Raypak Pool & Spa Gas Heaters
Residential & Premium Range
Installation and Operating Instructions
Natural Gas
Residential Models:
Premium Models:
Part No: 96131430
Models
Propane
P0131NCO/OD
P0200-N
P0280-N
P0350-N
P0430-N
P0131PCO/OD
P0200-P
P0280-P
P0350-P
P0430-P
P0127NNO
P0167NNO
PC0280-N
PC0430-N
P0127PNO
P0167PNO
PC0280-P
PC0430-P
1
Rev: 3
Please read this manual prior to installing this product. It contains all the necessary technical and installation
information that will be required by the contractor to correctly install this system. This product must be installed to the
Rheem installation instructions, AS5601, AS3500.4 and the relevant electrical authorities’ requirements.
Part No: 96131430
2
Rev: 3
TABLE OF CONTENTS
SAFETY ..........................................................................................................................................4 WATER TREATMENT ....................................................................................................................4 INSTALLATION INSTRUCTIONS...................................................................................................5 SAFETY PRECAUTIONS ...............................................................................................................9 COMMISSIONING .........................................................................................................................10 RESET BUTTON ...........................................................................................................................11 OPERATING INSTRUCTIONS......................................................................................................13 PROGRAMMING OF HEATER CONTROLLER ...........................................................................15 ELECTRICAL CONNECTIONS.....................................................................................................17 DIMENSIONAL DATA ...................................................................................................................20 WIRING DIAGRAMS .....................................................................................................................22 POOL HEATER OPERATION FLOW CHART..............................................................................28 WARRANTY (AUSTRALIA ONLY) ...............................................................................................30 SERVICE .......................................................................................................................................31 Date of installation:
Model No.
Serial No.
Installed by:
Purchased from:
This Installation and Operating Instructions manual is provided with the necessary information for the proper
installation, operation and maintenance of your Raypak Heater. Please review and follow these procedures carefully.
Keep this manual in a safe and accessible place for easy reference in the future.
Part No: 96131430
3
Rev: 3
SAFETY
WARNING!
For your safety do not operate this appliance before reading this instruction booklet! Improper installation, adjustment, alteration,
service or maintenance can cause injury or property damage.
DO NOT place articles on or against this appliance.
DO NOT use or store flammable materials near this appliance.
DO NOT spray aerosols in the vicinity of this appliance while it is in operation.
DO NOT operate this appliance with any panels, covers or guards removed.
DO NOT enclose this appliance unless it has been constructed for such an installation.
DO NOT operate this appliance whilst cleaning your pool.
DO NOT use this appliance to heat water for drinking.
DO NOT enter water heated by this appliance without testing temperature first. Prolonged exposure to elevated water
temperatures may be hazardous to your health.
WHAT TO DO IF YOU SMELL GAS!
¾
¾
¾
DO NOT try to light this appliance.
DO NOT touch any electrical switch.
TURN OFF the gas supply at the meter immediately, contact a licensed gas fitter or Rheem Service. N.B: Some gases
are heavier than air and it may be necessary to check for gas leaks at floor level.
Ceramic Firetile refractory is used in this appliance. For a current MSDS go to www.thermalceramics.com and enter “MSDS 354” in
the search. Ceramic Firetile refractory may produce smoke when the appliance is first started. Ensure area is well ventilated when
lighting appliance. Avoid breathing fumes.
For your own safety only have this appliance installed by a licensed gas fitter who must issue you with a compliance certificate
when complete. Persons taking medications which induce drowsiness should not use spas. Persons with a medical history of heart
disease circulatory or blood pressure problems, or diabetes should obtain their Doctor’s advice prior to using a spa.
WATER TREATMENT
IMPORTANT!
CORROSIVE WATER VOIDS YOUR WARRANTY.
For your health and the protection of your heater it is essential that your water quality is always chemically balanced. Only incorrect
water balance will cause your heat exchanger to corrode. After corrosion occurs, subsequent water chemical tests may not reveal
the water quality at the time that the damage occurred. Do not replace any corroded parts before bringing your water quality back
into balance. The following table provides a guide to good water balance:
pH
Total Alkalinity (PPM)
Calcium Hardness (PPM)
Salt (PPM)
Free Chlorine (PPM)*
Langelier Saturation Index
Fibreglass Pools
(less than 31C)
7.3 - 7.4
120 - 150
200 - 300
6,000 MAX
2-3
-0.3 to +0.3
Fibreglass Spas
(more than 31C)
7.3 - 7.4
120 - 150
200 - 300
6,000 MAX
2-3
-0.3 to +0.3
Other Pools &
Spas
7.6 - 7.8
80 - 120
200 - 400
6,000 MAX
2-3
-0.3 to +0.3
* FREE CHLORINE MUST NOT EXCEED 4 PPM
* FREE BROMINE MUST NOT EXCEED 5 PPM
There are several factors that need to be considered in order to avoid damage to your heater.
•
Automatic chemical dosing devices and chlorinators are usually more efficient in heated water and/or covered pools/spas.
Unless controlled, they may lead to excessive chlorine levels which can damage your heater.
•
If the sanitising level in your pool/spa is too high, your test kit or that of your pool shop may not show the correct
chlorine/bromine concentration.
•
If your salt chlorinator operates for extended periods whilst the pool is being heated and the weather is overcast or your
pool is enclosed / covered, the chlorine may exceed the recommended levels.
•
The balance of your pool water depends on a combination of pH, total alkalinity, calcium hardness and temperature.
Combined, these factors enable the Langelier Saturation Index to be calculated. It is essential these factors are
maintained at the recommended levels so that the water is balanced and the sanitation of your pool will be optimal.
•
When adding acid to lower your pH, it must always be added in small quantities and spread uniformly over the entire pool
surface. Do not add acid one litre at a time. Instead, add a cupful each day. Do not add acid into the skimmer box. This
may potentially lead to corrosion of your heat exchanger.
•
Note: You should monitor your chlorine and pH levels at least once a week or every day if your pool is in high use. Total
Alkalinity and Calcium hardness levels can be monitored less frequently. Do not operate heater if water balance is outside
the above parameters.
Part No: 96131430
4
Rev: 3
INSTALLATION INSTRUCTIONS
ATTENTION! This appliance must be installed in accordance with all local state and federal laws including the regulations of any
government bodies and in complete accordance with these instructions. Where these instructions are contrary to the law or
regulations of an appropriate government body those laws or regulations should take precedence subject to there being no
compromise to safety.
