CATALOG NO. 6000.52-AK Effective: 05-01-04 Replaces: 03-15-04 INSTALLATION AND OPERATING INSTRUCTIONS RP2100 SWIMMING POOL and SPA HEATER Atmospheric Models P-R185B to P-R405B C-R185B to C-R405B Low NOx Models P-R185BL to P-R405BL C-R185BL to C-R405BL Fig.# 9478 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
CONTENTS 4 PART ONE OWNER'S OPERATING INSTRUCTIONS 4 SECTION 1 START-UP PROCEDURES 4 5 Before Start-Up Lighting Instructions & Shut-Off ProceduresManually Lighted Pilots MV Operating Instruction & Shut-Off ProceduresAutomatically Lighted Pilots IID After Start-Up 6 7 7 SECTION 2 CAUTION 7 SECTION 3 MAINTENANCE & CARE PROCEDURES 8 8 9 Pool & Spa Water Chemistry Cold Weather Operation Winterizing the Pool & Spa Heater 10 PART TWO INSTALLATION & SERVICE INSTRUCTIONS 10 SECTION 1 RECEIVING EQUIPM
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. 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.
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters. LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES MANUALLY LIGHTED PILOTS MILLIVOLT SYSTEM 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.
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters. OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES AUTOMATICALLY LIGHTED PILOTS ELECTRONIC IGNITIONS SYSTEMS A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. *If you cannot reach your gas supplier, call the fire department. B.
AFTER START-UP SECTION 2 - CAUTION Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot. Elevated water temperature can be hazardous, and the U. S. Consumer Product Safety Commission recommends the following guidelines: WARNING: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control to the appliance. 1. Spa or hot tub water temperatures should never exceed 104°F (40°C).
4. Make visual check of the burner and pilot flame. Flame pattern on the main burner and pilot is indicated 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.
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.
PART TWO INSTALLATION AND SERVICE INSTRUCTIONS 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: 1. 2. 3. 4.
SECTION 3 - INSTALLATION INSTRUCTIONS CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT NOTICE These instructions are intended for the use of qualified personnel only, specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed.
OUTDOOR HEATER INSTALLATION 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. WARNING: Do not install within 3 feet of a heat pump or an outdoor condensing unit.
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.
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.
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.
SPECIFICATIONS AND DIMENSIONS Shipping Weights (lbs) Heater Model R185B R265B R335B R405B BTUH Input (000) 181 264 334 399 (A) Cabinet Width 18-1/4" 22-3/8" 25-3/4" 29-1/4" (B) Flue Dia. 6" 7" 8" 9" (C) Indoor Drafthood 62-5/8" 62-7/8" 63-3/4" 65-3/8" (J) 12-1/16" 11-1/8" 10-3/4" 12-1/2" Gas Conn. 3/4" 3/4" 3/4" 3/4" Water Conn.
VENT PIPING WARNING: Indoor boilers require a drafthood that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning. Vent piping the same size as the draft hood outlet is recommended, however, when the total vent height is at least ten (10) feet (draft hood relief opening to vent terminal), the vent pipe size may be reduced as specified in Chapter 10 of the National Fuel Gas Code, ANSI Z 223.
NOTE: Do not use Teflon tape on gas line pipe thread. A flexible sealant is recommended. ELECTRONIC IGNITION GAS VALVES-CONTINUED A minimum of 7" W.C. and a maximum of 14" W.C. upstream pressure under load, and no load conditions must be provided for natural gas or a minimum of 12" W.C. and a maximum of 14" for propane gas. GAS PRESSURE REGULATOR The gas pressure regulator is preset at 4" W. C. for natural gas, and 11" W. C. for propane gas.
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.
INLET/OUTLET HEADER - ASME 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. Flange Gasket 2" CPVC Adapters Fig. # 8093.
INTERNAL AUTOMATIC BY-PASS VALVE PRESSURE RELIEF VALVE INSTALLATION 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.
HEAT EXCHANGER PRESSURE DROP TABLES 22
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 thermostat temperature sensor by loosening the compression fitting nut (Figure 3). Reroute the sensor to the left side of the heater. 4.
ELECTRICAL WIRING NOTE: If it is necessary to replace any of the original wiring, it must be replaced with 105° C wire or its equivalent, and/or 150° C wire or its equivalent as originally built. Control Box (Factory Mounted Location) Option Location For Left Side Field Wiring MILLIVOLT SYSTEM 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.
