Raypak Swimming Pool Heater C R185A User Guide

CATALOGNO.6000.52-AG

Effective: 09-01-03

Replaces: 06-15-03

INSTALLATION

AND OPERATING

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

SPAHEATER

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'sinstructions.

• 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.

Thismanualshouldbemaintainedinlegibleconditionandkeptadjacenttothe

heater or kept in a safe place for future reference.

Part No. 240612

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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. This manual provides operation, installation, maintenance, and service information for these

heaters.

If your heater has been installed correctly, operating the heater is an easy task. 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 use of the controls in the Controls Adjustments/Replacements sub-section.

BEFORE START-UP

BURNERS

Cleanmainburners,combustionfanandairlouvers

WATER

Water must be flowing through the heater during

of dust, lint and debris. Keep heater area clear and free

fromcombustibles,flammableliquidsandchemicals. Do

not obstruct the flow of combustion and ventilating air.

operation. Insurethatsystemisfilledwithwaterandhave

pumpoperating.

RP2100DIGITALIIDCAPRON

RP2100DIGITALIIDASME

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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

*If you cannot reach your gas supplier, call

the fire department.

This appliance has a pilot that must be lighted

by hand. When lighting the pilot, follow these

instructions exactly.

Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will

not push in or turn by hand, do not try to repair

it. Call a qualified service technician. Force or

attempted repair may result in a fire or explo-

sion.

BEFORE LIGHTING 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 any appliance.

*Do not touch any electric 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.

Do not use this appliance if any part has been

underwater. Immediately call a qualified serv-

ice technician to inspect the appliance and to

replace any part of the control system and any

gas control which has been underwater.

LIGHTING INSTRUCTIONS

STOP! Read the safety information above.

Set the thermostat on the lowest setting.

Turn On/Off switch to the "Off" position.

Remove heater door panel.

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.

HONEYWELL PILOT

ROBERTSHAW PILOT

Wait5minutestoclearoutanygas. Ifyou then

smell gas, STOP! Follow "B" in the safety

information above. If you don't smell gas, go

to the next step.

Fig. # 8083.0

Fig. # 8084.1

8. Turn knob on gas control counter-clockwise

to "Pilot"

Locate pilot mounted on the right side panel of

theburnerdrawer. Forburnerdrawerlocation,

see location of control section, page 20.

9. Place flame to end of pilot tube. Push in

control knob all the way and hold to light pilot.

Continue to hold control knob in for about one

minute after the pilot is lighted, release knob

and it will pop back up. Pilot should remain

lighted. Ifitgoesout, repeatsteps5through9.

*If knob does not pop up when released, stop

and immediately call your service technician

or gas supplier.

GAS CONTROL KNOB SHOWN IN OFF POSITION

HONEYWELL

GAS VALVE

MILLIVOLT

10. Stand to the side of the heater and turn the gas

control knob counter clockwise to

11. Replace heater door panel.

"On".

12. Turn On/Off switch to the "On" position.

13. Set thermostat to the desired setting.

ROBERTSHAW

GAS VALVE

Fig. # 8081.0

MILLIVOLT

Fig. # 8079.0

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

2. Turn On/Off switch to the "Off" position.

3. Remove heater door panel.

4. Push the gas control knob slightly and turn

clockwise to "Off". Do not force.

5. Replace heater door panel.

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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

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.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will

not push in or turn by hand, don't try to repair

it; call a qualified service technician. Force or

attempted repair may result in fire or explo-

sion.

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 any appliance.

*Do not touch any electric 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.

D. Do not use this appliance if any part has been

underwater. Immediately call a qualified serv-

ice technician to inspect the appliance and 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.

GAS CONTROL KNOB SHOWN IN "ON" POSITION

HONEYWELL

VR 8300 GAS

GAS

INLET

VALVE IID

5. Remove heater door panel.

6. For Honeywell Valve: Turn gas control

knob clockwise

For Robertshaw valve: Turn gas control

knob clockwise to "Off".(Models

265-405) Push in and move gas control

to "Off".

ROBERTSHAW 7000

GAS VALVE IID

MODEL 265-405

lever counter-clockwise

position. (Model 185)

to "Off"

7. Wait 5 minutes to clear out any gas. If you

then smell gas STOP! Follow "B" in the

safety information previously stated. If you

don't smell gas, go to the next step.

8. Turn gas control knob counter-clockwise

to "On". (Honeywell VR 8300 and

Robertshaw 7000)

Fig. # 8080.0

GAS CONTROL

LEVER SHOWN

IN "OFF"

POSITION

ROBERTSHAW

7200 GAS VALVE

IID MODEL 185

9. Replace heater door panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the

instructions "To Turn Off Gas To Appliance"

and call your service technician or gas

supplier.

GAS

INLET

Fig. # 8934.1

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat at the lowest setting.

2. Turn off all the electric power to the appliance

if service is to be performed.

3. Remove heater door panel.

4. For Honeywell VR 8300 and Robertshaw

7000 gas valve.

to "Off". Make sure knob rest against stop.

For Robertshaw 7200 gas valve.

Push in and move gas control lever counter-

clockwise

to "Off" position.

5. Replace heater door panel.

Turn gas control knob clockwise

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AFTER START-UP

SECTION 2/CAUTION

Feeltheinletandoutletpipes. Outletpipeshouldbe

only slightly warmer than the inlet. It should not be hot.

Elevatedwatertemperaturecanbehazardous,and

the U. S. Consumer Product Safety Commission rec-

ommends 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

exceed104°F(40°C). Atemperatureof100°F(38°C)

is considered safe for a healthy adult. Special

caution is suggested for young children.

VISUAL INSPECTION

With the heater on, remove the door and make a

visual check of the pilot and burner.

The flame should be blue with a well-defined

pattern.

2. Drinkingofalcoholicbeveragesbeforeorduringspa

or hot tub use can cause drowsiness which could

leadtounconsciousnessandsubsequentlyresultin

drowning.

4" MAX

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.

Fig. # 8205.2

MAIN BURNER FLAME

4. Before entering the spa or hot tub, users should

check the water temperature with an accurate ther-

mometer; spa or hot tub thermostats may err in

regulating water temperatures by as much as 4°F

(2.2°C).

5. Persons with a medical history of heart disease,

circulatory problems, diabetes, or blood pressure

problemsshouldobtainaphysician'sadvicebefore

using pools or hot tubs.

Fig. # 8964.1

PILOT BURNER FLAME

6. Persons taking medications which induce drowsi-

ness, such as tranquilizers, antihistamines, or anti-

coagulant, should not use spas or hot tubs.

A yellow or "floating" flame indicates restricted air

openings or incorrect orifice size. Should this occur,

shut the heater off and contact your installer or gas

supplier.

SECTION 3/MAINTENANCE AND

CARE PROCEDURES

To be followed one month after start-up and then

semi-annually.

WATER PRESSURE SWITCH

A water pressure switch is provided in the heater to

shut off the burners in the event that water supply to the

heater is interrupted. It is very important to verify that

the switch electrically opens and shuts off the gas valve

whenwaterflowtotheheaterisinterrupted. Otherwise,

rapid and severe damage will likely occur to the heater.

(The water pressure switch should be checked and

adjusted for proper operation by a qualified service

person at the time of installation and periodically

checked thereafter. Refer to pressure switch servicing

instruction in Section 4 of this manual).

1. Inspecttopofheateranddrafthoodforsoot,asticky

black substance around finned tubes and "V"

baffles),andopenfluegaspassageways.Anyvisible

soot should be cleaned for proper operation.

CAUTION: Soot may be combustible. Wet sooted

surfaces completely prior to cleaning. Do not use steel

wire brush.

2. Cleanmainburnersandpilotburnerofdustandlint.

WARNING:Operationoftheheaterwithoutwatercircu-

lationwillcauserapidandseveredamagetotheheater.

3. Inspect and operate all controls, gas valve and

pressurereliefvalve.

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4. Make visual check of the burner and pilot flame. AUTOMATICCHLORINATORSANDCHEMICALFEED-

Flame pattern on the main burner and pilot is indi- ERS

cated in the previous illustration. Yellow flame

means restriction of the air openings. Lifting or

All chemicals must be introduced and completely

blowing flame indicates high gas pressure. Low dilutedintothepoolorspawaterbeforebeingcirculated

flame means low gas pressure. Should this occur, through the heater. Do not place chlorine tablets or

shut the heater off and contact your gas supplier or bromine sticks in the skimmer. High chemical concen-

qualified service agency.

trations will result when the pump is not running (i.e.

overnight).