BEFORE YOU COMMENCE INSTALLATION
1.
Read these instructions in full.
2.
Check that the heater you have been supplied is suitable for the gas type that is available.
3.
Ensure that your gas fitter checks that the gas supply pressure is between the minimum and maximum specified on the heater
data plate.
4.
Confirm that the heater you have purchased is suitable for the location it is to be installed, i.e. Outdoor or Indoor.
5.
Check that your pool system pump will provide water flow between the specified minimum and maximum flow rates required
for the heater to operate.
6.
Remove packaging and timber base before installation.
7.
Complete all details on the back page of this book.
BEFORE INSTALLATION
RESIDENTIAL OR COMMERCIAL!
Raypak “Residential” heaters are designed and built for installation in applications where the intention of its use is to heat a pool of
a single family dwelling. Residential heaters are not intended for installation in commercial applications such as multi residential
apartments. For these applications a Raypak “Commercial” (also referred to as “Premium”) heater should be selected.
See WARRANTY section in this book for details of the different warranties dependent on the heater type and its intended
application.
HEATER LOCATION
The heater must be located so that any possible water leaks will not damage adjacent areas or structures. When such locations
cannot be avoided it is recommended that a suitable drain pan be constructed and installed by your plumber. This must not restrict
air required for combustion.
The heater must be located on a level non-combustible surface such as concrete. All packaging must be removed before
installation.
OUTDOOR HEATERS
Raypak heaters are built as standard for outdoor installations. Their installation must conform to AS5601 as a minimum. They must
not be installed in any enclosed structure or under eaves, roof overhangs, or pool decks. Outdoor heaters must be installed at least
1500mm from any window or room ventilation opening. They must also have no obstructions above the appliance.
If installing the heater on a raised base, this base must be non-combustible and contain no air openings or perforations. Drafts
from below the heater can affect its operation.
High Wind Areas
Raypak gas heaters are atmospherically vented and so may not function correctly in areas of sudden changing air pressure often
caused by high or variable wind speeds. In some instances, it may be necessary to install either a Raypak High Wind Top or a
Raypak Induced Draft Fan to ensure correct operation. These options should be discussed with Raypak before installation.
INDOOR HEATERS
Combustion / Ventilation Air
Indoor heaters must only be installed in a protective enclosure or properly constructed room, with ventilation in accordance with
AS5601. Ventilation must be provided via two permanent openings, one at ceiling level and one at floor level. Minimum vent area
2
must be at least 630cm unless otherwise stated in AS5601. Minimum opening dimensions in the vent must be at least 6mm.
In indoor applications the heater must have at least the minimum clearances specified in the table below. Increased clearances
should be provided where possible to improve serviceability. Servicing may not always be possible where the minimum clearances
are observed therefore good installation practices should determine what reasonable clearances are required for each installation
location.
Part No: 96131430
5
Rev: 3
The following table details minimum acceptable clearances (mm) for indoor installations on non-combustible floors only:
Models 127, 200, 280, 350, 430
Rear
150
500
Front Water Non-Water Above
Side
Side
Non-Combustible Surfaces
750
600
150
1200
Combustible Surfaces
750
600
500
1200
Models 167
Rear
300
500
Front
Left
Right Above
Non-Combustible Surfaces
750
300
300
1200
Combustible Surfaces
750
500
500
1200
N.B: For outdoor clearances refer to AS5601
Air supply to the room must not be affected by mechanical exhausts of other equipment such as bathroom or kitchen fans, spa
blowers or air-conditioning equipment, etc.
FLUEING
Flueing must be in accordance with AS5601. Only the correctly-sized Raypak draft
diverter must be fixed to the heater and connected to a properly constructed flue,
vented to atmosphere using approved fittings, and cowl. Alteration to the Raypak
draft hood or reduction in cross section of connected flueing will void warranty.
AGA Approved Cowl
Dist. above
roof as stated
in AS5601
Where standard flueing options cannot be implemented Raypak should be contacted
for flueing advice.
Additional ductwork connected to the Raypak draft hood must be self supporting and
allow the removal of the Raypak heater and draft hood without removal of the flue.
The flue system beyond the Raypak draft hood must in no circumstances be
supported by the heater.
Where practical, the flue should be run vertically. Lateral flueing is allowed but must
rise a minimum of 20mm per 1m of lateral run and the total lateral run must not
exceed 50% of the total flue height.
Self supporting flue
Min. Flue
Length 3m
Raypak Draft Hood
Indoor Hood Conversion
To convert Model 200 to 430 heaters from outdoor configuration to indoor:
1. Remove all screws from the appliance top panel and discard sheet metal.
2.
Fit the indoor flue “stack adaptor” supplied with the indoor conversion kit to the
flue collector and screw in position.
3.
Fit the “draft diverter” over the indoor flue “stack adaptor” spigot.
4.
Ensure that all connections are secure and will not allow products of combustion to escape into the room.
Heater
To convert Model 127 & 167 heaters from outdoor configuration to indoor:
1. Remove all 4 screws on the supports for the appliance’s top hood and discard hood.
2.
Fit the indoor “draft diverter” to the flue collector and screw in position.
3.
Ensure that all connections are secure and will not allow products of combustion to escape into the room.
Part No: 96131430
6
Rev: 3
GAS SUPPLY
The gas supply pipe and gas meter must be sized so that both are capable of providing sufficient gas for all gas appliances on the
site to operate at the same time. Insufficient gas supply will cause the heater to operate below its designed performance or not at
all.
Correct pipe sizing for the gas fitting line should be obtained from AS5601. During commissioning of the heater the burner
pressure must be adjusted by the gas fitter to conform to the specifications provided on the Raypak Data plate - located inside the
heater. The heater and its gas line must be fully leak-tested prior to normal operation.
Note: It is more important than ever that when installing a new gas pool or spa heater, the commissioning must be carried out by a
licensed plumber. Gas supply companies are increasingly supplying natural gas to new installations with 2.75Kpa. This means if
the gas pressure is not adjusted to the correct working pressure (see data plate) the heater will be over gassed and cause serious
damage within minutes. This damage is not covered under the Warranty.
Caution! Excessive Gas Pressure will damage the gas valve and void warranty.
