Raypak 155C Swimming Pool Heater User Manual
Contents
1. Fig 8082 0 GAS CONTROL LEVER SHOWN IN OFF POSI TION Robertshaw Gas Valve IID GAS INLET Turn on all electrical power to appliance Set thermostat to desired setting If the appliance will not operate follow the in structions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Setthe thermostat at the lowest setting Turn off all the electric power to the appli ance if service is to be performed Remove heater door panel For Honeywell valve Push in gas control knob slightly and turn clockwise to Off For Robertshaw valve Push in and move gas control lever counter clockwise to OFF postion 5 Replace heater door panel 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 valve to the appliance 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 LII 8205 2 MAIN BURNERFLAME Fig 8964 PILOT BURNER FLAME A yellow or floating flame indicates restricted air openings or incorrect orifice size Should this2. Calculate temperature Filter not running long enough Dirty Gas line or meter undersized Bypassing too much water U G not functioning SOLUTION Check movement by putting in hot water 110 F or higher If no movement replace Locate the restriction and remove Flush system and clean Remove debris or blow out gas line Scale forming in heat exchanger clean heat exchanger and check pool pH and total alkalinity Backwash filter Raise water level Adjust bypass Adjust pressure switch Recommended pH should be between 7 4 and 7 8 Total alkalinity 100 150 PPM maximum Hardness 150 400 PPM maximum Reduce by adding manual bypass valve and adjust by putting thermometer in header 1 4 NPT drain opening Set bypass so thermometer reads between 105 and 110 F Check movement by putting in hot water 110 F or higher If no movement replace Refer to installation instructions Follow recommended installation instructions Clean burners Adjust gas pressure Clean pilot Replace pilot Adjust gas pressure Clean burners Replace refractory panels Determine cause of sooting amp correct 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 Reset time clock Clean filter
3. AFIELD WIRE MI BK BLACK haa Ware Black wie B BLUE BR BROWN G GREEN ORANGE R RED WS V VIOLET 120 wok neutral L2 Varr hot W WHITE Y YELLOW Fig 9240 WIRE NUT 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 Wehbe wire with rut attached Fig 8096 0 240 volt L Hot 240 volt L1 Hot Fig 9241 Heater must be electrically grounded and bonded in accordance with local codes or in the absence of local codes with the latest edition ofthe National Electrical code ANSI NFPA 70 NOTE Input power to the heater 120 240V should be supplied from the load Pump side of time clock or switch Connecting heater to continuous power source will allow Fail indications service and pressure switch when pump is not operating 18 WIRING DIAGRAM MILLIVOLT UNITS HI LIMIT HI LIMIT THERMO ALL WIRING IS BLACK GENERATOR Fig 2182e 19 WIRING DIAGRAM 152148 Model 155 IID FACTORY WIRED FOR 240V AC BK L1 R 12 SOLID STATE TERMOSTAT POTENTIOMETER 120 240V DUAL VOLTAGE TEMP TRANS 30VA SWITCH SENS
4. Cold Weather Operation Winterizing The Pool And Spa Heater PART TWO INSTALLATION SERVICE INSTRUCTIONS SECTION 1 RECEIVING EQUIPMENT SECTION 2 GENERAL SPECIFICATIONS SECTION 3 INSTALLATION INSTRUCTIONS Code Requirements Base Installation Clearances Combustion Air Venting Connections Gas Supply Connections Plumbing For Water Connections Electrical Wiring SECTION 4 SERVICING INSTRUCTIONS General Location Of Controls Control Adjustments Replacements Pressure Switch High Limit Removal Flame Roll Out Safety Switch Pilot Safety MV Units Pilot Safety IID Units Gas Valve Removal Main Burner amp Orifice Removal Pilot Removal amp Cleaning Heat Exchanger Removal Control Immersion Well Replacement Tube Cleaning Procedure Typical Tube Replacement Procedure Desooting Procedure Combustion Chamber Removal SECTION 5 TROUBLESHOOTING GUIDE Mechanical Electrical IID Units SECTION 6 REPLACEMENT PARTS 2 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 BEFORE START UP BURNERS WATER Clean main burners and air louvers of dust lint and Water must be flowing through the heater during debris Keep heater area clear and free from com Operation Insure that system is fil
5. Deg2236B Gasket Connectors BOOCOB B Control Box wit Thermostat OOS Teor n3 9 F Control Bax ID wo Thermostat Pro QQ4308F O04 3Q8F Ignition Canlzal ID Mat 0048178 DO4B17TE lgnilian Central TD Pre O04 B 185 HAEE Transhornmer 12024024 O05 345 DD5345F i 650761 amp 5 T61 FOR ALTITUDES ABOVE 2 000 FEET ABOVE SEA LEVEL CONSULT THE FACTORY FOR HEATERS BUILT AFTER APRIL 96 USE KIT S002440F FOR HEATERS BUILT AFTER APRIL 36 USE KIT WDOZODDF 32 eee ee DESCRIPTION BRONZE TRON 0622378 O32 T1F DIGAASF D GBaBBF 900741 900742 501 S07 F 1 DE38BBF s3naaF DO4O12F O12 004013 004013 005888 0058 005399 Pilot Mat Mv Pilat MV Pila ID Pilot Pra IP Pilot Crifica Mat Mv Pilot Orifice Pro MV Pilot Orifice Mai II Pilot Ondice Pro HD Pilot Generator MW Ignitian Control Mist Ignition Cantral Pra Pilot Mounting Bracket Pilot Mounting Bracket MV Plus Models Pilot Mounting Bracket ID Filat Mounling Bracket ID Plus Models Lighter Tube Unite Pilat Tube Hi Tensson Wire THE Hi Tension Wire ID wPilol Electrode Flue Collector zogar Door Assy 00201 OF Access Panel Group D O04890F Contra Panel Standing Pitot DO3T8 n3788F Cunirol Panal il Pitot 3788F 003710 mario Drafthiaod Indoor 003723 Mar2z3 Outdoor Stack wAdapier Cuidoor 0045571 Oubdaar Stack 351014 51016 CONVERSION KITS
6. GAS CONVERSIONS t Pro Standing Pilot Pro to Mat Standing Pilot Mai to Pro Elacironec Pilot Pro to Elecironec Pilot Gas Conversions are to be done only by qualified agency 33 LIMITED WARRANTY RAYPAK RESIDENTIAL SWIMMING POOL AND SPA HEATERS GENERAL Raypak Inc warrants that the cabinet burner tray minus controls and refractory will be free from defects in materials and workmanship under normal use and service for a period of FIVE YEARS FROM THE DATE OF ORIGINAL PURCHASE FOR SINGLE FAMILY RESIDENCE ONE YEAR IF OTHER THAN FOR SINGLE FAMILY RESIDENCE USE All other parts of this product are warranted by Raypak to be free from defects in materials and workmanship under normal use and service for a period of TWO YEARS FROM THE DATE OF ORIGINAL PURCHASE FOR A SINGLE FAMILY RESIDENCE ONE YEAR IF OTHER THAN FOR SINGLE FAMILY RESIDENCE USE In accordance with the terms of this warranty we will furnish a Raypak replacement for any defective part or repair the part at our option The replacementor repair will be warranted for only the unexpired portion of the original warranty Labor costs for removal or reinstallation of parts are not covered by this warranty nor are shipping charges to or from Raypak s designated repair center This warranty does not cover rusting or corrosion on cabinet or burners that does not affect heater s operation WARRANTY CONDITIONS This warranty applies only to the heater at its o
