Table of Contents
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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
SPA HEATER
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
— 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's instructions.
•
If you cannot reach your gas supplier, call the fire department.
— Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the
heater or kept in a safe place for future reference.
CATALOG NO. 6000.52-AH
Effective:
11-01-03
Replaces:
09-01-03
Fig.# 9478
Part No. 240612
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Table of Contents
Related Manuals for Raypak P-R185B To P-R405B, C-R185B To P-R405B, P-R185BL To P-R405BL, C-R185BL To C-R405BL, RP2100
Summary of Contents for Raypak P-R185B To P-R405B, C-R185B To P-R405B, P-R185BL To P-R405BL, C-R185BL To C-R405BL, RP2100
- Page 1 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 SPA HEATER WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. —...
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Page 3: Table Of Contents
PART ONE OWNER'S OPERATING INSTRUCTIONS SECTION 1 START-UP PROCEDURES Before Start-Up Lighting Instructions & Shut-Off Procedure (Manually Lighted Pilot MV) Operating Instruction & Shut-Off Procedures (Automatically Lighted Pilot IID) After Start-Up SECTION 2 CAUTION SECTION 3 MAINTENANCE & CARE PROCEDURE Pool &... -
Page 4: Part One
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. -
Page 5: (Manually Lighted Pilot Mv)
confined areas, extra care should be exercised when lighting propane heaters. LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES This appliance has a pilot that must be lighted by hand. When lighting the pilot, follow these instructions exactly. BEFORE LIGHTING smell all around the appliance area for gas. -
Page 6: (Automatically Lighted Pilot Iid)
confined areas, extra care should be exercised when lighting propane heaters. OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. BEFORE OPERATING, smell all around the appliance area for gas. -
Page 7: After Start-Up
AFTER START-UP Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot. WARNING: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control to the appliance. -
Page 8: Pool & Spa Water Chemistry
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. -
Page 9: Winterizing The Pool & Spa Heater
WINTERIZING THE POOL & SPA HEATER 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. -
Page 10: Part Two
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. -
Page 11: Installation Instructions
*Clearance from top of vent terminal 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"... - Page 12 OUTDOOR HEATERS These heaters are design certified for outdoor installation, when equipped with the approved tops designated for outdoor use. 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.
- Page 13 INDOOR HEATER 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.
- Page 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.
- Page 15 INSTALLING THE TOP COVER OUTDOOR KIT ONLY 22. Remove the two pieces ofg 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.
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Page 16: Specifications And Dimensions
SPECIFICATIONS AND DIMENSIONS " " " " *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. -
Page 17: Vent Piping
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. - Page 18 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.
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Page 19: Plumbing For Water Connections
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. - Page 20 CONNECTIONS (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.
- Page 21 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.
- Page 22 HEAT EXCHANGER PRESSURE DROP TABLES...
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Page 23: Rp2100 Heat Exchanger Reversal Procedure
RP2100 HEAT EXCHANGER REVERSAL PROCEDURE (POLYMER HEADER MODELS) 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). -
Page 24: Electrical Wiring
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. -
Page 25: Transformer Wiring
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. - Page 26 WIRING DIAGRAM - MILLIVOLT UNITS (MECHANICAL THERMOSTAT)
- Page 27 WIRING DIAGRAM - IID UNITS (atmospheric)
- Page 28 WIRING DIAGRAM - IID UNITS (Low NOx)
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Page 29: Servicing Instructions
SECTION 4 - SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS 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. -
Page 30: Digital Thermostat Controls
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. -
Page 31: Reading A Fault
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 DIAGNOSTICS The RP2100 Digital heater is equipped with on board... -
Page 32: Remote Control Operation And Installation
CAUTION: Before installing remote controls to the RP2100 Digital Heater, read the following: The Raypak RP 2100 Digital Heater is remote ready in most cases. 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. - Page 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.
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Page 34: Pressure Switch Adjustment
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. -
Page 35: Burner Drawer Removal
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. -
Page 36: Tube Cleaning Procedure
Extension Pieces (2) 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. - Page 37 LOW NOx POOL HEATERS The Raypak Low Nox Pool Heaters are certified and tested under the ANSI Z21.56.CSA 4.7 Standards for gas fired pool heaters. 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.
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Page 38: Low Nox
LOW NOX HEATERS (CONTINUED) LOW NOx BURNER TRAY ASSEMBLY 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. -
Page 39: Trouble Shooting Guide
SECTION 5 / TROUBLE SHOOTING GUIDE MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY) IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. - Page 40 Check for adequate water If main burner fires, flow from filter remove jumper Replace pressure switch Replace thermostat RAYPAK POOL OR SPA HEATER Light pilot If pilot burner goes out when main burner lights or when gas valve knob is released Remove both "TH"...
- Page 41 ELECTRICAL (ELECTRONIC IGNITION IID) TROUBLESHOOTING START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO PC BOARD (24 V NOMINAL) SPARK ACROSS IGNITER/SENSOR GAP TURN GAS SUPPLY ON PILOT BURNER LIGHTS? MAIN BURNER LIGHTS? SYSTEM RUNS UNTIL CALL FOR HEAT ENDS? CALL FOR HEAT ENDS SYSTEM SHUTS OFF?
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Page 42: Digital Control Logic
DIGITAL CONTROL LOGIC - FLOW CHART... - Page 43 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 Company freight prepaid.
- Page 45 Low NOx BURNER TRAY PILOT ASSEMBLIES 10-P Honeywell IID Atmospheric units for units produced prior to 06/01/2000 Honeywell MV 10-P Honeywell IID Low NOx and Atmospheric units Fig. #8124 for units produced after to 06/01/2000 Use KIT Number 008155F for Low NOx units Use KIT Number 002003F for Atmospheric units Fig.
- Page 52 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.