Raypak RP2100 ASME Operations Instructions

INSTALLATION & OPERATING INSTRUCTIONSGas-FiredPool & SpaHeaterCatalog No. 6000.59U Effective: 10-06-10 Replaces: 06-10-10 P/N 2

10PART TWOINSTALLATION AND SERVICE INSTRUCTIONSSECTION 1 - RECEIVING EQUIPMENTThe manufacturer recommends that this manual be reviewed thoroughly befo

11SECTION 3 - INSTALLATION INSTRUCTIONSCALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of Californiato cause can

12OUTDOOR HEATER INSTALLATIONThese heaters are design-certified for outdoor installation, when equipped with the approved tops designated foroutdoor u

13Heaters must not be installed under an overhang of less than three 3 ft from the top of the heater. Three sidesmust be open in the area under the o

14FLORIDA BUILDING CODE 2001WIND SPEED = 150 MPH, 3 SECOND GUSTEXPOSURE = CT O H B 28” 40” 3” Min. Conc. Pad by others 3” Min. Conc.Pad by othersMin.

15WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented tothe outside. Failure to follow this procedur

16SPECIFICATIONS AND DIMENSIONSHeaterModelBTUHInput(000)(A)CabinetWidth(B)FlueDia.(C)IndoorDrafthood(D)(J)Min. GasConn.WaterConn.Shipping Weights (lbs

17LO NOx UNITSHeaterModelBTUHInput(000)(A)CabinetWidth(B)FlueDia.(C)IndoorDrafthood(D)(J)Min. GasConn.WaterConn.Shipping Weights (lbs)StandardHeaterw/

VENT PIPINGVent piping the same size as the drafthood outlet is recommended, however, when the total vent height is atleast 10 ft (drafthood relief op

19The discharge opening must be a minimum of 2 ft ver-tically from the roof surface and at least 2 ft higher thanany part of the building within 10 ft

WATER CHEMISTRY(Corrosive water voids all warranties)For your health and the protection of your pool equipment, it is essential that you

GAS PRESSURE REGULATORThe gas pressure regulator is preset at 4.0 in. WCthroughout for natural gas, and 10.5 in. WC. forpropane gas.

21MODEL PIPE SIZE MIN. GPM MAX. GPM*206/207 1-1/4”–1-1/2” - 2” 20 125266/2671-1/4”–1-1/2” - 2”25125336/337 1-1/4”–1-1/2” - 2” 35 125406/4071-1/4”–1-1/

22CAST IRON HEADERS (ASME MODELS)Heater must be located so that any water leaks will notdamage the structure of adjacent area. High tempera-ture 2&quo

23INTERNAL AUTOMATIC BYPASS VALVEIn addition to the Unitherm Governor, a built-in auto-matic bypass valve is provided in the in/out hea

24The heater requires water flow and positive pressure to fire and operate properly. It must therefore be installeddownstream of the discharge side o

25HEAT EXCHANGER REVERSAL PROCEDURE - STANDARD MODELS1. Remove right and left side access panels(Figure 1).2. Disconnect wires at high limit, AG

26ATMOSPHERICWiring locationsLO NOxWiring locationsELECTRICAL WIRINGNOTE: If it is necessary to replace any of the originalwiring, use 105°C wire or i

27TRANSFORMER WIRING120 VAC WIRINGFor 120 VAC input power to the unit, connect the black wire to the “L1” or hot leg of the power supply. Connectthe w

28WIRING DIAGRAM - MILLIVOLT (MECHANICAL THERMOSTAT)

29WIRING DIAGRAM - DIGITAL MODELS - ATMOSPHERIC

4 PART ONEOWNER'S OPERATING INSTRUCTIONS4 SECTION 1START-UP PROCEDURES4 Before Start-Up5 Lighting Instructions & Shut-Off Procedures - Manual

30WIRING DIAGRAM - DIGITAL AND AFT MODELS - LO NOxRaypak Digital PC Board,Part No. 601769Raypak AFT Board,Part No. 601944

31SECTION 4 - SERVICING INSTRUCTIONSGENERAL LOCATION OF CONTROLSATMOSPHERICLO NOxDigital Thermostat Circuit BoardDrain Plug(Located in rear header)Uni

32CONTROL PANEL REMOVAL1. Remove screw from front door. Set aside door forserviceability.CONTROL ADJUSTMENTS - MILLIVOLT MODELSThe water temperature i

33THERMOSTAT OPERATION - DIGITAL BOARDThermostat operationYour heater is equipped with a microprocessor-controlled thermostat that controls the pool o

34Resets board to factory default settings.Resets faults in the History File.Change from Fahrenheit to Celsius.SPA setpoint maximum adjustment.POOL se

35If the PRS fault code is displayed, it indicates thatthere is insufficient water flow through the heater.Make sure the pool filter a

36REMOTE CONTROL INSTALLATION AND OPERATIONCAUTION: Before installing remote controls to the digital thermostat model heaters, read the following:The

37The pool heater touchpad, located on the upper frontpanel of the heater, allows the user to select eitherPOOL or SPA operation, and to

