Page 2 - CONTENTS; Low Nox Addenda
CONTENTS 2 3 PART ONEOWNER'S OPERATING INSTRUCTIONS 3 SECTION 1START-UP PROCEDURES 3 Before Start-Up 4 Lighting Instructions & Shut-Off Procedure (Manually Lighted Pilot MV) 5 Operating Instruction & Shut-Off Procedures (Automatically Lighted Pilot IID) 6 After Start-Up 6 SECTION 2CAUTION 6 ...
Page 3 - PART ONE - OWNER'S OPERATING INSTRUCTIONS; FOR YOUR SAFETY - READ BEFORE OPERATING; BURNERS
PART ONE - OWNER'S OPERATING INSTRUCTIONS FOR YOUR SAFETY - READ BEFORE OPERATING WARNING: IF YOU DO NOT FOLLOW THESEINSTRUCTIONS EXACTLY, A FIRE OREXPLOSION MAY RESULT, CAUSINGPROPERTY DAMAGE, PERSONAL INJURY ORLOSS OF LIFE. SECTION 1 / START-UP PROCEDURES Your Raypak Pool/Spa heater has been desig...
Page 4 - MILLIVOLT SYSTEM; GAS CONTROL KNOB SHOWN IN OFF POSITION
4. Push the gas control knob slightly and turn clockwise to "Off". Do not force. 5. Replace heater door panel. 1. Set the thermostat to the lowest setting.2. Turn On/Off switch to the "Off" position.3. Remove heater door panel. TO TURN OFF GAS TO APPLIANCE A. This appliance has a pil...
Page 5 - ELECTRONIC IGNITIONS SYSTEMS
A. This appliance is equipped with an ignitiondevice which automatically lights the pilot. Donot try to light the pilot by hand. B. BEFORE OPERATING, smell all around theappliance area for gas. Be sure to smell nextto the floor because some gas is heavier thanair and will settle on the floor. WHAT T...
Page 6 - Should overheating occur or the gas; MAIN BURNER FLAME; Operation of the heater without water circu-
AFTER START-UP Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot. WARNING: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control tothe appliance. VISUAL INSPECTION With the heater on, remove the doo...
Page 7 - Combustion air must not be contaminated by; POOL & SPA WATER CHEMISTRY; High chemical concentrates from feeders and; COLD WEATHER OPERATION; CAUTION
4. Make visual check of the burner and pilot flame. Flame pattern on the main burner and pilot is indi-cated in the previous illustration. Yellow flamemeans restriction of the air openings. Lifting orblowing flame indicates high gas pressure. Lowflame means low gas pressure. Should this occur,shut t...
Page 8 - WINTERIZING THE POOL & SPA HEATER; Return Header; Disconnect compression fittings from the pressure; For ASME; PART 2 - INSTALLATION/SERVICE INSTRUCTION; SECTION 1 / RECEIVING EQUIPMENT
WINTERIZING THE POOL & SPA HEATER When heaters installed outdoors in freezing climate areas are to be shut down for the winter, observe thefollowing 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/outle...
Page 9 - SECTION 3 / INSTALLATION INSTRUCTIONS; IMPORTANT NOTICE; The heater should not be located in an area; BASE INSTALLATION; This product contains chemicals known to the State of California
12" Minimum 12" Minimum 4" Minimum HEA TER Sheet Metal 24 Gauge SECTION 3 / INSTALLATION INSTRUCTIONS 9 IMPORTANT NOTICE These instructions are intended for the use of quali- fied personnel only, specifically trained and experiencedin the installation of this type of heating equipment an...
Page 10 - For installations in Canada; VENT TERMINAL (Outdoor) Stackless Top Installation
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 theheaters installed under overhangs with the use of gutters. For U.S. installations ,th...
Page 11 - OUTDOOR STACK / INDOOR STACK INSTALLATION; OUTDOOR KIT INCLUDES:; Clips
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 B...
Page 12 - Installing the clips: INDOOR & OUTDOOR KITS
12 Securing the top panel cover- INDOORKIT ONLY 7. Re-install the louvered top.8. Mount the draft hood onto the adapter plate lip inside the heater. See Fig. 6. 9. Proceed to installing the clips, step 14. Securing the top panel cover- OUTDOOR KITONLY 10. After removing the drafthood from the box, s...