7. Tray wiBurmers Sea Level 00185689F 00139349F Bumer Tray w Bumers and 1 piece manifold Sea Lewel OOF SS1F 007331 Burner Tray wo Burners Sea Lewel 001890 00 1480F Burner Tray wo Burners and 1 piece manifold Sea Lewe 007332 Burner Tray witsas Valve STG OABARF DD4848F Burner Tray wiGas Valve FRO STG 04850F DD4S850F Burner Tray wiGas Valve IID QUABASF D04848F Burner Tray was Valve PRO IID QU4BBTF DD4851F Burner Heald Dawn d198581F 00139391F Bumer 30121010 30112107410 Bumer Mat 50 Sea Lavell 35D078H0 350078H0 Bumer Cirifica Pro 57 Sea Level 3500830 35008310 CONTROLS High Limit 135 F BODE2B High Limit 140 F Thermostat Control Mv Mechanical 003348 Thermostat Control HD Sold State QU53BSF Baird 0050288 Potentiomeler OOS0878 Temperature Sensor 0050838 GAS VALVE Combination Wakas Mal M Do 3898F Combination Valve Pro MX O03499F Combination Valve Mat TD i O03900F Combination Valve Pro HD i DDAOSF HEAT EXCHANGER Heal Exchange Assy Complete OM4962F Inletulet Header OD4963F Return Header OM S646 Tube Bundle D04896F Heat Exhange Tuba 001999 Kil DptaG22F Carnage Boll Kit DDABSSF Siud Kit DOT 1 F Header Gasket Lnilhisrm Governor Da2234B U G Retainer Spring B50254 Bypass Valve De2235B Bypass Spring 950252 Drain Vale 500719 DD3785F 300203 Inlet amp Outlet Flange O03 66F Flange Gasket 1 1 2 Connections
8. can 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 1 Remove top and flue collector from cabinet 2 Remove V baffles from heat exchanger 3 Remove burner drawer See burner tray removal 4 Take garden hose and wash heat exchanger making sure soot is removed from between fins Avoid excessive water against refractory 5 Reassemble When heater is fired some steam will form from wet refractory This is normal NOTE n extreme cases it may be necessary to re move the heat exchanger completely for cleaning The simplest method is steam cleaning at the local car wash DO NOT WIREBRUSH COMBUSTION CHAMBER REMOVAL To remove combustion chamber you must first have removed the heat exchanger Unbolt metal com bustion chamber retainer from top and remove com bustion chamber panels individually REFRACTORY PANELS TOP VIEW Fig 8155 0 Wire Brush Fig 8154 0 SECTION 5 TROUBLE SHOOTING GUIDE 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 instru
9. occur shut the heater off and contact your installer or gas supplier WATER PRESSURE SWITCH A water pressure switch is provided in the heater to shutoffthe burners in the eventthat water supply to the heater is interrupted It is very important to verify that the switch electrically opens and shuts offthe gas valve when water flow to the heater is interrupted Other wise 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 Referto pressure switch servicing instruction in Section 4 of this manual WARNING Operation of the heater without water circulation will cause rapid and severe damage to the heater Pressure Switch Location Fig 8110 1 SECTION 2 CAUTION Elevated water temperature can be hazardous andthe U S Consumer Product Safety Commission recom mends the following guidelines 1 Spa or hot tub water temperatures should never exceed 104 F 40 C A temperature of 100 F 38 C is considered safe for a healthy adult Special caution is suggested for young children 2 Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsi ness which could lead to unconsciousness and subsequently result in drowning 3 Pregnant Women Beware Soaking in water over 102 F 39 C can cause fetal damage during the f
10. up to 2000 feet eleva tion For elevations above 2000 feet reduce input 4 for each 1000 feet above sea level as high elevation reduces combustion performance SECTION 3 INSTALLATION INSTRUCTIONS IMPORTANT NOTICE These instructions are intended for the use of qualified personnel only specifically trained and expe rienced in the installation of this type of heating equip ment and related system components Installation and service personnel may be required by some states to be licensed If your state is such be sure your contractor bears the appropriate license Persons not qualified shall not attempt to fix this equipment nor attempt repairs according to these instructions WARNING Improper installation adjustment altera tion service or maintenance may damage the equip ment create a hazard resulting in asphyxiation explo sion or fire and will void the warranty CODE REQUIREMENTS NOTE The heater should not be located in an area where possible water leakage will result in damage to the area adjacent to the appliance or to the structure When such locations cannot be avoided it is recom mended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Installation must be in accordance with local codes or in the absence of local codes with the latest edition of the National Fuel Gas Code ANSI Z223 1 and the National Electrical Code ANSI NF
11. ups Continuous pump operation is a must Additional protection may be required The heater is not warranted against freeze ups COLD CLIMATE Prolonged operation with water temperatures below 50 F is not recommended When starting the heater with pool temperatures below 50 F operate the heater continuously until higher tempera tures are reached Operating the heater for prolonged periods with pool water below 50 can seriously dam age the heater and is not covered by the warranty For cold climate areas please follow the winterizing proce dures listed WINTERIZING THE POOL amp SPA HEATER 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 electri cal supply to the heater 2 Open drain cock located on the inlet outlet header under water pipes Tilt heater to completely drain all the water from the heat exchanger PRESSURE SWITCH COMPRESSION FITTING RETURN HEADER Fig 8955 3 Disconnect compression fittings from the pressure switch and return header that connects to the 1 4 copper tube and allow the tube to drain PART 2 INSTALLATION SERVICE INSTRUCTIONS 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
12. 030 805 278 5300 FAX 800 872 9725 Litho in U S A 2 190 900 Certified Quality System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 1500 FAX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada LAT 1G2 905 677 7999 FAX 905 677 8036 Raypak Australia Pty Ltd 7 Geddes St Mulgrave Victoria Australia 3170 6139 560 4944 FAX 6139 560 4974 Litho in U S A
13. AT controller and wiring POWER TO MODULE YES Pull ignition lead and check spark at module SPARK ACROSS IGNITER SENSOR GAP Spark Okay YES 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 Check that all manual gas valves are open supply tubing and pressures are good PILOT BURNER LIGHTS and pilot burner orifice is not blocked ae 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 Check continuity of ignition cable and ground wire PILOT IS LIT Clean flame rod YES 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 MAIN BURNER LIGHTS Check electrical connections between module and gas control If okay replace YES gas valve or gas control operator i e pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system SYSTEM RUNS UNTIL CA