38Resets board to factory defaultsettings.Resets faults in the History File.Change from Fahrenheit toCelsius.SPA setpoint maximumadjustment.POO

39STATUS AND DIAGNOSTICSThe digital thermostat models are programmed to display a variety of status and diagnostic messages, depend-ing on the operati

4PART ONE OWNER'S OPERATING INSTRUCTIONSFOR YOUR SAFETY - READ BEFORE OPERATINGWARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE O

40REMOTE CONTROL INSTALLATION AND OPERATIONCAUTION: Before installing remote controls to the AFT thermostat model heaters, read the following:The digi

41REMOTE CONTROL WIRINGImportant Installation Notes for Remote or External Wiring Configuration• Remote wiring must be run in a separate conduit.• Rem

FLAME ROLL-OUT SAFETY SWITCHAtmospheric heaters areequipped with a thermal cutoffdevice to prevent flame roll-outin the event the heat exchang-er be

MAIN BURNER AND ORIFICE REMOVAL -ATMOSPHERIC MODELS1. Remove burner tray.2. Remove screws and burner hold-down bracket.NOTE: If the heat exchan

(Millivolt and ASME)1. Shut off water to heater and drain heat exchanger.2. Remove access panel on water connection side.3. Remove old immersion we

45The Lo NOx pool heaters are certified and testedunder the ANSI Z21.56/CSA 4.7 Standard for Gas-Fired Pool Heaters.The heater should

46LO NOx HEATERS (CONTINUED)BURNER TRAY REMOVAL1. Shut off main electrical power switch to heater.2. Shut off gas upstream of heater.3. Remove front d

47MECHANICALIMPORTANT NOTICE These instructions are intended for the use of qualified personnel who are specifically trained and experienced in theins

48ELECTRICAL - STANDING PILOT MILLIVOLTPOOL OR SPA HEATER ELECTRICAL CHECK WITH MILLIVOLT GAS VALVECAUTION: For qualified service personnel only.1. Fi

49STARTTURN GAS SUPPLY OFF.TURN THERMOSTAT(CONTROLLER) TO CALL FOR HEATPOWER TO PC BOARD?(24 V NOMINAL)YESSPARK ACROSSIGNITER/SENSOR GAP?YESTURN GAS

5CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate inconfined areas, extra care should be exercis

50 Power OnIs the water temperature displayed?NOYESPush MODEswitch to select "Pool" or "SPA"Push Temparrow to scroll todesired t

51SECTION 6 - REPLACEMENT PARTSNOTE: To supply you with the correct part, it is impor-tant that you supply the heater model number, serialnumbe

5210-M14-M9-M9-M5-C4-C11-S4-S5-S3-B4-B5-B1-B6-S7-S4-S2-R1-R1-J 16-M 3-R2-V4-V 1-V3-V1-S13-S2-S12-S4-HP5-HP7-HP6-HP6-HP3-HP12-HM17-HM14-M8-S2-J2-B1-G4-

53LO NOx HEATERS

5416-HM15-HM12-HM9-HM10-HM2-C3-M11-HM8-HM(OPTIONAL)POLYMER IN/OUT HEADER AND ACCESSORIES1-M3-C6-C5-HM17-HM14-HM13-HM2-HM4-HM7-HM3-HM6-HM2-S9-S4-SHONEY

55CALLA604A633A662A602NOITPIRCSEDTUOBBURNER TRAY F493010F393010F293010F193010*)level aes( srenruB/w yarT renruBB-1F893010F793010F693010F593010*)level

56CALLA604A633A662A602NOITPIRCSEDTUOHM HEAT EXCHANGER - METALF450010F350010F727600F150010 IC EMSA reppoC.yssA egnahcxE taeHMH-1Heat Exchange Assy.Cupr

57CALLA604A633A662A602NOITPIRCSEDTUOSSHEETMETALF050010F940010F840010F740010)derevuoL( poT tekcaJS-12-S Flue Collector (Units with Polymer Header) 0100

58CALLOUT DESCRIPTION 207A 267A 337A 407ABB BURNER TRAY***1-B Burner Tray w/Burners (0-5000) 010343F 010344F 010345F 010346Burner Tray w/o Burner (0-5

59CALLOUT DESCRIPTION 207A 267A 337A 407AJ CONTROL BOX1-J Transformer 120/240/24V 006736F 006736F 006736F 006736F2-J Rocker Switch 009493F 009493F 00

6CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate inconfined areas, extra care should be exercis

7AFTER START-UPFeel the inlet and outlet pipes. Outlet pipe should beonly slightly warmer than the inlet. It should not be hot.VISUAL INSPECTION - A

SECTION 3 - MAINTENANCE AND CARE PROCEDURESTo be followed one month after start-up and then semi-annually.1. Inspect top of heater and drafthood

9COLD WEATHER OPERATIONIMPORTANT FREEZE INFORMATIONMODERATE CLIMATE: Heater operation can contin-ue during short-term cold spells. When temperaturesa