Raypak 185A User's Manual
Contents
1. P N 241169 Rev 3 Page 3 Registered Quality Management System REMOVING THE CIRCUIT BOARD MODELS 185A B 265A B 335A B 405A B Make sure the power and gas are off Unplug all connectors from old circuit board Fig 7 2 Unplug keypad ribbon from old circuit board 3 Remove four screws as shown in Fig 8 4 Remove old circuit board ok Al a i eo 4 f tlh j TS usi T ae ue E P if if E i e r ir al Wks 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 P N 241169 Rev 3 Page 4 Registered Quality Management System REMOVING THE CIRCUIT BOARD MODELS 206A 207A 266A 267A 336A 337A 406A 407A Make sure the power and gas are off 1 Unplug all connectors from old circuit board Fig 9 2 Unplug keypad ribbon from old circuit board 3 Remove screws as shown in Fig 10 4 Remove old circuit board Fig 10 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 ale P N 241169 Rev 3 Registered Quality Management System DISCONNECTING IGNITION CONTROL MODELS 185A 265A 335A AND 405A ONLY Make sure the power and gas are off 1 Unplug all wires and connectors from ignition control See Fig 11 Note The ignition control is now part of the new2. control circuit board Old module can be left in place but not used TaMcauoHy ance di adO LNWS 008 open ae Ee EA Y Fig 11 Dig 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 Paga P N 241169 Rev 3 Registered Quality Management System PROPANE HEATERS ONLY Make sure the power and gas are off 1 Locate the propane tab on the board as shown in Fig 12 2 Break off tab with pliers as shown in Fig 13 amp Fig 14 Fig 12 Fig 14 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 agent P N 241169 Rev 3 Registered Quality Management System MODELS 185 265 335 amp 405 A amp B SERIES LOW NOX ONLY Make sure the power and gas are off 1 DO NOT break tab See Fig 15 and Fig 16 2 No additional wiring or connections are necessary Fig 15 j om MODEL TERE cog HSCI 1134 8 Fig 16 a 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 ragag P N 241169 Rev 3 Registered Quality Management System LOW NOX MODELS 207A 267A 337A amp 407A Make sure the power and gas are off 1 Locate Lo Nox tab and P 10 air swi
3. eg 102 F for spa ORN BLK To Spa COMM 3 For a 2 Wire Remote Control from a remote with its own sensor push the mode button POOL or SPA mode and set the temperature to the highest setting available on the control The actual setpoint will be Eecoooonoaaadandh en ee a controlled by the remote control Seal EA 5 4 Turn the mode button to OFF and remove power from the heater 5 On the Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and connect the other side to either the ORANGE BLACK wire for SPA operation or the BLACK ORANGE wire for POOL operation 6 Attach wire nut on unused wire to the Remote Interface Harness 7 Install the 7 Pin Remote Interface Harness to the P8 connector and turn power On to the heater See instructions on previous page to activate the remote control 3 Wire Remote Control Using Three Position Switch Pool Off Spa or Low Off High This application assumes that both heating functions pool and spa are required 1 Turn on power to the heater BLK ORN To Pool COMM 2 Push the mode button to the POOL or SPA mode and set the desired temperature for each ORN BLK To Spa COMM eg 80 F for Pool and 102 F for Spa 3 Turn the mode button to OFF and remove power K 24VAC from the heater B 24VAC P8 Connector 4 On the Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and c
4. of the pool or spa WATER SET TEMP POINT mm LCD Display Temp Buttons Mode Button THERMOSTAT CONTROL OPERATION The pool heater thermostat located on the upper front panel of the heater controls the pool spa water tem perature This control center contains a mode button up and down temperature adjustment buttons and an LCD display Mode Button The MODE button functions as a means to turn the heater off or on in either the POOL or SPA setting The LCD display indicates the mode the heater is in and the actual water temperature Temp Buttons If the heater is in POOL or SPA mode the desired water temperature SETPOINT will also be displayed and may be changed using the UP or DOWN buttons A manual toggle switch is also provided right below the MODE button to allow the heater to be turned off Operation In the POOL or SPA modes the actual water temper ature is displayed along with the desired water temper ature SETPOINT If the heater is firing a flame icon will be visible To adjust the setpoint temperature make sure the con trol is in the appropriate mode POOL or SPA and push the UP or DOWN buttons o s tT cele was a ae ae a u PL alle mel 3 d i i mt ret oe i H e Y ij its s fad eS caf 4 se ys 2 Program button Mode Pool or Spa Actual Water Temperature Flame Icon Setpoint Temperature DISPLAY CALL FOR HEAT Fault History File To access the Fault History File press th
