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INSTALLATION AND OPERATING INSTRUCTIONS Part No. 240612
CATALOG NO. 6000.52-AG
Effective:
09-01-03
Replaces: 06-15-03
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. CONTENTS
2
3
PART ONE
OWNER'S OPERATING INSTRUCTIONS
3
SECTION 1
START-UP PROCEDURES
3
Before Start-Up
4
Lighting Instructions & Shut-Off Procedure
(Manually Lighted Pilot MV)
5
Operating Instruction & Shut-Off Procedures
(Automatically Lighted Pilot IID)
6
After Start-Up
6
SECTION 2
CAUTION
6
SECTION 3
MAINTENANCE & CARE PROCEDURE
7
Pool & Spa Water Chemistry
7
Cold Weather Operation
8
Winterizing the Pool & Spa Heater
8
PART TWO
INSTALLATION/SERVICE INSTRUCTIONS
8
SECTION 1
RECEIVING EQUIPMENT
8
SECTION 2
GENERAL SPECIFICATIONS
9
SECTION 3
INSTALLATION INSTRUCTIONS
11
Indoor Heater
14
Combustion Air
15
Vent Piping
15
Gas Supply Connections
16
Plumbing For Water Connections
19
RP2100 Heat Exchanger Reversal Procedure
21
Electrical Wiring
22
Wiring Diagram-Millivolt
23
Wiring Diagram-Electronic Ignition
24
Wiring Diagram- Low NOx
25
SECTION 4
SERVICING INSTRUCTIONS
25
General Location of Controls
25
Control Adjustments/Replacements
26
Electronic Controls
27
Remote Control Installation
29
Pressure Switch Adjustment
29
Flame Roll-Out Safety Switch
29
High Limit Removal
29
Pilot Safety Millivolt and IID
30
Burner Drawer Removal
30
Gas Valve Removal
30
Main Burner and Orifice Removal
30
Pilot Removal and Cleaning
30
Heat Exchanger Removal
31
Tube Cleaning Procedure
31
Desooting Procedure
31
Control Immersion Well replacement
31
Unitherm Governor (U.G.) Replacement
32
Low Nox Addenda
34
SECTION 5
TROUBLE SHOOTING GUIDE
34
Mechanical
35
Electrical MV Units
36
Electrical IID Units
37
Digital Diagnostics
38
SECTION 6
REPLACEMENT PARTS
39
IPL Drawing
41
Part Numbers
45
Warranty 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
Your Raypak Pool/Spa heater has been designed for years of safe and reliable pool/spa water heating. It is
available in millivolt or electronic control options. ASME certified units, typical used in commercial applications,
are also available. This manual provides operation, installation, maintenance, and service information for these
heaters.
If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the
heater contains the control center that allows you to turn the heater on or off and adjust the temperature settings
for the pool or spa. The temperature range is 65°F (18°C) to 104°F (40°C). The heater with the electronic control
option also has a manual switch located on the right cabinet side to allow you to turn the heater off. Section 4
contains more details about the use of the controls in the Controls Adjustments/Replacements sub-section.
BEFORE START-UP
BURNERS
3
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.
WATER
Water must be flowing through the heater during
operation. Insure that system is filled with water and have
pump operating.
RP2100 DIGITAL IID CAPRON
RP2100 DIGITAL IID ASME 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 lighted
by hand. When lighting the pilot, follow these
instructions exactly.
B.
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:
*Do 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 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 a qualified service technician. Force or
attempted repair may result in a fire or explo-
sion.
D.
Do not use this appliance if any part has been
underwater. Immediately call a qualified serv-
ice technician to inspect the appliance and to
replace any part of the control system and any
gas control which has been underwater.
LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES
MANUALLY LIGHTED PILOTS

MILLIVOLT SYSTEM
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.
6.
Wait 5 minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go
to the next step.
7.
Locate pilot mounted on the right side panel of
the burner drawer. For burner drawer location,
see location of control section, page 20.
HONEYWELL PILOT
ROBERTSHAW PILOT
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.
8. Turn knob on gas control counter-clockwise
to "Pilot"
9. Place flame to end of pilot tube. Push in
control knob all the way and hold to light pilot.
Continue to hold control knob in for about one
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.
10. Stand to the side of the heater and turn the gas
control knob counter clockwise to "On".
11. Replace heater door panel.
12. Turn On/Off switch to the "On" position.
13. Set thermostat to the desired setting.
Fig. # 8083.0
Fig. # 8084.1
GAS CONTROL KNOB SHOWN IN OFF POSITION
HONEYWELL
GAS VALVE
MILLIVOLT

ROBERTSHAW
GAS VALVE
MILLIVOLT
Fig. # 8081.0
Fig. # 8079.0
4
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 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.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
AUTOMATICALLY LIGHTED PILOTS

ELECTRONIC IGNITIONS SYSTEMS
to "Off". Make sure knob rest against stop.
For Robertshaw 7200 gas valve