMOVAL

To remove combustion chamber, you must first have

removed the heat exchanger. Unbolt metal combustion

chamber retainer from top and remove combustion cham-

ber panels individually.

REFRACTORY PANELS-TOP VIEW

Extension Pieces (2) Auger with Carbide Tip Wire Brush Fig. # 8154.0

36

IMMERSION WELL REPLACEMENT

(Millivolt and ASME)

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

2. Remove access panel on water connection side of

heater.

3. Remove old immersion well with bushing and sleeve.

4. Install in header.

NOTE: Installation in plastic should be hand tight plus

1/2 turn.

Well Assembly

Fig. #2010

UNITHERM GOVERNOR (U.G.) REPLACEMENT

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

relieve pressure.

2. Drain heat exchanger.

3. Remove retainer plug located next to the outlet pipe

connection.

4. Unsnap old U.G. to remove from retainer plug. Snap

in new U.G.

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

ket with a non-petroleum based grease such as

AquaLube.

Retainer Plug

U.G.

Spring

Gasket

Fig. #2011

To test the operation of the Unitherm Governor, place in

hot water (over 100°F) and watch for movement against

spring. If there is no movement, replace unit.

CAUTION: SOOT IS COMBUSTIBLE. EXERCISE

EXTREME CARE:

Fig. #RP 8155.0

The Raypak Low NOx Pool Heaters are certified and

tested under the ANSI Z21.56.CSA 4.7 standards for

gas-fired pool heaters.

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.

OPERATION

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

electronic spark module, gas valve and pilot system, is

energized. Providing the 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-UP PROCEDURES

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. Turn control down to end call for heat and wait 60

seconds on lockout models before beginning step

3.

3. Turn on gas supply.

4. Set controller to call for heat.

5. System should start as follows:

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

the blower will begin running.

b. Heater will operate until call for heat is satisfied.

LOW NOx POOL HEATERS

Fig # 9361

BURNER ADJUSTMENT

This burner assembly does not require any primary air

adjustments.

BLOWER ADJUSTMENT

The Raypak RP2100 Low NOx pool heater is equipped

with a combustion air baffle mounted at the air intake to

the combustion air blower. The baffle has a slot that is

utilized to align with a square window cutout on the

shutter assembly.

The factory setting will be adequate for most field condi-

tions and adjustment will not normally be required.

However in some cases, field conditions including un-

usual gas characteristics may create a need for adjust-

ment to achieve optimum performance. When the com-

bustion air setting is proper, there will be some lifting of

the flames on some areas of the burner deck under cold-

start conditions. After about five minutes of operation, the

flames should settle down and blue tips should become

visible. Lifting of flames beyond the five minutes would

indicate too much combustion air. Loosening the knurled

screw and opening the air baffle (move to the left)

increases the amount of combustion air; closing it (move

to the right) decreases the amount of combustion air.

After a steady blue flame is attained, the knurled screw

must be re-tightened.

VISUAL INSPECTION

Flame can be observed through the slot opening above

the plenum. Flame color is blue and evenly spread on the

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

visual inspection should be made of the burners. In case

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

sure in manifold. Gas pressure in manifold should be 3.9"

W.C.

ELECTRICAL

Be sure that electrical service to the boiler has proper

overload fuse or circuit breaker protection, wire size and

connections which comply with all applicable codes.

FLAME ROLL-OUT SAFETY SWITCH

Low NOx heaters are equipped with a cutoff device to

prevent flame roll-out in the event the heat exchanger

becomes blocked. This is a "manual reset" type roll-out

switch that must be reset by a service technician after

any over temperature conditions have been fixed. Exces-

sive restriction in the heat exchanger flue passage may

cause the switch to disable the heater.

37

38

BURNER DRAWER REMOVAL

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door.

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, following above procedure.

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 BURNER AND ORIFICE REMOVAL

1. Remove burner drawer, following above procedure.

2. Remove pilot. See pilot removal procedure.

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

ets, front and rear of tray.

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.

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

from the gas manifold.

LOW NOx HEATERS (CONTINUED)

Fig # 9362

PILOT REMOVAL

1. Disconnect pilot tubing from gas valve.

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

trol box.

3. Remove the pilot wire from the ignition wire.

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

the air manifold assembly.

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.