5. On indoor heaters, clean room intake openings to

Chlorinatorsmustfeeddownstreamoftheheaterand

assureadequateflowofcombustionandventilation haveananti-siphoningdevicetopreventchemicalback-

air. up into the heater when the pump is shut off.

CAUTION:Combustionairmustnotbecontaminatedby NOTE: High chemical concentrates from feeders and

corrosivechemicalfumeswhichcandamagetheheater chlorinators that are out of adjustment will cause very

andvoidthewarranty.

rapid corrosion to the heat exchanger. Such damage is

notcoveredunderthewarranty.

6. Keepareaaroundheaterclearandfreefromcombus-

tible materials, gasoline and other flammable and COLDWEATHEROPERATION

corrosivevaporsandliquids.

MODERATECLIMATE:Heateroperationcancontinue

BASIC TIPS IF HEATER WILL NOT FIRE:

during short term cold spells. When temperatures are

below freezing, flow (continuous pump operation) must

1. Ifyouhavenoelectricalpower;itmaybeyour "circuit bemaintained.

breakers" have tripped. Try re-setting them.

CAUTION: Do not use the heater to maintain water

Ifyouhaveelectricalpowerbuttheheaterwillnotfire temperaturesjustabovefreezingorforfreezeprotection.

check the following:

Whenheaterisusedduringfreezingweather,caremust

be taken to avoid freeze ups. Continuous pump opera-

3. The time clock must be moved to the "ON" position. tion is a must. Additional protection may be required.

The heater is not warranted against freeze ups.

4. Yourpumpstrainerbasketmaybefull. Ifsoremove

debris.

COLD CLIMATE: Prolonged operation with water tem-

peratures below 50°F is not recommended. When

5. Your filter may be dirty. If so, backwash or clean starting the heater with pool temperatures below 50°F

filter. (To tell if your filter is dirty, look to see if the operate the heater continuously until higher tempera-

filter pressure will be higher than usual).

tures are reached. Operating the heater for prolonged

periodswithpoolwaterbelow50°Fcanseriouslydamage

6. The pump may have lost it's prime. It may be run- the heater, and is not covered by the warranty.

ning dry, check the pressure on the filter. If there is

nopressure;thenyouarenotmovingwater(oryour For cold climate areas, please follow the winterizing

gauge is broken). Try to get the pump to run at it's procedureslisted.

normalflowrate.

POOL & SPA WATER CHEMISTRY

Chemical imbalance can cause severe damage to

your heater and associated equipment. Maintain your

waterpHbetween7.4and7.8andtotalalkalinitybetween

100and150p.p.m. Ifthemineralcontentanddissolved

solids in the water become too 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.

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WINTERIZINGTHEPOOL&SPAHEATER

Return Header

Whenheatersinstalledoutdoorsinfreezingclimate

areas are to be shut down for the winter, observe the

followingstep-by-stepprocedure:

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 op-

posite water piping to gain access to the drain

plug on the return header. Open drain plug on

return header.

Drain Plug

Fig. #2001

Disconnect compression fittings from the pressure

switch and return header that connects to the 1/4"

copper tube and allow the tube to drain. For ASME

Heaters only.

PART 2 - INSTALLATION/SERVICE INSTRUCTION

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:

STANDARD UNIT

ASME UNIT

1. "Pagoda" Top

2. 2" PVC Union with "O" rings (2)

3. Plastic pipe finish flange for gas line

4. Bonding lug with mounting screw

(IID units only)

2. In/Out Flanges (2)

3. 1-1/2" Flange Gaskets (2)

4. 2" Flange Gaskets (2)

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 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.

SECTION 2 / GENERAL SPECIFICATIONS

These heaters are design certified and tested under the requirements of ANSI Z21.56 / CSA 4.7 American

National Standard / CSA Standard for Gas-Fired Pool Heaters. All heaters are inter-changeable and can be used

either indoor or outdoors. The appropriate top designated for that type of use is required. If desired, the top can

bechangedatalaterdatetochangefromoutdoortoindoororviceversa. Millivoltheatercontainsaself-generating

electrical system operating between .25 and .75 volts.

Ambient Temperature Rating of Heater Components

Millivolt Heater with Honeywell Gas Valve +32°F to +175°F

Millivolt Heater with Robertshaw Gas Valve 0°F to +175°F

Electronic Ignition Heaters* -32°F to + 175°F

*Requires 120V or 240V Power Supply

Rated inputs suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each

1000 feet above sea level, as high elevation reduces combustion performance.

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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.

IMPORTANTNOTICE

CLEARANCES

ALLHEATERS

For clearances from combustible surfaces, see the

These instructions are intended for the use of quali-

fiedpersonnelonly,specificallytrainedandexperienced chart below.

in the installation of this type of heating equipment and

related system components. Installation and service CLEARANCEFROMCOMBUSTIBLECONSTRUCTION

personnelmayberequiredbysomestatestobelicensed. INDOORINSTALLATIONS:

If your state is such, be sure your contractor bears the Top*(Drafthood) - 30" Back - 6"

appropriate license. Persons not qualified shall not Front - Alcove

attempttofixthisequipmentnorattemptrepairsaccord- Vent - 6"

ing to these instructions.

Right Side-(Water Side) 12"

Left Side-(Opposite Water

side) 6"

OUTDOORINSTALLATION:

WARNING:

Improper installation, adjustment, alteration,ser-

vice or maintenance may damage the equipment,

Top* (Stackless top or outdoor stack) - Unobstructed

Back - 6"

Side - 6"

create a hazard resulting in asphyxiation, explosion or *Clearance from top of vent terminal.

fire, and will void the warranty.

CODE REQUIREMENTS

When installed according to the listed minimum

NOTE: The heater should not be located in an area clearancesfromcombustibleconstructionmaterials,the

where possible water leakage will result in damage to Raypakpoolheaterscanstillbeservicedwithoutremov-

the area adjacent to the appliance or to the structure. ingpermanentstructuralconstructionaroundtheheater.

When such locations cannot be avoided, it is recom-

mended that a suitable drain pan, adequately drained,

However for ease of servicing, we recommend a

be installed under the appliance. The pan must not clearance of at least 24" in the front, and at least 18" on

restrict combustion air flow.

thewaterconnectionside. Thiswillenabletheheaterto

be serviced in its installed location, that is, without

Installationmustbeinaccordancewithlocalcodes, movement or removal of the heater.

or, in the absence of local codes, with the latest edition

oftheNationalFuelGasCode,ANSI Z223.1andNational

Clearances less than these (6" minimum), may

Electrical Code, ANSI/NFPA 70, and for Canada, the require removal of the heater to service either the heat

latest edition of CAN/CGA-B149.1 and B149.2, and exchanger or the burner tray. In either case, the heater

Canadian Electrical Code, CSA C22.1 Part 1 and Part mustbeinstalledinamannerthatwillenabletheheater

tobeservicedwithoutremovinganystructurearoundthe

heater.

BASEINSTALLATION

Heater must be mounted on a level base, such as OUTDOOR HEATERS

cement slab, cement blocks or other non-combustible

These heaters are design certified for outdoor

surface. An optional non-combustible base is available installation,whenequippedwiththeapprovedtopsdes-

forallmodels. Analternativemethodforprovidingabase ignated for outdoor use.

forcombustiblefloorsisillustratedbelow. Heatersmust

not be installed on carpeting.

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.

12"

Minimum

12"

TER

Minimum

HEA

WARNING:Donotinstallwithin3feetofaheatpumpor

anoutdoorcondensingunit. Strongairintakefromthese

equipment can disturb the combustion process and

cause damage or personal injury.

Sheet Metal

24 Gauge

Minimum

Fig.#8148.1

Utilize hollow concrete cinder blocks, align holes and

leaveendsopen.

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HEATERWITHOUTDOORSTACKLESSTOP

VENT TERMINAL (Outdoor) Stackless Top Installation

1. Insert tabs into keyhole (4 places).

Outdoor Top

Pagoda Top

(Shipped

Loose with

Heater)

2. Snap tabs into keyholes so as not to pull out.

Fig. # 8278.1

Fig. #RP8280.1

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.

ForU.S.installations,thepointfromwheretheflueproductsexittheheatermustbeaminimumoffour(4)feet

below, four (4) feet horizontally from, or one (1) foot above any door, window or gravity inlet into any building. The

top surface of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten

(10) feet horizontally.

ForinstallationsinCanada,poolheatersshallnotbeinstalledwiththetopoftheventassemblywithin10feet

below,ortoeitherside,ofanyopeningintothebuilding. RefertothelatestrevisionsofCAN/CGA-B149.1andB149.2.

foot

Minimum

foot

Minimum

foot

Minimum

foot

Minimum

foot

10 foot

Minimum

Forced Air Inlet

U.S. Installations only

Fig# 8245.1

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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.