5. pilot wire side B to new board See ah we Fig 35 Ce Fig 35 a 1s Piscine in Het INSTALLING PILOT HI TENSION WIRE EXTENSION SIZES 335A TO 407A Ensure the power and the gas has been shut off 1 Re connect pilot wire side B to new board with new extension Fig 36 amp Fig 37 2 Connect side A to existing pilot wire and center protective sleeve over connection Fig 37 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 Registered Quality Management System DIGITAL THERMOSTAT CONTROLS Thermostat operation Page 14 P N 241169 Rev 3 Your heater is equipped with a microprocessor controlled thermostat that controls the pool or spa temperature by measuring the temperature of the water coming back through the heater It will then monitor the water tem perature and turn the heater back on when it senses that the water temperature is falling below the set point It is normal to experience small fluctuations in the return water temperature during the operation of the heater The thermostat is calibrated with a very narrow tolerance to ensure accuracy of the set temperature Thus slight fluctuations in water temperature may cause your heater to cycle on and off frequently This is not a problem It will not harm the heater nor interfere with the thermostat s ability to precisely control the tem perature
6. 12 P N 241169 Rev 3 Registered Quality Management System PLASTIC SHIELD amp BRACKET INSTALLATION MODELS 185 265 335 amp 405 A amp B SERIES Make sure the power and gas are off 1 Note that the plastic shield is installed under the front bracket as pictured Install the shield brackets and plastic shield using the existing screws on the control panel as shown in Fig 32 Reconnect the wire harnesses to the board Note the location of the clear plastic strip with the thin connector This is sometimes disconnected when there is a remote control in the system Fig 32 Refer to the remote wiring instructions for further details Note Make sure 3 wire sensor plug is connected Install the plastic shield over the board and attach to the brackets using the screws and washers provided in the kit See Fig 33 and Fig 34 Re install the sheet metal panel holding the board l back into the heater Fig 33 Go to remote operation instructions OR Return the control panel to the upright position and re attach using the screws previously removed Fig 34 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 Page 13 P N 241169 Rev 3 Registered Quality Management System INSTALLING PILOT HI TENSION 206 TO 267A Ensure the power and the gas has been shut NNN off I See 1 Re connect
7. 67A PRODUCED NOV 1998 PRODUCED NOV 2003 390A SST A UGA AOLA THROUGH OCT 2003 THROUGH OCT 2004 PRODUCED OCT 2004 SERIAL 9811 TO 0310 SERIAL 0310 TO 0410 THROUGH CURRENT SERIAL 0410 CURRENT 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 P N 241169 Rev 3 Page 2 Registered Quality Management System ACCESSING THE BOARD MODELS 185A B 265A B 335A B 405A B 1 Turn off the power to the heater 2 Turn off the gas to the heater 3 Remove front door 4 Remove the four screws on the side of the heater holding the control panel See Fig 1 and Fig 2 5 Lay control panel forward toward you to access the back of the temperature control board Fig 1 REMOVE THESE SCREWS ACCESSING THE BOARD MODELS 206A 207A 266A 267A 336A 337A 406A 407A 1 Turn off the power to the heater 2 Turn off the gas to the heater 3 Remove front door by removing the large door screw shown in Fig 3 4 Remove the four screws on the side of the control panel See Fig 5 and Fig 6 5 Lay control panel forward toward you to access the back of the temperature control board REMOVE THESE SCREWS Fig 4 Close up Wall lye Fig 6 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975
8. P N 241169 Rev 3 Page 1 ISD 900 Registered Quality Management System RAYPAK REPLACEMENT INSTRUCTIONS P C BOARD TEMPERATURE CONTROL amp SENSOR KIT 010253F FOR ALL DIGITAL GAS POOL HEATERS SEE SCOPE FOR APPLICABLE MODELS IMPORTANT NOTICE These instructions are intended primarily for use by 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 to be licensed in some states Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions DANGER SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components DANGER PROPANE HAZARD Make sure to determine if unit is propane and see special instructions on page 6 SCOPE This version of the temperature control board has the capability of an integrated ignition module plus 3 wire temperature sensor The kit includes a gasket and a plastic shield that is mounted to the back side of the control panel to eliminate moisture accumulation on the LCD display It is a direct replacement for the following models 185A 185B 206A 207A 265A 265B 266A 267A 335A 335B 336A 337A 405A 405B 406A 407A This kit includes MODELS MODELS MODELS 185A 265A 335A 405A 185B 265B 335B 405B 206A 207A 266A 2
9. PERATION The digital model heaters are equipped with the ability to work with external remote controls The supplied 7 pin remote wiring connector supplies power out to either a toggle switch or the switch contacts of a third party remote The remote works by either making or breaking the circuit created by the remote wiring Typically a remote does not supply power to the heater it only provides a switching function to turn the heater On or Off If your remote is suppling its own voltage to the heater it will not work with this heater and may damage the digital circuit board The digital display format will change and indicate REMoFF or REMOn REMOn External remote control active display will flash REM REMoFF Remote disabled heater thermostat will control m z Y n m E heater use this mode to test heater operation NOTE When in remote operation the keypad mode and temp buttons are disabled Remote will flash even when the unit is off Note Electrostatic Discharge ESD damage can be caused by direct or indirect contact with the wiring or circuit board When one walks to the heater area an electrostatic charge accumu ATTENTION lates on the body Contact of a finger allows the body to dis OBSERVE PRECAUTIONS charge possibly causing device damage This damage can be TA ELECTROSTATIC limited if the service person discharges himself following ESD ad SENSITIVE DEVICES preventive removal practices and h
