Raypak P-R185B To P-R405B, C-R185B To, Installation And Operating Instructions Manual

Page 1: ... 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 Instal...

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Page 3: ...For Water Connections 23 RP2100HeatExchangerReversalProcedure 24 Electrical Wiring 25 TransformerWiring 26 WiringDiagram Millivolt MechanicalTherm 27 WiringDiagram Atmospheric 28 Wiring Diagram Low NOx 29 SECTION4 SERVICINGINSTRUCTIONS 29 GeneralLocationofControls 29 ControlAdjustments 30 DigitalThermostatControls 31 Digital Diagnostics and Faults 32 RemoteControlOperationandInstallation 34 Pressu...

Page 4: ...stalled correctly operating the heater is an easy task The upper front panel of the heater containsthecontrolcenterthatallowsyoutoturntheheateronoroffandadjustthetemperaturesettingsforthepool 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 toggleswitchtoturntheheateronandoff seefig 9472aboveforlocation Section4ofthismanualcontainsmore det...

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: ...agesbeforeorduringspa or hot tub use can cause drowsiness which could leadtounconsciousnessandsubsequentlyresultin drowning 3 Pregnant Women Beware Soaking in water over 102 F 39 C cancausefetaldamageduringthefirst three months of pregnancy resulting in the birth of a brain damagedordeformedchild Pregnantwomen should stick to the 100 F 38 C maximum rule 4 Before entering the spa or hot tub users s...

Page 8: ...low 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 AUTOMATICCHLORINATORSAND CHEMICALFEEDERS Allchemicalsmustbeintroducedandcompletelydiluted intothepoolorspawaterbeforebeingcirculatedthrough the heater Do not place chlorine tablets or bromine sticksintheskimmer Highch...

Page 9: ... electrical supply to the heater 2 Open drain plug located on the inlet outlet header under water pipes Remove the heat exchanger inspectionpanelonthesideoppositewaterpipingto gain access to the drain plug on the return header Open drain plug on return header 9 Return Header Drain Plug Disconnect compression fittings from the pressure switchandreturnheaderthatconnectstothe1 4 copper tube and allow...

Page 10: ...reviewed thoroughly before installingyourRaypakpool spaheater Ifthereareanyquestionsthatthismanualdoesnotanswer pleasecontact the factory or your local Raypak representative SECTION 2 GENERAL SPECIFICATIONS TheseheatersaredesigncertifiedandtestedundertherequirementsofANSIZ21 56 CSA4 7AmericanNational Standard CSAStandardforGas FiredPoolHeaters Allheatersareinter changeableandcanbeusedeitherindoor ...

Page 11: ...NING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Analternativemethodforprovidingabaseforcombustible floorsisillustratedbelow Heatersmust notbeinstalled oncarpeting CLEARANCES ALLHEATERS Forclearancesfromcombustiblesurfaces seethe chart below SECTION 3 INSTALLATION INSTRUCTIONS WARNING Improperinstallation adjustment alte...

Page 12: ...to keyholes so as not to pull out Fig RP8280 1 12 Fig 8278 2 OUTDOORHEATERS These heaters are design certified for outdoor installation when equipped with the approved tops designated for outdooruse HEATERWITHOUTDOORSTACKLESSTOP Fig 8245 1 U S Installations only WARNING Theheatershallnotbelocatedinanareawherewatersprinklers orotherdevices maycausewater tospraythroughthecabinetlouversandintotheheat...

Page 13: ...Drafthood unpainted 1 Adapter plate 3 Mounting brackets clips 3 Screws 1 Instructions ASSEMBLY PROCEDURE 1 Makesurethatthegasandelectrichasbeenturned off to the unit 2 Removethe pagoda topfromthelouveredtopand 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 t...

Page 14: ...th side This is to temporarily keep the top panelcoveroutofthewaywhileyouareattachingthe clips as shown in the next steps See Fig 7 INSTALLING THE CLIPS INDOOR OUTDOORKITS 14 Noticethattherearethreepilotholesabovethebase of the drafthood as shown in Fig 8 These are the locations where the three clips are to be attached 15 Insertthelongedgeofoneclipbetweenthetoppanel cover and the drafthood see Fig...

Page 15: ...heheatertop andslidethetoppanelcoverbackwards SeeFig 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 Lowerthetoppanelcoverflushtothetopandrelease the tabs They will spring into place as shown in Fig 15 26 Turn the gas and electricity to the heater on ...

Page 16: ...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 rate is required for elevations up to 4500 feet Manufactured under Patent No 3 623 458 Note Plastic Polymer Headers cannot be used for ASME installation...

Page 17: ...eroofsurfaceandatleasttwofeethigher 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 reliefequipment The weight of the...