Part No: 96131430
7
Rev: 3
Part No: 96131430
8
Rev: 3
SAFETY PRECAUTIONS
Ceramic fire tile refractories are used in Raypak pool and spa heaters. Refractories must be treated with care
because they can be harmful by inhalation and irritating to the skin, eyes and respiratory system.
DURING FIRST FIRING OF THE WATER HEATER
•
Fumes and smoke may be produced.
•
Avoid breathing fumes and ventilate the area to clear.
•
Production of smoke should cease within 30 minutes.
WHEN HANDLING
•
Minimise airborne dust.
•
Wear an approved mask or respirator.
•
Avoid any contact with the skin and eyes.
•
Wear suitable loose-fitting, long-sleeved clothing or disposable overalls.
•
Wear gloves and eye protection.
•
Consult Occupational Health and Safety Authorities for any further information.
AFTER HANDLING
•
Rinse any exposed skin areas with clean water.
•
Wash work clothing separately.
REMOVAL OF USED PRODUCT
•
Follow the precautions as detailed in the section ‘WHEN HANDLING’ above, over-exposure to dust formed after
service may cause respiratory disease as cristobalite, a form of crystalline silica, may be formed above 900
degrees Celsius.
•
Seal used product in a disposable bag and dispose of via normal garbage collection methods.
Consult Occupational Health and Safety Authorities for further Information regarding removal of used
ceramic fibre lining.
Part No: 96131430
9
Rev: 3
CO
OMMISSIONING
C
COMMISSIO
ONING MUST
T ONLY BE UNDERTAK
KEN BY AN APPROPRIA
A
ATELY LICE
ENSED PERSON WHO IS
FAMILIAR WITH
W
SAFE
E COMMISSIONING PRO
OCEDURES..
Ceramic fire tile refra
actories are used
u
in Rayp
pak pool and
d spa heaterrs. Refractoriies must be treated with care
because
e they can be
e harmful by inhalation an
nd irritating to
o the skin, eyyes and resp
piratory syste
em.
Refe
er to “Safety Precautionss” on page 7 for the preca
autions to be
e taken when
n the water heater is first operated.
PRE-START CHECKS
•
Ensure all packaging ma
aterials have been removved from the pool/spa heater.
•
v
inspecction of the pool/spa
p
hea
ater and equ
uipment for any
a damage or installatio
on problems and
Conduct a visual
report as ne
ecessary.
•
Ensure thatt the pool/sp
pa heater is clean and the
t
surround
ding area is clear of all combustible
e and flamm
mable
materials.
•
or installation
n, check thatt combustion air openings
s are not obsstructed.
For an indoo
•
Test ALL ga
as connection
ns for leaks, using soapyy water. NOT
T A NAKED FLAME
F
•
Check that the correct power
p
supply is availablle and the circulation
c
pu
ump is suppllied from the
e same electtrical
e pool/spa he
eater.
circuit as the
•
Check that the
t ventilation to the unit complies witth the require
ements, of AS
A 5601 and local authority regulation
ns.
•
If mechanica
al ventilation or power flu
uing is provid
ded, check th
he operation of the fan(s) and interloc
cks.
•
Check that the
t flue comp
plies with the
e appropriate
e regulations and is fitted with an app
proved cowl.
•
Ensure that the main gas isolation va
alve is closed
d.
OPERATIONAL CHECKS (must be
b complete
ed by installler prior to le
eaving the s
site)
•
Turn on the pool/spa hea
ater, then co
onfirm start-up of the elec
ctronic contro
oller and “o” iindication in display.
•
mp and confirrm that “o” disappears fro
om display.
Turn on pum
•
Test the ope
eration of the
e pool/spa he
eater with no
o gas flow to confirm its operation up tto lockout sta
age, then turrn off
the power.
•
as isolation valve
v
and switch on powe
er to the pooll/spa heater.
Open the ga
•
With the ma
ain burner lit, check the in
nlet gas presssure.
•
Check the pool/spa
p
heatter gas train and compon
nents for gas leaks using soapy waterr. NOT A NA
AKED FLAME
•
Set the burn
ner gas presssure to that shown
s
on the
e rating labell.
•
Make a visu
ual check of the burnerss. The flame should be blue
b
with a well-defined
w
pattern. A yellow
y
or floa
ating
flame indica
ates restricted
d air opening
gs or incorrecct burner pre
essure setting
g.
•
Check that the
t flue on an
n indoor installation is dra
awing correc
ctly.
•
It is normal for the poo
ol/spa heaterr to produce some smok
ke and posssibly condenssation for the first thirty (30)
minutes of operation
o
from
m new (referr to “Safety Precautions”
P
on page 7).
W
WARNING:
Upon completion of the installation and commis
ssioning of th
he pool/spa heater, leav
ve this guide with
the householderr or a respon
nsible officer. DO NOT lea
ave this guid
de inside of th
he cover of the pool/spa heater, as it may
interrfere with the
e safe operattion of the po
ool/spa heate
er or ignite when
w
the poo
ol/spa heater is turned on
n.
Explain to the ho
ouseholder or
o a responsiible officer th
he functions and
a operatio
on of the pool/spa heater..
Part No: 96131430
0
10
Rev: 3
RESET BUTTON
Your Raypak pool or spa heater has been fitted with an additional safety feature and weather shielding.
The additional safety feature incorporates a red reset button located on either the front control panel or right hand side panel,
together with a power failure recovery circuit.
When power is first supplied to the heater, or restored after being interrupted or isolated, the red reset button will illuminate briefly
before the power failure recovery circuit operates. To operate the heater when power is first supplied or restored after being
interrupted or isolated:
1.
The red reset light should go out and the control panel should display “OFF”. If the light does not go out, the heater must
be serviced by a qualified service technician.
2.
Press and release the POWER button on the control panel. The control panel will display the current water temperature.
3.
If power is being supplied for the first time the internal time clock will need to be set. This may also apply if power has
been interrupted or isolated for some time and then restored. To reset the heater’s internal time clock follow the procedure
‘Setting Time & Day’ located on page 9 of the Installation and Operating Instructions.
4.
If power is being supplied for the first time any required auto mode time periods will need to be programmed. If power has
been interrupted or isolated and then restored, any auto mode time periods previously programmed may need to be
reprogrammed.
To program auto mode time periods follow the ‘Programming Mode’ procedure located on page 14 of the Installation and Operating
Instructions.
The heater can now be operated as normal.
If during operation the heater stops working and the red reset button illuminates, check the following:
1.