14. CATALOG NO 6000 50 N Effective 03 01 01 Replaces 05 15 00 OPERATING AND INSTALLATION INSTRUCTIONS Models 155C t 4 i E ai VERSA SWIMMING POOL and SPA HEATER viewer WARNING If the information in these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or death Donotstore 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 s instructions 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 This manual should be maintained in legible condition and keptadjacentto the heater or kept in a safe place for future reference Part No 240472 CONTENTS RWW CONN PART ONE Owner s Operating Instructions SECTION 1 START UP PROCEDURES Before Start Up Lighting Instructions amp Shut Off Procedures Manually Lighted Pilot MV Operating Instructions amp Shut Off Procedures Automatically Lighted Pilots 110 After Start Up SECTION 2 CAUTION SECTION 3 MAINTENANCE amp CARE PROCEDURES Pool amp Spa Water Chemistry
15. E MATCH WITHIN 20 PERCENT Disconnect potentiometer leads from circuit board Measure resistance with ohmmeter If resistance is Reconnect all leads and check out system 0 100 ohms at minimum setting 9k to 11k at maximum setting replace circuit board Above 11k ohms but less than 15 k ohms replace potentiometer bove 15k ohms fix loose or broken wires replace potentiometer if necessary MEASURED AND ESTIMATED RESISTANCE DON T MATCH Replace sensor Reconnect all leads and check out system If the pool spa hot tub water is too hot troubleshoot the system as follows Check voltage at 24 V terminals VOLTAGE BETWEEN 21 5 28 5 V Set control to max temperature After 2 3 cycles check water temperature VOLTAGE OUTSIDE RANGE 21 5 28 5 V Check transformer 120 V supply correct as necessary TEMPERATURE ABOVE 108 F Disconnect sensor leads from circuit board Measure sensor resistance with ohmmeter TEMPERATURE 105 106 F Control ok RESISTANCE 1 14k OHMS Check water temperature estimate expected sensor resistance from chart below RESISTANCE ABOVE 15k OHMS OPEN CIRCUIT OR SHORT CIRCUIT Fix loose or broken wires Replace sensor if necessary MEASURED AND ESTIMATED RESISTANCE MATCH WITHIN 20 PERCENT Disconnect potentiometer leads from circuit board Measure resistance with ohmmeter If r
16. LL FOR HEAT ENDS Check continuity of ignition cable and ground wire 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 Check for proper thermostat controller operation SYSTEM SHUTS OFF Remove MV lead at module if valve closes recheck temperature controller and YES wiring if not replace gas valve ger dS Repeat procedure until troublefree operation is obtained 28 ELECTRICAL SOLID STATE THERMOSTAT IID If the pool spa hot tub water is too cold troubleshoot the system as follows Check voltage at 24 V terminals VOLTAGE BETWEEN 21 5 28 5 V Set control to max temperature After 2 3 cycles check water temperature 1 VOLTAGE OUTSIDE RANGE 21 5 28 5 V Check transformer 120 V supply correct as necessary TEMPERATURE BELOW 105 F Disconnect sensor leads from circuit board Measure sensor resistance with ohmmeter 1 TEMPERATURE 105 106 Control ok RESISTANCE 1 14k OHMS Check water temperature estimate expected sensor resistance from chart below RESISTANCE OHMS SHORT CIRCUIT Check system for shorted wires or open circuits Replace sensor if necessary MEASURED AND ESTIMATED RESISTANC
17. 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 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 The gas pressure regulator is present and sealed at 4 W C for natural gas and 11 W C for propane gas Between the gas valve and the burners is a 1 8 pipe plug The pressure at this point taken with a manometer should be about 3 7 W C natural gas and 10 5 W C propane gas If an adjustment is needed remove seal and turn adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure 14 Manometer Gas Pressure Test Upstream Manual Shut Off Valve Gas Valve Gas Pressure Test at Gas Valve Gas Pressure Test at Heater Fig 8149 0 ROBERTSHAW VALVE W C adjustment HONEYWELL VALVE W C adjustment Fig 8081 0 PIPE SIZING FOR GAS CONNECTIONS MAXIMUM EQUIVALENT PIPE LENGTH Natural Gas 1000BTU FT 60 Specific Gravity 0 5 WC Pressure Drop Propane Gas 2500BTU FT 1 53 Specific Gravity 0 5 WC Pressure Drop 1 2 3 4 MODEL P 155B 15 35 60 145 PLUMBING FOR WATER CONNECTIONS LOCATION The VERSA heater requires water flow and posi tive pressur
18. OR BL IGNITION MV 1 BK MV 2 pv 3 GND 4 24V GND 24 6 SPK 9 HI LIMIT HI LIMIT PRESS THERMAL SWITCH FUSE PILOT VALVE HIGH TENSION l ALTERNATE SOLID STATE THERMOSTAT BK POTENTIOMETER POT BK MANUAL SWITCH BK TEMP SENSOR SEN 1 BK TEMP SENSOR Y IGNITION 24V BL TRANSFORMER BR BK HIGH LIMIT N O 20 SECTION 4 SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS VIEW OF HEATER FROM FRONT VIEW OF HEATER FROM BACK HIGH LIMITS SOLID STATE THERMOSTAT CONTROL UNITHERM IGNITION CONTROL GOVERNOR PRESSURE SWITCH DRAIN VALVE GAS VALVE PILOT THERMAL FUSE Fig 8110 1 CONTROL PANEL REMOVAL CONTROLS ADJUSTMENTS REPLACEMENTS 1 Remove lower door TEMPERATURE CONTROLS Remove 2 screws from bottom flange of The pool or spa water temperature is controlled by control panel the pool heater thermostat on the upper front panel of 3 Slide down control panel to clear jacket top the heater The control center contains an On Off panel toggle switch a thermostat The switch functions 4 Rotate control panel down until panel stops Do as a means for turning the heater on or off pus phate tod The thermostat is fitted with a means of limiting the 2 NOTO damage upper temperature limit below the maximum level The 9 knob stop adjustment ring illustrated below is adjust able by loosening the set screw rotating the knobstop Jacket Top Pane
19. PA 70 BASE INSTALLATION Heater must be mounted on a level base such as cement slab cement blocks or another non combus tible surface An optional non combustible base is avail able for all models An alternate method for providing a base for combustible floors is illustrated Heaters may not be installed on carpeting ALTERNATE METHOD FORPROVIDING A NON COMBUSTIBLEBASE 12 Minimum 12 Minimum Fig 8148 1 Sheet Metal 24 Gauge Hollow concrete cinder block align holes and leave ends open CLEARANCES 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 heavy internal rusting or damage some electrical components and this would void the warranty ALL HEATERS For clearances from combustible surfaces see the following chart CLEARANCES FROM COMBUSTIBLE CONSTRUCTION INDOOR INSTALLATION OUTDOOR INSTALLATION Top Drafthood 42 Right Side 6 Top Stackless Top or Outdoor Stack Unobstructed Vent 6 Left Side 12 Back 12 Back 12 Front Alcove Sides 6 Clearance from Top of Vent Terminal For servicing provide at least 24 in front of the heater for burner tray removal and at least 18 on the back of the heater to inspect and delime the heat exchanger OUTDOORHEATERS These heaters are design certified for outdoor installation when equippe
