Raypak P-R405A manual

Part No. 240612 CATALOG NO. 6000.52-AG Effective: 09-01-03 Replaces: 06-15-03 INST ALLA TION AND OPERA TING INSTRUCTIONS Models P-R185A to P-R405A C-R185A to P-R405A Low NOx P-R185AL to P-R405AL C-R185AL to C-R405AL RP2100 SWIMMING POOL and SP A HEA TER This manual should be maintained in legible condition and kept adjacent to the heater or kept in[...]

CONTENTS 2 3 PART ONE OWNER'S OPERATING INSTRUCTIONS 3 SECTION 1 START-UP PROCEDURES 3 Before Start-Up 4 Lighting Instructions & Shut-Off Procedure (Manually Lighted Pilot MV) 5 Operating Instruction & Shut-Off Procedures (Automatically Lighted Pilot IID) 6 After Start-Up 6 SECTION 2 CAUTION 6 SECTION 3 MAINTENANCE & CARE PROCEDURE[...]

P ART ONE - OWNER'S OPERA TING 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[...]

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 lighted by hand. When lighti[...]

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 a[...]

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. VISUAL INSPECTION With the heater on, remove the door and make a visual check of the pilot and burner[...]

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 this occur, shut the heater off and contact your gas supplier o[...]

WINTERIZING THE POOL & SPA HEATER When heaters installed outdoors in freezing climate areas are to be shut down for the winter, observe the following step-by-step procedure: 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 ex[...]

12" Minimu m 12" M inimum 4" Minimum HEA TER Sheet Metal 24 Gauge SECTION 3 / INSTALLATION INSTRUCTIONS 9 IMPORTANT NOTICE These instructions are intended for the use of quali- fied personnel only, specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation an[...]

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 hea[...]

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 [...]

12 Securing the top panel cover- INDOOR KIT ONLY 7. Re-install 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. [...]

13 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 . Lower the top panel cover and using your thumbs, push tabs in and insert the two front tabs into[...]

14 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 1 85 1 8 1 335 333 2 65 2 6 4 405 399 b. All Air From Outdoors: When air is supplied directly from outside of building, [...]

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 [...]

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 pr[...]

17 Plumbing from the heater back to the pool must not have any valves or restriction that could prevent flow when the pump is operating. CAUTION: An additional source of heated water, i.e. 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 provid[...]

18 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. PRESSURE RELIEF VALVE INSTALLATION To conform to local building codes, it[...]

19 ACCESS PANEL Fig. #1 Fig. #2 PRESS SWITCH AGS HI-LIMIT RP2100+ Heat Exchanger Reversal Procedure (Capron Resin 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 t[...]

Fig. #4 Fig. #5 Fig. #3 JACO FITTING BULB & CLIP RE-INSTALLED IN/OUT HEADER ON OPPOSITE SIDE. 20 NOTE: Tighten almost flushed (1/32" to 1/8") to the header to avoid leaks.[...]

21 Option Location For Left Side Field Wiring Sway Brace Bonding Lug (Standard Location) Bonding Lug (Optional Location) Fig. # 9030.1 Control Box (Factory Mounted Location) LOW NOx ATMOSPHERIC 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[...]

22 WIRING DIAGRAM KEY PINK CONNECTOR BLUE CONNECTOR Fig. # RP8096 *If required by Local Code, install at this location. Fig. #2353 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.[...]

WIRING DIAGRAM - IID UNITS (atmospheric) 23[...]

WIRING DIAGRAM - IID UNITS (Low NOx) 24[...]

Control Panel Mounting Screws (4) Fig. #RP 8267 CONTROLS/ADJUSTMENTS/REPLACEMENTS Temperature Adjust Buttons Mode Button LCD Display Fig. #2000 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 thermosta[...]

The RP2100 Spa/Pool Digital Control Panel features an LCD display that provides status and service informa- tion. During normal operation, the heater can be in the POOL, SPA, or OFF modes. In the OFF mode, the actual water temperature is displayed. NOTE: The digital temperature display may not coincide with the temperature reading of your pool or s[...]

RP2100 REMOTE CONTROL INSTALLATION CAUTION: Before installing remote controls to the RP2100 Digital Heater, read the following: The Raypak RP 2100 Digital Heater is remote ready in most cases. The digital liquid crystal (LCD) display shows the actual pool temperature, operating status, and service codes (See examples below). The touch pad on the co[...]

28 1. Turn off power to the heater. 2. Turn off gas to the heater. 3. Remove the four screws on the side of the heater holding the control panel (see figure # 9375). 4. Perform ESD charge removal procedures: Lay control panel forward towards you. This will provide access to the back of the temperature control board. 5. Remove the Remote Wire Harnes[...]

FLAME ROLL-OUT SAFETY SWITCH The heater is 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 fl[...]

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. [...]

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. The heater may be cleaned from the return header side, without breaking pipe connections. It is prefer- able, however, to remove[...]

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 a[...]

33 BURNER DRA WER REMOV AL 1. Shut off main electrical power switch to heater . 2. Shut off gas up stream 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. U[...]

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. Pe[...]

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 limi[...]

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. Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 NOTE:Before troubleshooting, familiarize yourself with the startup and checkout procedure. Che[...]

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SECTION 6/REPLACEMENT PARTS LIST NOTE: To supply the correct part it is important that you state the model number, serial number and type of gas when applicable. Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag, completely filled in with the heater serial number, model number, [...]

39 9-S 2-R 1-R 7-S 2-J 6-S 4-J 1-J 12-P Fig# 240739[...]

40 Fig. #8124 Honeywell MV Fig. #8107 Fig. #9369 13-P 5-P 16-P 15-P 1-P 9-P 3-P Low NOx BURNER TRAY PILOT ASSEMBLIES 14-P 16-P 3-P 7-P 16-P 3-P 17-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 KI[...]

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LIMITED WARRANTY RAYPAK RESIDENTIAL SWIMMING POOL AND SPA HEATERS GAS MODELS 185, 265, 335 & 405 MILLIVOLT 185, 265, 335 & 405 ELECTRONIC GENERAL Raypak, Inc. warrants that the cabinet, burner tray (minus controls) and refractory will be free from defects in materials and workmanship under normal use and service for a period of FIVE YEARS F[...]

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 .rayp ak.com[...]