Ensure skimmer box is not jammed and that the filter is not blocked.
2.
Ensure all valves are in the correct position and that there is adequate water flow through the heater.
If these conditions are checked and found to be satisfactory and the red reset button cannot be reset and/or continues to be
illuminated; the heater must be attended by a qualified service technician. For service Ph 131031
WATER – PRESSURE, CONNECTIONS, & FLOW
Pressure Relief Valve
If the filtration system incorporates any valves or accessories that may isolate the heater from the pool or spa, a pressure relief
valve must be fitted to the heater. Specifications and installation advice relating to this valve can be obtained from Raypak.
Flow Switch
Note: If the installation is outside of our suggested limits as per the below diagram a flow switch kit
(Part/No: FS-Watts) will need to be fitted to the heater. Specifications and installation advice relating to the Flow Switch can
be obtained from Raypak.
MAXIMUM HEIGHT ABOVE OR BELOW WATER LEVEL
1500mm Max
1500mm Max
Pressure Switch Function
The heater is supplied standard with a Pressure Switch that when correctly adjusted will only allow the heater to operate when
there is sufficient water pressure. In every installation the Pressure Switch operation must be checked as part of the
commissioning process.
Caution! The Pressure Switch is only suitable as a means of ensuring adequate water pressure if the Inlet/Outlet piping of the
heater is less than 1500 mm above or below the water level of the pool. For installations which exceed this range a flow switch
must be installed. Specifications and installation advice relating to this switch can be obtained from Raypak.
Part No: 96131430
11
Rev: 3
Pressure Switch Adjustment
Models: 131, P0200- 430.
1. Remove the In/Out access cover (water connection side) to gain access to the pressure switch.
Models: 127, 167, PC0280, PC0430
1. Remove the Return access cover (opposite to water connection side) to gain access to the pressure switch.
2.
Check that all water valves are correctly positioned to enable normal water flow to the pool heater.
3.
Start the system pump and ensure that water is flowing through the heater.
4.
Turn the power on at the heater.
5.
Adjust the set point of the heater to 40ºC.
6.
If the heater lights the water pressure is within the pressure switch range and the pressure switch will not need to be adjusted.
7.
If the heater did not light after Step 6, turn the Pressure Switch knurled adjustment wheel located on the pressure switch,
8.
Turn off the pump and the heater should now go out. If the heater does not go out, the heater must be turned off immediately
clockwise until the heater ignites, then continue a further ¼ of a turn.
and Raypak should be contacted.
9.
The pump should be cycled on and off several times to ensure that the adjustment is correct.
Voiding Warranty as a result of Incorrect Chemical Dosing
All Raypak heaters must be installed after the pool/spa system pump and prior to any chemical dosing or chlorination system.
Chemical dosing or chlorination systems must be located as far from the heater as possible and a backflow prevention device must
be installed between the heater and such systems.
Ideally any chemical dosing system should also be installed below the water connection level of the heater.
Installation above this level may lead to chemical seepage back into the heater even with a backflow prevention device. This will
result in damage to the heat exchanger and will void warranty.
Caution! Chemicals that are allowed to enter the heater without having first passed through the pool or spa will damage the heat
exchanger of the heater and consequently will void warranty.
Never add chemicals to the skimmer box, leaf basket, or near the return line from the pool to the heater.
Water Connections
Raypak heaters with Polymer headers are designed for direct connection to PVC pipe. Use only Class 12 PVC fittings or better.
Raypak Premium heater models 127 and 167 with Bronze headers must be connected to PVC pipe. Use only Class 12 PVC
fittings or better.
Water Flow
Correct flow rate of water to the heater is critical for correct operation.
Raypak heaters are fitted with an internal by-pass to redirect excessive water flow however should the flow rate exceed that given
in the table below; an external PVC type by-pass valve must be fitted. Setting of the valve must be done at the time of
commissioning.
Caution! Sooting caused by incorrect setting of a by-pass valve or failure to fit a by-pass valve when required will void warranty.
The Raypak heater must be commissioned by the installer prior to normal operation or handover. Installation or connection of the
heater to the gas supply by unqualified trades’ persons will void warranty.
The installer must also supply the owner with a compliance certificate at the completion of commissioning.
Min/Max Flow Rates
Model
131
127
167
200
280
350
430
Part No: 96131430
Min. l/s
1.3
1.0
1.0
1.3
1.6
2.3
2.5
12
Max. l/s
6.9
3.7
3.9
6.9
6.9
6.9
6.9
Rev: 3
OPERATING INSTRUCTIONS
HEATER CONTROLLER LAYOUT
Note: The MODE button switches between Pool and Spa modes.
BEFORE OPERATING
1.
Ensure that the immediate area around the heater is clear of all combustible materials including chemicals and gases.
2.
Familiarise yourself with the hand operated gas isolation valve located outside your heater.
3.
Ensure that the heater is free from obvious damage.
4.
Ensure that the correct power connections have been made and are able to be isolated.
5.
Reset Button must be pressed prior to initial operation once heater is powered on. (Reset lamp is illuminated)
SERVICE CODES
If the controller detects an error in one of its safety circuits it will display a Service code. The codes are as follows:
1.
2.
3.
4.
5.
6.
PO
o
F1
F2
F3
F4
– No mains power to the unit
– Insufficient water pressure
– Wiring or Electronics Fault
– Main sensor open circuit
– Main sensor short circuit
– Secondary sensor short circuit
When the mains power supply is interrupted, the unit will revert to a standby mode utilising the back-up capacitor supply. (This will
last for at least two hours providing the unit has had sufficient operating time to charge the capacitor).
The unit will not provide heat whilst there is no mains power. The controller will, however, retain its settings as long as the
capacitor has charge. Upon resumption of mains power, the unit will revert to the state it was in prior to the mains power being
interrupted.
Whenever the controller is on and there is insufficient water pressure to activate the pressure switch it will display the letter “o”.
There is either insufficient water pressure in the system (e.g. pump is not operating) or the pressure switch requires adjustment.
In the event of an over-temperature situation, the heater will shut down and lockout. The reset lamp will be illuminated and the
reset button must be pressed to resume operation. (This is a safety requirement of the Australian Standard AS4560). Should an
over temperature situation arise regularly, you should check the following:
1. Ensure skimmer box is not jammed and that the filter is not blocked.
2.
Ensure all valves are in the correct position and that there is adequate water flow through the heater.