20. Refer to installation instructions Inspect bypass for movement if no movement replace Replace if no movement when heated Usually occurs on initial start up 26 Leaking at well Replace well and maintain water chemistry properly Leaking at heat exchanger Replace heat exchanger maintain chemistry properly Gasket brittle and leaking Heater running after pump overheated Shuts erence See pressure switch adjustment Refractory Replace refractory Sooted Determine cause of sooting and correct ELECTRICAL MILLIVOLT RAYPAK POOL OR SPA HEATER ELECTRICAL CHECK WITH MV GAS VALVE CAUTION For qualified service personnel only Filter must be on with adequate water flow through heater Gas valve must be ON position Thermostat set higher than pool water temperature Jumpers are for temporary check only If left in place they could cause the heater to burn up Light pilot If pilot burner goes out If pilot burner when main burner lights does not light or when gas valve knob Jump across both TH is released Check gas supply gas wires on gas valves line size gas pressure Also check for insects If main burner fires If main burner does not or debris in pilot output remove jumper fire remove jumper Jump across press
21. able codes The boiler top and draft hood must be readily removeable 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 10 OR LESS e gy CAP 1 E i VENT PIPE DRAFT HOOD HEATER Fig 8119 0 GAS SUPPLY CONNECTIONS Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve lo cated outside the heater jacket All gas piping should be tested after installation in accordance with local codes Manual Shut off Heater Jacket Valve a Gas Inlet Valve Sediment Trap Fig 8090 0 CAUTION The heater and its manual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1 2 psig 3 45 KPA Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut off valve to gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVER PRESSURED GAS VALVES ARE NOT COVERED BY WARRANTY The heater and its gas connections shall be leak tested before placing the appliance in operation Use soapy water for leak test Do NOT use open flame
22. both tube sheets leaving studs in the tube sheets Then proceed to collapse studs in the tube sheets with a chisel or screwdriver Use caution not to cut into the tube sheet Replacement tubes will have the fins stripped off longer on one end The long end is inserted into the opening of the tube sheet first then the short endis fitted through the opposite tube sheet If the tube ends become dented or bent straighten at least 4 inches back from the tube end by means of a tapered punch Insert tube roller into tube opening up to stop against tube then push center rod in until roller is tight Be careful to keep replacement tube squared up 1 8 outside each tube sheet A loose tube will sometimes pull toward the roller Attach drill motor to tube roller holding it straight and level Proceed to expand tube until the tool begins to grab At this point 1 2 to 1 should be exposed on the tool shank Reverse drill motor or wrench out by hand Care should be exercised to avoid applying excessive torque during rolling op eration and to avoid thinning out any part of the tube wall excessively over 015 Use same procedure at the opposite end of the tube Apply line pressure test and re roll if necessary before reassembly of the heater Extension Pieces 5 RAYPAK TUBE CLEANING KIT 1 3 I CS Auger with Carbide Tip DESOOTING PROCEDURE CAUTION SOOT 15 COMBUSTIBLE EXERCISE EXTREME CARE Soot
23. ctions MECHANICAL FOR QUALIFIED SERVICE PERSONNEL ONLY PROBLEM Harmonics or whining noise Heater going on and off continously Liming or scale forming on Sooting Pilot outage Yellow lazy flame Outer jacket very hot paint blistered Takes long time to heat pool or spa Liming CAUSE U G Debris or restriction in system Debris in gas line Low flow iie Dirty filter Low water level in pool External bypass setting out of Pressure switch out of Pool heat exchanger High flow U G Inoperative Air Improper venting Insects or debris clogging burner intake ports Low gas Restricted pilot Weak pilot generator Low gas Insects or debris clogging burner intake ports Broken refractory caused by shipping damage or improper Excessive sooting of heat
24. d with the approved tops designated for outdoor use HEATER WITH OUTDOOR STACKLESS TOP Fig 8116 WARNING Do not install within 3 feet of a Heat Pump or an outdoor condensing unit Strong air intake from this equipment can disturb the combustion process and cause damage or personal injury 10 Heaters must not be installed under an overhang of less than three 3 feet from the top of 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 The point from where the flue products exit the heater must be a minimum of four 4 feet below four 4 feet horizontally from or one 1 foot above any door window or gravity inlet to a 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 4 foot Minimum 4 foot Minimum f 1 foot Minimum 4 foot Minimum 1 3 foot Minimum 10 foot d Forced Air Inlet Fig 8245 1 HIGH WIND CONDITIONS OUTDOOR UNITS ONLY In areas where high winds are frequent it may be necessary to locate the heater a minimum of 3 from high vertical walls or install a wind break so the heater is not in direct w
25. e control system and any gas control which has been underwater LIGHTING INSTRUCTIONS 1 STOP Read the safety information above 2 Set the thermostat on the lowest setting 3 Turn On Off switch to the Off position 4 Remove heater door panel 5 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 Wait 5 minutes to clear out any gas If you then smell gas STOP Follow in the safety information above If you don t smell Robertshaw Pilot Fig 8045 1 8 Turn knob on gas control counter clockwise Honeywell Pilot Fig 8083 0 gas go to the next step Locate pilot mounted on the right side panel of the burner drawer For burner drawer location see location of control section page 22 9 to Pilot Push in control knob all the way and hold it in Immediately place flame to end of pilot tube to light pilot Continue to hold control knob in for about 1 minute after the pilot is lighted release knob and it will pop back up Pilot should remain lighted If it goes out repeat steps 5 through 9 If knob does not pop up when released stop and immediately call your service technician or gas supplier If the pilot does not stay lit after several tries turn the gas control knob to Off and call your service technician or gas supplier Stand to the side of the heater and turn the gas c