Page 13 - Installing the top cover- OUTDOOR KIT ONLY; Remove the two pieces ofg metal tape
13 Installing the top cover- OUTDOOR KIT ONLY 22. Remove the two pieces ofg metal tape holding the top panel cover up anddiscard. 23. Insert the rear two tabs into the slots on the heater top and slide the top panelcover backwards. See Fig. 13. 24. Lower the top panel cover and using your thumbs, pu...
Page 14 - SPECIFICATIONS AND DIMENSIONS; Each opening shall have a minimum net free square; For Canada; Plastic (Capron) Headers cannot be used for ASME installations.
14 SPECIFICATIONS AND DIMENSIONS *Electrical Connection On Left Side is 19-1/8". a. All Air From Inside The Building: Each opening shall have a minimum net free square inches as noted: Model Square Inches Model Square Inches 185 181 335 333 265 264 405 399 b. All Air From Outdoors: When air is s...
Page 15 - VENT PIPING; ANSI; Gas piping must have a sediment trap ahead of the
VENT PIPING WARNING: Indoor boilers require a drafthood that must be connected to a vent pipe and properly vented to theoutside. Failure to follow this procedure can cause fireor fatal carbon monoxide poisoning. Vent piping the same size as the draft hood outlet is recommended, however, when the tot...
Page 16 - GAS PRESSURE REGULATOR; MILLIVOLT GAS VALVES
Fig. # 8149 NOTE: Do not use teflon tape on gas line pipe thread. A flexible sealant is recommended. A minimum of 7" W.C. and a maximum of 14" W.C. upstream pressure under load, and no load conditionsmust be provided for natural gas or a minimum of 12"W.C. and a maximum of 14" for pr...
Page 17 - NEVER install PVC directly into header; DO NOT; PVC Pipe; Flange Gasket
17 Plumbing from the heater back to the pool must not haveany valves or restriction that could prevent flow when thepump is operating. CAUTION: An additional source of heated water, i.e. asolar system, must be connected to the main line aheadof the heater inlet pipe in order for it to act as the pri...
Page 18 - To avoid water damage or scalding due to valve
18 AUXILIARY BYPASS VALVE ADJUSTMENT To set bypass: With clean filter, adjustment is made by feeling the inlet and outlet pipes at the heater. Outletpipes should be slightly warmer than inlet and comfort-able to the touch. If pipe is hot, close bypass; if cold, openbypass. PRESSURE RELIEF VALVE INST...
Page 19 - RP2100+ Heat Exchanger Reversal Procedure; Remove right and left side access panels (; Reroute the sensor to the left side of the heater.; Electronic Ignition Heaters:; Insert sensor bulb and retainer clip into sensor well.
19 ACCESS PANEL Fig. #1 Fig. #2 PRESS SWITCH AGS HI-LIMIT RP2100+ Heat Exchanger Reversal Procedure (Capron Resin Header Models) 1. Remove right and left side access panels ( Figure 1). 2. Disconnect wires at high limit, AGS (automatic gas shutoff), and pressure switch on the inlet/outlet header ( F...
Page 21 - LOW NOx; ELECTRICAL WIRING; If it is necessary to replace any of the original
21 Option Location For LeftSide Field Wiring SwayBrace Bonding Lug (Standard Location) Bonding Lug(Optional Location) Fig. # 9030.1 Control Box (Factory Mounted Location) LOW NOx ATMOSPHERIC Fig.# 9366.1 ELECTRICAL WIRING NOTE : If it is necessary to replace any of the original wiring, it must be re...
Page 22 - WIRING DIAGRAM KEY; PINK CONNECTOR BLUE CONNECTOR
22 WIRING DIAGRAM KEY PINK CONNECTOR BLUE CONNECTOR Fig. # RP8096 *If required by Local Code, install at this location. Fig. #2353 For 120 V input power to the unit, connect the blackwire to the “L1” or hot leg of the power supply. Connectthe white wire to the “L2” or neutral leg of the powersupply....
Page 25 - MILLIVOLT CONTROLS; KNOB STOP SHOWN ABOVE IS; SECTION 4 / SERVICING INSTRUCTIONS; GENERAL LOCATION OF CONTROLS; CONTROL PANEL REMOVAL
Control Panel Mounting Screws (4) Fig. #RP 8267 CONTROLS/ADJUSTMENTS/REPLACEMENTS TemperatureAdjust Buttons Mode Button LCD Display Fig. #2000 MILLIVOLT CONTROLS The pool or spa water temperature is controlled by the pool heater thermostat on the upper front panel ofthe heater. The control center co...