If the above conditions check ok and the reset lamp continues to illuminate, contact your Rheem Service agent.
F2, F3 and F4 are errors relating to the unit’s temperature sensors. The errors arise from problems with the sensors or the sensor
connections. In the event one of these errors is displayed you should contact your Rheem Service agent.
OVER-TEMPERATURE SHUTDOWN
If the inlet water temperature exceeds 45°C, the heater will shut down and require a manual reset to restart. Once the unit has
cooled to approx 35°C, the red reset button will illuminate and need to be pressed, after which the reset lamp will go out and the
heater will resume normal operation.
Note: There is no immediate indication of the over temperature shutdown; the control panel will still indicate a call for heat (small
flame symbol). If the heater has gone out during normal operation, and the flame symbol appears on the display, allow up to 4
hours for the heater to cool (If the pump has ceased operation the reset time may be shortened by restarting the pump). If the reset
button has failed to illuminate and the temperature display reads less than 32°C, contact your Rheem service agent PH 131031.
Part No: 96131430
13
Rev: 3
SETTING TIME & DAY
Each time that power is reconnected to the heater the internal heater time clock should be set. Each and every time the heater has
been isolated at the GPO, e.g. for service, this process must be repeated.
1.
Connect the heater to a 240V 10A GPO and turn on.
2.
With the controller displaying OFF, simultaneously press and hold the ▼ and PROG and buttons to access the time set mode.
3.
The system time will then flash on the display. To adjust the time of day, press the ▲or ▼buttons until the correct time is
reached.
4.
Once the time has been set, press and release the PROG button to access the day of week mode.
5.
The day will flash on the display. To adjust the day, press the ▲or ▼buttons.
6.
Press and release the PROG button to lock the day setting and return the control to the OFF mode.
OPERATING INSTRUCTIONS
1.
Before switching the heater On, ensure all water flow control valves are in their correct position. This can be tested by
manually operating the system pump and ensuring that water is flowing through the heater.
2.
Ensure that the gas supply is turned on.
3.
Press the POWER button on the face panel of the heater. The heater will display the current water temperature of the pool.
4.
Press the ▲button on the control panel of the heater until the desired temperature set point is reached.
5.
If initial operation, or if reset lamp is on, press the reset button
6.
The heater will ignite when the set point temperature is above the measured water temperature. If a pump is connected to the
heater this will also commence operation.
Note: The heater will not ignite if there is no water flow through the heater.
7.
If the heater does not ignite after 90 seconds, turn off the power by pressing the POWER button and wait 1 minute before
repeating all steps.
8.
If the heater does not light on the second attempt, turn off the heater and isolate the gas supply and contact your installer or
Raypak.
TEMPERATURE SELECTION
Caution! Prolonged exposure to elevated water temperatures can be hazardous.
Temperature selection is made by selecting either the ▲or ▼arrow buttons located on the face of the heater controller. After
depressing either of these buttons the current desired temperature set point will be displayed. Continuing to press either button will
alter the heater set point. Once the desired set point temperature is selected the display will return to show the current water
temperature, after a short delay.
For continued manual operation of the heater in this manner ensure that the display is not showing AUTO. If AUTO is displayed
pressing the PROG button will return the heater to manual operation.
MODE SELECTION (POOL/SPA)
The MODE button on the control panel enables both the pool and spa temperatures to be set independently. The two set point
temperatures are stored by the heater controller and are used when the desired mode is selected.
To select the desired mode press the MODE button. The selected mode is shown on the heater display. The heater will then
operate according to the mode selected.
If the Pool mode is selected, the heater will heat the water until the pool set point temperature is reached. If Spa mode is selected
the heater will heat the water until the spa set point temperature is reached.
Motorised Valves (if installed)
Models: 200, 280, 350, 430 Only
The pool heater controller included in the above models is fitted standard with a 24VAC output for operation of motorised diverter
valves (if fitted by your pool system installer). Where motorised diverter valves are installed they may be connected to the heater
by the installer so that when the MODE button is pressed, the diverter valves direct flow to and from the desired destination, i.e.
Pool or Spa after a delay of approximately 5 seconds.
Part No: 96131430
14
Rev: 3
Caution! Motorised valves must never be installed so that they can move through a closed inlet position while the pump is
operating and allow the system to pressurise. This situation will void warranty and may significantly damage the pool heater and
other system equipment and possibly lead to personal injury.
Note: Control of motorised diverter valves requires connection of the valve actuators to the 24VAC terminal strip included in the
pool heater. This terminal strip is built as standard on pool heater models 200 to 430 but is not included on any other model. A
relay may be added by a licensed electrician in accordance with the wiring diagram included in this booklet to provide this function.
Note: Wired connection of actuators must be completed by a licensed electrician.
SERVICE
Caution! Always isolate all connections to the heater, including any pump connections, before commencing any service work.
Only a properly trained service technician should carry out work on your pool or spa heater. Regular service (at least annually)
should be carried out to ensure that the gas valves and burner are clean and free from damage and that the heat exchanger is
unobstructed and free from sooting.
It is recommended that prior to commencing operation of your pool heater each year a service inspection be undertaken.
PROGRAMMING OF HEATER CONTROLLER
The controller located on the front of your Raypak heater is capable of both manual and programmable operation. The following
instructions describe how the controller may be programmed for timer operation.
Before the controller can be programmed the time of day clock and day of week must be set.
SETTING TIME & DAY
Before the heater is operated the internal heater time clock should be set. Each and every time the heater has been isolated at the
GPO, e.g. for service, this process must be repeated.
1.
Connect the heater to a 240V 10A GPO and turn on.
2.
With the controller displaying OFF, simultaneously press and hold the ▼ and PROG and buttons to access the time set mode.
3.
The system time will then flash on the display. To adjust the time of day, press the ▲or ▼buttons until the correct time is
reached.
4.
Once the time has been set, press and release the PROG button to access the day of week mode.
5.
The day will flash on the display. To adjust the day, press the ▲or ▼buttons.
6.
Press and release the PROG button to lock the day setting and return the control to the OFF mode.
AUTO MODE
Auto mode allows the controller to:
1.
Turn the pool heater on or off over 4 separate time periods each day.
2.
Control water temperature.
3.
Control mode settings (Pool or Spa)
4.
Control and auxiliary equipment that may be connected via the Raypak Equipment Interface Box (if installed).