26. e latest edition National Fuel Gas Code ANSIZ 223 1 As muchas possible avoid long horizontal runs of vent pipe and too many elbows If installation requires horizontal non vertical runs the vent pipe must have a minimum of 1 4 inch per foot rise and should be supported at not less than five foot intervals Plumbers tape criss crossed will serve to space both horizontal and vertical piping Gas vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads We recommend use of insulated vent pipe spacer through the roofs and walls For protection against rain or blockage by snow the vent pipe must terminate with a vent cap which com plies with the local codes or in the absence of such codes latest edition of the National Fuel Gas Code ANSI 2223 1 The discharge opening must be 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 minimum clearance of 4 feet horizontally from and in no case above or below unless a four foot horizontal distance is maintained from electric meters gas me ters regulators and relief equipment The weight of the vent stack or chimney must not rest on boiler draft hood Support must be provided in compliance with applic
27. e mineral content and dissolved solids in the water become too high scale forms inside the heat exchanger tubes reducing heater efficiency and also damaging the heater If the pH drops below 7 2 the heater will be severely dam aged This will result in corrosion of the heat ex changer Heat exchanger damage resulting from chemicalimbalance is not covered by the warranty AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS All chemicals must be introduced and completely diluted into the pool or spa water before being circu lated through the heater Do not place chlorine tablets or bromine sticks in the skimmer High chemical concentrations will result when the pump is not running i e overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical back up into the heater when the pump is shut off NOTE High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid corrosion to the heat exchanger in the heaters Such damage is not covered under the warranty COLD WEATHER OPERATION MODERATE CLIMATE Heater operation can con tinue during shortterm cold spells When temperatures are below freezing flow continuous pump operation must be maintained CAUTION Do not use the heater to maintain water temperatures just above freezing or for freeze protec tion When heaters are used during freezing weather care must be taken to avoid freeze
28. e to fire and operate properly It must therefore be installed downstream of the discharge side of the filter 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 2 The outlet side of the filter is then plumbed to the inlet of the heater and 3 The outlet of the heater is plumbed to the return line to the pool or spa The pump filter and heater are thus plumbed in series Plumbing from the heater back to the pool must not have any valves or restriction that could prevent flow when the pump is operating To do so will void the warranty Heater must be located so that any water leaks will not damage the structure of adjacent area High temperature 2 plastic pipe CPVC may be threaded directly into the header flanges This is not the same as the Schedule 80 PVC pipe which is also colored gray PVC may be used immediately after the CPVC adapt ers 2 CPVC Adapters Fig 8192 1 INLET OUTLET HEADER CAUTION NEVER install PVC directly into header flanges Use the 2 CPVC adapter supplied loose with the heater FLOW RATES MINGPM 20 MAX GPM 115 When flow rates exceed 115 GPM an external auxil iary bypass valve is required See external auxiliary bypass valve section for details COMPANION FLANGE CONNECTIONS DO NOT use petroleum base assembly fluids such as Petroleum Jelly orlubricating oil If assemb
29. esistance is Reconnect all leads and check out system 0 100 ohms at minimum setting 9k to 11k at maximum setting replace circuit board Above 11k ohms replace potentiometer 0 ohms short circuit replace potentiometer MEASURED AND ESTIMATED RESISTANCE DON T MATCH Replace sensor Reconnect all leads and check out system SENSOR RESISTANCE AT VARIOUS TEMPERATURES Temperature deg F 61 68 70 77 86 88 95 104 106 Resistance k ohms 14 92 12 49 11 88 10 00 8 06 7 69 6 53 5 33 5 10 29 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 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 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 31111 Agoura Road Westlake Village CA 91361 4699 30 HEADER DETAIL FIG 240626 HONEYWELL MILLIVOLT PILOT FIG 8107 FIG 8124 FIG 8123 FIG 8122 31 Bronze _ DESCRIPTION BRONZE IRON BURNER TRAY Burner
30. g each opening shall have a minimum of 38 net free square inches VENTING CONNECTIONS Top Vent Opening VENT TERMINAL Outdoor STACKLESS TOP STEP 1 Remove the front 4 screws which fasten jacket top to heater STEP 2 Line up top vent opening over heater vent opening STEP 3 Lower outdoor top onto unit lining up slots in outdoor top with screw holes in jacket top STEP 4 Reinstall 6 screws to secure jacket top HEATER VENT OPENING and outdoor top to unit JACKET TOP Fig 9306 12 VENT TERMINAL Outdoor OUTDOOR STACK STEP 1 Line up 8 holes in jacket top with 8 holes in adapter assembly STEP 2 Lower entire outdoor stack assembly on to jacket top STEP3 Secure with fasteners provided OUTDOOR STACK MOUNTING WITH ADAPTER SCREWS 8 JACKET TOP Fig 9307 VENT TERMINAL Indoor Locate and assemble as shown Secure with screws supplied in envelope inside carton DRAFT HOOD MOUNTING SCREWS 8 Fig 9308 VENT PIPING WARNING ndoor 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 or larger than 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 specified in Chapter 10 of th
31. hanger 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 inhibited de scale solvent Fig 8128 0 TUBE REPLACEMENT PROCEDURE On Raypak units tube replacement may be ef fected without rolling as a temporary means of repair providing there are two or more tubes rolled in to act as stays on the left or right sides The O rings should provide a seal up to 125 PSI working pressure Use 3 8 heavy duty reversible drill motor or larger to power the tube roller If a reversible drill is not available after rolling the tube in remove the drill motor and wrench out the roller A tube roller is available from the factory Shut gas and power offto the unit close the system off and drain the heater Remove the draft diverter Remove the access panel and jacket top Lift the flue collector off Remove V baffles over tube s to be replaced If no pipe unions have been provided use the header as a union remove the flange nuts off the inlet outlet header break gas connection and slide heater away from piping to allow room to work Pull wedge clips out of control wells and remove sensing bulbs Lift heat exchanger straight up and out Inspect header gaskets at this time Unless sev ered they are reusable The tube may be cut out with a hacksaw or hammer and chiseled adjacent to