Page 18: ...Ox and 10 5 W C propanegas Ifanadjustmentisneeded removeseal and turn adjustment screw clockwise to increase pressure or counter clockwise_____to decrease pres sure 18 Gas Pressure Adjustment GASPRESSUREADJUSTMENTLOCATIONS MILLIVOLTGASVALVES ELECTRONICIGNITIONGASVALVES Robertshaw7000 Models 185 thru 405 Gas Pressure Adjustment Honeywell VR8304 Models 185 thru 405 Robertshaw7200 Model185 ELECTRONIC...

Page 19: ...t of the heater is plumbed to the return line to the pool or spa The pump filter and heater are thus plumbed in series Plumbingfromtheheaterbacktothepoolmustnothave anyvalvesorrestrictionthatcouldpreventflowwhenthe 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 S...

Page 20: ...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 OUTLETHEADER ASME HeaderFlange 2 CPVC Adapters PVC Pipe ASME Inlet OutletHeader Flange Gasket Fig 8093 1 UNITHERMGOVERNOROPERATION CAUTION NEVER install PVC directly into header flanges Usethe2 CPVCadaptersuppliedloosewith theheater CAUTION Th...

Page 21: ...RNALAUTOMATICBY PASSVALVE InadditiontotheUnithermGovernor abuilt inautomatic by passvalveisprovidedinthein outheader Whilethe 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 ...

Page 22: ...22 HEATEXCHANGERPRESSUREDROPTABLES ...

Page 23: ...leum based lubri cant to the gasket such as Aqua Lube Reattach the headerstotheoppositesides makingsuretheyare 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 ElectronicIgnitionHeaters Insertthetemperature sensorinthecompressionfittingandtighten1 2turn past hand tight 8 Millivolt Heaters Insert s...

Page 24: ... 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 junctionboxtotheswaybrace Untieexcessyellow 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 junct...

Page 25: ...uld 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...

Page 26: ...26 WIRING DIAGRAM MILLIVOLT UNITS MECHANICAL THERMOSTAT ...

Page 27: ...WIRING DIAGRAM IID UNITS atmospheric 27 ...

Page 28: ...WIRING DIAGRAM IID UNITS Low NOx 28 ...

Page 29: ...e 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 CONTROLPANELREMOVAL 1 Remove 4 screws from sides of control panel 2 Rotate control panel down until panel stops Do no...

Page 30: ...red 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 maxim...

Page 31: ...TUS 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 fa...

Page 32: ... 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 POOLCOMMON BLK ORG SPA COMMON ORG BLK 24VAC HOT BLU 7 PINREMOTE WIRINGCONNECTOR Note ElectrostaticDischarge ESD damagecanbecausedbydirect or indirect contact with the wiring or circuit board When one walks to the heater area an electrostatic charge accumulates on the ...

Page 33: ...SPA operation and the BLACK ORANGE wire for the POOL operation 5 Installthe RemoteInterfaceHarness totheP8connec 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 modes and set the desired temperature example 102 F 3 Turnthemodebuttonto OFF andremovepowerfromthe heater 4 On th...

Page 34: ...D PUMPS In some cases the flow on the low speed is insufficient tooperatetheheater Thisisapparentwhenthepressure 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 clockwise until ...

Page 35: ...ER REMOVAL 1 Shut off main electrical power switch to heater 2 Shut off gas upstream of heater 3 Removefrontdoor 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 Reverseaboveproceduretoreinstall GAS VALVE REMOVAL 1 Shutoffgassupplytotheheater Re...

Page 36: ...tween fins 5 Reverseaboveproceduretoreinstall NOTE In extreme cases it may be necessary to do steam cleaning at the local car wash DO NOT WIRE BRUSH COMBUSTION CHAMBERREMOVAL To remove combustion chamber you must first have removed the heat exchanger Unbolt metal combustion chamberretainerfromtopandremovecombustioncham berpanelsindividually REFRACTORYPANELS TOPVIEW Extension Pieces 2 Auger with Ca...

Page 37: ...or 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 Heaterwilloperateuntilcallforheatissatisfied LOW NOx POOL HEATERS Fig 9361 FLAMEROLL OUTSAFETYSWITCH 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 tha...

Page 38: ...tal 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 LOW NOX HEATERS CONTINUED Fig 9362 PILOT REMOVAL 1 Disconnect pilot tubing from gas valve 2 Remove 4 ...

Page 39: ...ace 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 bu...

Page 40: ...er 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 ...

Page 41: ...trol 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 repla...

Page 42: ...42 DIGITAL CONTROL LOGIC FLOW CHART ...

Page 43: ...turn 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 STREET MISSISSAUGA ONTARIO L4T ...

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Page 45: ...ILOT 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 ...

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Page 52: ...pak 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 ...