Auto mode can be selected by pressing the PROG button and releasing. AUTO should now be displayed. The heater has been
factory set with four default time periods. These will be used if no other program is set and AUTO is selected on the controller. The
following table shows the factory set AUTO mode program settings. The controller will retain all program settings even with the
removal of the power supply.
Part No: 96131430
Timer Period
Start Time
Temp ° C
Mode
Auxiliary Outputs
1
6:00am
24
Pool
All Off
2
10:00am
OFF
Pool
All Off
3
2:00pm
24
Pool
All Off
4
6:30pm
OFF
Pool
All Off
15
Rev: 3
PROGRAMMING MODE
IMPORTANT!
Heater must be in AUTO mode before timer periods can be set. AUTO mode is selected by pressing the PROG button.
All time periods must be programmed, even if not required and must be set in the correct time sequence for the controller to
operate correctly in AUTO mode. Note: The programming operation can be exited at anytime by selecting the POWER button.
Example:
TIMER
PERIOD
1
2
3
4
START
TIME
7:00am
9:00am
8:30pm
9:00pm
If these time periods are set the
operation sequence will be as
follows:
Period1>Period2> Period4
Period 3 will be ignored
With the controller in the AUTO mode, switched “On” and displaying the current water temperature, press the PROG button for at
least 5 seconds to access the programming mode. The time of day will be displayed briefly prior to accessing programming mode.
1.
Once the programming mode has been accessed SET and day of week selection will flash.
2.
The first item to be programmed is the day of the week. Use the ▲or ▼buttons to scroll through the days of the week. Press
PROG to lock in the day selection/s.
3.
The start time of period 1 will then flash. Press the ▲or ▼buttons to adjust the start time. Press the PROG button to lock in the
start time.
4.
Either POOL or SPA will now flash in the display indicating the mode selected. Use the MODE button to toggle between Pool
and Spa modes. Press the PROG button to lock in the selected mode.
5.
The desired temperature for the selected mode must now be set for period 1. On first use the temperature will flash OFF. This
setting is used when the heater is not required to heat the water but the time setting is to be used for operating auxiliary
equipment. Use the ▲or ▼buttons to scroll through the temperature settings. The minimum set temperature is 18°C. Pressing
the ▼button when the temperature is at 18°C will select the OFF mode for period 1. Press PROG to lock in the temperature
selection.
6.
The Auxiliary Output selection/s will now flash. Use the ▲or ▼buttons to scroll through the six (6) auxiliary selections.
Note: Programming auxiliary equipment operation is only necessary if the Raypak Equipment Interface Box (EIB) is installed and
auxiliary equipment has been connected.
7.
To turn an auxiliary output “On” press the AUX button when the desired AUX item (1 to 6) is flashing. The word On is then
displayed above the auxiliary selection. Press the ▲button to move to the next available auxiliary output.
8.
Once the desired selection/s have been made, press PROG to lock in the auxiliary output/s.
9.
The display will now move to timer period 2 which may be programmed in the same manner.
Note: All four timer periods must be programmed even if all temperature selections and auxiliary outputs are set to off or not
required. The program function will operate each timer period in the sequence 1 to 4.
10. The display will now return to its normal position.
CHILD LOCK FUNCTION
The child lock function will render all 6
controller switches inactive.
1.
To activate the child lock function press and hold both the ▲and ▼buttons for 10 seconds. The lock symbol will be displayed.
2.
To cancel the child lock function press and hold the ▲and ▼buttons for 10 seconds.
Part No: 96131430
16
Rev: 3
ELECTRICAL CONNECTIONS
WARNING! – ALL ELECTRICAL WORKS MUST BE COMPLETED BY A LICENSED ELECTRICIAN
DANGER! This heater may be coupled to two sources of 240V AC power. Isolate all power sources prior to commencing any
installation, service, or other work. See also warnings included on the heater.
POWER CONNECTION(S)
The heater includes a loosely coiled 3-pin 240VAC power lead for connection to a mains power 10A GPO. This connection is
required for operation of the heater.
The heater should be properly connected to a GPO that is suitable for either indoor or outdoor use. Prior to connection inspect the
supplied power connection lead for any damage.
DO NOT connect the heater to any power source if there is any sign of damage.
For models 200, 280, 350, and 430 a second 3-pin 240VAC power lead is connected to the underside of your heaters control panel,
inside the door.
This power lead is included for use when a filtration system pump is to be connected to the heater for control by both the heater
and the filtration system.
Where two 240VAC connections are to be made it must be ensured that both operate of the same supply phase.
PUMP CONNECTION
Models: 200, 280, 350, 430 Only
The above model pool heaters are fitted standard with a 240V AC power socket to enable connection of a pool/spa circulation
pump. In most circumstances this pump will be the system pump, required also for filtration and would normally be connected to a
filtration system time clock.
To enable operation of the pump via the heater controller the pump must be connected to the heater power socket located inside
the heater cabinet on the underside of the controller housing. This is accessed by removing the front door of the heater.
If the pump is required to operate with the filtration system (as is normally the case), the additional lead included with the heater
(coiled inside heater cabinet) must be connected to the pump power outlet located on the filtration system time clock controller. If
this connection is not made the pump will fail to operate the filtration system correctly. If the pump is not required to operate in
conjunction with the filtration system it is possible to connect the additional 3-pin lead and plug included with the heater to a
suitable GPO. This GPO should normally be left in the “off “position. Switching the GPO “on” will override and heater control of the
pump and power the pump directly from the GPO.
Once the correct pump power connection is made, the pump will operate as per the approximate time periods of the following table.
Condition
At start up
At shut down (when heating)
Each 30 min’s from switching on.
In spa mode
In pool mode and below temp.
Filtration operating
Filtration in manual operation
In Auto mode
Period
3 mins
5 mins
3 mins
Continuous
Continuous
Continuous
Continuous
Program
In the connection diagram shown, power supply to the pump will be provided under normal conditions by the Filtration Controller.
Failure to connect the pump via the Filtration Controller will in most cases cause the filtration system to operate incorrectly.
It is also possible to connect a non filtration system pump to the heater. This is done by leaving the labelled power lead inside the
heater coiled and unused. This will enable manual operation of the pump as required.
