Raypak RP2100 manual

Part No. 240612 CATALOG NO. 6000.52-AK Effective: 05-01-04 Replaces: 03-15-04 INST ALLA TION AND OPERA TING INSTRUCTIONS This manual should be maintained in legible condition and kept adjacent to the heater or kept in a safe place for future reference. WARNING: If the information in these instructions is not followed exactly, a fire or explosion ma[...]

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CONTENTS 3 4 PART ONE OWNER'S OPERATING INSTRUCTIONS 4 SECTION 1 START-UP PROCEDURES 4 Before Start-Up 5 Lighting Instructions & Shut-Off Procedures- Manually Lighted Pilots MV 6 Operating Instruction & Shut-Off Procedures- Automatically Lighted Pilots IID 7 After Start-Up 7 SECTION 2 CAUTION 7 SECTION 3 MAINTENANCE & CARE PROCEDUR[...]

4 BEFORE START-UP BURNERS Clean main burners, combustion fan and air louvers of dust, lint and debris. Keep heater area clear and free from combustibles, flammable liquids and chemicals. Do not obstruct the flow of combustion and ventilating air. RP2100 DIGITAL IID POLYMER SECTION 1 - START-UP PROCEDURES Your Raypak Pool/Spa heater has been designe[...]

4. Push the gas control knob slightly and turn clockwise to "Off". Do not force. 5. Replace heater door panel. 1. Set the thermostat to the lowest setting. 2. Turn On/Off switch to the "Off" position. 3. Remove heater door panel. TO TURN OFF GAS TO APPLIANCE A. This appliance has a pilot that must be lit by hand. When lighting t[...]

A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B. BEFORE OPERATING, 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: *Do not try to light a[...]

AFTER START-UP Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot. 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. 4" MAX Fig. # 8205.2 MAIN BURNER FLAME Fig. # 8964.1 PILOT [...]

4. Make visual check of the burner and pilot flame. Flame pattern on the main burner and pilot is indi- cated in the previous illustration. Yellow flame means restriction of the air openings. Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure. Should the latter occur, shut the heater off and contact your gas supp[...]

WINTERIZING THE POOL & SPA HEATER Heaters installed outdoors in freezing climate areas are subject to be shut down for the winter. Observe the following procedure for winterizing the heater: 1. Turn off gas valve, manual gas valve, and electrical supply to the heater. 2. Open drain plug located on the inlet/outlet header, (under water pipes). R[...]

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 when signing for equipment. Remove the heater from the carton and if it is damaged, report the damage to the carrier immediately. Save the carto[...]

12" Minimu m 12" M inimum 4" Minimum HEA TER Sheet Metal 24 Gauge 11 IMPORTANT NOTICE These instructions are intended for the use of qualified personnel only, 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 [...]

Heaters must not be installed under an overhang of less than three (3) feet from the top of the heater. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters. For U.S. installations ,the point from where the flue products exit the hea[...]

INDOOR HEATER INSTALLATION The design is also certified for indoor installation when equipped with the approved draft hood. For Canada , indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with occupied area. Refer to the latest edition of CAN/CGA-B149.1 and B149.2 for specific requirements. Loca[...]

14 SECURING THE TOP PANEL COVER INDOOR KIT ONLY 7. Reinstall the louvered top. 8. Mount the draft hood onto the adapter plate lip inside the heater. See Fig. 6. 9. Proceed to installing the clips, step 14. SECURING THE TOP PANEL COVER OUTDOOR KIT ONLY 10 . After removing the drafthood from the box, slide the top panel cover over the draft hood. 11 [...]

15 INSTALLING THE TOP COVER OUTDOOR KIT ONLY 22 . Remove the two pieces of metal tape holding the top panel cover up and discard. 23 . Insert the rear two tabs into the slots on the heater top and slide the top panel cover backwards. See Fig.13. 24 . Lower the top panel cover and using your thumbs, push tabs in and insert the two front tabs into th[...]

16 SPECIFICATIONS AND DIMENSIONS *Electrical Connection On Left Side is 19-1/8". a. All Air From Inside The Building: Each opening shall have a minimum net free square inches as noted: Model Square Inches Model Square Inches 185 1 8 1 335 333 265 2 6 4 405 399 b. All Air From Outdoors: When air is supplied directly from outside of building, ea[...]

VENT PIPING Vent piping the same size as the draft hood outlet is recommended, however, when the total vent height is at least ten (10) feet (draft hood relief opening to vent terminal), the vent pipe size may be reduced as speci- fied in Chapter 10 of the National Fuel Gas Code, ANSI Z 223.1 (Canada-CAN/CGA-B149.1 and B149.2). As much as possible [...]

Fig. # 8149 NOTE: Do not use Teflon tape on gas line pipe thread. A flexible sealant is recommended. A minimum of 7" W.C. and a maximum of 14" W.C. upstream pressure under load, and no load 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 pr[...]

19 High temperature CPVC Header Flanges and header Flange Nuts are provided. If there is any possibility of back- siphoning when the pump stops, it is suggested that a check valve (or valves) also be installed in the system. INLET/OUTLET HEADER (Polymer) POLYMER HEADERS (STANDARD MODELS) Before attaching the 2-inch unions to the inlet/outlet header[...]

20 CAST IRON HEADRERS (ASME MODELS) 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 adap[...]

21 PRESSURE RELIEF VALVE INSTALLATION To conform to local building codes, it may be necessary to install a pressure relief valve. A 3/4" pressure relief valve having a capacity equal to BTU/HR output of the model to be installed is recommended for this heater. The maximum acceptable pressure relief valve setting is 125 psi. A 3/4" NPT con[...]

