Raypak C-R185A to P-R405A, Installation And Operating Instructions Manual

Page 1: ... 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 In...

Page 2: ...tial connection to the heater is made with a 2 PVC union adapter to which PVC may then be connected with appropriate cement This newly authorized piping arrangement is described in the installation manual provided by Raypak and has been successfully tested by Raypak to assure its acceptability Larry J Ashton P E Vice President of Engineering and Technical Services ...

Page 3: ...ctions 18 RP2100HeatExchangerReversalProcedure 20 Electrical Wiring 21 WiringDiagram Millivolt 22 WiringDiagram ElectronicIgnition 23 Wiring Diagram Low NOx 24 SECTION4 SERVICINGINSTRUCTIONS 24 GeneralLocationofControls 24 ControlAdjustments Replacements 25 ElectronicControls 26 RemoteControlInstallation 27 Pressure Switch Adjustment 27 Flame Roll Out Safety Switch 27 HighLimitRemoval 27 Pilot Saf...

Page 4: ...ask 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 65 F 18 C to 104 F 40 C The heater with the electronic control option also has a manual switch located on the right cabinet side to allow you to turn the heater off Section 4 contains more details about the...

Page 5: ... 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 Wait5minutestoclearoutanygas Ifyou then smell gas STOP Follow B in the safety ...

Page 6: ... 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 ...

Page 7: ...ion rec ommends the following guidelines 1 Spa or hot tub water temperatures should never exceed104 F 40 C Atemperatureof100 F 38 C is considered safe for a healthy adult Special caution is suggested for young children 2 Drinkingofalcoholicbeveragesbeforeorduringspa or hot tub use can cause drowsiness which could leadtounconsciousnessandsubsequentlyresultin drowning 3 Pregnant Women Beware Soaking...

Page 8: ...high scale forms inside theheatexchangertubes reducingheaterefficiencyand alsodamagingtheheater IfthepHdropsbelow7 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 AUTOMATICCHLORINATORSANDCHEMICALFEED ERS All chemicals must be introduced and completely diluted into the po...

Page 9: ... 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 r...

Page 10: ...providingabase forcombustiblefloorsisillustratedbelow Heatersmust not be installed on carpeting Fig 8148 1 Utilize hollow concrete cinder blocks align holes and leave ends open CLEARANCES ALLHEATERS For clearances from combustible surfaces see the chart below CLEARANCEFROMCOMBUSTIBLECONSTRUCTION INDOORINSTALLATIONS Top Drafthood 30 Back 6 Front Alcove Right Side Water Side 12 Vent 6 Left Side Oppo...

Page 11: ...ater shall be at least three 3 feet above any forced air inlet or intake ducts located within ten 10 feet horizontally For installations in Canada pool heaters shall not be installed with the top of the vent assembly within 10 feet below ortoeitherside ofanyopeningintothebuilding RefertothelatestrevisionsofCAN CGA B149 1andB149 2 VENT TERMINAL Outdoor Stackless Top Installation 1 Insert tabs into ...

Page 12: ...cket top will be trapped between the brackets and the top of the stack Place the stack over the inner adapter panel flanged hole and lower the louvered jacket top panel back into its original position Reinstall the four 4 green 10 flat head screws removed in step 1 above VENT TERMINAL INDOOR STACK INSTALLATION WARNING Indoorboilersrequireadrafthoodthatmustbeconnectedtoaventpipeandproperlyventedtot...

Page 13: ...free air supply openings one 12 inches from ceiling for ventilation and one 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 CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty...

Page 14: ...r than any part of the building within ten feet Vent stack shall be at least five feet in vertical height above the drafthood outlet The vent cap location shall have a 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 r...

Page 15: ...TION TheRP2100heaterrequireswaterflowandpositive pressure to fire and operate properly It must therefore beinstalleddownstreamofthedischargesideofthefilter pump A typical installation is plumbed as follows 1 The inlet side of the filter is plumbed directly to the discharge side of the filter pump 2 Theoutletsideofthefilteristhenplumbedtotheinlet of the heater and 3 The outlet of the heater is plum...

Page 16: ...eader 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 Fig 2003 EXTERNAL AUXILIARY BYPASS VALVE Where Required Anauxiliarybypas...

Page 17: ...all be installed in a vertical position Do not over tighten Install pressure relief valve hand tight plus 1 2 turn Pressure Relief Valve PRV Discharge Connection Inlet Outlet Header Fig 2004 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 connectio...

Page 18: ...rn headers to the tube sheets Clean off tube sheet area where the gasket seats Also clean off the header and its gasket Apply a non petroleum based lubricant 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 wir...

Page 19: ...Fig 4 Fig 5 Fig 3 JACO FITTING BULB CLIP RE INSTALLED IN OUT HEADER ON OPPOSITE SIDE 19 ...

Page 20: ...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 20 Option Location For Left Sid...

Page 21: ...e wire There should be no connection to the white wire for 240V operation for Low NOx pool heaters wire nut each white wire inde pendently Fig 9241 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 NOTE Input ...