10. djustment 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 Page 17 P N 241169 Rev 3 i90 SUOT Registered Quality Management System REMOTE CONTROL INSTALLATION AND OPERATION CAUTION Before installing remote controls to the digital thermostat model heaters read the following The digital thermostat model is remote ready in most cases The digital liquid crystal display LCD shows the actual pool temperature operating status and service codes See examples below The touch pad on the con trol 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 heater to a remote system iden tify whether it is a two or three wire remote system Select the appropriate instruction listed below to properly install the remote to the heater 1S oFF 15 a REN OFF Mode Heating in the POOL Mode Heating in the SPA Mode Remote Mode Pool Common ACTIVATING THE REMOTE BLK ORN The digital thermostat heaters have the ability to dis connect from the remote it is wired to To activate or _ Spa Common deactivate the remote follow these steps 3 ORN BLK AVAC HOT Press and hold all three buttons for 5 to 7 seconds BLU 7 PIN Remote Wiring Connector Iii REMOTE O
11. e Mode but ton until the display reads OFF Press both the UP and DOWN buttons at the same time 5 7 seconds until the display changes and shows a fault code The latest fault code will be displayed first By pressing the UP or DOWN buttons a series of faults will be dis played from the last highest number to the first low est number If the buttons are not touched after 5 7 seconds the display will return to its normal operation 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 FO Registered Quality Management System Program Button To access the program screen press the Mode button until the display reads OFF Remove the four screws holding the control cover on Swing control panel down so the back side of the board is visible see page 30 Locate the Program Mode button as shown in the figure on pg 32 Press the program button 5 7 seconds until SETdef appears on the digital display Release the pro gram button _ be Press the Mode button sequentially until the desired program event is reached There are 5 dif ferent events that can be programmed They appear in the sequence listed below Resets board to factory default settings SET JEF Resets faults in the History File Bl R ES Fi cr Change from Fahrenheit to Celsius FCC FFF f SET i SPA setpoin
12. l panel SETspa 104 SPA Set Point Maximum Adjustment Refer to step one above to access the program screen Press the Mode button until SETspa 104 appears on the digital display Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value The con trol can be set for a maximum of 107 F Once this is done reassemble the control panel SETpool 104 POOL Set Point Maximum Adjustment Refer to step one above access into the program screen Press the Mode button until SETpool 104 appears on the digital display Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value The con trol can be set for a maximum of 107 F Once this is done reassemble the control panel 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 Page 16 P N 241169 Rev 3 NOTE The LCD temperature display may not agree with the temperature reading of your pool or spa ther mometer The heater reads the water temperature at the inlet Due to the circulation characteristics of any pool or spa the water temperature at the inlet to the heater may differ from that observed at a given location in the pool or spa DIAGNOSTICS The digital thermostat models are equipped with on board diagnostic controls If there is a safety fault a fault code will be displayed al
13. olds on to the heater enclo sure for 5 seconds before proceeding 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 Page 18 P N 241169 Rev 3 b Registered Quality Management System REMOTE CONTROL WIRING Important Installation Notes for Remote or External Wiring Configuration Remote wiring must be run in a separate conduit Remote wiring must not be run parallel to high voltage lines For runs of under 30 feet remote wiring should have stranded conductors with a minimum of 22 AWG 600V cable twisting 1 5 to 2 5 in lay 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 is 200 feet e For both two and three wire remote systems the provided 7 pin wiring connector must be utilized Please refer to the wiring instructions Note The remote wires must be connected to the 7 pin connector before the connector is plugged into the board 2 Wire Remote Control On Off This application assumes that only one heating function pool or spa is required 1 Turn on power to the heater 2 For a 2 Wire Remote Control from a remote without Wire Nut BLK ORN its own sensor push the mode button to the POOL To Pool COMM or SPA mode and set the desired setpoint
