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INSTALLATION AND OPERATING INSTRUCTIONS Part No. 240612
CATALOG NO. 6000.52-AL
Effective:
07-01-04
Replaces: 05-01-04
INSTALLATION
AND OPERATING
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 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.
Fig.# 9478
RP2100
SWIMMING POOL
and
SPA HEATER
Atmospheric Models
P-R185B to P-R405B
C-R185B to C-R405B
Low NOx Models
P-R185BL to P-R405BL
C-R185BL to C-R405BL
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 PROCEDURES
8
Pool & Spa Water Chemistry
8
Cold Weather Operation
9
Winterizing the Pool & Spa Heater
10
PART TWO
INSTALLATION & SERVICE INSTRUCTIONS
10
SECTION 1
RECEIVING EQUIPMENT
10
SECTION 2
GENERAL SPECIFICATIONS
11
SECTION 3
INSTALLATION INSTRUCTIONS
11
Code Requirements
11
Clearances
12
Outdoor Heater Installation
12
Indoor Heater Installation
16
Specifications and Dimensions
16
Combustion Air
17
Vent Piping
17
Gas Supply Connections
19
Plumbing For Water Connections
23
Heat Exchanger Reversal Procedure
24
Electrical Wiring
25
Transformer Wiring
26
Wiring Diagram-Millivolt (Mechanical Therm.)
27
Wiring Diagram-IID (Atmospheric)
28
Wiring Diagram-IID (Low NOx)
29
SECTION 4
SERVICING INSTRUCTIONS
29
General Location of Controls
29
Millivolt Controls
30
Digital Thermostat Controls
31
Digital Diagnostics and Codes
32
Remote Control and Operation Installation
34
Pressure Switch
34
Flame Roll-Out Safety Switch
34
High Limit
34
Pilot Safety
35
Burner Drawer Removal
35
Gas Valve Removal
35
Main Burner and Orifice Removal
35
Pilot Removal and Cleaning
35
Heat Exchanger Removal
36
Tube Cleaning Procedure
36
Desooting Procedure
36
Combustion Chamber Removal
36
Immersion Well Replacement
36
Unitherm Governor (U.G.) Replacement
37
Low NOx Pool Heaters
39
SECTION 5
TROUBLE SHOOTING GUIDE
39
Mechanical
40
Electrical MV Units
41
Electrical IID Units
42
Digital Control Logic
43
SECTION 6
REPLACEMENT PARTS
44
Illustrated Parts List
46
Part Numbers 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 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 factory set from 65°F (18°C) to 104°F (40°C). The heater is also equipped with a
toggle switch to turn the heater on and off, see fig. # 9472 above for location. Section 4 of this manual contains more
details about the use of the controls in the Controls Adjustments subsection (page 29).
WATER
Water must be flowing through the heater during opera-
tion. Insure that system is filled with water and have pump
operating.
Fig.# 9472
ON
OFF
Fig.# 9478
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. 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 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
under water. 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 under water.
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
5
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.
Push in and move gas control lever counter-
clockwise
to "Off" position.
5. Replace heat