Fig # 9477

IID PILOT

LOW NOx BURNER TRAY ASSEMBLY

COMBUSTION FAN REMOVAL

1. Remove burner drawer. See Burner Drawer

Removal procedure on this page.

2. Remove (4) screws that mount the combustion

blower to the manifold assembly.

3. Reverse above procedure to reinstall.

7. Reverse above procedure to reinstall.

Fig# 9368

MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY)

IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in

the installation of this type of heating equipment and related system components. Installation and service personnel may be required by

some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.

PROBLEM CAUSE 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 Dirty filter.............................................. Backwash filter.

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

heat exchanger Total alkalinity 100-150 PPM maximum.

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...................................... Clean pilot.

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 *Broken refractory caused by

(paint blistered) shipping damage or improper

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

Excessive sooting of heat

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

Takes long time to heat Calculate temperature in °/hr................ Heat rise (°/hr.)= Htr. output

pool or spa. 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 - Heater running after pump

(overheated). 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

39

SECTION 5 - TROUBLESHOOTING GUIDE

* Indicates symptom which usually occurs on initial start-up.

If pilot burner remains lit.

Jump across pressure

switch terminals

If main burner does not

fire, remove jumper

Check for adequate water

flow from filter

Replace pressure switch

Jump across thermostat

If main burner fires,

remove jumper

If main burner does

NOT fire...

Jump across each

high limit and remove

jumper

Replace thermostat

Replace high limit that

caused heater to fire

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.

If pilot burner

does not light

Light pilot

If pilot burner goes out

when main burner lights

or when gas valve knob

is released

If burner does not remain

lit, attach millivolt meter

and read pilot output.

If below 500mV, check

gas pressure. Also check

for insects or debris in

the pilot burner

If main burner fires,

remove jumper

Replace

gas

valve

If main burner does not

fire, remove jumper

Remove both "TH"

wires from gas valve.

Relight pilot

If pilot burner stays on

Problem is a wire or

component short to

cabinet or low gas

pressure

If above 500mV,

replace gas valve

Clean filter

If main burner fires,

remove jumper

ELECTRICAL (STANDING PILOT MILLIVOLT)

If output is still low,

replace pilot generator.

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.

RAYPAK POOL OR SPA HEATER

ELECTRICAL CHECK WITH MV GAS VALVE

40

1Raw Output (700mV± 100)

Pilot generator disconnected from valve (knob must

be held down to keep pilot on).

White – Negative

Red + Positive

2Pilot 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

3Main Valve Load (200mV± 100)

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

TP(Thermopile-Robertshaw)

PP(Power Pile-Honeywell)

TH TP – Common

TH PP – Common

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.

Pull ignition lead and check spark at PC board.

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.

• 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.

• 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.

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.

• Check for proper thermostat (controller) operation.

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

wiring; if not, replace gas valve.

START

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

POWER TO PC BOARD?

(24 V NOMINAL)

YES

SPARK ACROSS

IGNITER/SENSOR GAP?

YES

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

TROUBLESHOOTING

ENDS

NO

NO

NO

NO

41

NO

NO

Repeat procedure until trouble free operation is obtained.

ELECTRICAL (ELECTRONIC IGNITION IID) TROUBLESHOOTING

WARNING HIGH VOLTAGE

For qualified technicians ONLY

NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas

if pilot fails to light. To reset, interrupt power to heater.

42

DIGITAL CONTROL LOGIC - FLOW CHART

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

tant that you supply the model number, serial number

and type of gas when applicable.

Any part returned for replacement under standard com-

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 Com-

pany freight prepaid.

If determined defective by the Company and within

warranty, a like part or equal substitution will be returned,

freight collect. Credit will not be issued.

RAYPAK, INC.

2151 Eastman Avenue

Oxnard, CA 93030

For Canada:

RAYPAK CANADA LTD.

2805 SLOUGH STREET

MISSISSAUGA, ONTARIO

L4T 1G2

43

SECTION 6 - REPLACEMENT PARTS

44

ILLUSTRATED PARTS LIST

45

Fig. #8124

Honeywell MV Fig. #8107

Fig. #9369

6-P

3-P

9-P

8-P

1-P

5-P

2-P

LOW NOx BURNER TRAY

PILOT ASSEMBLIES

7-P 9-P

2-P

4-P

9-P

7-P

10-P

Honeywell IID Atmospheric units

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

4-P

10-P

46

47

48

51

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.

www.raypak.com