Locateheaterascloseaspracticaltoachimneyorgasvent.Heatermustalwaysbeventedtotheoutside. See

Vent Piping Section for venting details. Minimum allowable space is shown on the nameplate.

WARNING:

Indoorboilersrequireadrafthoodthatmustbeconnectedtoaventpipeandproperlyventedtotheoutside.Failure

to follow this procedure can cause fire or fatal carbon monoxide poisioning.

OUTDOORSTACK/INDOORSTACKINSTALLATION

INDOORKITINCLUDES:

1-Drafthood,unpainted

1- Adapter plate

OUTDOORKITINCLUDES:

1-Drafthood, painted

1- Adapter plate

3- Mounting brackets

3- Screws

1-Instructions

3- Mounting brackets

1-Toppanelcover

2- 1 foot sections of metal tape

3- Screws

Clips

1-Instructions

Clips

INSTRUCTIONS:

1. Make sure that the gas and electric has been

turned off to the unit.

2. Remove the "pagoda" top from the louvered top and

discard. See Fig. 3.

3. Remove the louvered top and set aside, saving the

four phillips screws for re-assembly. See Fig. 3.

4. Remove and discard the rain shield. See Fig. 4.

5. Install adapter plate on top of heater flue collector.

See Fig. 5.

6. Re-install louvered top on heater and fasten with

Phillips screws set aside in step 3.

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Securing the top panel cover- INDOOR

KITONLY

7. Re-installthelouveredtop.

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. Afterremovingthedrafthoodfromthe

box, slide the top panel cover over the

draft hood. See Fig. 1.

11. Holding both pieces together, mount

the draft hood on the adapterr plate

lip inside the heater. See Fig. 6.

12. Take the two pieces of metal tape and

attach to each side of the drafthood

leaving6"hangingdown.

13. Slide the top panel cover up and attach

the metal tape to the underneath side.

This is to temporarily keep the top panel

cover out of the way while you are

attaching the clips as shown in the next

steps. See Fig. 7.

Installing the clips: INDOOR & OUTDOOR KITS

14. Notice that there are three pilot holes

above the base of the drafthood as

shown in Fig.8. These are the locations

where the three clips are to be attached.

15. Insert the long edge of one clip between

the top panel cover and the drafthood,

see Fig. 9.

16. With a twisting motion, rotate the clip up,

see Fig. 10.

17. Pull up on clip, see Fig. 11.

18. Hold the clip up and align the clip hole to

the pilot hole, see Fig. 12.

19. Insert screw into hole and secure using a

5/16"nutdriver.

20. Repeat steps 6-10 using remaining two

clips.

21. This completes the indoor drafthood installation.

Ifinstallinganoutdoordrafthood,proceed

to step 13.

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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 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. Turn the gas and electric heater on.

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SPECIFICATIONSANDDIMENSIONS

*Designation for Propane is "EP", Natural gas is "EN". Prefix "C" is for Cast Iron (ASME) Headers; "P" is for Plastic (Capron)

Headers. Reduce input 4% for each 1000 ft. above sea level when installed above 2000 ft. elevation. For Canada, no de-

rate is required for elevations up to 4500 feet. Manufactured under Patent No. 3,623,458.

Note: Plastic (Capron) Headers cannot be used for ASME installations.

Fig#9037.1

*Electrical Connection On Left Side is 19-1/8".

COMBUSTIONAIR(IndoorUnitsOnly)

Air For Combustion And Ventilation

(Indoor Units Only)

a. All Air From Inside The Building:

Eachopeningshallhaveaminimumnetfreesquare

inches as noted:

Model SquareInches Model SquareInches

Theheatermusthavebothcombustionandventila-

tion air. Minimum requirements for net 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) andanylocalcodesthatmayhavejurisdiction.

185

265

181

264

335

405

333

399

b. All Air From Outdoors:

Whenairissupplieddirectlyfromoutsideofbuilding,

each opening shall have a minimum net free square

inches as noted:

Model Square Inches

CAUTION: Combustion air must not be contaminated

by corrosive chemical fumes which can damage the

heater and void the warranty.

185

265

335

405

100

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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,whenthetotalventheightisat

least ten (10) feet (draft hood relief opening to vent

terminal), the vent pipe size may be reduced as speci-

fied in Chapter 10 of the National Fuel Gas Code, ANSI

Z 223.1. (Canada-CAN/CGA-B149.1 and B149.2) As

muchaspossibleavoidlonghorizontalrunsofventpipe

and too many elbows. If installation requires horizontal

non-verticalruns,theventpipemusthaveaminimumof

1/4inchperfootriseandshouldbesupportedatnotmore

thanfivefootintervals. Plumberstape,criss-crossed,will

serve to space both horizontal and vertical piping. Gas

ventssupportedonlybytheflashingandextendingabove

the roof more than five feet should be securely guyed or

braced to withstand snow and wind loads. We recom-

menduseofinsulatedventpipespacerthroughtheroofs

and walls. Another option for installation that requires

horizontalrunsisusingtheD-2powerventkitoption. The

powervent is certified for category III venting up to 40 ft.

equivalent4"diameterventing.

Forprotectionagainstrainorblockagebysnow,the

ventpipemustterminatewithaventcapwhichcomplies

with the local codes or, in the absence of such codes, to

the latest edition of the National Fuel Gas Code, ANSI

Z223.1. (Canada-CAN/CGA-B149.1 and B149.2)

The discharge opening must be a minimum of two feet

vertically from the roof surface and at least two feet

higher 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

minimumclearanceof4feethorizontallyfrom,andinno

case below, unless a 4-foot horizontal distance is main-

tained, from electric meters, gas meters regulators and

relief equipment.

Fig.#RP8119.2

GASSUPPLYCONNECTIONS

Gas piping must have a sediment trap ahead of the

heatergascontrols,andamanualshut-offvalvelocated

outside the heater jacket. All gas piping should be

tested after installation in accordance with local codes.

The weight of the vent stack or chimney must not

rest on heater draft hood. Support must be provided in

compliance with applicable codes. The heater top and

draft hood must be readily removable for maintenance

and inspection. Vent pipe should be adequately sup-

ported to maintain proper clearances from combustible

construction.

Type "B" double wall or equivalent vent pipe is

recommended. However single wall metal vent pipe

may be used as specified in the latest edition of the

National Flue Gas Code ANSI Z 223.1. (Canada-CAN/

CGA-B149.1andB149.2)

Fig.#8090.0

CAUTION:Theheateranditsmanualshutoffvalvemust

bedisconnectedfromthegassupplyduringanypressure

testing of that system at test pressures in excess of 1/

2 psig (3.45 KPA). Dissipate test pressure in the gas

supplylinebeforereconnectingtheheateranditsmanual

shutoffvalvetogassupplyline. FAILURETOFOLLOW

THISPROCEDUREMAYDAMAGETHEGASVALVE.

OVER PRESSURED GAS VALVES ARE NOT COV-

EREDBYWARRANTY. Theheateranditsgasconnec-

tionsshallbeleaktestedbeforeplacingtheappliancein

operation. Use soapy water for leak test. DO NOT use

openflame.

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NOTE: Donotuseteflontapeongaslinepipethread. A

ELECTRONICIGNITIONGASVALVES-CONTINUED

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

Fig # 9328

Fig # 9329

Gas

Pressure

Adjustment

The gas pressure regulator is preset at 4" W. C. for

naturalgas,and11"W.C.forpropanegas. Thepressure

atthegasvalve,takenwithamanometer,shouldbeabout

3.7"W.C.naturalgas(3.9"W.C.forLowNOx)and10.5"

W. C. propane gas. If an adjustment is needed, remove

Robertshaw7200

Model185

Robertshaw7000BDER

Model265-335

seal and turn adjustment screw clockwise

increase pressure or counter-clockwise

decreasepressure.

Gas

Pressure

Adjustment

Fig # 9327

Robertshaw7000DERHC

Model405

PIPESIZINGFORGASCONNECTIONS

Fig. # 8149

Fig.#9365

ATMOSHPERIC

LOW NOx

GAS PRESSURE ADJUSTMENT LOCATIONS

MILLIVOLTGASVALVES

Low NOx units are not available in propane.