Part No: 96131430
17
Rev: 3
Pump Connection
240VAC 50 Hz
Heater Supply
240VAC 50 Hz
Pump Supply
Heater
Filtration
Controller
Pump
WARNING! – USE THE SAME PHASE WHEN CONNECTING TO 3 PHASE POWER
If 3-phase power is being used, care must be taken to ensure the same phase is used to power both the heater and the filtration
controller. Failure to connect both power supplies to the same phase will result in damage to the heater and tripping of the
electrical circuit breakers.
MOTORISED VALVE ACTUATORS
Models 200, 280, 350, 430 Only
Up to two 24V AC motorised diverter valves may be wired to the terminal strip included with the above heater models. This must
be completed by a licensed electrician. A relay switches supply between the Red and White wires connected to the terminal strip
when the MODE button is pressed. In Pool mode the Red wire terminals will be provided with 24V and the White wire terminals 0V.
Following connection of the valves to the terminal strip, the valves will be activated each time the MODE button is selected (See
Motorised Valves).
Motorised Valve Connection Details
1. Isolate the heater from all power sources.
Caution: Two 240V power connections may be present. Ensure both are disconnected before continuing.
2.
Remove the heater front door.
3.
Thread the 24VAC motorised valve actuator wires through the side of the heater via opening provided.
4.
Connect the wires into the terminal strip as required (See diagram).
Note: With “Jandy” valves and most other brands a Red, White and Black wire will be present. In most cases colours should be
matched with the factory terminal connections. Any pin type connector at the actuator wire end will need to be removed to enable
direct connection to the terminal strip.
5.
Once all connections are made and the door has been replaced, the heater should be reconnected to the electrical supply and
the motorised actuators checked for correct positioning when the MODE button is selected. If necessary direction of valve
actuation may be varied by swapping Red and White wires at the terminal strip.
Part No: 96131430
18
Rev: 3
Black
White
Red
Neutral
Switched Closed
Normally Closed
White
Switched Closed
Neutral
Red
Normally Closed
24V AC
Actuator Connection
Terminal Strip
WARNING! Ensure that each valve operated by the actuator is not able to pass through a position that will close supply from the
pump and result in pressurisation of the pool system. Failure to observe this may result in severe damage to the pool system
piping, equipment and or cause personal injury and property damage. Correct installation is the responsibility of the system
installer.
WARNING! Do not attempt to connect 240V equipment to the 24VAC relay.
Note: For models, Spartan 131, 127 and 167 a 24VAC relay can be added to enable operation of actuators as previously
described. This component must be installed and connected by a licensed electrician.
FLUE DILUTION KIT & EXTERNAL CONTROLS
Models 200, 280, 350, 430 Only
These models include a second terminal strip, which enables connection of the optional Dilution Fan Kit (for Indoor installations
only) and an external thermostat control (see figure below).
The Dilution Fan Kit is installed as shown in the wiring diagram supplied with the kit, between terminals A1 and A2, after removing
the corresponding link.
To install an external thermostat control, remove the link between terminal 1 and 2 and connect the thermostat between the
terminals (voltage-free, normally-closed contacts only).
External Controls
Terminal Strip
Part No: 96131430
19
Rev: 3
DIMENSIONAL DATA
Models 200 - 430
Part No: 96131430
20
Rev: 3
Model 127
Model 167
Part No: 96131430
21
Rev: 3
Model 131
WIRING DIAGRAMS
Part No: 96131430
22
Rev: 3
Part No: 96131430
23
Rev: 3
Part No: 96131430
24
Rev: 3
Part No: 96131430
25
Rev: 3
Part No: 96131430
26
Rev: 3
PRODUCT SPECIFICATIONS
MODEL
GAS
Spartan
131
Natural
Propane
127
Natural
Propane
167
Natural
Propane
200
Natural
Propane
280
Natural
Propane
350
Natural
Propane
430
Natural
Propane
Part No: 96131430
INPUT
120
MJ/hr
130
MJ/hr
110
MJ/hr
103
MJ/hr
164
MJ/hr
154
MJ/hr
196
MJ/hr
185
MJ/hr
278
MJ/hr
261
MJ/hr
343
MJ/hr
323
MJ/hr
420
MJ/hr
396
MJ/hr
OUTPUT
BURNER
PRESSSURE
INJECTOR
DIA.
HEIGHT
OUTDOOR
WIDTH
DEPTH
WEIGHT
24 kW
0.85 kPa
1.36 mm
860 mm
440 mm
650 mm
35 kg
28.8 kW
2.56 kPa
0.85 mm
24 kW
0.77 kPa
1.90 mm
895 mm
505 mm
280 mm
42 kg
23 kW
2.75 kPa
1.10 mm
36 kW
0.77 kPa
1.95 mm
905 mm
365 mm
610 mm
67 kg
34 kW
2.75 kPa
1.10 mm
44 kW
0.77 kPa
1.90 mm
1,085 mm
460 mm
650 mm
70 kg
41 kW
2.75 kPa
1.10 mm
62 kW
0.77 kPa
1.90 mm
1,085 mm
565 mm
650 mm
75 kg
58 kW
2.75 kPa
1.10 mm
76 kW
0.77 kPa
1.90 mm
1,085 mm
655 mm
650 mm
85 kg
72 kW
2.75 kPa
1.10 mm
94 kW
0.77 kPa
1.90 mm
1,085 mm
740 mm
650 mm
90 kg
88 kW
2.75 kPa
1.10 mm
27
Rev: 3
POOL HEATER OPERATION FLOW CHART
Is there any
display on the
LCD?
NO
YES
Book service call
NO
YES
Press ‘PROG’
button to access
manual mode
Is ‘OFF’ displayed
on the LCD?
Is the power point
switched on?
YES
YES
Press ‘ON’ button
Check power point
and/or power
supply
NO
Turn power
point on
Is ‘AUTO’ on the
LCD Display
NO
Is set temperature
set above the pool
temperature?
NO
Press UP button
to increase set
temp above the
pool temperature
YES
Is the flame
symbol displayed?
NO
YES
Is the reset
light on?
Is system pump
running?
NO
YES
Press the
reset button
Switch system
pump on
NO
YES
Does the pool
heater light?
