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Raypak RP2100 P-R405A User Manual

Raypak RP2100 P-R405A
43 pages
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Part No. 240612
CATALOG NO. 6000.52-Z
Effective: 11-01-01
Replaces: 08-01-01
®
INSTALLATION
AND OPERATING
INSTRUCTIONS
Models
P-R185A to P-R405A
C-R185A to P-R405A
Low NOx
P-R185AL to P-R405AL
C-R185AL to C-R405AL
RP2100
SWIMMING POOL
and
SPA HEATER
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 are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
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.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
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Do you have a question about the Raypak RP2100 P-R405A and is the answer not in the manual?

Raypak RP2100 P-R405A Specifications

General IconGeneral
ModelRP2100 P-R405A
CategorySwimming Pool Heater
Fuel TypeNatural Gas or Propane
IgnitionElectronic
Control TypeDigital
Efficiency82%
Voltage120V
Warranty5 years
Heat ExchangerCopper

Summary

Installation and Operating Instructions Overview

Critical Safety Warnings

Crucial safety warnings about fire, explosion, and gas leaks.

Model Identification

Lists the various heater models covered by this manual.

Service Personnel Requirements

Specifies that installation and service require qualified personnel.

RP2100 Heater Design Overview

PVC Piping Arrangement

Discusses the new PVC union adapter for piping connections on the RP2100.

Owner's Operating Instructions

Pre-Operation Safety Checklist

Emphasizes reading safety information before operating the heater.

Heater Start-Up Overview

Introduces the general start-up process for the heater.

Burner Area Preparation

Instructions for cleaning burners and ensuring a clear operating area.

Water Flow Requirement

Ensures water is flowing through the heater before operation.

Millivolt Pilot Lighting and Shut-Off

Propane Gas Safety Precautions

Caution regarding propane gas handling and potential hazards.

Manually Lighted Pilot Instructions

Step-by-step guide for lighting the pilot manually on millivolt systems.

Appliance Shut-Off Procedure

Steps to safely turn off the gas supply to the appliance.

Electronic Ignition Pilot Lighting and Shut-Off

Automatic Pilot Ignition Procedure

Instructions for heaters with automatic pilot ignition systems.

Electronic Ignition Shut-Off

Steps to safely turn off the gas supply for electronic ignition systems.

Post Start-Up Checks and Cautions

Visual Flame Inspection Guide

How to check burner and pilot flame appearance for correct operation.

Water Pressure Switch Safety

Importance of the water pressure switch for heater safety.

Spa and Hot Tub Water Safety

Safety guidelines for user health and well-being in spas and hot tubs.

Maintenance and Environmental Guidelines

Chemical Feeder Installation Best Practices

Guidelines for installing chemical feeders and chlorinators correctly.

Cold Weather Operation Protocols

Procedures for operating the heater safely in cold conditions.

Water Chemistry Maintenance

Importance of proper water chemistry for heater longevity and efficiency.

Installation Preparation and Specifications

Pool Heater Winterizing Procedure

Step-by-step guide for shutting down the heater for winter.

Equipment Receiving and Inspection

Instructions for checking heater components upon arrival.

Heater General Specifications

Technical specifications and ratings of the heater.

Installation Requirements and Clearances

Qualified Installer and Code Compliance

Requirements for qualified installers and adherence to local codes.

Base Installation Guidelines

Guidelines for mounting the heater on a suitable and level base.

Required Installation Clearances

Specifies necessary clearances from combustible surfaces for safety.

Outdoor Heater Venting Specifications

Outdoor Stackless Top Installation

Instructions for installing the outdoor stackless vent top assembly.

Vent Terminal Clearance Requirements

Specifies required clearances for vent terminals in US and Canada.

Indoor Heater Venting Installation

Indoor Installation Certification

Notes certification for indoor installation when using a draft hood.

Indoor Stack Installation Guide

Detailed steps for assembling and installing the indoor vent stack.

Heater Specifications and Airflow

Model Specifications and Dimensions

Table detailing BTU, dimensions, and shipping weights for various models.

Combustion Air Requirements

Specifies minimum air openings needed for combustion and ventilation.

Vent Piping and Gas Supply Connections

Vent Piping Installation Guidelines

Recommendations for vent pipe sizing, runs, and support.

Gas Supply Connection Requirements

Instructions for safely connecting the gas supply line to the heater.

Gas Pressure and Water Plumbing

Gas Pressure Regulator Adjustment

Details on gas pressure settings, testing, and adjustments.

Gas Pipe Sizing Chart

Table for selecting correct gas pipe size based on equivalent length and gas type.

Water Plumbing Connection Guide

Instructions for connecting water lines to the heater inlet and outlet.

Water Flow Management and Bypass Valves

Water Flow Restrictions and Additions

Notes on avoiding restrictions and connecting additional heated water sources.

Internal Automatic Bypass Valve Function

Explanation of how the built-in bypass valve regulates water flow.

Flow Rates and External Bypass Valve Use

Required flow rates and when to use an external bypass valve.

Unitherm Governor Operation Explained

Description of the Unitherm Governor's role in temperature regulation.

Pressure Relief Valve Installation

Pressure Relief Valve Requirements

Details on installing a pressure relief valve and its safety function.

Heat Exchanger Reversal Procedure

Step-by-Step Heat Exchanger Reversal

Detailed instructions for reversing the heat exchanger for Capron header models.

Electrical Wiring and Connections

Wiring Replacement Guidelines

Guidelines for replacing existing heater wiring with correct types.

Millivolt System Electrical Setup

Description of the millivolt system's self-generating electrical setup.