32. ht up using caution not to damage refractory 7 Reverse above procedure to reinstall CONTROL IMMERSION WELL REPLACEMENT 1 Shut water off to heater and drain heat exchanger 2 Remove jacket top panel 3 Remove old control well with bushing and sleeve with 7 8 wrench or socket 4 Slip ring gasket over control well and install in header O RING GASKET WELL ASSEMBLY Fig 8101 0 UNITHERM GOVERNOR U G REPLACEMENT 1 Shutwater gas and electricity off close valves and relieve pressure 2 Drain heat exchanger 3 Remove retainer plug located under outlet pipe connection 4 Remove spring and replace old U G with a new U G 5 Reverse above procedure to re install GASKET RETAINER PLUG SPRING Flig 8071 0 To test the operation of the Unitherm Governor place in hot water over 110 F and watch for move ment against spring If there is no movement replace unit TUBE CLEANING PROCEDURE Typical Establish a regular inspection schedule frequency depending on local water condition and severity of service Do notletthe tubes clog up solidly Clean out deposits over 1 16 in thickness The heater must be cleaned from the rear as shown It is preferable however to remove the heat exchanger and the in out header for better visibility through the tubes and to be sure the ground up lime dust does not get into the system Note that you do not remove the top panel or the heat exc
33. ignated repair center which may be the dealer bring or ship transportation prepaid the defective part for replacement or repair to the designated repair center However Raypak reserves the right at all times to inspect the claimed defect and verify warranty coverage at its factory MISCELLANEOUS No one is authorized to make any other warranties on our behalf ANY IMPLIED WARRANTIES INCLUDING MERCHANT ABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS SPECIFIED ABOVE RAYPAK S SOLE LIABILITY WITH RESPECT TO ANY DEFECT SHALL BE AS SETFORTH IN THIS WARRANTY AND ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING DAMAGE FROM WATER LEAKAGE ARE EXCLUDED Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential damages so the above limitation or exclusion may not apply to you We suggest you immediately complete the information below and retain this Warranty Certificate in the event warranty service is needed Reasonable proof of the effective date ofthe warranty must be presented otherwise the effective date will be based upon the date of manufacture plus THIRTY 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 Name of Dealer Address Address Model No Serial No Date of Purchase RAYPAK INC 2151 Eastman Avenue Oxnard 93
34. ind current In areas of daily high winds it may be necessary to replace the outdoor stackless top with a stack adapter in combination with a wind resistant weather proof outdoor stack See illustration below The outdoor stack serves the same function as the low profile stackless top and should be installed in accordance with the same clearance requirements OUTDOOR STACK STACK ADAPTER Fig 9304 11 INDOOR HEATERS The design is also certified for indoor installation when equipped with the approved draft hood 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 allowable space is shown on the nameplate INDOOR DRAFT HOOD Fig 9305 COMBUSTION AIR INDOOR UNITS ONLY AIR FOR COMBUSTION AND VENTILATION Indoor Units Only The heater must have both combustion and ventilation 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 Z 223 1 1988 and any local codes that may have jurisdiction CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty a All Air From Inside the Building Each opening shall have a minimum of 151 net free square inches b All Air From Outdoors When air is supplied directly from outside of buildin
35. irst three months of pregnancy resulting in the birth of a brain damaged or deformed child Pregnant women should stick to the 100 F 38 C maximum rule 4 Before entering the spa or hot tub users should check the water temperature with an accurate thermometer spa or hot tub thermostats may err in regulating water temperatures by as much as 4 F 2 2 5 Persons with a medical history of heart disease circulatory problems diabetes or blood pressure problems should obtain a physician s advice before using pools or hot tubs 6 Persons taking medications which induce drowsiness such as tranquilizers antihista mines or anticoagulants should not use spas or hot tubs SECTION 3 MAINTENANCE AND CARE PROCEDURES To be followed one month after start up and then semi annually 1 Inspect top of heater and draft hood for soot a sticky black substance around finned tubes and V baffles and open flue gas passageways CAUTION Soot may be combustible Wet sooted surfaces completely prior to cleaning Do not use steel wire brush 2 Clean main burners and pilot burner of dust and lint 3 Inspect and operate all controls gas valve and pressure relief valve 4 Make a visual check of the burner and pilot flame Flame pattern on the main burner and pilot is indicated in the previous illustration Yellow flame means restriction of the air openings Lifting or blowing flame indicates high gas pressure Low fla
36. l ring to the desired location and retightening the set screw Typical z Typical Comfortable pa Pool Temperature Temperature R ange Range iy oo 1 Mounting Screws 2 Knobstop Ring Set Screw Fig 8104 0 Fig 8267 0 21 PRESSURE SWITCH The pressure switch or heater actuator insures that the heater operates only when the filter pump is in operation It is factory set at 1 75 PSI for deck level installations When the heater is located below the level ofthe spa or pool it may be necessary to reset the pressure switch to compensate for the no flow static head If itis necessary to reset the pressure switch we recommend the following procedure PRESSURE SWITCH ADJUSTMENT 1 With pump and heater on turn adjustment knob clockwise until a click is heard from the gas valve 2 Turn adjustment knob counter clockwise 1 4 turn 3 Turn pump off and on several times Heater should shut off immediately If it does not repeat steps above until proper adjustment is made Adjustment Knob Fig 8069 1 PRESSURE SWITCH ADJUSTMENT RANGE Heat Exchanger Height 5 Max Pool or Spa Es Heat Exchanger Height Fig 8152 0 NOTE fheaterisinstalled outside ofthe limits shown a flow switch must be used in place of the pressure switch when mounted and wired adjacent to the heater 22 TWO SPEED PUMPS In some cases the flow on the low speed is insuf ficientto operate the heater This is ap
37. led with water and bustibles flammable liquids and chemicals Do not have pump operating obstruct the flow of combustion and ventilating air Fig 8111 0 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 This appliance has a pilot that must be lighted by hand When lighting the pilot follow these instructions exactly 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 do not try to repair it Call qualified service technician Force or attempted repair may result in a fire or explosion 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 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 suppliers in structions Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to re place any part of th