TRANSFORMER WIRING 120V WIRING For 120 V input power to the unit, connect the black wire to the “L1” or hot leg of the power supply. Connect the white wire to the “L2” or neutral leg of the power supply. Attach the wire nut to the red wire. There should be no connection to the red wire for 120V operation. For Low NOx pool heaters wire nut each red wire independently. Fig. #9471 240V WIRING For 240 V input power to the unit, connect the black wire to the “L1” or hot leg of the power supply.
WIRING DIAGRAM - MILLIVOLT (MECHANICAL THERMOSTAT) 26
WIRING DIAGRAM - IID (Atmospheric) 27
WIRING DIAGRAM - IID (Low NOx) 28
SECTION 4 - SERVICING INSTRUCTIONS CONTROL ADJUSTMENTS GENERAL LOCATION OF CONTROLS Bypass Temperature Adjust Buttons Hi Limit on I/O header (ASME on Return Header) Drain Plug (Located in Return Header) Mode Button ON AGS HiLimit (Located on Inlet/ Outlet Header) Digital Thermostat Circuit Board OFF Unitherm Governor Roll-Out Switch LCD Display Drain Plug Gas Valve Pilot Fig.
DIGITAL THERMOSTAT CONTROLS Notice to owner- Thermostat operation Your heater is equipped with a microprocessor controlled thermostat that controls the pool or spa temperature by measuring the temperature of the water coming back through the heater. It will then monitor the water temperature and turn the heater back on when it senses that the water temperature is falling below the set point. It is normal to experience small fluctuations in the return water temperature during the operation of the heater.
NOTE: The digital temperature display may not coincide with the temperature reading of your pool or spa thermometer. The RP2100 reads the water temperature at the inlet of the heater. Due to the circulation characteristics of any pool or spa, the water temperature at the inlet to the heater may differ from that observed at a given location in the pool or spa. DIAGNOSTICS The RP2100 Digital heater is equipped with on-board diagnostic controls.
REMOTE CONTROL INSTALLATION AND OPERATION Heating in the SPA Mode POOL COMMON (BLK/ORG) Remote Mode 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: SPA COMMON (ORG/BLK) 24VAC HOT (BLU) Fig# 9494 Fig# 9488 Fig# 9486 Heating in the POOL Mode Press and hold all three buttons for 5 to 7 seconds.
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.
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.
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.
Extension Pieces (2) Auger with Carbide Tip TUBE CLEANING PROCEDURE Establish a regular inspection schedule, frequency depending on local water condition and severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness. Wire Brush Fig. # 8154.0 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.
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. BURNER ADJUSTMENT This burner assembly does not require any primary air adjustments. 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.
LOW NOx HEATERS (CONTINUED) 7. Reverse above procedure to reinstall. IID PILOT Fig # 9477 Fig # 9362 PILOT REMOVAL LOW NOx BURNER TRAY ASSEMBLY 1. Disconnect pilot tubing from gas valve. 2. Remove (4) screws from control box. Open the control 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.
SECTION 5 - TROUBLESHOOTING GUIDE MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY) IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.
ELECTRICAL (STANDING PILOT MILLIVOLT) RAYPAK POOL OR SPA HEATER ELECTRICAL CHECK WITH MV GAS VALVE CAUTION: For qualified service personnel only. 1. Filter must be on with adequate water flow through heater. 2. Gas valve must be "ON" position. Thermostat set higher than pool water temperature. 3. Jumpers are for temporary check only. If left in place, they could cause the heater to burn up.
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. START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO PC BOARD? (24 V NOMINAL) YES NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout procedure.
DIGITAL CONTROL LOGIC - FLOW CHART 42
SECTION 6 - REPLACEMENT PARTS NOTE: To supply you with the correct part it is important that you supply the model number, serial number and type of gas when applicable. 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.
ILLUSTRATED PARTS LIST 44
LOW NOx BURNER TRAY PILOT ASSEMBLIES 2-P 2-P 4-P 4-P 7-P 7-P 9-P 9-P 10-P 10-P Honeywell IID Atmospheric units Fig. #8124 for units produced prior to 06/01/2000 Honeywell IID Low NOx and Atmospheric units for units produced after to 06/01/2000 Use KIT Number 008155F for Low NOx units Use KIT Number 002003F for Atmospheric units 1-P 5-P 8-P 6-P 3-P 9-P Honeywell MV Fig. #8107 45 Fig.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (800) 872-9725 Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A.