PLUMBINGFORWATERCONNECTIONS

LOCATION

Gas

Pressure

Adjustment

Fig # 9263

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;

Robertshaw7000

Models 185 thru 405

ELECTRONICIGNITIONGASVALVES

Gas

Pressure

Adjustment

2. Theoutletsideofthefilteristhenplumbedtotheinlet

of the heater; and

3. Theoutletoftheheaterisplumbedtothereturn line

to the pool or spa. The pump, filter and heater are

thus plumbed in series.

Honeywell VR8304

Models 185 thru 405

Fig # 9264

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COMPANIONFLANGECONNECTIONS

(CASTIRONHEADER)

Plumbingfromtheheaterbacktothepoolmustnothave

anyvalvesorrestrictionthatcouldpreventflowwhenthe

pump is operating.

Heater must be located so that any water leaks will not

CAUTION: An additional source of heated water, i.e. a damagethestructureofadjacentarea.Hughtemperature

solarsystem, mustbeconnectedtothemainlineahead 2" plastic pipe (CPVC) may be threaded directly into the

of the heater inlet pipe in order for it to act as the primary headerflanges.ThisisnotthesameastheSchedule80

heat source. If the primary system provides adequate PVC pipe which is also colored gray. PVC may be used

heattomaintainsetpoint,theRP2100heaterwillnotfire. immediately after the CPVC adapters.

Be advised that the RP2100 control panel will then

2" CPVC Adapters

display sensed water temperatures downstream of the

primary heating system, rather than the temperature of

the water exiting the pool.

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

PVC Pipe

Inlet/OutletHeader

MODEL

185

265

335

405

PIPE SIZE

MIN.GPM *MAX.GPM

CAUTION: NEVER install PVC directly into header

flanges.Usethe2"CPVCadaptersuppliedloosewiththe

heater.

1-1/4"-1-1/2" - 2

125

DO NOT use petroleum base assembly fluids (such

as Petroleum Jelly or lubricating oil). If assembly lube is

required, use a silicon base such as Amoral etc.

There are two sets of flange gaskets supplied with

your heater. Use the appropriate gaskets for all your

heater connections. Discard unused set.

*When flow rates exceed maximum GPM an external

auxiliary bypass valve is required. See external bypass

valve section for details.

CONNECTIONS(PLASTICHEADER)

Beforeattachingthe2-inchunionstotheinlet/outlet

header,makesuretheo-ringsareproperlyseatedinthe

grooves. Use AquaLube or equivalent non-petroleum

based lubricant on the o-ring. Tighten the unions hand

tight. Glue PVC piping directly to the unions.

GASKET DESIGN #1: Accepts 1-1/2" copper tube or

1-1/4" galvanized pipe as a slip connection.

GASKET DESIGN #2: Accepts 2" copper tube as a slip

connection. The flange is threaded for 2" screw in pipe

connections. Also used with the 2" CPVC adapters.

INLET/OUTLETHEADER

Flange Gasket

Header Flange

(CPVC)

Header Flange Nut

(CPVC)

Fig.#8097.1

Fig.#8095.1

INLET/OUTLETHEADER

Inlet

FlangeGasket

Fig. #2002.1

HightemperatureCPVCHeaderFlangesandheader

Flange Nuts are provided. If there is any possibility of

back- siphoning when the pump stops, it is suggested

that a check valve (or valves) also be installed in the

system.

HeaderFlange

Fig.#8093.1

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UNITHERMGOVERNOROPERATION

CAUTION:

AUXILIARYBYPASSVALVEADJUSTMENT

Tosetbypass:Withcleanfilter, adjustmentismade

ThepatentedUnithermGovernorisathermostaticmixing by feeling the inlet and outlet pipes at the heater. Outlet

valve specifically designed to maintain constant heater pipes should be slightly warmer than inlet and comfort-

internal temperature between 105° to 115°F despite abletothetouch. Ifpipeishot,closebypass;ifcold,open

continuallychangingflowratesfromthefilterandchang- bypass.

ing pool temperatures. This narrow range is needed to

preventdamagingcondensationontheburnerswhichwill PRESSURERELIEFVALVEINSTALLATION

occuriftheheaterrunsforanylengthoftimebelow100°F.

It is also needed to inhibit scale formation in the tubes Toconformtolocalbuildingcodes,itmaybeneces-

by maintaining temperatures well below accelerated sarytoinstallapressurereliefvalve. A3/4"pressurerelief

scalingtemperatures.

valve having a capacity equal to BTU/HR output of the

modeltobeinstalledisrecommendedforthisheater.The

maximumacceptablepressurereliefvalvesettingis125

psi.

INTERNALAUTOMATICBY-PASSVALVE

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.

A 3/4" NPT connection is provided in the plastic

headerforinstallationofapressurereliefvalve. Thevalve

shall be installed in a vertical position. Do not over

tighten. Install pressure relief valve hand tight plus 1/2

turn.

PLASTICHEADER

Pressure Relief Valve

PRV Discharge

Connection

Inlet/Outlet Header

Fig.#2003

EXTERNALAUXILIARYBYPASSVALVE

(WhereRequired)

Fig.#2004

A 3/4" NPT connection is provided in the header for

installation of a pressure relief valve. The valve shall be

installed in a vertical position.

Anauxiliarybypassvalveshouldbeusedwhenflow

rates exceed 125 GPM (usually a high performance

pump size larger than two horsepower will exceed this

flow rate). This valve is required to complement the

function of the automatic bypass valve, particularly

when starting the heater in winter or early spring when

the spa or pool temperature is down below 50°F. It also

serves to eliminate needless pressure drop through the

heater and accompanying reduction in the flow rate to

the spa jets, etc.

PressureRelief

Valve

CASTIRONHEADER

PRVDischarge

Connection

From Heater

To Heater

Fig.#8095.0

Inlet/OutletHeader

NOTE: To avoid water damage or scalding due to valve

operation, drain pipe must be connected to valve outlet

andruntoasafeplaceofdischarge. Drainpipemustbe

the same size as the valve discharge connection

throughout its entire length and must pitch downward

from the valve. No shutoff valve shall be installed

between the relief valve and the drain line. Valve lever

should be tripped at least once a year to ensure that

waterwaysareclear.

To Pool

From Pool

AUXILLARY BYPASS VALVE

(DO NOT USE GATE VALVE)

Fig.#8150.0ss

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RP2100+ Heat Exchanger Reversal Procedure

(CapronResinHeaderModels)

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. Millivolt Heaters: Remove the temperature sensor bulb and retainer clip from the sensor well (Figure 4).

Reroute the sensor bulb to the left side of the heater.

5. Remove (12) bolts holding the inlet/outlet and return headers to the tube sheets. Clean off tube sheet area

where the gasket seats. Also clean off the header and the 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 wires.

7. Electronic Ignition Heaters: Insert the temperature sensor in the compression fitting and tighten 1/2 turn

past hand tight.

8. Millivolt Heaters: Insert sensor bulb and retainer clip into sensor well.

9. Allow for water flow through the heater and check for leaks.

10. Reattach access panels to the opposite sides.

For ASME Models call your factory representative.

ACCESS PANEL

Fig. #1

PRESS SWITCH

AGS

HI-LIMIT

Fig. #2

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JACO FITTING

Fig. #3

NOTE: Tighten almost flushed (1/32" to 1/8") to the header to

avoid leaks.

BULB & CLIP

Fig. #4

RE-INSTALLED IN/OUT HEADER ON OPPOSITE SIDE.

Fig. #5

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Option Location For Left

Side Field Wiring

Control Box

(Factory Mounted Location)

ELECTRICALWIRING

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.

MILLIVOLTSYSTEM

The Millivolt System residential heater is equipped

with a self-generating electrical system in which the

electriccurrentisprovidedbymeansofapilotgenerator.

No external electrical connections are required.

When installing a remote switch, do not exceed 10

feetofwiringfromtheheater. Use18gagestrandedwire.

Sway

Brace

Bonding Lug

(Optional Location)

Bonding Lug

(Standard Location)

Fig.#9030.1

ELECTRONICINTERMITTENTIGNITIONDEVICESYS-

TEM (IID)

ATMOSPHERIC

NOTE:Heatersarefactorywiredfor240Vpowersupply.

The standard field wiring connection is on the right side

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.

Fig.#9366.1

LOW NOx

TheElectronicIntermittentIgnitionDevice automatically

lights the pilot and main burners upon a call for the heat.

Theheaterissuppliedwithadualvoltagetransformerfor

120V or 240V input power hookup.

4. Connect the wires inside the junction box, either

120V or 240V depending on the field wiring.

NOTE: 7/8" Dia. holes not utilized on jacket and control

box can be used for fireman switch or auxiliary control

interfacewiring.