Electronic Ignition Field Wiring

Notes on field wiring connections for electronic ignition heaters.

Wiring Diagrams Explained

Wiring Diagram Color Key

Explains the color coding and symbols used in wiring diagrams.

Millivolt Unit Wiring Diagram

Provides the specific wiring diagram for millivolt units.

Electronic Ignition Wiring Diagrams

IID Atmospheric Unit Wiring Diagram

Wiring diagram for IID atmospheric units.

Low NOx Electronic Ignition Wiring Diagrams

IID Low NOx Unit Wiring Diagram

Wiring diagram for IID Low NOx units.

Control Panel and Millivolt Controls

General Location of Controls

Identifies the location of various control components on the heater.

Control Panel Removal Procedure

Steps for safely removing the heater's control panel.

Millivolt Control Operation and Adjustment

Details on operating and adjusting millivolt thermostats.

Electronic Control System Operation

Digital Control Panel Features

Explains the function of the digital control panel and its modes.

Setting Maximum Temperature Limits

How to adjust maximum temperature limits for pool and spa modes.

Temperature Display Unit Conversion

Instructions for switching between Fahrenheit and Centigrade displays.

Remote Control System Installation

Remote Wiring Configuration Notes

General notes for remote wiring installations, including conduit and cable type.

Two-Wire Remote System Installation

Installation guide for two-wire remote control systems.

Three-Wire Remote System Installation

Installation guide for three-wire remote control systems.

Safety Systems and Controls

Pressure Switch Adjustment Procedure

Procedure for adjusting the pressure switch for proper operation.

Flame Roll-Out Safety Switch Function

Explanation and function of the flame roll-out safety switch.

High Limit Switch Operation and Removal

Information on high limit switches, their settings, and replacement.

Pilot Safety Device Operation

How pilot safety features work in millivolt and electronic ignition systems.

Component Removal and Cleaning Procedures

Burner Drawer Removal Steps

Steps to remove the burner drawer for servicing or inspection.

Gas Valve Removal Procedure

Procedure for safely removing and replacing the gas valve.

Main Burner and Orifice Servicing

How to remove main burners and clean or replace orifices.

Pilot Assembly Removal and Cleaning

Steps for removing and cleaning the pilot assembly.

Heater Cleaning and Component Replacement

Heat Exchanger Tube Cleaning

Method for cleaning the heat exchanger tubes to maintain efficiency.

Desooting the Heater Components

Steps for removing soot from the heater to prevent damage.

Immersion Well & Unitherm Governor Replacement

Procedures for replacing the control immersion well and Unitherm Governor.

Low NOx Heater Operation and Start-Up

Low NOx Heater System Overview

General information and certification for Low NOx heaters.

Low NOx Burner Inspection and Adjustment

Notes on burner visual inspection and adjustment for Low NOx models.

Low NOx Heater Start-Up Sequence

Specific start-up steps for Low NOx heater ignition systems.

Low NOx Component Servicing Procedures

Low NOx Burner Tray and Gas Valve Servicing

Procedures for removing burner tray and gas valve on Low NOx units.

Low NOx Pilot and Fan Component Removal

Steps for removing pilot assembly and combustion fan on Low NOx units.

Troubleshooting Guide: Mechanical Issues

Noise, Flow, and Cycling Problems

Troubleshooting for humming, whining, and intermittent heater operation.

Sooting, Pilot, and Flame Issues

Solutions for sooting, lazy flames, pilot outages, and burner issues.

Heating, Leak, and Gasket Problems

Troubleshooting for slow heating, leaks, and brittle gasket issues.

Millivolt Electrical System Troubleshooting

Millivolt Electrical Check Flowchart

A flowchart for diagnosing electrical issues in millivolt systems.

Electronic Ignition Electrical Troubleshooting

Honeywell S8600 Troubleshooting Guide

Flowchart for troubleshooting Honeywell S8600 intermittent pilot ignition systems.

Diagnostic Readouts and Fault Code Interpretation

Understanding Diagnostic Readouts

Explains how to interpret various diagnostic codes displayed on the unit.

Troubleshooting Specific Fault Codes

Details on common fault codes (SNS, PRS, HL1, etc.) and their solutions.

Replacement Parts Information

How to Order Replacement Parts

Guidelines for specifying model, serial, and gas type when ordering parts.

Low NOx Burner Tray and Pilot Assemblies

Low NOx Burner Tray Exploded View

Exploded view diagram of the Low NOx burner tray assembly.

Pilot Assembly Identification Diagrams

Diagrams identifying different pilot assemblies used in the heaters.

Replacement Parts List - Components

Burner Tray, Controls, and Gas Valve Parts

Part numbers for burner trays, controls, and gas valves.

Heat Exchanger and Bypass Valve Parts

Part numbers for heat exchanger components and bypass valves.

Replacement Parts List - Components (Continued)

Heat Exchanger and Control Box Parts

Part numbers for metal heat exchangers and control box components.

Pilot Assembly and Ignition Component Parts

Part numbers for pilot assemblies, generators, and ignition wires.

Replacement Parts List - Components (Continued)

Refractory, Sheet Metal, and Venting Parts

Part numbers for refractory, sheet metal, and venting components.

Gas Conversion Kit Part Numbers

Part numbers for various gas conversion kits.

Limited Warranty Information

General Warranty Terms and Conditions

Outlines the basic warranty coverage, duration, and conditions.

Warranty Exclusions and Claim Process

Details warranty exclusions and the process for making a claim.

Owner's Warranty Registration Details

Section for recording owner, dealer, model, and serial numbers.

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