38. ly lubrication is required use a silicone base such as Amoral etc Theinlet outlet single headerflanges are designed for four type of water connections There are two sets of flange gaskets supplied with your header one set installed between flanges and in out header and the other set shipped loose in the unit Use the appropriate gasket design for all your heater connections GASKET DESIGN 1 Factory installed Accepts 1 1 2 copper tube or 1 1 4 galvanized pipe as a slip connections GASKET DESIGN 2 Loose In a bag 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 G 0 Fig 8095 1 Fig 8097 1 INLET OUTLET HEADER FLANGE GASKET HEADER FLANGE Fig 8093 1 15 UNITHERM GOVERNOR OPERATION The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105 115 F de spite continually changing flow rates from the filter and changing pool temperatures This narrow range is needed to prevent damaging condensation on the burn ers which will occur if the heater runs for any length of time below 100 F It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures INTERNAL AUTOMATIC BY PASS VALVE In addition to the Unitherm Governor a built in automatic by pass val
39. me means low gas pressure Should this occur shut the heater off and contact your gas supplier or qualified service agency 5 Onindoor heaters clean room intake open ings to assure adequate flow of combustion and ventilation air CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty 6 Keep area around heater clear and free from combustible materials gasoline and other flammable and corrosive vapors and liquids BASIC TIPS IF HEATER WILL NOT FIRE 1 If you have no electrical power it may be your circuit breakers have tripped Try re setting them 2 lf you have electrical power but the heater will not fire check the following 3 The time clock must be moved to the ON position 4 Your pump strainer basket may be full If so remove debris 5 Your filter may be dirty If so backwash or clean filter To tell if your filter is dirty the gauge pressure will be higher than usual 6 The pump may have lost it S prime It may be running dry check the pressure gauge on the filter If there is no pressure then you are not moving water or your gauge is broken Try to get the pump to run at it s normal flow rate POOL amp SPA WATER CHEMISTRY Chemical imbalance can cause severe damage to your heater and associated equipment Maintain your water pH between 7 4 and 7 8 and total alkalinity between 100 and 150 p p m If th
40. ment 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 explosion Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater m OPERATING INSTRUCTIONS STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Remove heater door panel For Honeywell valve Push in gas control knob slightly and turn clockwise to Off Knob cannot be turned to Off unless it is pushed in slightly Do not force For Robertshaw valve Push in and move gas control lever counter clockwise to OFF position 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 Turn gas control knob counter clockwise to On Honeywell Move gas control lever clockwise to ON position Robertshaw Replace heater door panel GAS CONTROL KNOBS SHOWN IN ON POSITION Honeywell Gas Valve IID
41. ontrol knob counter clockwise to On 11 Replace heater door panel 12 Turn On Off switch to the On position Fig 8079 0 13 Set thermostat to the desired setting TO TURN OFF GAS TO APPLIANCE memm 1 Setthe thermostat to the lowest setting 4 Push the gas control knob slightly and turn 2 Turn On Off switch to the Off position clockwise to Off Do not force 3 Remove heater door panel 5 Replace heater door panel GAS CONTROL KNOBS SHOWN IN OFF POSITION Robertshaw Gas Valve Millivolt Honeywell Gas Valve Millivolt Fig 8081 0 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 IGNITION SYSTEMS This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell all around the appli ance 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 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 If you cannot reach your gas supplier call the fire depart
42. parent when the pressure switch cannot be further adjusted or if the heater makes banging noises In these cases the pump must be run at high speed when heating the water CAUTION Do not operate the heater without the function of a properly adjusted pressure switch HIGH LIMITS The heater is equipped with two automatic high limits Set to operate at 135 F and 140 F NOTE Anerratic high limit is often characteristic of an internal heat exchanger problem i e scale buildup U G operation Refer to troubleshooting section E E Fig 8153 0 HIGH LIMIT REMOVAL 1 Shut off main electrical power switch to heater 2 Remove inspection panels 3 Drain heater 4 Remove defective high limit and replace with a new high limit 5 Reverse above procedure to re install FLAME ROLL OUT SAFETY SWITCH The heater is equipped with a thermal cutoff device to prevent flame roll out in the event the heat ex changer becomes blocked This is a Single use type fusible link or thermal fuse that must be replaced when disabled by an over temperature condition caused by excessive restriction in the heat exchanger flue pas sage Fig 9177 PILOT SAFETY Millivolt System The heaters equipped with the standing pilot millivolt system have pilot generators which act as a safety device to shut off the flow of gas to the main burners and the pilot burner in case the pilot flame is extinguished The pilot burne
43. r must be manually re lighted to place the heater in operation again Refer to the lighting instructions provided on the heater label PILOT SAFETY IID Units ELECTRIC IGNITION The heater employs a pilot safety which closes the main gas valve within 8 1 0ths of a second whenever the pilot flame is interrupted Pilot flame is automatically lit when the device is powered Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit BURNER DRAWER REMOVAL Shut off main electrical power switch to heater Shut off gas upstream of heater Remove front door Disconnect gas line from gas valve Remove 2 screws that mount burner tray to unit and 2 screws that secure gas valve to jacket Disconnect wires that terminate at gas valve Slide out burner tray Reverse above procedure to reinstall GAS VALVE REMOVAL 1 Shut off gas supply to the heater Remove gas piping to gas valve inlet 2 Disconnect wires pilot tubing and bleed line if required 3 Turn vertical gas pipe from manifold slightly and unscrew gas valve 4 Reverse above procedure to re install MAIN BURNER AND ORIFICE REMOVAL 1 Remove burner drawer See burner drawer removal procedure 2 Remove screws and burner hold down bracket NOTE f the heat exchanger is sooted badly the burner hold down bracket and spacer can become distorted from direct flame impingement and this usu ally necessitate