Page 26 - The digital temperature display may not coincide
The RP2100 Spa/Pool Digital Control Panel features an LCD display that provides status and service informa-tion. During normal operation, the heater can be in thePOOL, SPA, or OFF modes. In the OFF mode, the actual water temperature is displayed. NOTE: The digital temperature display may not coincid...
Page 27 - RP2100 REMOTE CONTROL INSTALLATION; Important Installation Notes for; that is shielded and jacketed.; NOTE: Do Not connect wiring to fireman switch location.; TEMPERATURE DISPLAY-Fahrenheit vs. Centigrade
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 showsthe actual pool temperature, operating status, and service co...
Page 28 - ElectroStatic Discharge (ESD) damage can be caused by direct; Remote Wiring Instructions
28 1. Turn off power to the heater.2. Turn off gas to the heater.3. Remove the four screws on the side of the heater holding the control panel (see figure # 9375). 4. Perform ESD charge removal procedures: Lay control panel forward towards you. This will provide access tothe back of the temperature ...
Page 30 - If the heat exchanger is sooted badly, the
BURNER DRAWER REMOVAL1. Shut off main electrical power switch to heater.2. Shut off gas upstream of heater.3. Remove front door.4. Disconnect gas line from gas valve.5. Remove (2) screws that mount burner tray to unit, and (2) screws that secure gas valve to jacket. 6. Disconnect wires that terminat...
Page 31 - Well Assembly
TUBE CLEANING PROCEDURE Establish a regular inspection schedule, frequency depending on local water condition and severity ofservice. Do not let the tubes clog up solidly. Clean outdeposits over 1/16" in thickness. The heater may be cleaned from the return header side, without breaking pipe conn...
Page 32 - OPERATION; d. Turn control down to end call for heat and wait 60; ADDENDA: LOW NOx POOL HEATERS; FLAME ROLL-OUT SAFETY SWITCH
The Raypak Low Nox Pool Heaters are certified andtested under the ANSI Z21.56.CSA 4.7 Standards for gasfired pool heaters. The heater should be installed to meet all local codes, thelatest editions of the National Fuel Gas Code Z223.1 andthe National Electrical Code, ANSI/NFPA 70. OPERATION On call ...
Page 33 - ADDENDA: LOW NOX HEATERS; PILOT REMOVAL; IID PILOT; COMBUSTION FAN REMOVAL
33 BURNER DRAWER REMOVAL 1. Shut off main electrical power switch to heater.2. Shut off gas upstream of heater.3. Remove front door.4. Disconnect gas line from gas valve.5. Remove (2) screws that mount burner tray to the base of the unit, and (2) screws that secure gasvalve to jacket. 6. Disconnect ...
Page 34 - SECTION 5 / TROUBLE SHOOTING GUIDE
MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY) IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel...
Page 35 - only; RAYPAK POOL OR SPA HEATER
If pilot burner remains lit. Jump across pressure switch terminals If main burner does not fire, remove jumper Check for adequate water flow from filter Replace pressure switch Jump across thermostat If main burner fires, remove jumper If main burner does NOT fire... Jump across each high limit and ...
Page 36 - WARNING; HIGH VOLTAGE; Intermittent Pilot System; TROUBLESHOOTING HONEYWELL S8600; START
WARNING HIGH VOLTAGE For qualified Technicians ONLY NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gasif pilot fails to light. To reset, interrupt power to heater. Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 NOTE:Before troubleshooting, familiarize your...
Page 38 - SECTION 6/REPLACEMENT PARTS LIST
SECTION 6/REPLACEMENT PARTS LIST NOTE: To supply the correct part it is important thatyou state the model number, serial numberand type of gas when applicable. Any part returned for replacement under standardcompany warranties must be properly tagged withRAYPAK return parts tag, completely filled in...
Page 40 - Honeywell MV; Low NOx BURNER TRAY; Honeywell IID Atmospheric units
40 Fig. #8124 Honeywell MV Fig. #8107 Fig. #9369 13-P 5-P 16-P 15-P 1-P 9-P 3-P Low NOx BURNER TRAY PILOT ASSEMBLIES 14-P 16-P 3-P 7-P 16-P 3-P 17-P Honeywell IID Atmospheric units for units produced prior to 06/01/2000 Honeywell IID Low NOx and Atmospheric units for units produced after to 06/01/20...
Page 46 - Raypak Canada LTD
Raypak, Inc. , 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX (800) 872-9725 Raypak Canada LTD , 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036 Litho in U.S.A. www.raypak.com
