Instruction/ maintenance manual of the product RP2100 Raypak
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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.
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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 In.
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.
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.
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.
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. 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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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 .
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 .
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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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.
An important point after buying a device Raypak RP2100 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Raypak RP2100 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Raypak RP2100 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Raypak RP2100 you will learn all the available features of the product, as well as information on its operation. The information that you get Raypak RP2100 will certainly help you make a decision on the purchase.
If you already are a holder of Raypak RP2100, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Raypak RP2100.
However, one of the most important roles played by the user manual is to help in solving problems with Raypak RP2100. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Raypak RP2100 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