NOTE: IIDPropaneUnitsandIIDLowNOxnaturalgas

units only

Heaterisequippedwithanelectronicignitiondevicewith

a 100% safety lockout feature. If the heater fails to start

or lockout, reset the ignition device by interrupting the

power to the heater for 60 seconds.

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

necessaryforbondingtheunit. Mountingholeisprovided

on the jacket.

Caution: Ifservicereplacementoftheelectronicignition

device is required, replace only with a 100% safety

lockout device with 90 second trial for pilot ignition.

HONEYWELL

IGNITION

CONTROL

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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 indepen-

WIRINGDIAGRAMKEY

PINK CONNECTOR BLUE CONNECTOR

dently.

Fig.#RP8096

WIRING DIAGRAM MILLIVOLT UNITS

WITHMECHANICALTHERMOSTAT

Fig. #9240

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 operation.

For Low NOx pool heaters wire nut each white wire inde-

pendently.

*If required by Local Code, install at this location.

Fig.#2353

NOTE: Input power to the heater (120/240V) can be

supplied from the load (pump) side of time clock or

directly from the switch/GFCI power source. It is pre-

ferred to make connection to the load/pump side of the

Fig. # 9241

Heater must be electrically grounded and bonded in timeclock.WhenusingtheswitchedGFCIpowersource

accordance with local codes, or, in the absence of local the heater could display false service indicators on the

codes, with the latest edition of the National Electrical delay panel if the pump is turned off.

code, ANSI/NFPA 70. (Canada- Canadian Electrical

Code, CSA C22.1, Part 1 and Part 2.)

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WIRING DIAGRAM - IID UNITS (atmospheric)

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WIRING DIAGRAM - IID UNITS (Low NOx)

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SECTION 4 / SERVICING INSTRUCTIONS

GENERAL LOCATION OF CONTROLS

CONTROLS/ADJUSTMENTS/REPLACEMENTS

Temperature

Adjust Buttons

Bypass

Hi Limit

Drain Plug

(Located

(Located in

in Return

Return

Mode Button

LCD Display

Header)

AGS Hi-

Limit

(Located

Ignition

Control (IID)

in Inlet/

Oulet

Digital

Header)

Thermostat

Module

Unitherm

Governor

Roll-Out

Fig. #2000

Switch

Drain Plug

On-Off Switch

Transformer

Gas Valve

MILLIVOLT CONTROLS

Pilot

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 thermostats.

Fig #2005

CONTROL PANEL REMOVAL

Thermostats are fitted with a means of limiting the

upper temperature limit below the maximum level. The

knobstopadjustmentringillustratedbelowisadjustable

bylooseningthesetscrew, rotatingtheknobstopringto

the desired location and retightening the set screw.

1. Remove (4) screws from sides of control panel.

2. Rotate control panel down until panel stops. Do

not force.

NOTE: Caution must be taken not to damage controls

or wiring.

SPA TEMPERATURE RANGE POOL TEMPERATURE RANGE

Control Panel

Mounting Screws (4)

STAND-BY

TEMPRATURE

SET SCREW

KNOB STOP RING

Fig. #8103.2

KNOB STOP SHOWN ABOVE IS

INTHESPATEMPERATURERANGE

Fig. #RP 8267

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ELECTRONICCONTROLS

Notice to owner- Thermostat operation

TheRP2100Spa/PoolDigitalControlPanelfeatures

anLCDdisplaythatprovidesstatusandserviceinforma-

tion. During normal operation, the heater can be in the

POOL, SPA, or OFF modes.

Your heater is equipped with a microprocessor-

controlled thermostat that controls the pool or spa

temperature by measuring the etmperature of water

coming back through the heater. It will then monitor the

temperatureandturntheheaterbackonwhenitsenses

that the temperature is falling below set point. Small

fluctuations in the return temperature are experienced

during the operation of the heater. The thermostat is

calibratedwithaveryclosetolerancetoinsureaccuracy

of the set temperature. Thus, slight fluctuations may

cause your heater to cycle on and off frequently.

Thisphenomenonisnotaproblem.Itwillnotharmthe

heater nor interfere with its function to precisely control

the temperature of the pool or spa.

In the OFF mode, the actual water temperature is

displayed.

NOTE:Thedigitaltemperaturedisplaymaynotcoincide

withthetemperaturereadingofyourpoolorspathermom-

eter. TheRP2100readsthewatertemperatureattheinlet

oftheheater.Duetothecirculationcharacteristicsofany

pool or spa, the water temperature at the inlet to the

heatermaydifferfromthatobservedatagivenlocationin

the pool or spa.

In the POOL or SPA modes, the actual water

temperature is displayed along with the desired pool or

spa temperature. If the heater is firing, a flame icon will

bevisible.

Thepoolheaterthermostatontheupperfrontpanel

of the heater controls the pool/spa water temperature.

Thiscontrolcentercontainsamodebutton,upanddown

temperatureadjustmentbuttons,andaLCDdisplay. The

MODEbuttonfunctionsasameanstoturntheheateroff

or on in either the pool or spa temperature setting. The

LCD display indicates the mode the heater is in and the

actualwatertemperature. IfthemodeisinPOOLorSPA,

thedesiredpoolorspatemperaturewillalsobedisplayed

and may be changed using the UP or DOWN 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

probleminoperatingtheheater,thefaultwillbedisplayed

and a service indicator will flash.

To adjust the desired pool or spa temperature set-

ting, make sure the control is in the appropriate mode

(POOLorSPA)andpushtheUPorDOWNbuttonstoget

the desired set point temperature.

Ifthereisasafetyfault,afaultcodewillbedisplayed

along with a service indication. If the PRS fault code is

displayed, it indicates that there is insufficient flow

through the heater. Make sure the pool filter and pump

strainerarecleanbeforecallingaservicerepresentative.

Remotecontroloperationispossiblebyconnection

totheremoteterminalsonthecontrolboard. (P7)When

theremotecontrolisoperatingtheheater,thedisplaywill

alternativelyindicateREMandtheactualwatertempera-

ture.

The electronic thermostat cannot be set above

selected maximum set points. The maximum set point

arefactoryselectedat104°Fforspaandpool.Thesecan

bechangedtoahigherorlowervaluetosuityourneeds,

butcanneverbesetabove107°F.Inordertochangethe

maximum set point, push the MODE button to the OFF

mode. Open the front panel as shown in the previous

section. Find the SETMAX button on the back of the

circuitboard. PushtheSETMAXbuttonuntilthedisplay

indicates SET. Either POOL or SPA will be displayed

with the upper temperature limit. If the desired mode is

notbeingdisplayed,presstheMODEbuttontoswitchto

the desired mode. Using the UP or DOWN arrow

buttons, adjust the upper temperature to the desired

maximumsetting. Ifabuttonisnotpushedfor5seconds,

the control will return to the OFF mode.

A list of the status and service codes are shown

below:

DISPLAY STATUS

CFH – CALLFORHEAT

SPK – SPARK

SERVICE – CALLYOURLOCALINSTALLER/SERVICE

CONTRACTOR/FACTORYFORSERVICE

HEAT – HEATING

REM – REMOTECONTROL

CLK – HEATERINCOOLDOWNCYCLE

ORFIREMANSWITCHOPEN

DISPLAY FAULTS

BRD

SNS

–

BOARDFAILURE

1) SENSOR IS FAULTY

2)TEMPERATUREISABOVE110°F

3)TEMPERATUREISBELOW36°F

PRESSURESWITCHOPEN

HILIMIT–1SWITCHOPEN

PRS

HL 1

HL 2

ROL

IGN

–

HILIMIT–2SWITCHOPEN

Fig #2007

HEATROLL-OUTSAFETYSWITCHOPEN

IGNITIONCONTROLFAILURE

PILOTFAILURE

PLT

LOW

WATERTEMPBETWEEN36°FAND44°F

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TEMPERATUREDISPLAY-Fahrenheitvs.Centigrade

TheRP2100digitalheaterswilldisplaymetric(Centigrade)units.ThefactorydefaultsettingisFarenheit. Ifyou

openupthefrontpanelsoyouarelookingatthefrontofthedigitalboard,youwillfindtwosmallroundbuttons,labled

S1 and S2. S1 is labeled "C of F". Hold down the S1 button for several seconds, until the board displays "CCC",

this will set the board to display in Centigrade. Repeating the process will return the board to "FFF" which is

Fahrenheit.

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

control panel allows you to select the desired pool or spa temperature. It also indicates when a remote system is

controlling the heater by displaying REM in the display. When connecting the RP2100 Digital to a remote system,

identify whether it is a two or three wire remote system. Select the appropriate instruction listed below to properly

install the remote to the heater.

