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CATALOG NO. 6000.52-Z
Effective: 11-01-01
Replaces: 08-01-01
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
SPA HEATER
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 app
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TO WHOM IT MAY CONCERN: The new Raypak series RP2100 pool heaters have been designed to eliminate the need for conventional heat sinks (high temperature piping). The initial connection to the heater is made with a 2" PVC union adapter to which PVC may then be connected with appropriate cement. This newly authorized piping arrangement is described in the installation manual provided by Raypak, and has been successfully tested by Raypak to assure its acceptability. Larry J. Ashton, P.E. Vice Pres
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CONTENTS 4 PART ONE 24 SECTION 4 SERVICING INSTRUCTIONS OWNER'S OPERATING INSTRUCTIONS 24 General Location of Controls 4 SECTION 1 24 Control Adjustments/Replacements START-UP PROCEDURES 25 Electronic Controls 26 Remote Control Installation 4 Before Start-Up 27 Pressure Switch Adjustment 5 Lighting Instructions & Shut-Off Procedure 27 Flame Roll-Out Safety Switch (Manually Lighted Pilot MV) 27 High Limit Removal 6 Operating Instruction & Shut-Off Procedures 27 Pilot Safety Millivolt and IID (Aut
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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 avail
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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 A. This appliance has a pilot that must be lighted the fire department. by hand. When lighting the pilot, follow these instructions exactly.
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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 A. This appliance is equipped with an ignition *If you cannot reach your gas supplier, call the fire device which automatically lights the pilot. Do department. not try to light the pilot by ha
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AFTER START-UP SECTION 2/CAUTION Feel the inlet and outlet pipes. Outlet pipe should be Elevated water temperature can be hazardous, and only slightly warmer than the inlet. It should not be hot. 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 1. Spa or hot tub water temperatures should never the appliance. exceed 104°F (40°C). A temperature of 100°F (3
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4. Make visual check of the burner and pilot flame. AUTOMATIC CHLORINATORS AND CHEMICAL FEED- 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 diluted into the pool or spa water before being circulated flame means low gas pressure. Should this occur, through the heater. Do not place chlorine ta
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WINTERIZING THE POOL & SPA HEATER Return Header When heaters installed outdoors in freezing climate areas are to be shut down for the winter, observe the following step-by-step procedure: 1. Turn off gas valve, manual gas valve, and electrical supply to the heater. 2. Open drain plug located on the inlet/outlet Drain Plug header, (under water pipes). Remove the heat Fig. #2001 exchanger inspection panel on the side op- Disconnect compression fittings from the pressure posite water piping to ga
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SECTION 3 / INSTALLATION INSTRUCTIONS IMPORTANT NOTICE CLEARANCES ALL HEATERS These instructions are intended for the use of quali- For clearances from combustible surfaces, see the fied personnel only, specifically trained and experienced chart below. in the installation of this type of heating equipment and related system components. Installation and service CLEARANCE FROM COMBUSTIBLE CONSTRUCTION personnel may be required by some states to be licensed. INDOOR INSTALLATIONS: If your state is
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HEATER WITH OUTDOOR STACKLESS TOP 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 ove
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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. Locate heater as close as practical to a chimney or gas vent. Heater must always be vented to the outside. See Vent Piping Section for venting details. Minimum allow
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SPECIFICATIONS AND DIMENSIONS *Designation for Propane is "EP", Natural gas is "EN". Prefix "C" is for Cast Iron (ASME) Headers; "P" is for Plastic (Capron) Headers. Above input ratings are per A.G.A. specifications. 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. *Electri
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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, when the total vent height is at least ten (10) feet (draft hood relief opening to vent terminal), the vent pipe size may be reduced as speci- fied in Chapter 10 of the National Fuel Gas Code, ANSI Z 223.1. (C
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NOTE: Do not use teflon tape on gas line pipe thread. A ELECTRONIC IGNITION GAS VALVES-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 The gas pressure regulator is preset at 4" W. C. for Pressure natural gas, and 11" W. C. for propane gas. The pressure Adju
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Plumbing from the heater back to the pool must not have INTERNAL AUTOMATIC BY-PASS VALVE any valves or restriction that could prevent flow when the pump is operating. In addition to the Unitherm Governor, a built-in automatic by-pass valve is provided in the in/out CAUTION: A source of additional heated water, i.e. solar header. While the Unitherm Governor responds to the systems, must be connected to the heater outlet pipe. If changes in water temperature in the heater, the internal this is c
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PRESSURE RELIEF VALVE INSTALLATION To conform to local building codes, it may be necessary to install a pressure relief valve. A 3/4" pressure relief valve having a capacity equal to BTU/HR output of the model to be installed is recommended for this appliance. The maximum acceptable pressure re- lief valve setting is 125 psi. A 3/4" NPT connection is provided in the inlet/outlet header for installation of a pressure relief valve. The valve shall be installed in a vertical position. Do not ove
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RP2100+ Heat Exchanger Reversal Procedure (Capron Resin Header Models) 1. Remove right and left side access panels (Figure 1). 2. Disconnect wires at high limit, AGS (automatic gas shutoff), and pressure switch on the inlet/outlet header (Figure 2). 3. Electronic Ignition Heaters: Remove 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 c
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JACO FITTING Fig. #3 BULB & CLIP Fig. #4 RE-INSTALLED IN/OUT HEADER ON OPPOSITE SIDE. Fig. #5 19
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Option Location For Left Control Box ELECTRICAL WIRING Side Field Wiring (Factory Mounted Location) 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. MILLIVOLT SYSTEM The Millivolt System residential heater is equipped with a self-generating electrical system in which the Sway electric current is provided by means of a pilot genera- Brace tor. No external electrical