22 HEAT EXCHANGER PRESSURE DROP TABLES[...]

23 1. Remove right and left side access panels (Figure 1). 2. Disconnect wires at high limit, AGS (automatic gas shutoff), and pressure switch on the inlet/outlet header (Figure 2). 3. Electronic Ignition Heaters: Remove the thermo- stat temperature sensor by loosening the compres- sion fitting nut (Figure 3). Reroute the sensor to the left side of[...]

24 Option Location For Left Side Field Wiring Sway Brace Bonding Lug (Standard Location) Bonding Lug (Optional Location) Fig. # 9470 Control Box (Factory Mounted Location) LOW NOx Wiring locations ATMOSPHERIC Wiring locations Fig.# 9366.1 ELECTRICAL WIRING NOTE : If it is necessary to replace any of the original wiring, it must be replaced with 105[...]

25 NOTE: Input power to the heater (120/240V) can be supplied from the load (pump) side of time clock or directly from the switch/GFCI power source. It is preferred to make connection to the load/pump side of the time clock. When using the switched GFCI power source the heater could display false service indicators on the delay panel if the pump is[...]

26 WIRING DIAGRAM - MILLIVOLT (MECHANICAL THERMOSTAT)[...]

WIRING DIAGRAM - IID (Atmospheric) 27[...]

WIRING DIAGRAM - IID (Low NOx) 28[...]

Control Panel Mounting Screws (4) Fig. #RP 8267 CONTROL ADJUSTMENTS MILLIVOLT CONTROLS The pool or spa water temperature is controlled by the pool heater thermostat on the upper front panel of the heater. The control center contains an On/Off switch and one or two thermostats. Thermostats are fitted with a means of limiting the upper temperature li[...]

30 PROGRAM MODE BUTTON Notice to owner- Thermostat operation Y our heater is equipped with a microprocessor controlled thermostat that controls the pool or sp a temperature by measuring the temperature of the water coming back through the heater . It will then monitor the water temperature and turn the heater back on when it senses that the water t[...]

31 DIAGNOSTICS The RP2100 Digital heater is equipped with on-board diagnostic controls. If there is a safety fault, a fault code will be displayed along with a service indication. NOTE: The digital temperature display may not coincide with the temperature reading of your pool or spa thermometer . The RP2100 reads the water temperature at the inlet [...]

32 REMOTE CONTROL INST ALLA TION AND OPERA TION CAUTION: Before installing remote controls to the RP2100 Digit al Heater , read the following: The Raypak RP 2100 Digital Heater 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 touc[...]

33 REMOTE CONTROL WIRING Important Installation Notes for Remote or External Wiring Configuration • Remote wiring must be run in 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.[...]

FLAME ROLL-OUT SAFETY SWITCH Atmospheric heaters are equipped with a thermal cutoff device to prevent flame roll-out in the event the heat exchanger 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 ex[...]

PILOT REMOVAL AND CLEANING 1. Disconnect pilot tubing and wires from gas valve. 2. Remove pilot assembly from burner tray. 3. Remove pilot from bracket. 4. 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. 5. Reverse above procedure to reinstall. HONEYWE[...]

TUBE CLEANING PROCEDURE Establish a regular inspection schedule, frequency de- pending on local water condition and severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness. The heater may be cleaned from the return header side, without breaking pipe connections. It is preferable, however, to remove[...]

The Raypak Low NOx Pool Heaters are certified and tested under the ANSI Z21.56.CSA 4.7 standards for gas-fired pool heaters. The heater should be installed to meet all local codes, the latest editions of the National Fuel Gas Code Z223.1 and the National Electrical Code, ANSI/NFPA 70. OPERATION On call for heat, the ignition system, consisting of a[...]

38 BURNER DRA WER REMOV AL 1. Shut off main electrical power switch to heater . 2. Shut off gas up stream of heater . 3. Remove front door . 4. Disconnect gas line from gas valve. 5. Remove (2) screws that mount burner tray to the base of the unit, and (2) screws that secure gas valve to jacket. 6. Disconnect wires that terminate at gas valve. 7. U[...]

MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY) IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Pe[...]

If pilot burner remains lit. Jump across pressure switch terminals If main burner does not fire, remove jumper Check for adequate water flow from filter Replace pressure switch Jump across thermostat If main burner fires, remove jumper If main burner does NOT fire... Jump across each high limit and remove jumper Replace thermostat Replace high limi[...]

NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout procedure. Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Pull ignition lead and check spark at PC board. Spark Okay? YES • Check ignition cable, ground wiring, ceramic insulator and gap, and correct. • Che[...]

42 DIGITAL CONTROL LOGIC - FLOW CHART[...]

NOTE: To supply you with the correct part it is impor- tant that you supply the model number, serial number and type of gas when applicable. Any part returned for replacement under standard com- pany warranties must be properly tagged with a Raypak return parts tag, completely filled in with the heater serial number, model number, etc., and shipped[...]

44 ILLUSTRATED PARTS LIST[...]

45 Fig. #8124 Honeywell MV Fig. #8107 Fig. #9369 6-P 3-P 9-P 8-P 1-P 5-P 2-P LOW NOx BURNER TRAY PILOT ASSEMBLIES 7-P 9-P 2-P 4-P 9-P 7-P 10-P Honeywell IID Atmospheric units for units produced prior to 06/01/2000 Honeywell IID Low NOx and Atmospheric units for units produced after to 06/01/2000 Use KIT Number 008155F for Low NOx units Use KIT Numb[...]

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Raypak, Inc. , 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (800) 872-9725 Raypak Canada LTD , 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A. www .rayp ak.com[...]