OFFMode

Heating in the POOL

Mode

Heating in the SPA

Mode

RemoteMode

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.

• Forrunsofunder30feet,remotewiringshouldhavestrandedconductorswithaminimumof22AWG,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.

• Maximum cable length of 200 feet.

• For both Two and Three wire remote systems, the provided P-7 wiring connector must be utilized. Please refer

to the wiring instructions.

Two-Wire Remote Operation:

To remotely select a single operating ON/OFF mode (2 wire/single function) requires two wires to be connected to

theheater. Thisrequiresaswitchingmechanismthatcanbea2-wayswitchoraremotecontrolsystemwithasingle

dry contact closure. See remote wiring instructions for Two-Wire One Function.

Three-Wire Remote Systems:

Toremotelyselecteitherpoolorspaoperation(3-wire/2-function)requires3wirestobeconnectedtotheheater. A

switch mechanism that will provide contact closure between HIGH/SPA or LOW/POOL and common, 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 for Three-Wire Two Function.

NOTE: Do Not connect wiring to fireman switch location.

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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 body.

Contact of a finger allows the body to discharge, possibly causing

device damage. This damage can be limited if the service person

discharges himself by removing that charge by adhereing to ESD

preventative/removalpracticesandreducingthatchargebyholdingon

to the heater enclosure for 5 seconds before proceeding.

RemoteWiringInstructions

1.Turn off power to the heater.

2.Turn off gas to the heater.

3.Removethefourscrewsonthesideoftheheaterholdingthecontrol

panel(seefigure#9375).

Fig#9375

4.PerformESDchargeremovalprocedures:

Laycontrolpanelforwardtowardsyou. Thiswillprovideaccessto

the back of the temperature control board.

5.RemovetheRemoteWireHarnessAdaptorfromthewirebundleor

from the P7 terminal (see figure # 9373).

Fig#9373

THREEWIRETWOFUNCTION

6.Fora3-wire/2functionconfiguration, connecttheHIGH/SPAwire

totheorangewirewiththeblackstripe;theLOW/POOLwiretothe

blackwirewiththeorangestripe;andthecommonwiretotheyellow

wire with the black stripe (see figure # 9373).

7.For the 2-wire/1 function configuration, connect the orange/black

andblack/orangewirestoonecontactandtheyellow/blackwireto

the other contact (see figure # 9374).

8.PerformESDchargeremovalprocedures:

Fig#9374

Install the Remote Wiring Harness Adaptor on the P7 terminal.

TWOWIREONEFUNCTION

ON/OFFONLY

To Disconnect Remote Controller and Re-connect

Factory Wiring:

1.Turn OFF power to the heater.

2.Access the back of the digital board.

3.Disconnect the P7 plug where the remote wires are connected

4.Reconnect the black connector at P5 terminal.

5.Turn ON power to the heater.

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PRESSURESWITCH

FLAMEROLL-OUTSAFETYSWITCH

Thepressureswitch,orheateractuator,insuresthat

Theheaterisequippedwithathermalcutoffdeviceto

the heater operates only when the filter pump is in prevent flame roll-out in the event the heat exchanger

operation. It is located on the inlet/outlet header. It is becomesblocked. Thisisa"Single-use"typefusiblelink

factorysetat1.75PSIfordecklevelinstallations. When orthermalfuse,thatmustbereplacedwhendisabledby

the heater is located below the level of the spa or pool, it an over temperature condition, caused by excessive

may be necessary to reset the pressure switch to restriction in the heat exchanger flue passage.

compensatefortheno-flowstatichead. If itisnecessary

to reset the pressure switch, utilize the following proce-

dure:

PRESSURESWITCHADJUSTMENT

Fig.#9440

1. With pump and heater on,

turn adjustment knob

(clockwise) until a click is

heardfromthegasvalve.

2. Turn adjustment knob

(counter clockwise) 1/4

turn.

HIGHLIMITS

The heater is equipped with two automatic high

limits. Both are located in the inlet/outlet header. Both

are set to open at 135°F.

3. Turnpumpoffandonseveral

times. Heater should shut

off immediately. If it does

not,repeatstepsaboveuntil

properadjustmentsmade.

Fig.#9438

NOTE: An erratic high limit is often characteristic of

internal heat exchanger problem, i.e. scale buildup,

defective bypass. Refer to troubleshooting sections.

Adjustment

Knob

HIGHLIMITREMOVAL

1. Shut off main electrical

power switch to heater.

2. Remove inlet/outlet in-

spectionpanel.

PRESSURE SWITCH

ADJUSTMENT RANGE

3. Remove defective high

limit and replace with a

new high limit.

4. Replace inspection

panel.

Fig.#9439

Fig.#8152.1

PILOTSAFETY(Millivolt)

NOTE: If heater is installed outside of the limits shown,

ahigherpressurerated(11psi)switchmaybeusedora

flowswitchmountedandwiredadjacenttotheheatermay

beusedinplaceofthefactorymountedpressureswitch.

See Parts List for 11 psi pressure switch.

Theheatersequippedwiththestandingpilot(millivolt

system), have pilot generators which act as a safety

devicetoshutofftheflowofgastothemainburnersand

the pilot burner in case the pilot flame is extinguished.

The pilot burner must be manually relighted to place the

heater in operation again. Refer to the lighting instruc-

tions provided on the heater label.

TWO SPEED PUMPS

In some cases, the flow on the low speed is insuffi-

cient to operate the heater. This is apparent when the

pressureswitchcannotbefurtheradjustedoriftheheater

makesbangingnoisesorgoesoffonhighlimit. Inthese

cases,thepumpmustberunathighspeed whenheating

thewater.

PILOTSAFETY(Electronic)

The heater employs a pilot safety which closes the

maingasvalvewithin8/10thsofasecondwheneverthe

pilot flame is interrupted. Pilot flame is automatically lit

whenthedeviceispowered. Unitperformsitsownsafety

CAUTION:Donotoperatetheheaterwithoutthefunction check and opens the main valve only after the pilot is

of a properly adjusted pressure switch or flow switch. proven to be lit.

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BURNER DRAWER REMOVAL

PILOTREMOVALANDCLEANING

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Removefrontdoor.

1. Disconnect pilot tubing, and wires from gas valve.

2. Remove pilot assembly from burner tray.

3. Removepilotfrombracket.

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.

4. Removepilotorificeandairopening(HoneywellMV

unit only), and clean with wire or small brush.

CAUTION! Do not enlarge hole in pilot orifice.

5. Reverseaboveproceduretore-install.

8. Reverseaboveproceduretoreinstall.

HONEYWELL PILOT

ROBERTSHAW PILOT

GAS VALVE REMOVAL

1. Shutoffgassupplytotheheater. Removegaspiping

to gas valve inlet.

2. Disconnect wires, pilot tubing and bleed line, if

required.

Pilot

3. Turn vertical gas pipe from manifold slightly and

unscrewgasvalve.

4. Reverseaboveproceduretore-install.

Air

Opening

MAINBURNERANDORIFICEREMOVAL

1. Removeburnerdrawer. Seeburnerdrawerremoval

procedure.

Orifice

2. Removescrewsandburnerholddownbracket.

NOTE: If the heat exchanger is sooted badly, the

burner hold down bracket and spacer can become

distortedfromdirectflameimpingementandthisusually

necessitates replacement of these parts.

Fig. # 8045.1

Fig. # 8102.0

HEATEXCHANGERREMOVAL

1. Shut water, gas and electricity off, close valves and

relievepressure, removereliefvalve. Removeside

inspectionpanels.

2. Removetopholdingscrews.

3. Remove draft diverter, lift and remove top and flue

collector. Remove inspection panels.

3. Lift burners from slotted spacers and slide from

orifices. Clean with a wire brush.

4. Orificesusuallydonotneedtobereplaced. Toclean,

run either copper wire or wood toothpick through

orifice. Do not enlarge hole. To remove orifice, use

asocketwrenchandremovefrommanifold. DONOT

overtightenwhenreinstalling.

4. Disconnect wires from high limits and pressure

switch. Remove temperature sensor.

5. Disconnectflangenutsoninlet-outletheader,loosen

union(s)atgaspipeandslideboilerawayfrompiping.

6. Lift heat exchanger straight up using caution not to

damagerefractory.

Burner Hold Down Bracket

7. Reverseaboveproceduretoreinstall.Makesurethe

insulation strips are properly replaced on top of the

refractoryretainer.