14. ong with a service indication If the PRS fault code is displayed it indicates that there is insufficient water flow through the heater Make sure the pool filter and pump strainer are clean before calling a service representative CLEAN FILTER STRAINER SERVICE 1 T Z SPA STATUS CODES Display Definition CFH Call for heat CLK Time clock EOL End of line test Factory Use Only LON Low NOx Unit LOW Caution low water temperature OFF Off mode PRO Propane gas configured REM Remote control activated SPK Spark SPR Spare fault code indicator FAULT CODES Display Definition BD1 Board failure EEP Microprocessor error FAN Blower pressure failure FFL Flame sensing when pilot and gas valves are closed GVC Gas valve closed GVO Gas valve open HL1 High limit switch 1 open HL2 High limit switch 2 open IGN Ignition failure ILO Ignition lockout PLI Pilot failure PRS Water pressure switch open ROL Heat roll out safety switch open SNS Sensor failure VNT Vent switch open Bid READING A FAULT The word SERVICE will flash on and off if the PC board detects a known fault The fault will be dis played in three big letters on the lower left of the dis play 3 Letter Service Will Fault Code Flash See table for fault definition PROGRAM MODES Display Definition ccc Celsius setting F C Change from Fahrenheit to Celsius FFF Fahrenheit setting RES Reset defaults SET Set point max a
15. onnect the ORANGE BLACK wire for SPA operation and the BLACK ORANGE wire for the POOL operation 5 Install the Remote Interface Harness to the P8 connector and turn power ON to the heater See instructions on previous page to activate the remote control 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975
16. rd to plastic bezel using the three mounting screws as shown in Fig 26 F LAY BEZEL DOWN Fig 24 Fig 25 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 Page 11 P N 241169 Rev 3 i UE Registered Quality Management System REMOVING amp REPLACING SENSOR MODELS 185 265 335 amp 405 A amp B SERIES Make sure the power and gas are off 1 Loosen drain plug to relieve pressure in heat exchanger See Fig 27 2 Remove five screws and in out access panel as shown in Fig 28 3 Re route the 2 wire sensor connector from the board P1 back towards the in out header 4 Unscrew compression nut and loosen compression fitting to replace old sensor with new sensor See Fig 29 5 Install new sensor and tighten compression fitting and compression nut 6 Re route the new 3 wire sensor connector back to the board 7 Plug the 3 wire sensor connector to its correct location P1 shown in Fig 30 and close up in Fig 31 Fig 28 f 1 Te rs Be AS TRETE aaa vel ee pe ee ee ae a TER r Pa o en C Rayp kM Aa a at gt aly E aa gg Fie 1 gt j a Fig 31 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 Page
17. t maximum adjustment 1 GY POOL setpoint maximum adjustment al GET i SETdef Default Settings Refer to step one above to access the program screen SETdef should appear on the screen If not press the Mode button until SETdef appears on the digital display Press and hold both UP and DOWN buttons for 5 7 seconds until 3 dashes appear This operation resets the operating program to its fac tory default values Both the POOL and SPA setpoints will revert to 65 F 18 5 C and both POOL and SPA maximum temperature settings will be 104 F 40 0 C Once this is done reassemble the control panel RESfl Reset Fault History Refer to step one above to access the program screen Press the Mode button until RESfl appears on the digital display Press and hold both UP and DOWN buttons for 5 7 seconds until 2 dashes appear This operation resets the Fault History file to 0 and clears all the stored faults Once this is done reassemble the control panel Page 15 P N 241169 Rev 3 F Cfff Fahrenheit to Celsius Refer to step one above to access the program screen Press the Mode button until F Cfff appears on the digital display The digital display is capable of displaying Celsius as well as Fahrenheit temperatures The UP or DOWN buttons will select F or C on the temperature display Choose the desired tempera ture scale Once this is done reassemble the contro
18. tch terminal on the board as shown in Fig 17 and Fig 18 2 Break off tab shown in Fig 19 with pliers 3 Attach the wire from the air switch to the P 10 location shown in Fig 20 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 agen P N 241169 Rev 3 Registered Quality Management System NEW CIRCUIT BOARD amp GASKET INSTALLATION USING OLD BEZEL MODELS 185 265 335 amp 405 A amp B SERIES Make sure the power and gas are off Note Disregard window gasket installation if already present 1 Remove backing on gasket and install adhesive side on the control panel bezel as shown in Fig 21 2 Re assemble with new board to plastic bezel using the three mounting screws as shown in Fig 22 amp Fig 23 a LAY BOARD S x DOWN 2151 Eastman Ave Oxnard CA 93030 805 278 5300 Fax 800 777 7026 Technical support is available M F 5 30 AM to 5 00 PM PST at 800 947 2975 or 800 627 2975 agen P N 241169 Rev 3 Registered Quality Management System GASKET amp NEW CIRCUIT BOARD NEW BEZEL INSTALLATION MODELS 206A 207A 266A 267A 336A 337A 406A 407A Make sure the power and gas are off Note Disregard window gasket installation if already present 1 Remove backing on gasket and install adhesive side on the control panel bezel as shown in Fig 24 amp Fig 25 2 Re assemble with new boa
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