NO
System
operational
Part No: 96131430
Book service call
YES
28
Rev: 3
TYPICAL POOL/SPA SYSTEM DIAGRAM
Heater Power
240V
GPO
240V
GPO
Filtration
Controller
Remote
Non Return Valves
Chlorinator
Pump Power
(Optional Connection)
Alternative
Connection
Cat 5 Cable
Cat 5 Cable
240V - 30A
Hard Wired
Supply
Heater
Raypak EIB
Filter
6 / 240V - 10A (Max)
Switched Outlets for
Auxiliary Equipment
Pump
240V
GPO
24VAC
Motorised
Valve
Pool
Pump
Spa
24VAC
Motorised
Valve
Blower
•
Free chlorine must not exceed 4ppm!
IMPORTANT!
The most frequent cause of damage to a Raypak pool heater is incorrect water balance
resulting from overdosing of chemicals. All chlorinators must feed downstream
of the heaters and have an anti-siphoning device to prevent chemical
back up into the heater when the pump is shut off.
Part No: 96131430
29
Rev: 3
WARRANTY (AUSTRALIA ONLY)
Rheem Australia will repair or if necessary replace any Raypak pool or spa heater; or any component of the pool or spa heater which fails
within the Warranty Periods specified hereafter, in accordance with and subject to the conditions and exclusions mentioned herein.
WARRANTY PERIODS
Residential Model Heaters:
P0131, P0200, P0280, P0350, P0430
When installed at a Single Family Dwelling for the purpose of heating a pool or spa:
ƒ
Parts
3 years
ƒ
Labour 1 year
When installed at other than a Single Family Dwelling for the purpose of heating a pool or spa:
ƒ
Parts
6 months
ƒ
Labour 6 months
Premium (Commercial) Model Heaters:
P0127, P0167, PC0280, PC0430
When installed for the purpose of heating any pool or spa:
ƒ
Parts
3 years
ƒ
Labour 1 year
Notes:
1.
2.
3.
Rheem Australia is responsible for all service activities relating to Raypak Australia product.
Rheem Australia reserves the right to transfer fully functional components from a defective heater to a replacement heater if required.
In addition to this warranty, the Trade Practices Act 1974 and similar laws in each State and Territory, provide the owner with certain
minimum statutory rights in relation to your heater. This warranty must be read subject to all relevant legislation and nothing in this
warranty has the effect of excluding, restricting or modifying those rights.
WARRANTY CONDITIONS
1.
2.
3.
This warranty is applicable only to pool and spa heaters manufactured from August 1st, 2005.
The pool or spa heater must be installed in accordance with the Raypak installation instructions included with the heater and in
accordance with all statutory, local and State requirements.
Where a failed component or heater is replaced under warranty the balance of the original warranty period only will remain effective.
The replaced part or heater does not carry a new warranty.
4.
Where the heater is installed outside the boundaries of a metropolitan area as defined by Rheem, or further than 25km from a
regional Rheem branch office or an accredited Rheem service Agent, the cost of transport, insurance and travelling costs between the
nearest Rheem branch or Rheem Agents premises and the installed site shall be the owner’s responsibility.
5.
The warranty only applies to the Raypak supplied heater and genuine (Rheem or Raypak sourced) component replacement parts and
therefore does not cover any plumbing or electrical parts supplied by the installer and not an integral part of the Raypak supplied
heater, e.g. pressure limiting valves, isolation valves, non-return valves, electrical switches, pumps, fuses, etc.
The heater must have been correctly sized for the pool/spa hot water demand in accordance with Raypak pool and spa heater
literature available from Raypak on request.
6.
WARRANTY EXCLUSIONS
Repair and replacement work will be carried out as described in the Warranty Period, however the following exclusions may cause the
warranty to become void and may incur a service charge and/or the cost of any parts used.
1.
2.
3.
4.
5.
6.
7.
Accidental damage to the heater or any component, including:
a. Acts of God;
b. Failure due to misuse;
c. Incorrect installation;
d. Attempts to repair carried out by other than Rheem or an accredited Agent;
Where it is found that there is nothing wrong with the heater.
Where the complaint is related to excessive discharge from the pressure relief valve (if fitted) due to excessive water pressure.
Where there is no flow of water due to faulty plumbing;
Where water leaks are related to plumbing including connections to the heater.
Where there is a failure of gas or electricity supply or they do not comply with relevant codes or acts.
Where the heater or its components have failed directly or indirectly as a result of:
a. Excessive water pressure;
b. Excessive temperature and/or thermal input;
c. Corrosive atmosphere;
d. Incorrect flow rate through the heat exchanger.
8. Where the heater is located in a position that does not comply with the Raypak installation instructions or relevant statutory
requirements causing the need for major dismantling or removal of any structure, or the requirement of special equipment to bring the
heater to a serviceable position.
9. Repairs of any nature due to corrosion or scale formation of any of the heater components in contact with the pool or spa water.
Subject to any Statutory provisions to the contrary, this warranty excludes all claims for damage to furniture, carpets, walls, foundations or
any other consequential loss either directly or indirectly due to leakage from the pool heater or its fittings caused by any mode of failure.
Part No: 96131430
30
Rev: 3
SERVICE
SERVICE ASSISTANCE
Service must only be undertaken by properly authorised personnel
It is a requirement of Raypak and all gas authorities that the heater be serviced at least once per year, where it is used in a specific
application, e.g. pool heating, it would be practical to perform the service at the commencement of the heating season, or at any
time there may be an indication of a problem.
This service should include the cleaning of the gas burners, inspection of waterways, and checking of all controls for correct
operation.
It is important and very often will save time if you state the model number, serial number and type of gas used. This information will
be found on the heater data plate.
Your local Raypak distributor will arrange for your service or recommend a qualified service organisation.
Part No: 96131430
31
Rev: 3
Part No: 96131430
32
Rev: 3
Raypak Pool & Spa Heater
Service Enquiries: 13
10 31
NEW ZEALAND
0800 657 335
NATIONAL
Service:
SYD/ACT
NEWCASTLE
(07) 3412 9254
(02) 9684 9188
(02) 4961 3117
SA/NT
WA
(03) 9212 8955
(08) 8359 6002
(08) 9353 4101
(08) 8359 6003
(08) 9356 9914
1800 812 916
Phone:
Fax:
VIC/TAS
131031
Phone:
Fax:
Spares:
QLD
(07) 3412 9219
(02) 9016 2999
(02) 4961 3117
(03) 9212 8984
Proudly Manufactured by
Raypak Australia
Head Office & Sales
Tel: (03) 9757 3333
Fax: (03) 9757 4974
Sales Enquiries: 1300 729 725
www.raypak.com.au
Part No: 96131430
33
Rev: 3