Burner

8057.0

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Extension Pieces (2)

Auger with Carbide Tip

Wire Brush

Fig. # 8154.0

TUBE CLEANING PROCEDURE

CONTROL IMMERSION WELL REPLACEMENT

Establish a regular inspection schedule, frequency (Millivolt and ASME)

1. Shut water off to heater and drain heat exchanger.

2. Remove access panel on water connection side of

heater.

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.

3. Remove old control well with bushing and sleeve.

4. Install in header.

The heater may be cleaned from the return header

side, without breaking pipe connections. It is prefer-

able, however, toremovebothheadersforbettervisibil-

ity through the tubes and to be sure the ground-up lime

dust does not get into the system.

NOTE: Installation in plastic should be hand tight plus

1/2 turn.

Note that you do not remove the top panel or the

heater exchanger, generally.

After reaming, mount the wire brush in place of the

auger and clean out debris remaining in the tubes.

Another method is to remove the heat exchanger,

ream tubes and immerse heat exchanger in non-inhib-

ited de-scale solvent for severe scale build-up.

Well Assembly

DESOOTING PROCEDURE

CAUTION: SOOT IS COMBUSTIBLE. EXERCISE

EXTREME CARE:

Fig. #2010

Soot will clog areas between fins and cause even-

tual tube failure. Any sign of soot at the base of the

burners or around the outer jacket indicates a need for

cleaning.

UNITHERM GOVERNOR (U.G.) REPLACEMENT

1. Shut water, gas and electricity off, close valves and

relievepressure.

2. Drainheatexchanger.

1. Remove top and flue collector from cabinet.

2. Remove"V"bafflesfromheatexchanger.

3. Removeburnerdrawer. (Seeburnertrayremoval).

4. Remove heat exchanger from the heater and wash

with a garden hose, making sure soot is removed

from spaces between fins.

3. Removeretainerpluglocatednexttotheoutletpipe

connection.

4. RemoveoldU.G.fromretainerplug. Itissnappedin

place. Snap in new U.G.

5. Reinstall retainer plug, taking care to lubricate gas-

ket with a non-petroleum based grease such as

AquaLube.

5. Reverseaboveproceduretore-install.

NOTE: In extreme cases it may be necessary to do

steam cleaning at the local car wash. DO NOT

WIREBRUSH.

Retainer Plug

U.G.

Spring

COMBUSTION CHAMBER REMOVAL

To remove combustion chamber, you must first

have removed the heat exchanger. Unbolt metal com-

bustionchamberretainerfromtopandremovecombus-

tion chamber panels individually.

Gasket

Fig. #2011

TotesttheoperationoftheUnithermGovernor,placein

hotwater(over100°F)andwatchformovementagainst

spring. If there is no movement, replace unit.

REFRACTORYPANELSTOPVIEW

Fig.#RP8155.0

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ADDENDA: LOW NOx POOL HEATERS

The Raypak Low Nox Pool Heaters are certified and BURNERADJUSTMENT

testedundertheANSIZ21.56.CSA4.7 Standardsforgas

firedpoolheaters.

This burner assembly does not require any primary air

adjustments.

Theheatershouldbeinstalledtomeetalllocalcodes,the

latesteditionsoftheNationalFuelGasCodeZ223.1and VISUAL INSPECTION

the National Electrical Code, ANSI/NFPA 70.

Flame can be observed through the slot opening above

theplenum. Flamecolorisblueandevenlyspreadonthe

top surface of the burner. At least every three months a

visualinspectionshouldbemadeoftheburners. Incase

flame lifting is observed on the burner, check gas pres-

sure on manifold. Gas pressure in manifold should be

3.9" W.C.

ELECTRICAL

Be sure that electrical service to the boiler has proper

overloadfuseorcircuitbreakerprotection,wiresizeand

connections which comply with all applicable codes.

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"typeroll-outswitchthat

must be reset by a service technician after any over

temperature conditions have been fixed. Excessive

restrictionintheheatexchangerfluepassagemaycause

the switch to disable the heater.

Fig#9361

OPERATION

On call for heat, the ignition system, consisting of an

electronic spark module, gas pilot system is energized.

Providing pilot is proven blower will start running, the

main gas valve will open and the heater will operate.

When the operating control is satisfied the heater will

shut down.

START-UPPROCEDURES(S8610B)

1.Turn on power to the heater with gas supply off.

2.Check ignition module as follows:

a. Set the thermostat or controller to call for heat.

b. Watch for continuous spark at the pilot burner.

c. Check the ignition spark operation. Time must be

within the lockout timing period (15 or 90 seconds).

d. Turn control down to end call for heat and wait 60

seconds on lockout models before beginning step

3.Turn on gas supply.

4.Set controller 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.

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ADDENDA: LOW NOX HEATERS (CONTINUED)

6. Use a long 9/16” socket wrench to remove orifices

from the gas manifold.

7. Reverse above procedure to re-install.

Fig#9363

IIDPILOT

Fig#9362

LOW NOx BURNER TRAY ASSEMBLY

BURNER DRAWER REMOVAL

PILOT REMOVAL

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.

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door.

5. Pull the pilot bracket slightly, then drop and pull

downwards and outwards.

6. Reverse above procedure to re-install. Make sure

the pilot bracket is all the way up on the pilot side,

see drawing below.

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. Unscrew (4) screws that secure the control box.

8. Disconnect pilot wire from the ignition module.

9. Disconnect wire harness from the combustion blower.

10. Carefully slide out the burner tray assembly.

11. Reverse above procedure to reinstall.

GAS VALVE REMOVAL

1. Remove burner drawer. See burner removal

procedure.

2. Disconnect, pilot tubing from gas valve.

3. Turn vertical gas pipe from manifold slightly and

unscrew gas valve.

4. Reverse above procedure to re-install.

MAIN BURNERAND ORIFICE REMOVAL

Fig#9368

1. Remove burner drawer. See burner drawer removal

procedure.

2. Remove pilot. See pilot removal procedure.

3. Remove (8) total screws from the hold down brack-

ets, front and rear of tray.

COMBUSTION FAN REMOVAL

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.

1. Remove burner drawer. See burner drawer

removal procedure.

2. Remove (4) screws the mount the combustion

blower to the manifold assembly.

3. Reverse above procedure to re-install.

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SECTION 5 / TROUBLE SHOOTING GUIDE

MECHANICAL(FORQUALIFIEDSERVICEPERSONNELONLY)

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.

PROBLEM

CAUSE

SOLUTION

Harmonics, or whining noise

U.G. inoperative.................................... Check movement by putting in hot water (110°F or hig

higher). If no movement, replace.

*Debris or restriction in system............ Locate the restriction and remove. Flush system

and clean.

*Debris in gas line................................. Remove debris or blow out gas line.

Low flow.............................................. Scale forming in heat exchanger - clean heat

exchanger and check pool pH and total alkalinity.

Heater going on and off

continously

Dirty filter.............................................. Backwash filter.

Low water level in pool........................ Raise water level.

External bypass setting out of

adjustment............................................ Adjust bypass

*Pressure switch out of

adjustment............................................. Adjust pressure switch

Liming or scale forming on

heat exchanger

Pool water............................................. Recommended pH should be between 7.4 and 7.8

Totalalkalinity100-150PPMmaximum.

Hardness 150-400 PPM maximum.

Sooting

High flow rates..................................... Reduce by adding manual bypass valve. Adjust

manual bypass valve until heater outlet water

temperature is between 105° and 110°F.

U.G. Inoperative.................................... Check movement by putting in hot water (110°F

or higher). If no movement, replace.

*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 burners.

Outer jacket very hot

(paint blistered)

*Broken refractory caused by

shipping damage or improper

combustion.......................................... Replace refractory panels.

Excessive sooting of heat

exchanger........................................... Determine cause of sooting & correct.

Takes long time to heat

pool or spa.

Calculate temperature in °/hr................ Heat rise (°/hr.)=

Htr. output

Pool gallonage x 8.33

or refer to heater sizing chart. This does not take into

account heat loss due to weather.

Filter not running long enough............... Reset time clock.

Dirty filter............................................... Clean filter.

Gas line or meter undersized................ Refer to installation instructions.

Liming

Bypassing too much water................... Inspect bypass for movement, if no movement,

replace.

U.G. not functioning.............................. Replace if no movement when heated.

Leaking at well.

Overacid............................................... Replace well and maintain water chemistry properly.

Leaking at heat exchanger.

Overacid............................................... Replace heat exchanger and maintain chemistry

properly.

Gasket brittle and leaking -

(overheated).

Heater running after pump

shuts off............................................... See pressure switch adjustment.

Refractory damage............................... Replace refractory.

Sooted heater....................................... Determine cause of sooting and correct.