44. riginal 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 WARRANTY EXCLUSION This warranty does not cover defects or malfunctions resulting from Failure to properly install operate or maintain the heater in accordance with our printed instructions Abuse alteration accident fire flood freeze and the like 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 outletand 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 Useofnon factory authorized accessories or other components in conjunction with the heater HOW TO MAKE A CLAIM Immediately notify the dealer from whom the heater was purchased supplying model and serial numbers of the unit date of purchase and a description of the problem The dealer should then promptly contact Raypak about the warranty claim and forthe location of Raypak s nearest designated repair center Ifthe dealer for any reason is not available call or write Raypak directly at the address shown below Attention Warranty Service After such notification has been given and Raypak has advised the location of its des
45. rior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components MILLIVOLT SYSTEM The Millivolt System Residential Heater is equip ped with a self generating electrical system in which the electric current is provided by means of a pilot generator No external electrical connections are re quired ELECTRONIC INTERMITTENT IGNITION DEVICE SYSTEM IID NOTE When the electrical hookup to the heater requires both 24V and 115V or 240V each input voltage must be isolated in separate conduit The Electronic Intermittent Ignition Device automati cally lights the pilot and main burners upon a call for heat The heater is supplied with a dual voltage trans former for 120V or 240V input power hookup Heaters are factory wired for 240V power supply 17 HONEYWELL INTERMITTENT IGNITION DEVICE Fig 8929 1 For 120 V input power to the unit connect the black wire to the L1 or hot leg of the power supply Connect the WIRING DIAGRAM KEY 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 y 120 V ad wind 24 V 105 h attached 24 150 A
46. s replacement of these parts 23 Lift burners from slotted spacers and slide from orifices Clean with a wire brush Orifices usually do not need to be replaced To clean run either copper wire or wood toothpick through orifice Do not enlarge hole To remove orifice use a socket wrench and remove from manifold DO NOT overtighten when reinstalling Burner Hold Down Bracket Burners Fig 8057 0 PILOT REMOVAL AND CLEANING Disconnect pilot tubing and wires from gas valve Remove pilot assembly from burner tray Remove pilot from bracket Remove pilot orifice and air opening Honeywell MV unit only and clean with wire or small brush CAUTION Do not enlarge hole in pilot orifice Reverse above procedure to reinstall PONS Pilot Pilot Air Opening Orifice A Orifice HONEWELL PILOT Fig 8045 1 ROBERTSHAW PILOT Fig 8102 0 HEAT EXCHANGER REMOVAL 1 Shut water gas and electricity off close valves and relieve pressure remove relief valve Re move side inspection panels 2 Remove top holding screws 3 Remove draft diverter lift and remove top and flue collector on stack type models Remove inspec tion panels 4 Loosen bolts and disconnect flange nuts on inlet outlet header loosen union s at gas pipe and slide boiler away from piping until studs clear the header 5 Remove combustion chamber clips at the four corners of the heat exchanger 6 Lift heat exchanger straig
47. ure Switch terminals If pilot burner stays on If burner does not remain lit attach millivolt meter If main burner fires If main burner does not and read pilot output remove jumper fire remove jumper Problem is a wire or 2 Fabove500nV Clean filter Jump across thermostat pressure replace gas valve Check for adequate water flow from filter If pilot burner remains lit Remove both TH wires from gas valve Relight pilot If below 500mV check gas pressure Also check for insects or debris in the pilot burner Replace pressure switch If output is still low If main burner fires If main burner does replace pilot generator NOT fire remove jumper Replace thermostat Jump across each high limit and remove jumper Replace high limit that caused heater to fire WARNING HIGH VOLTAGE For qualified Technicians ONLY NOTE Some heaters may be equipped with Intermittent Pilot System d ignition module that shuts off pilot gas if TROUBLESHOOTING HONEYWELL 58600 fails to light To reset interrupt power to A START NOTE Before troubleshooting familiarize yourself with the start up and checkout TURN GAS SUPPLY OFF TURN THERMOSTAT CONTROLLER TO CALL SS ELECTRICAL ELECTRONIC IGNITION IID 3 SNL SSSSSSSS SSSSSSSSSSSS Check line voltage power low voltage transformer limit controller thermostat FOR HE
48. ure relief valve having a capacity equalto BTU HR output of the heater to be installed is recommended for this appliance 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 PRESSURE RELIEF INLET OUTLET HEADER Fig 8095 0 NOTE To avoid water damage or scalding due to valve operation drain pipe must be connected to valve outlet and run to a safe place of discharge Drain pipe must be the same size as the valve discharge connection throughout its entire length and must pitch downward from the valve No shut off 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 waterways are clear ELECTRICAL WIRING NOTE f it is necessary to replace any of the original wiring it must be replaced with 105 C wire or its equivalent except all black wire must be replaced with 150 C wire or its equivalent NOTE IID PROPANE UNITS ONLY Heater is equipped with an electronic ignition device with 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 CAUTION f service replacement of the electronic ignition device is required replace only with a 100 safety lockout device with 90 second trial for pilot ignition CAUTION Label all wires p
49. ve 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 Fig 8078 0 EXTERNAL AUXILIARY BYPASS VALVE where required An auxiliary bypass valve should be used when flow rates exceed 115 GPM usually a high performance pump size larger than 2 HP 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 etcetera 16 From Heater To Heater To Pool m From Pool Auxiliary Bypass Valve do not use gate valve Fig 8150 0 AUXILIARY BYPASS VALVE ADJUSTMENT Tosetbypass With clean filter adjustmentis made by feeling the inlet and outlet pipes atthe heater Outlet pipes should be slightly warmer than inlet and comfort able to the touch If pipe is hot close bypass if cold open bypass PRESSURE RELIEF VALVE INSTALLATION To conform to local building codes it may be necessary to install a pressure relief valve A 3 4 press
50. when signing for equipment Remove the heater from the carton and if it is damaged report the damage to the carrier immediately On occasion we ship some items loose 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 the 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 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 Theheaterisinterchangeable and can be used either indoor or outdoors The appropriate top designated for that type of use is required If desired the top can be changed ata later date to change from outdoor to indoor or vice versa Millivolt heaters contain a self 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 Heater 32 F to 175 F Requires 120V or 240V Power Supply Rated inputs suitable for
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