Page 22: ...WIRING DIAGRAM IID UNITS atmospheric 22 ...

Page 23: ...WIRING DIAGRAM IID UNITS Low NOx 23 ...

Page 24: ...e knobstop ring to the desired location and retightening the set screw SPA TEMPERATURE RANGE POOL TEMPERATURE RANGE STAND BY TEMPRATURE SET SCREW KNOB STOP RING Fig 8103 2 KNOB STOP SHOWN ABOVE IS IN THE SPA TEMPERATURE RANGE 24 Bypass Hi Limit Located in Return Header AGS Hi Limit Located in Inlet Oulet Header Unitherm Governor Drain Plug Fig 2005 SECTION 4 SERVICING INSTRUCTIONS GENERAL LOCATION...

Page 25: ...buttons A manual switch is also provided on the right side heater cabinet to allow the heater to be turned off If there is a problem in operating the heater the fault will be displayed and a service indicator will flash The electronic thermostat cannot be set above selected maximum set points The maximum set points are factory selected at 104 F for spa and 90 F for pool These can be changed to a h...

Page 26: ... to be connected to the heater A switch mechanism that will provide contact closure betweenHIGH SPAorLOW POOLandcommon needs to be supplied This mechanism can be a 3 way switch or any other remote control system that provides dry contact closure for either setting See remote wiring instructions on this page Two or Three Wire Remote Operation To remotely select a single operating ON OFF mode 2 wire...

Page 27: ... switch or flow switch 5 Max 5 Max 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 dis abled by an over temperature condition caused by excessive restriction in the heat exchanger flue pas sage Fig 9177 HIGH LIM...

Page 28: ...ean run either copper wire or wood toothpick through orifice Do not enlarge hole To remove orifice use asocketwrenchandremovefrommanifold DONOT overtightenwhenreinstalling Burner Hold Down Bracket Burner 8057 0 PILOTREMOVALANDCLEANING 1 Disconnect pilot tubing and wires from gas valve 2 Remove pilot assembly from burner tray 3 Removepilotfrombracket 4 Removepilotorificeandairopening HoneywellMV un...

Page 29: ...d wash with a garden hose making sure soot is removed from spaces between fins 5 Reverseaboveproceduretore install NOTE In extreme cases it may be necessary to do steam cleaning at the local car wash DO NOT WIREBRUSH COMBUSTION CHAMBER REMOVAL To remove combustion chamber you must first have removed the heat exchanger Unbolt metal com bustionchamberretainerfromtopandremovecombus tion chamber panel...

Page 30: ...oller to call for heat 5 System should start as follows a Spark will turn on and pilot gas valve will open and the blower will begin running b Heater will operate until call for heat is satisfied ADDENDA LOW NOx POOL HEATERS Fig 9361 FLAMEROLL OUTSAFETYSWITCH The heater is equipped with a cutoff device to prevent flame roll out in the event the heat exchanger becomes blocked Thisisa manualreset ty...

Page 31: ...crews 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 ADDENDA LOW NOX HEATERS CONTINUED Fig 9362 PILOT REMOVAL 1 Disconnect pilot tubing from gas valve 2 Remove...

Page 32: ...ce Air starvation Refer to installation instructions Improper venting Follow recommended installation instructions Insects or debris clogging burner intake ports Clean burners Pilot outage Low gas pressure Adjust gas pressure Restricted pilot Cleanpilot Weak pilot generator Replace pilot Yellow lazy flame Low gas pressure Adjust gas pressure Insects or debris clogging burner intake ports Clean bur...

Page 33: ...ach 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...

Page 34: ...Check electrical connections between flame rod and module Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adjust pilot flame If problem persists replace module Check for 24 Vac across MV MV PV terminals If no voltage replace module Check electrical connections between module and gas control If okay replace gas valve or gas control operat...

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Page 36: ...properly tagged with RAYPAK return parts tag completely filled in with the heater serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty the part will be returned in kind or equal substitution freight collect Credit will not be issued RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 For Canada RAYPAKCANADALTD 2805 SLOUGH S...

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Page 38: ...RAY 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 KIT Number 002003F for Atmospheric units ...

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Page 42: ... heater HOWTOMAKEACLAIM Immediatelynotifythedealerfromwhomtheheaterwaspurchased supplyingmodelandserialnumbersoftheunit dateofpurchase and adescriptionoftheproblem ThedealershouldthenpromptlycontactRaypakaboutthewarrantyclaim andforthelocationofRaypak s nearestdesignatedrepaircenter Ifthedealerforanyreasonisnotavailable callorwriteRaypakdirectlyattheaddressshownbelow Attention WarrantyService Afte...

Page 43: ... 5300 FAX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada L4T 1G2 905 677 7999 FAX 905 677 8036 Raypak Australia Pty Ltd 7 Geddes St Mulgrave Victoria Australia 3170 6139 560 4944 FAX 6139 560 4974 Litho in U S A www raypak com ...