Combustion fan not running

Fan relay............................................... Replace fan relay

Fan........................................................ Loose connection or failed motor

Burned motor ....................................... Incorrect wiring, replace blower

(* Indicates symptom usually occurs on initial start-up.)

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ELECTRICAL ( STANDING PILOT MILLIVOLT)

RAYPAKPOOLORSPAHEATER

ELECTRICALCHECKWITHMVGASVALVE

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.

Light pilot

If pilot burner

does not light

If pilot burner goes out

If pilot burner remains lit.

when main burner lights

or when gas valve knob

is released

Jump across both "TH"

wires on gas valves

Check gas supply, gas

line size, gas pressure.

Also check for insects

or debris in pilot output.

Remove both "TH"

wires from gas valve.

Relight pilot

Replace

gas

valve

If main burner fires,

remove jumper

If main burner does not

fire, remove jumper

Jump across pressure

switch terminals

If burner does not remain

lit, attach millivolt meter

and read pilot output.

If pilot burner stays on

If main burner fires,

If main burner does not

remove jumper

fire, remove jumper

Problem is a wire or

component short to

cabinet or low gas

pressure

If above 500mV,

replace gas valve

Clean filter

Jump across thermostat

Check for adequate water

flow from filter

If below 500mV, check

gas pressure. Also check

for insects or debris in

the pilot burner

Replace pressure switch

If output is still low,

replace pilot generator.

If main burner does

If main burner fires,

remove jumper

NOTfire...

Jump across each high

limit and remove jumper

Replace thermostat

Replace high limit that

caused heater to fire

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WARNINGHIGHVOLTAGE

ForqualifiedTechniciansONLY

ELECTRICAL

(ELECTRONICIGNITIONIID)

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

START

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

NOTE:Before troubleshooting, familiarize yourself with the startup and checkout

procedure.

Check line voltage power, low voltage transformer, limit controller, thermostat

(controller) and wiring.

POWER TO MODULE

(24 V NOMINAL)

YES

Pull ignition lead and check spark at module.

SPARK ACROSS

IGNITER/SENSOR GAP

YES

Spark Okay?

YES

• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.

• Check boot of the ignition cable for signs of melting or buckling. Take protective

action to shield cable and boot from excessive temperatures.

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

• Check that all manual gas valves are open, supply tubing and pressures are good,

and pilot burner orifice is not blocked.

• Check electrical connections between module and pilot operator on gas control.

• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,

replace gas control; if not, replace module.

NOTE:If S8600H goes into lockout, reset system. Lockout is used on L.P.G. models.

SPARK STOPS WHEN

PILOT IS LIT?

YES

• Check continuity of ignition cable and ground wire.

• Clean flame rod.

• 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 operator, i.e. pilot gas valve, flow switch etc.

MAIN BURNER LIGHTS?

YES

NOTE: IF S8600H goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

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, replace module.

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

• Check for proper thermostat (controller) operation.

• Remove MV lead at module; if valve closes, recheck temperature controller and

wiring; if not, replace gas valve.

TROUBLESHOOTING

ENDS

Repeat procedure until troublefree operation is obtained.

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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.

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

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, etc., and shipped

to the Company freight prepaid.

For Canada:

RAYPAKCANADALTD.

2805 SLOUGH STREET

MISSISSAUGA,ONTARIO

L4T 1G2

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9-S

6-S

4-J

2-R

1-R

1-J

12-P

7-S

2-J

Fig# 240739

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Low NOx BURNER TRAY

PILOT ASSEMBLIES

3-P

7-P

3-P

16-P

14-P

16-P

17-P

Fig.#8124

Fig.#9369

HoneywellIIDAtmosphericunits

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

9-P

15-P

13-P

5-P

16-P

Honeywell MV

Fig. #8107

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LIMITEDWARRANTY

RAYPAKRESIDENTIALSWIMMINGPOOLANDSPAHEATERS

GASMODELS185,265,335&405MILLIVOLT

185,265,335&405ELECTRONIC

GENERAL

Raypak,Inc.warrantsthatthecabinet,burnertray(minuscontrols)andrefractorywillbefreefromdefectsinmaterialsandworkmanship

undernormaluseandserviceforaperiodofFIVEYEARSFROMTHEDATEOFORIGINALPURCHASEFORASINGLEFAMILYRESIDENCE

(ONEYEARIFOTHERTHANFORSINGLEFAMILYRESIDENCEUSE). AllotherpartsofthisproductarewarrantedbyRaypaktobefree

fromdefectsinmaterialsandworkmanshipundernormaluseandserviceforaperiodofTWOYEARSFROMTHEDATEOFORIGINAL

PURCHASEFORASINGLEFAMILYRESIDENCE(ONEYEARIFOTHERTHANFORSINGLEFAMILYRESIDENCEUSE). Inaccordance

withthetermsofthiswarranty,wewillfurnishaRaypakreplacementforanydefectivepartorrepairthepartatouroption. Thereplacement

or repair will be warranted for only the unexpired portion of the original warranty. Labor costs for removal or reinstallation of parts are

notcoveredbythiswarranty,norareshippingchargestoorfromRaypak'sdesignatedrepaircenter. Thiswarrantydoesnotcoverrusting

or corrosion on cabinet or burners that does not affect heater's operation.

WARRANTYCONDITIONS

This warranty applies only to the heater at its original place of installation. This warranty will be void if the heater is installed in violation

of applicable local codes and ordinances or if the rating plate or serial number is altered or removed.

WARRANTYEXCLUSION

This warranty does not cover defects or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions;

2. Abuse, alteration, accident, fire, flood, freeze and the like:

3. Misuse or neglect, including but not limited to, freeze-ups, operating the heater with the cabinet door off, having

flow restrictions or obstructions between the heater outlet and the pool/spa, or not maintaining a proper chemical

balance (PH level must be between 7.4 and 7.8 and total alkalinity between 100 and 150 PPM. Total dissolved solids

(TDS) must be no greater than 3000 PPM);

4. Use of non-factory authorized accessories or other components in conjunction with the heater.

HOWTOMAKEACLAIM

Immediatelynotifythedealerfromwhomtheheaterwaspurchased,supplyingmodelandserialnumbersoftheunit,dateofpurchase,and

adescriptionoftheproblem. ThedealershouldthenpromptlycontactRaypakaboutthewarrantyclaim,andforthelocationofRaypak's

nearestdesignatedrepaircenter. (Ifthedealerforanyreasonisnotavailable,callorwriteRaypakdirectlyattheaddressshownbelow,

Attention:WarrantyService). AftersuchnotificationhasbeengivenandRaypakhasadvisedthelocationofitsdesignatedrepaircenter

(whichmaybethedealer),bringorship,transportationprepaid,thedefectivepartforreplacementorrepairtothedesignatedrepaircenter.

However, Raypak reserves the right at all times to inspect the claimed defect and verify warranty coverage at its factory.

MISCELLANEOUS

Nooneisauthorizedtomakeanyotherwarrantiesonourbehalf,ANYIMPLIEDWARRANTIES,INCLUDINGMERCHANTABILITYORFITNESS

FORAPARTICULARPURPOSE,SHALLNOTEXTENDBEYONDTHEAPPLICABLEWARRANTYPERIODSSPECIFIEDABOVE. RAYPAK'S

SOLELIABILITYWITHRESPECTTOANYDEFECTSHALLBEASSETFORTHINTHISWARRANTYANDANYCLAIMSFORINCIDENTALOR

CONSEQUENTIALDAMAGES(INCLUDINGDAMAGEFROMWATERLEAKAGE)AREEXCLUDED. Somestatesdonotallowlimitationson

howlonganimpliedwarrantylasts,orfortheexclusionofincidentalorconsequentialdamages,sotheabovelimitationorexclusionmay

not apply to you.

WesuggestyouimmediatelycompletetheinformationbelowandretainthisWarrantyCertificateintheeventwarrantyserviceisneeded.

Reasonable proof of the effective date of the warranty must be presented; otherwise, the effective date will be based upon the date of

manufactureplusTHIRTY(30)Days.

This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

________________________________________________

Name of Owner

________________________________________________

NameofDealer

________________________________________________

Address

________________________________________________

Address

________________________________________________

ModelNo.

________________________________________________

SerialNo.

DateofPurchase____________________________________________________________________________________

RAYPAK,INC.,2151EastmanAvenue,Oxnard,CA93030•(805)278-5300 FAX(800)872-9725

RAYPAKCANADALTD.,2805SloughStreet,Mississauga,OntarioL4T1G2(905)677-7999FAX(905)677-8036

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

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